Abstract: A rapid preparation method of transition metal borides includes steps of: using a tungsten rod as the cathode, and a block mixture of boron powder and metal oxide as the anode, the block mixture and the tungsten rod are placed in an plasma device; the plasma device is evacuated, and then filled with a buffer gas and an electric arc is started to obtain a transition metal boride. The present disclosure adopts the direct current arc plasma method with the advantages of simple operation, low cost, environmental friendliness and controllable reaction atmosphere to prepare the transition metal boride, the preparation process is simple, the preparation process is fast, and the environment will not be affected.

Abstract: A method and a system for manufacturing a structure includes the steps of: (a) supplying a mixture consisting a plurality of primitive materials at a target spot; (b) melting and solidifying the mixture disposed at the target spot to form a portion of a metallic structure consisting of an alloy of the plurality of the primitive materials; and (c) repeating steps (a) and (b) at a plurality of target spots in a three-dimensional space to produce the metallic structure of the alloy.

Abstract: Tantalum powder that is highly spherical is described. The tantalum powder can be useful in additive manufacturing and other uses. Methods to make the tantalum powder are further described as well as methods to utilize the tantalum powder in additive manufacturing processes. Resulting products and articles using the tantalum powder are further described.

Abstract: A method of processing a metallic material includes introducing an electrically conductive metallic material comprising at least one of a metal and a metallic alloy into a furnace chamber maintained at a low pressure relative to atmospheric pressure. A first electron field having a first area of coverage is generated using at least a first ion plasma electron emitter, and the material within the furnace chamber is subjected to the first electron field to heat the material to a temperature above a melting temperature of the material. A second electron field having a second area of coverage smaller than the first area of coverage is generated using a second ion plasma electron emitter. At least one of any solid condensate within the furnace chamber, any solidified portions of the electrically conductive metallic material, and regions of a solidifying ingot to the second electron field, is subjected to the second electron field, using a steering system.

Abstract: A method and composition for removing sulfur from molten ferrous material, particularly molten iron. The desulfurization agent includes one or more pucks or briquettes of deoxidizing and/or desulfurization agent. The pucks or briquettes of deoxidizing and/or desulfurization agent include at least one deoxidizing metal and at least one ferrous metal.

Abstract: The various embodiments herein provide a method of producing silver nanoparticles using an electromagnetic levitation melting process. The method comprises levitating and melting a silver sample using a suitable levitation coil and stabilizing a droplet of molten silver. The silver droplet is heated and levitated simultaneously by an induction furnace as a generator. Argon gas is used to provide the inert atmosphere and also applied to cool and condense the silver vapor into a silver nano powder to obtain a silver nano particle. The synthesized silver nanoparticles are collected by brushing them off the brass cylinder using inert gas and are kept in pure Hexane. The size of the nanoparticles is controlled by rate of cooling and heating temperature. The electromagnetic levitation melting method is applied to provide the high purity of silver nano particles with no vacuum equipments.

Abstract: A method for producing conductor fine particles in which the advantages of conventional vapor phase method and liquid phase method are utilized while eliminating the drawbacks of both methods remarkably. Furthermore, definite guidelines and measure for improvement are given to the greatest problems common to the vapor phase method and liquid phase method, i.e., enhancement in quality of the unit fine particle and a fine particle production method controllably temporarily and regionally. The method for producing conductor fine particles comprises a step for applying a voltage to a pair of electrode consisting of a positive electrode and a negative electrode arranged in conductive liquid and generating plasma in the vicinity of the negative electrode, and a step for producing conductor fine particles by melting the metal material of the negative electrode and then re-solidifying.

Abstract: One non-limiting embodiment of an apparatus for forming an alloy powder or preform includes a melting assembly, an atomizing assembly, and a field generating assembly, and a collector. The melting assembly produces at least one of a stream of a molten alloy and a series of droplets of a molten alloy, and may be substantially free from ceramic in regions contacted by the molten alloy. The atomizing assembly generates electrons and impinges the electrons on molten alloy from the melting assembly, thereby producing molten alloy particles. The field generating assembly produces at least one of an electrostatic field and an electromagnetic field between the atomizing assembly and the collector. The molten alloy particles interact with the at least one field, which influences at least one of the acceleration, speed, and direction of the molten alloy particles. Related methods also are disclosed.

Abstract: One non-limiting embodiment of an apparatus for forming an alloy powder or preform includes a melting assembly, an atomizing assembly, and a field generating assembly, and a collector. The melting assembly produces at least one of a stream of a molten alloy and a series of droplets of a molten alloy, and may be substantially free from ceramic in regions contacted by the molten alloy. The atomizing assembly generates electrons and impinges the electrons on molten alloy from the melting assembly, thereby producing molten alloy particles. The field generating assembly produces at least one of an electrostatic field and an electromagnetic field between the atomizing assembly and the collector. The molten alloy particles interact with the at least one field, which influences at least one of the acceleration, speed, and direction of the molten alloy particles. Related methods also are disclosed.

Abstract: The various embodiments herein provide a method of producing silver nanoparticles using an electromagnetic levitation melting process. The method comprises levitating and melting a silver sample using a suitable levitation coil and stabilizing a droplet of molten silver. The silver droplet is heated and levitated simultaneously by an induction furnace as a generator. Argon gas is used to provide the inert atmosphere and also applied to cool and condense the silver vapor into a silver nano powder to obtain a silver nano particle. The synthesized silver nanoparticles are collected by brushing them off the brass cylinder using inert gas and are kept in pure Hexane. The size of the nanoparticles is controlled by rate of cooling and heating temperature. The electromagnetic levitation melting method is applied to provide the high purity of silver nano particles with no vacuum equipments.

Abstract: A metal powder production system includes a vacuum chamber having a vacuum chamber interior, a stock feed mechanism communicating with the vacuum chamber interior, a radiation source provided in the vacuum chamber interior, a cooling chamber having a cooling chamber interior communicating with the vacuum chamber interior and a container communicating with the cooling chamber interior. A metal powder production method is also disclosed.

Abstract: Particles and manufacturing methods thereof are provided. The manufacturing method of the particle includes providing a precursor solution containing a precursor dissolved in a solution, and irradiating the precursor solution with a high energy and high flux radiation beam to convert the precursor to nano-particles. Particles with desired dispersion, shape, and size are manufactured without adding a stabilizer or surfactant to the precursor solution.

Abstract: One non-limiting embodiment of an apparatus for forming an alloy powder or preform includes a melting assembly, an atomizing assembly, and a collector. The melting assembly produces at least one of a stream of a molten alloy and a series of droplets of a molten alloy, and may be substantially free from ceramic in regions contacted by the molten alloy. The atomizing assembly generates electrons and impinges the electrons on molten alloy from the melting assembly, thereby producing molten alloy particles.

Abstract: Methods and apparatus for producing large diameter superalloy ingots are disclosed. A material comprising at least one of a metal and a metallic alloy is introduced into a pressure-regulated chamber in a melting assembly. The material is subjected to a wide-area electron field within the pressure-regulated chamber to heat the material to a temperature above the melting temperature of the material to form a molten alloy. At least one stream of molten alloy from the pressure-regulated chamber is provided from the melting assembly and is fed into an atomizing assembly, where particles of the molten alloy are generated by impinging electrons on the molten alloy to atomize the molten alloy. At least one of an electrostatic field and an electromagnetic field are produced to influence the particles of the molten alloy. The particles of the molten alloy are deposited onto a collector in a spray forming operation to form an alloy ingot.

Abstract: Metal particles approximately in the form of spheres having a mean diameter of about 40 ?m to about 100 ?m, including magnesium silicide particles having a mean diameter of about 1 ?m to about 10 ?m uniformly dispersed in the metal particles, the metal particles being obtained by mixing about 90 wt. % to about 95 wt. % of magnesium and about 5 wt. % to about 10 wt. % of silicon, and the magnesium silicide particles being formed in the metal particles by the reaction of the magnesium and the silicon.

Abstract: Apparatus to eject on demand discrete hollow microsphere droplets that are characterized by a highly regular and predictable spherical shape, devoid of tails or other irregularities common in the prior art with a selected pure gas contained in the center. With this method and apparatus, droplets may be formed of any suitable material including glass, ceramic, plastic, or metal. A variety of gases at various pressures including complete vacuums may be contained in the hollow microsphere. Microspheres filled with ionizable gas may be used as pixels in a plasma display panel. Microspheres used as a pixel elements may be referred to as Plasma-spheres. The inside of each Plasma-sphere may contain a luminescent material such as a phosphor and/or a secondary electron emission material such as magnesium oxide or a rare earth oxide introduced during the gas filling of the microsphere.

Abstract: Porous microparticles of high-purity tantalum may be processed in a vacuum plasmatron using a hollow cathode and spraying apparatus in which the coolant is in the form of a metal surface. In one embodiment, the initial powder of tantalum is introduced through a coaxial hole in a hollow cathode and supplied to a vertical column of plasma by inert gas and exposed to heating to temperatures close to the melting point of tantalum. The atomizing tantalum particles are directed through a hole in the anode and collide with a rotating inclined tantalum substrate and cooled from within water, thereby flattened and solidifying the particles.

Abstract: Provided is an aerosol method, and accompanying apparatus, for preparing powdered products of a variety of materials involving the use of an ultrasonic aerosol generator (106) including a plurality of ultrasonic transducers (120) underlying and ultrasonically energizing a reservoir of liquid feed (102) which forms droplets of the aerosol. Carrier gas (104) is delivered to different portions of the reservoir by a plurality of gas delivery ports (136) delivering gas from a gas delivery system. The aerosol is pyrolyzed to form particles, which are then cooled and collected. The invention also provides powders made by the method and devices made using the powders.

Abstract: The invention concerns a process for the spheroidisation, densification and purification of powders through the combined action of plasma processing, and ultra-sound treatment of the plasma-processed powder. The ultra-sound treatment allows for the separation of the nanosized condensed powder, referred to as ‘soot’, from the plasma melted and partially vaporized powder. The process can also be used for the synthesis of nanopowders through the partial vaporization of the feed material, followed by the rapid condensation of the formed vapour cloud giving rise to the formation of a fine aerosol of nanopowder. In the latter case, the ultra-sound treatment step serves for the separation of the formed nanopowder form the partially vaporized feed material.

Abstract: A method for producing composite, shelled, alloy and compound nanoparticles as well as nanostructured films of composite, shelled, alloy and compound nanoparticles by using laser ablation of microparticles is disclosed.

Abstract: The present invention relates to a nanostructured metal powder and a method of fabricating the same. A twin-wire electric arc process is performed to melt the wire tips, and metal melt is formed. Simultaneously, the metal melt is broken up into melt droplets by an atomizing device. The operating temperature of the electric arc process is controlled between melting point and boiling point of the wire, to avoid vaporization of the melt droplets. Then, a fast cooling is performed to quench the melt droplets. Thus, melt droplets are solidified to ?m-scaled, spherical and dense powders comprising nano-grains (d<100 nm).

Abstract: The present invention is directed to methods and apparatus that use electrostatic and/or electromagnetic fields to enhance the process of spray forming preforms or powders. The present invention also describes methods and apparatus for atomization and heat transfer with non-equilibrium plasmas. The present invention is also directed to articles, particularly for use in gas turbine engines, produced by the methods of the invention.

Abstract: The present invention is directed to methods and apparatus that use electrostatic and/or electromagnetic fields to enhance the process of spray forming preforms or powders. The present invention also describes methods and apparatus for atomization and heat transfer with non-equilibrium plasmas. The present invention is also directed to articles, particularly for use in gas turbine engines, produced by the methods of the invention.

Abstract: A method of producing ultrafine particles by vaporization comprising: vaporizing a target by sputtering; causing particles that fly from the target by vaporization to be deposited on an oil surface; and recovering the oil on which the flown particles have deposited to obtain individually dispersed ultrafine particles.

Abstract: A method of forming metal spheres includes ejecting a precisely measured droplet of molten metal from a molten metal mass, buffering the molten metal droplet to reduce the internal kinetic energy of the droplet without solidifying the droplet and cooling the buffered droplet until the droplet solidifies in the form of a metal sphere. An apparatus for fabricating metal spheres includes a droplet generator that generates a droplet from a molten metal mass, a buffering chamber that receives the droplet from the droplet generator, and diminishes internal kinetic energy of the droplet without solidifying the droplet, and a cooling drum that receives the droplet from the buffering chamber, and cools the droplet to the extent that the droplet solidifies into a metal sphere. The apparatus may further include a collector arrangement that receives the metal spheres from the cooling drum and makes the metal sphere available for collection.

Abstract: A method of manufacturing a multilayer material including a back metal and a metal plate made from a metal differing from the back metal is disclosed. The method includes heating powder of the metal formed into the metal plate in a reducing atmosphere so that an oxide on a surface of the metal powder is deoxidized, and spreading the deoxidized metal powder onto the back metal and irradiating laser beam having an energy density of 10 to 100 kW/cm2 onto the metal powder spread on the back metal so that the metal powder is partially heated to be melted, while the laser beam is moved relative to the spread metal powder, and quenching the melted part of the metal powder at an underside of the back metal so that the melted part is rapidly solidified, whereupon the multilayer material has a dendritic structure in which the metal plate extends substantially vertically from a surface of the back metal, and the dendritic structure has a crystal grain size equal to or smaller than 0.

Abstract: A plasma arc reactor and process for producing a powder from a solid feed material, for example aluminium, is provided. The reactor comprises: (a) a first electrode (5), (b) a second electrode (10) which is adapted to be spaced apart from the first electrode by a distance sufficient to achieve a plasma arc therebetween, (c) means for introducing a plasma gas into the space between the first and second electrodes, (d) means for generating a plasma arc in the space between the first and second electrodes, wherein the first electrode has a channel (7) running therethrough, an outlet of the channel exiting into the space between the first and second electrodes, and wherein means are provided for feeding solid material (20) through the channel to exit therefrom via the outlet into the space between the first and second electrodes.

Abstract: A particle forming method includes feeding a first set of precursors to a first energy application zone. Energy is applied to the first set of precursors in the first energy application zone effective to react and form solid particles from the first set of precursors. The application of any effective energy to the solid particles is ceased, and the solid particles and a second set of precursors are fed to a second energy application zone. Energy is applied to the second set of precursors in the second energy application zone effective to react and form solid material about the solid particles from the second set of precursors. At least one precursor is fed to at least one of the first and second energy application zones as a liquid. Other aspects are contemplated.

Abstract: A solder jet apparatus is disclosed The solder jet apparatus is a continuous mode solder jet that includes a blanking system and raster scan system. The use of the raster scan and blanking systems allows for a continuous stream of solder to be placed anywhere on the surface in any desired X-Y plane. This allows for greater accuracy as well as greater product throughput. Additionally, with the raster scan system, repairs to existing soldered surfaces can be quickly and easily performed using a map of the defects for directing the solder to the defects.

Abstract: The present invention relates to a nanostructured metal powder and a method of fabricating the same. A twin-wire electric arc process is performed to melt the wire tips, and metal melt is formed. Simultaneously, the metal melt is broken up into melt droplets by an atomizing device. The operating temperature of the electric arc process is controlled between melting point and boiling point of the wire, to avoid vaporization of the melt droplets. Then, a fast cooling is performed to quench the melt droplets. Thus, melt droplets are solidified to &mgr;m-scaled, spherical and dense powders comprising nano-grains (d<100 nm).

Abstract: A process for manufacturing alloy powder with dual consumable rotary electrodes arc melting is suitable for manufacturing pure and low-surface-area powder of metal, active metals and their alloys. In the process, rotary electrode and tungsten electrode adopted by conventional rotary electrode and arc process for manufacturing powder are respectively replaced with a rotary or anodic electrode containing a first metal and a feed or cathodic electrode containing a second metal. An inert gas is supplied into equipment for implementing the process to serve as a protective atmosphere and stabilize generated electric arc. The cathodic electrode melts under the high temperature of the arc at a cathodic spot, and droplets of the molten cathodic or second metal are sprayed toward the anodic electrode to mix with molten anodic or first metal and thrown out by a centrifugal force of the rotary electrode to produce round-shaped alloy powder containing the first and the second metal.

Abstract: Provided are palladium-containing powders and a method and apparatus for manufacturing the palladium-containing particles of high quality, of a small size and narrow size distribution. An aerosol is generated from liquid feed and sent to a furnace, where liquid in droplets in the aerosol is vaporized to permit formation of the desired particles, which are then collected in a particle collector. The aerosol generation involves preparation of a high quality aerosol, with a narrow droplet size distribution, with close control over droplet size and with a high droplet loading suitable for commercial applications. Powders may have high resistance to oxidation of palladium. Multi-phase particles are provided including a palladium-containing metallic phase and a second phase that is dielectric. Electronic components are provided manufacturable using the powders.

Abstract: A method of converting metal-containing or metal alloy-containing compounds into a metal or metal alloy by rapidly heating the metal-containing or metal alloy-containing compound to an elevated temperature to instigate conversion and holding the metal-containing or metal alloy-containing compound at the elevated temperature for a time sufficient to effect formation of the metal or metal alloy is an efficient and economical method of producing metals and metal alloys.

Abstract: In a high-speed fabrication process for producing highly uniform ultra-small metallic micro-spheres, a molten metal is passed through a small orifice, producing a stream of molten metal therefrom. A series of molten metal droplets forms from the break up of the capillary stream. Applied harmonic disturbances are used to control and generate satellite and parent droplets. Significantly, the satellite droplets formed are smaller than the orifice, allowing for the production of smaller metal balls with larger orifices. The satellite droplets are separated from the parent droplets by electrostatic charging and deflection or by aerodynamic or acoustic sorting. Preferably, the satellite droplets are cooled before being collected to avoid defects and achieve high uniformity of the resulting metal balls.

Abstract: In a high-speed fabrication process for producing highly uniform metallic microspheres, a molten metal is passed through a small orifice, producing a stream of molten metal therefrom. A series of molten metal droplets forms from the break up of the capillary stream. To achieve high uniformity of the spheres and avoid defects, the droplets are cooled before being captured. Separating the droplets, by causing them to travel in different paths than their adjacent droplets, helps to facilitate the cooling of the droplets. The droplets can be separated by electrostatically charging them as they break off from the capillary stream. The droplets are then passed through an electric field, which can be produced by a pair of deflection plates. The droplets are dispersed by varying the electric field—e.g., by rotating the plates or by varying the voltage applied thereto—or by varying the electrostatic charge of the droplets.

Abstract: It is the object to provide a production process of monodisperse particle in which monodisperse particle with uniform particle size (particle diameter) can be stably mass-produced, and monodisperse particle produced by this process, and its production apparatus. The supply pipe diameter &dgr;f is set to be greater than the orifice diameter &dgr;o and the internal and external pressure of the slurry retention part b is controlled, and this allows to facilitate supply of the slurry through the supply pipe (21c), and continuously and efficiently supply the slurry, and then to produce monodisperse particle with uniform particle size (particle diameter).

Abstract: The present invention provides a novel thermoelectric semiconductor material having excellent thermoelectric property which is not lowered like a conventional PbTe-based or PbSnTe-based semiconductor material even if a strength is improved by sintering. The thermoelectric semiconductor material of the invention is characterized by having chemical formula AB2X4 (where, A is a simple substance or mixture of Pb, Sn and Ge (IV family elements), B is a simple substance or mixture of Bi and Sb (V family elements), and X is a simple substance or mixture of Te and Se (VI family elements). In this case, a spark plasma sintering device is used to apply a pulsed current through the powder material to cause an electrical discharge among particles of the powder to synthesize the compound AB2X4 having a uniform structure. And, the invention synthesizes a compound, which is to be a thermoelectric semiconductor material, so to have a uniform structure.

Abstract: The spheroidized hard material powders are produced by introducing a finely ground basic mixture of hard material into a thermal, inductively coupled high-frequency plasma so that at the same time a chemical conversion reaction to form an alloy and/or chemical reaction and spheroidization of the particles in the plasma take place. The hard material mixture may be powder, granules, or a suspension or any combination thereof. Hence, a mixture consisting of MexMy, wherein Me is a metal and M is a metalloid so that different metals and metalloids may be combined in the required metal-metalloid ratio is injected axially into an inductively coupled, high-frequency plasma with the aid of a carrier gas stream. The spheroidized hard material powder has excellent suitability for protection against wear.

Abstract: There is disclosed an apparatus for production of nanosized particulate matter by vaporization of solid materials, comprising a first chamber (14), a vacuum pump (15) connected to the first chamber (14), a body (2) inserted in the first chamber (14), a cavity (3) formed in the body (2), means (7, 9) for in-feeding a gas flow (8) to the cavity (3), an anode (4) and a cathode (5) partly inserted in the cavity (3), a power supply (6) to apply a voltage between the anode (4) and cathode (5), and a nozzle (11) communicating with the cavity (3) and conveying a beam (12) of particles consisting of vaporized material from the cathode (5), the cathode (5) being disposed facing the gas flow (8) to intercept the latter, and the anode (4) and cathode (5) being positioned so as to allow propagation of an electrical discharge to the gas flow (8) and ionization of the gas itself.

Abstract: In a high-speed fabrication process for producing highly uniform metallic microspheres, a molten metal is passed through a small orifice, producing a stream of molten metal therefrom. A series of molten metal droplets forms from the break up of the capillary stream. To achieve high uniformity of the spheres and avoid defects, the droplets are cooled before being captured. Separating the droplets, by causing them to travel in different paths than their adjacent droplets, helps to facilitate the cooling of the droplets. The droplets can be separated by electrostatically charging them as they break off from the capillary stream. The droplets are then passed through an electric field, which can be produced by a pair of deflection plates. The droplets are dispersed by varying the electric field—e.g., by rotating the plates or by varying the voltage applied thereto—or by varying the electrostatic charge of the droplets.

Abstract: Provided are silver-containing powders and a method and apparatus for manufacturing the silver-containing particles of high quality, of a small size and narrow size distribution. An aerosol is generated from liquid feed and sent to a furnace, where liquid in droplets in the aerosol is vaporized to permit formation of the desired particles, which are then collected in a particle collector. The aerosol generation involves preparation of a high quality aerosol, with a narrow droplet size distribution, with close control over droplet size and with a high droplet loading suitable for commercial applications.

Abstract: The invention comprises particle forming methods, laser pyrolysis particle forming methods, chemical mechanical polishing slurries, and chemical mechanical polishing processes. In but one preferred implementation, a particle forming method includes feeding a first set of precursors to a first energy application zone. Energy is applied to the first set of precursors in the first energy application zone effective to react and form solid particles from the first set of precursors. Application of any effective energy to the solid particles is ceased and the solid particles and a second set of precursors are fed to a second energy application zone. Energy is applied to the second set of precursors in the second energy application zone effective to react and form solid material about the solid particles from the second set of precursors. Preferably, at least one of the first and second applied energies comprises laser energy.

Abstract: A method for efficiently producing particles from gas phase chemical reactions induced by a radiation beam. The apparatus includes a reaction chamber and an elongated reactant inlet, where the reaction chamber is configured to conform generally to the elongated shape of the reactant inlet. Shielding gas may be introduced to form a blanket of inert gas on both sides of the reactant stream. A feed back loop may be used to maintain the desired pressure within the reaction chamber.

Abstract: The present invention is a process and apparatus for producing nano-scale particles using the interaction between a laser beam and a liquid precursor solution. There are two embodiments. The first embodiment includes the use of a solid substrate during the laser-liquid interaction. In this embodiment the laser beam is directed at the solid substrate which is immersed in the liquid precursor solution and rotating. The second embodiment includes the use of a plasma during the laser-liquid interaction. In the second embodiment, a mixture of a liquid precursor and a carrier gas is injected into a laser beam. Injection of the mixture can be performed either perpendicular or parallel to the laser beam. The apparatus for injecting the liquid precursor and carrier gas into the laser beam includes a plasma nozzle designed to allow the laser beam to enter the plasma nozzle so that the laser beam may irradiate what is flowing through the plasma nozzle to create a plasma flow.

Abstract: A method for manufacturing precise complex three dimensional structures in which minute drops of both a product layer and a sacrificial layer are emitted from an acoustic device. The process is a two step process wherein first the three dimensional structure is built in layers which are composed of either a sacrificial layer or a product layer or some configuration of both. Once the structure has been completely built up, then the sacrificial layer is removed leaving only the complex three dimensional structure.

Abstract: A method for stably producing metal beryllium pebbles each ranging from 0.1 to 1.8 mm in particle diameter and 0.05 to 0.6 mm in crystal grain average diameter. The metal beryllium pebbles obtained by the invention are excellent not only in tritium emission power but also in anti-swelling property, and are thus useful as a material for nuclear fusion reactors. The metal beryllium pebbles can also be advantageously employed for aerospace structural materials and the like, by utilizing their light weight and high melting point properties.

Abstract: A method of manufacturing metallic droplets (9), comprising the following steps:(a) providing a substrate (1) which is substantially transparent to radiation of wavelength .lambda., one face (1a) of the substrate (1) being provided with a metallic layer (3) which is partitioned into an array of lands (5);(b) directing a laser beam (7) of wavelength .lambda. through the substrate (1) onto a land (5), thereby causing rapid melting of the land (5) and its detachment from the substrate (1) in the form of a molten droplet (9). In a preferential embodiment of the method, the molten droplet (9) is "shot" onto a target substrate (21) before solidifying.

Abstract: A system and method for producing fine powders. The system includes a rotary atomization device for forming a moving flow of a molten source material; a source of atomizing material; a nozzle for directing a jet of the atomizing material at the moving flow of molten source material for atomizing and for producing fine droplets of the source material; and a chamber for collecting the fine droplets.

Abstract: The present invention is a process and apparatus for producing nano-scale particles using the interaction between a laser beam and a liquid precursor solution. There are two embodiments. The first embodiment includes the use of a solid substrate during the laser-liquid interaction. In this embodiment the laser beam is directed at the solid substrate which is immersed in the liquid precursor solution and rotating. The second embodiment includes the use of a plasma during the laser-liquid interaction. In the second embodiment, a mixture of a liquid precursor and a carrier gas is injected into a laser beam. Injection of the mixture can be performed either perpendicular or parallel to the laser beam. The apparatus for injecting the liquid precursor and carrier gas into the laser beam includes a plasma nozzle designed to allow the laser beam to enter the plasma nozzle so that the laser beam may irradiate what is flowing through the plasma nozzle to create a plasma flow.

Abstract: A method and apparatus for the accurate formation of a three-dimensional article comprises providing a supply of substantially uniform size droplets of a desired material wherein each droplet has a positive or negative charge. The supply of droplets is focused or aligned into a narrow stream by passing the droplets through or adjacent an alignment means which repels each droplet toward an axis extending through the alignment means. The droplets are deposited in a predetermined pattern at a predetermined rate onto a target to form the three-dimensional article without the use of a mold of the shape of the three-dimensional article. A means for reducing stress anneals portions of the deposited droplets which form a newly formed surface of the three-dimensional article.