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: An iron or copper based metal powder useful for plasma deposition of a coating that has a dry coefficient of friction 0.75 or less and readily conducts heat through the coating. The powder comprises (a) H.sub.2 O atomized and annealed particles consisting essentially of (by weight) carbon 0.15-0.85%, oxygen 0.1-0.45%, an air hardening agent selected from manganese and nickel of 0.1-6.5%, and the remainder iron or copper, with at least 90% of the particles having oxygen and iron or copper combined in the lowest atomic oxygen form for an oxide of such metal.A method of making anti-friction iron powder that is economical, selectively produces FeO and promotes fine flowable particles. The method comprises (a) steam atomization of a molten steel that excludes other oxygen, the steel containing carbon up to 0.4% by weight to produce a collection of comminuted particles, and (b) annealing the particles in an air atmosphere for a period of time of 0.25-2.0 hours in a temperature range of 800.degree.-1400.degree. F.

Abstract: A collection of agglomerated anti-friction grains for plasma deposition, the grains each consisting essentially of (a) H.sub.2 O atomized stainless steel particles, (b) solid lubricant particles consisting of at least one of boron nitride or a eutectic of calcium fluoride and lithium fluoride, and (c) a binder holding said steel and solid lubricant particles together for plasma spraying, said binder being present in an amount of 0.5-4.0% by weight and is vaporizable at the temperature of plasma spraying and does not interfere with the deposited process. A method of making agglomerated grains of powder suitable for plasma deposition, by (a) H.sub.

Abstract: The yield of flat powder (6) of Al, Mg or their alloy is enhanced by forming, on a rotary cooling body (4), a film (8) which can prevent the flat metal powder (8) from sticking to the cooling surface. The film (8) adheres to the cooling surface at a force which is sufficient for forming the film but which enables the film material to adhere to the flat powder which then separates from the cooling body (4). The film consists essentially of at least one liquid lower fatty acid and at least one solid higher fatty acid.

Abstract: A method of producing coated powder material is provided. In the method, molten metal or metal alloy is caused to fall in a stream (3) and is then atomized into a spray. A liquid or solid material of different composition is introduced and caused to contact the stream or spray so that a coating is formed over all or part of the surface of the atomized droplets. The coating may be the introduced material or a reaction product.

Abstract: Method and apparatus for making metallic powder particles wherein a metallic melt is atomized by a rotating disk or other atomizer at an atomizing location in a manner to form molten droplets moving in a direction away from said atomizing location. The atomized droplets pass through a series of thin liquid quenching sheets disposed in succession about the atomizing location with each successive quenching sheet being at an increasing distance from the atomizing location. The atomized droplets are incrementally cooled and optionally passivated as they pass through the series of liquid quenching sheets without distorting the atomized droplets from their generally spherical shape. The atomized, cooled droplets can be received in a chamber having a collection wall disposed outwardly of the series of liquid quenching sheets.

Abstract: A metal or an alloy thereof, or a ceramic that has a liquid phase is introduced in the form of a rod or a wire or as a liquid stream into the apex formed by a plurality of converging plasma jets. Atomization takes place and upon controlled cooling good quality spheroidal powders are obtained whose size varies generally between about 10 and 300 .mu.m.

Abstract: Close-coupled atomization methods employing non-axisymmetric fluid flow geometries have demonstrated superior efficiency in the production of fine superalloy powder, such as, for example, nickel base superalloys compared to conventional close-coupled atomization utilizing an axisymmetric gas orifice and an axisymmetric melt nozzle. It is believed that the principal physical mechanisms leading to non-axisymmetric atomization system fine powder yield improvement are atomization plume spreading, the at least lessening of the melt pinch down at the interaction point between the atomization liquid and the liquid melt and improved melt film formation at the melt guide tube tip. The greatest fine powder yield improvement occurred when the non-axisymmetric atomization systems are operated with atomization parameters that result in the formation of multiple atomization plumes.

Abstract: A method for manufacturing hydrogen storage alloy particles comprises steps of obtaining a melt of the hydrogen storage alloy and pulverizing the hydrogen storage alloy by water atomizing process, whereby the melt is pulverized by contacting or colliding with high-speed jetting thereto to be dispersed in the form of solidified fine particles. By employing an aqueous solution of hypophosphorous acid or an alkali aqueous solution in place of water during the water atomizing process, or by etching the oxide films once formed on the surface of the hydrogen storage alloy particles with an aqueous solution of a strong acid, the thickness of the oxide film can be made thinner, and thus a high discharge capacity of a battery configured with a negative electrode comprising the alloy particles can be realized.

Abstract: Alloy powder which is low in price and is unlikely to be oxidized on the surface, and a dispersion-type conductor using the alloy powder in which electromigration is not likely to occur. Melt of copper and silver is cooled at a high cooling speed of 10.sup.5 .degree.C./s or higher. Alloy powder having a composition expressed by a chemical formula Cu.sub.x Ag.sub.1-x (where 0.80.ltoreq..times..ltoreq.0.99) is obtained. Also, a dispersion-type conductor is produced by dispersing 100 parts by weight of the alloy powder in between 5-100 parts by weight of a binder. Thus, the low-priced alloy powder and the dispersion-type conductor of high quality and high reliability can be obtained.

Abstract: Apparatus and method for making powder from a metallic melt by atomizing the melt to form droplets and reacting the droplets downstream of the atomizing location with a reactive gas. The droplets are reacted with the gas at a temperature where a solidified exterior surface is formed thereon and where a protective refractory barrier layer (reaction layer) is formed whose penetration into the droplets is limited by the presence of the solidified surface so as to avoid selective reduction of key reactive alloyants needed to achieve desired powder end use properties. The barrier layer protects the reactive powder particles from environmental constituents such as air and water in the liquid or vapor form during subsequent fabrication of the powder to end-use shapes and during use in the intended service environment.

Abstract: A dispersion-strengthened copper alloy is disclosed having an exceptional combination of strength, ductility, and thermal conductivity. The copper alloy comprises: copper, 0.01 to 2.0 weight % boron and 0.1 to 6.0 weight % cobalt, and cobalt-boride disperoids that range in size between 0.025 and 0.25 microns in diameter. A copper alloy is made by rapid solidification of the melt into a powder. Strong, thermally conductive articles can be made by compacting the powder at temperatures below the melting temperature of the copper alloy, and optionally warm working, cold working, and annealing.

Abstract: An apparatus and method for atomizing liquid metal are disclosed. A liquid metal supply is coupled to a nozzle for atomizing a stream of liquid metal in an atomizing zone extending from the nozzle. A viewing instrument provides a field of view extending to the atomization zone. A sensor coupled with the viewing instrument generates an image of the atomizing zone, and a control adjusts a flow rate of the stream responsive to the image.

Abstract: The invention relates to cobalt metal powders as a binder metal for the production of diamond and/or hard-metal tools and/or wear-resistant coatings and to composite sintered articles produced therefrom.

Abstract: The invention provides a method of producing metal powders which is less likely permit variations in cooling rate, ensures rapid solidification at a great cooling rate and readily gives fine particles, and a production apparatus for the method. The method comprises injecting a cooling liquid into a cooling tubular body (1) along an inner peripheral surface thereof to form a cooling liquid layer (9) moving toward a cooling liquid discharge end of the tubular body (1) while swirling along the inner peripheral surface of the tubular body (1); supplying a molten metal (25) to a space (23) inside the cooling liquid layer (9); applying a gas jet (26) as directed toward the cooling liquid layer (9) to the molten metal (25) to divide the molten metal and supply the divided molten metal to the cooling liquid layer (9); and discharging the cooling liquid containing a metal powder solidified in the liquid layer (9) from the cooling liquid discharge end of the tubular body (1) to outside.

Abstract: A method for atomizing high temperature melts to achieve greater efficiency and smaller particle size is described. The method involves the employment of lower pressure gas coupled with an atomization nozzle larger than prior art structures. The atomization nozzle is part of a close coupled atomization structure having shallow depth dimension. The method allows atomization at melts with reduced likelihood of freeze off. The method reduces heat extraction from the melt while the melt is still contained in the atomization nozzle.

Abstract: A moly permalloy powder core (MPP core) to be used in SMPS (switching mode power supply) and DC converters is disclosed. Particularly, a process for manufacturing an MPP core forming powder and a process for manufacturing the MPP core using the MPP core forming powder are disclosed, in which the MPP core forming powder can be directly manufactured from melts. The process for manufacturing a powder for an MPP core (moly permalloy powder core) includes the steps of: melting an alloy composed of, in wt %, 1.6-4.0% of Mo, 78-83% of Ni, and the balance of Fe; and manufacturing a powder by spouting a fluid into the flow of the melts. As the Mpp core forming material is manufactured directly from the melts, the workability and productivity are improved, and the yield and the forming density can be also improved, as well as improving the frequency characteristics of the MPP core.

Abstract: Apparatus for close coupled atomization of melts of metals having high melting points with low superheats is taught. The atomization apparatus includes means for supplying melt to be atomized at the relatively low superheat, melt guide means for guiding the melt as a stream to an atomization zone and a gas supply and means for delivering the gas as a stream to the atomization zone where both the melt supply and gas supply to the atomization zone are in very close proximity. The melt supply has an inwardly tapered lower end disposed immediately above the atomization zone. The gas supply surrounds the melt guide tube and the gas is delivered as a jet against the melt emerging from the melt guide tube. The temperature of the gas impacting the end of the melt guide tube is very low because of the gas expansion.

Abstract: In order to develop a method for producing at least approximately ball-shaped metallic particles at least almost equal in diameter such that a greater yield of particles at least almost equal in diameter is achieved than in known methods, it is suggested that a continuous stream of liquid metal is acted on locally by compressional vibrations that thereby cross-sectional constrictions are formed in the stream at a distance from each other in longitudinal direction of the stream which lead to the dissection of the stream and that the segments of the dissected stream adopting a ball shape due to the surface tension of the liquid metal are cooled to solidify the liquid metal.

Abstract: A method of making quasicrystalline alloy particulates wherein an alloy is superheated and the melt is atomized to form generally spherical alloy particulates free of mechanical fracture and exhibiting a predominantly quasicrystalline in the atomized condition structure. The particulates can be plasma sprayed to form a coating or consolidated to form an article of manufacture.

Abstract: A method of producing continuous lengths of metallic strip comprises the steps of forming a spray of molten metal particles, causing the particles to be deposited onto a surface of a hollow receptor roll, rotating and internally heating the receptor roll to form continuous lengths of metallic strip, holding the deposited particles in contact with the receptor roll surface by means of a roll positioned immediately upstream of the knife in the direction of rotation of the receptor roll, and peeling from the receptor roll surface such continuous lengths of metallic strip by means of a knife positioned adjacent to or in contact with the receptor roll surface. Apparatus for performing this process is also disclosed.

Abstract: Apparatus and method for making powder from a metallic melt by atomizing the melt to form droplets and reacting the droplets downstream of the atomizing location with a reactive gas. The droplets are reacted with the gas at a temperature where a solidified exterior surface is formed thereon and where a protective refractory barrier layer (reaction layer) is formed whose penetration into the droplets is limited by the presence of the solidified surface so as to avoid selective reduction of key reactive alloyants needed to achieve desired powder end use properties. The barrier layer protects the reactive powder particles from environmental constituents such as air and water in the liquid or vapor form during subsequent fabrication of the powder to end-use shapes and during use in the intended service environment.

Abstract: A metallic melt is atomized using a high pressure atomizing gas wherein the temperature of the melt and the composition of the atomizing gas are selected such that the gas and melt react in the atomization spray zone to form a refractory or intermetallic compound in the as-atomized powder particles.A metallic melt is also atomized using a high pressure atomizing gas mixture gas wherein the temperature of the melt and the ratio of a reactive gas to a carrier gas are selected to form powder particles comprising a supersaturated solid solution of the atomic species of the reactive gas in the particles. The powder particles are then heat treated to precipitate dispersoids in-situ therein to form a dispersion strengthened material.

Abstract: A multi-component composition suitable for amalgamation with mercury to form a dental amalgam, an amalgam and a method for producing such a multi-component composition. The multi-component composition has: from 30 to 90% (by weight) of a first component containing at least 30% silver, at least 20% tin and at least 10% copper; from 10 to 70% (by weight) of a second component containing at least 30% silver, at least 20% tin and at least 10% copper; and up to 15% (by weight) of a third component containing silver and/or alloy powder containing at least 80% (by weight) silver. The first component is spherically shaped atomized alloy powder. The second component is mechanically worked atomized alloy powder. The surface area to volume ratio of the powder of the second component is greater than the surface area to volume ratio of the powder of the first component.

Abstract: A flat-shaped fine Fe-Ni alloy powder suitable for use as a magnetic shield coating material for cards or the like. The powder has a mean particle size of 0.1 to 30 .mu.m, a mean thickness not greater than 2 .mu.m and a coercive force not greater than 400 A/m. The flat-shaped fine powder is produced by preparing an Fe-Ni alloy powder of a composition which exhibits, in a bulk state, a saturated magnetostriction constant value falling within the range of .+-.15.times.10.sup.-6 and which contains, by weight, 70 to 83% Ni, 2 to 6% Mo, 3 to 6% Cu, 1 to 2% Mn, not more than 0.05% C and the balance Fe and incidental impurities, pulverizing the alloy powder by an attrition mill, and annealing the pulverized powder in a fluidized or moving state in a substantially non-oxidizing atmosphere.

Abstract: A cooling liquid is injected into and supplied to a cooling tubular body along its inner periphery to form a cooling liquid layer flowing down the inner peripheral surface of the body while revolving. A molten metal is then injected into the cooling liquid layer from the inner peripheral side thereof to divide, rapidly cool and solidify the stream of molten metal with the cooling liquid layer and obtain a metal powder. Since the metal powder is continuously obtained upon flowing down the tubular body along with the cooling liquid, the liquid can be continuously removed from the powder by suitable means, and the power can be subsequently dried continuously.

Abstract: A method and apparatus for atomizing liquid metal are disclosed. A vessel supplies liquid metal through a pouring channel to an atomizing nozzle. A flow sensor provides at least one gas flow into the liquid metal, and determines a pressure difference from the gas flow. A processor determines the liquid metal flow rate through the nozzle from the pressure difference. A control adjusts the liquid metal flow rate in response to the determined liquid metal flow rate, and the liquid metal is atomized.

Abstract: Apparatus for producing metal powders by atomization, the apparatus including melting means for melting the material to be atomized, an atomizing enclosure in which a dispersion head rotating at high speed is disposed to scatter the molten material in atomized form, means for cooling the atomized material and the head, and means for collecting the cooled powder material obtained in this way, said melting means including at least one vertical inductive plasma furnace producing an envelope of plasma-generating gases containing the top face of the dispersion head, and said cooling means comprising both a first series of members for dispensing a cooling fluid disposed in the top portion of the atomizing enclosure to create a cold zone at the periphery of the envelope, and a second series of members for circulating a cooling fluid disposed in the bottom portion of the enclosure to create a cold zone at the bottom face of the head.

Abstract: There is disclosed a molten metal-atomizing apparatus which prevents the formation of a blocking in an ultra-high pressure atomizing of molten metal, and can produce finer metal powder. A vertical distance from the position of occurrence of a primary atomizing effect to a lower end of a jet injection port of a nozzle is 40% to 85% of a vertical distance from the lower end of the injection port to the position of intersection of jets.

Abstract: A method and apparatus for forming a stream of molten material. The apparatus includes a melt container having a bottom wall in which is formed an aperture. A funnel is adapted and constructed to receive molten material from the aperture in the container, and includes a plurality of fluid-cooled metallic segments. The funnel segments define an inner funnel contour that decreases in cross-sectional area from the inlet end to the outlet end of the funnel. An electrically conductive coil surrounds the funnel, and has a shape corresponding to the outer shape of said funnel. A source of medium-frequency current in selective electrical connection with the coil. The method begins with the step of providing a predetermined quantity of molten material in a melt container. A metallic funnel is provided in fluid communication with the melt container, and includes a plurality of fluid-cooled funnel segments. The method also includes the step of providing an electrically conductive coil surrounding the funnel.

Abstract: A process and apparatus for producing a spray of atomized metal droplets includes providing an apparatus that forms a spray of molten metal droplets, the apparatus including a metal source and a metal stream atomizer, producing a stream of liquid metal from the metal source, and atomizing the stream of liquid metal with the metal stream atomizer to form the spray of molten metal droplets. A controlled spray of atomized metal droplets is achieved by selectively varying the temperature of the droplets in the spray of molten metal droplets, the step of selectively varying including the step of varying the flow rate of metal produced by the metal source, responsive to a command signal, and sensing the operation of the apparatus and generating the command signal indicative of the operation of the apparatus. The step of atomizing may be accomplished by directing a flow of an atomizing gas at the stream of liquid metal, and then selectively controlling the flow rate of the atomizing gas.

Abstract: A process for producing charged uniformly sized metal droplets in which a quantity of metal is placed in a container and liquified, the container having a plurality of orifices to permit passage of the liquified metal therethrough. The liquified metal is vibrated in the container. The vibrating liquified metal is forced through the orifices, the vibration causing the liquified metal to form uniformly sized metal droplets. A charge is placed on the liquified metal either when it is in the container or after the liquified metal exits the container, the charging thereof causing the droplets to maintain their uniform size. The uniformly sized droplets can be used to coat a substrate with the liquified metal.

Abstract: Metal and metal alloy preforms having closed cell, spherical porosity are spray formed at high deposition rates by introducing blowing agents into the thixotropic semisolid deposition layer, within which gas formed in thermal decomposition reactions are trapped. Density reductions of nearly 30% were generated in a phosphor bronze matrix, using barium carbonate as the blowing agent. Hollow glass particles were produced in the same matrix alloy by injection of microsphere precursor frit containing sulfur. A simple Newtonian heat transfer model of agent heating in the spray predicts agent/matrix compatibility. Along with modest improvements in damping capacity, tensile and compressive properties were found to be equal or superior to powder metallurgy product at the same porosity levels.

Abstract: The present invention produces a cold gas stream having a constant temperature and pressure. The gas stream is obtained from two initial streams, one being a liquefied gas and the other being a gas at ambient temperature. The liquefied gas stream is combined with the warm gas stream, causing the liquid to vaporize. The two streams are combined in proportions that yield a cold gas mixture having a desired temperature. The resulting cold gas mixture is directed into an insulated container having a volume significantly larger than the volume of the conduits through which the streams flow. The container therefore acts as a buffer to reduce pressure fluctuations in the stream. A temperature equalization coil is located in the interior of the container. The coil has one open end which communicates with the interior region of the container, the other end of the coil being connected to an outlet line.

Abstract: An apparatus for viewing the atomization of liquid metal is disclosed. A nozzle for atomizing liquid metal having a cylindrical plenum, and a melt guide tube extending axially therethrough to a melt exit orifice. The plenum defines an inner chamber coupled with an atomizing gas orifice spaced from the exit orifice and configured to provide an annular jet of atomizing gas converging in an atomizing zone extending below the exit orifice The plenum having an inner sidewall and an outer sidewall defining the inner chamber therebetween. The inner sidewall extends below the exit orifice so that the inner sidewall is spaced from the atomizing zone. A cylindrical sleeve extends through the outer sidewall to a first end in the inner chamber. A camera mounted in the sleeve has a field of view extending from the first end. A transparent window is mounted to seal the first end. The sleeve is positioned so the field of view extends through the atomization zone.

Abstract: A method for making an isotropic permanent magnet comprises atomizing a melt of a rare earth-transition metal alloy (e.g., an Nd--Fe--B alloy enriched in Nd and B) under conditions to produce protectively coated, rapidly solidified, generally spherical alloy particles wherein a majority of the particles are produced/size classified within a given size fraction (e.g., 5 to 40 microns diameter) exhibiting optimum as-atomized magnetic properties and subjecting the particles to concurrent elevated temperature and elevated isotropic pressure for a time effective to yield a densified, magnetically isotropic magnet compact having enhanced magnetic properties and mechanical properties.

Abstract: Prealloyed high-vanadium, cold work tool steel particles are provided for use in the powder-metallurgy production of tool steel articles. The particles are of a cold work tool steel alloy having an MC-type vanadium carbide dispersion of a carbide particle size substantially entirely less than 6 microns and in an amount of 18.5 to 34.0% by volume. The particles are produced by atomizing a molten tool steel alloy at a temperature above 2910.degree. F. and rapidly cooling the atomized alloy to form solidified particles therefrom. The particles have the MC-type vanadium carbide dispersion therein.

Abstract: A method of manufacture of a net form product, including directing a stream of liquid from a nozzle onto a collector of the shape of the desired product, applying an amplitude and time dependent modulated disturbance to the stream to produce a droplet stream, and with the nozzle and collector in a chamber, controlling the chamber environment. An apparatus for manufacturing a net form product having a source of molten material under pressure, a support for positioning a product collector in a chamber with the collector defining a desired product, a droplet stream generator positioned within the chamber and including a nozzle, a conduit for conducting molten material from the material source to the generator nozzle, a mechanism, typically a modulator, for amplitude and time dependent modulation disturbance of the droplet stream, and a drive mechanism for relative movement of the nozzle and support.

Abstract: A method for atomizing a titanium-based material to particulates in a controlled atmosphere. In the method, titanium is skull melted in a crucible. The molten titanium-based material is transferred to a heated tundish. The molten titanium-based material may be stabilized in the heated tundish and then formed into a free-falling stream. The free-falling stream of the molten titanium-based material is impinged with an inert gas jet to atomize the molten titanium-based material. The method also includes cooling the atomized titanium-based material, and collecting the cooled atomized titanium-based material.

Abstract: A process is described for the preparation of an aluminum-strontium master alloy suitable for use as structure refiner during the solidification of molten aluminum-silicon alloys, comprising atomizing a stream of molten alloy containing aluminum and 5 to 35% by weight of strontium and collecting atomized particles as solid material on a collecting surface.

Abstract: An apparatus for making metal powders has a supply tank (2) for the molten starting material, at least one exchangeable pouring funnel (11, 13), at least one atomizing nozzle (12, 14) and at least one fall shaft (7) disposed thereunder for the solidification of the metal powder product. A chamber (1) enveloping the supply tank and the pouring funnel is disposed on the fall shaft (7). To be able more easily to change the pouring funnel or funnels, the chamber (1) has in the area of the pouring funnel a closable lateral opening (15), at which a lock chamber (16) for the introduction of the at least one pouring funnel (11, 13) is placed. A car (24) is held on tracks (18, 19) and can be driven into the chamber (1) and fully retracted into the lock chamber (16), and on its bottom is fastened a number of atomizing nozzles (12, 14) corresponding to the number of the pouring funnels (11, 13). The pouring funnels (11, 13) can be set downwardly onto the cars.

Abstract: Apparatus for the production of powders or spray deposits is provided in which a metal or metal alloy stream is broken up into atomized droplets by primary jets of atomizing gas. In order to remove further heat from the atomized droplets, secondary jets are positioned adjacent the primary jets for directing cooling fluid in the form of cryogenic liquified gas at the atomized droplets. The apparatus permits the formation of coarser powders, powders from alloys with a wide solidus/liquidus gap in a shorter atomizing chamber, or spray deposits with increased yield of deposited material.

Abstract: Method and apparatus for atomizing a liquid to form a fine powder. The method includes the steps of mixing the liquid with a first fluid medium jet and projecting this first fluid medium jet into a barrier means which comprises a solid body or a second fluid medium jet projected by a nozzle in a direction substantially opposite to the first fluid medium jet. The first fluid medium jet containing fine particles diverges away from the barrier means, thus increasing contact surface between the first fluid medium jet and the liquid and increasing the intermixing therebetween.

Abstract: To manufacture spherical particles out of liquid phase with a narrow grain spectrum using melting temperatures of up to 1500.degree. C. by generating droplets by means of vibrating nozzles, the liquid phase, the nozzle and the drop distance for the droplets are maintained at a constant temperature of 1.degree. to 10.degree. C. above the melting temperature of the liquid phase until the spherical shape of the falling droplets has stabilized. The particles must then be abruptly chilled.

Abstract: A process for producing salt free titanium powder by reacting zinc and a titanium halide in the presence of a reducing agent to form a solid zinc titanium product. Titanium halide vapor is introduced into a liquid alloy of zinc and the reducing agent at a temperature between 650.degree.-907.degree. C. The titanium halide is introduced beyond the titanium solubility limit in zinc to precipitate a zinc titanium intermetallic compound and also produce a liquid halide salt. The intermetallic compound forms and accumulates at an interface between the salt and liquid alloy. The compound is periodically removed from the interface, crushed into a powder, and the zinc is evaporatively separated from the titanium to produce pure titanium powder. The process preferably occurs above the peritectic decomposition temperature of Zn.sub.3 Ti, and most preferably above the peritectic decomposition temperature of Zn.sub.2 Ti, to maximize the titanium content of the resulting product.

Abstract: A process and apparatus for producing a spray of atomized metal droplets includes providing an apparatus that forms a spray of molten metal droplets, the apparatus including a metal source and a metal stream atomizer, producing a stream of liquid metal from the metal source, and atomizing the stream of liquid metal with the metal stream atomizer to form the spray of molten metal droplets. A controlled spray of atomized metal droplets is achieved by selectively varying the temperature of the droplets in the spray of molten metal droplets, the step of selectively varying including the step of varying the flow rate of metal produced by the metal source, responsive to a command signal, and sensing the operation of the apparatus and generating the command signal indicative of the operation of the apparatus. The step of atomizing may be accomplished by directing a flow of an atomizing gas at the stream of liquid metal, and then selectively controlling the flow rate of the atomizing gas.

Abstract: Apparatus and a method for producing submicron and smaller metal alloy pacles using a main chamber having a longitudinal axis and a feeder for introducing a quantity of molten alloy under pulsed gas pressure in a direction generally radial to the axis. The feeder has a gas stream for forming metal droplets from said alloy. A gas accelerator directs axially flowing gas against the droplets from the feeder in the chamber. The accelerator directs the droplets in an axial direction to a substrate located along the axis and in the direction of flow from the accelerator to receive the droplets at a predetermined distance from the feeder, whereby the particles are produced.

Abstract: Techniques for producing fine metal powder are described, including producing droplets of molten metal to be formed into a powder, providing an environment including a substance specifically introduced for combining with the droplets, and submitting the droplets to the environment for combining the introduced substance with the droplet metal to form at least a partial coating on the powder including the introduced substance.

Abstract: There is provided a method of spray deposition in which a stream of liquid metal or metal alloy is atomized inside a spray chamber into a spray of atomized droplets. A metal or metal alloy collector is rotated about an axis transverse to the mean axis of the spray and in the path of the spray so that a deposit is formed about the collector with a bond between the deposit and the collector sufficient to isolate the interface from oxygen penetration. The collector is then retained as an integral part of the final product and further processed to substantially eliminate porosity in the region of the bonded interface. The collector and the deposit may be the same or different materials, and the bond between the deposit and the collector is preferably enhanced by plasma heating in the region disposition. The invention also provides a plant for carrying out the preferred method arc plasma heating.

Abstract: This invention describes a process for producing copper alloys by rapid sdification in order to improve their strength and thermal stability after being exposed to elevated temperatures. The method used to rapidly solidify the molten alloy is either by use of a high pressure non-oxidizing gas spray to atomize the molten alloy into a powder or to pour the molten alloy onto a rotating wheel to form a ribbon which is then attrited into powder. The powder is canned, compacted to full density and cold worked to the desired shape.