Abstract: There are provided high melting point metal or alloy powder atomization manufacturing processes comprising providing a melt of the high melting point metal or alloy through a feed tube; diverting the melt at a diverting angle with respect to a central axis of the feed tube to obtain a diverted melt; directing the diverted melt to an atomization area; and providing at least one atomization gas stream to the atomization area. The atomization process can be carried out in the presence of water within an atomization chamber used for the atomization process.

Abstract: The invention relates to an apparatus and a process for granulating a metal melt. The apparatus substantially comprises a round water tank, into which water is injected in a tangential direction with the aid of a number of nozzles, so that the water in the tank rotates and forms a parabolic surface. The nozzles are arranged such that they are distributed in height and around the circumference of the tank wall. The uppermost nozzle is located in the region of the surface of the water and produces a stream of water or fan of water lying in the surface of the water. For granulating a metal melt, it is poured continuously from a melting crucible into the stream of water or fan of water of the uppermost nozzle.

Abstract: Multicomponent nanoparticles materials and apparatuses and processes therefor are disclosed. In one aspect of the disclosure, separate particles generated from solution or suspension or by flame synthesis or flame spray pyrolysis, and the resultant particles are mixed in chamber prior to collection or deposition. In another aspect of the disclosure, nanoparticles are synthesized in stagnation or Bunsen flames and allowed to deposit by thermophoresis on a moving substrate. These techniques are scalable allowing mass production of multicomponent nanoparticles materials and films. The foregoing techniques can be used to prepare composites and component devices comprising one or more lithium based particles intimately mixed with carbon particles.

Abstract: A solidified mass for a high-purity multicrystal silicon material that is preferably applicable to producing crystal type silicon ingots for photo voltaics, and a process for producing the solidified mass are provided. The mass of silicon solidified from molten state is a solidified mass produced by dropping molten silicon into a receiving vessel and allowing the vessel to receive the molten silicon, said solidified mass containing bubbles and having (i) an apparent density of not less than 1.5 g/cm3 and not more than 2.2 g/cm3 and (ii) a compressive strength of not less than 5 MPa and not more than 50 MPa. The process for producing a mass of silicon solidified from molten state includes the steps of dropping molten silicon into a receiving vessel and allowing the vessel to receive the molten silicon, wherein the surface temperature of the vessel for receiving the molten silicon is not lower than 0° C. and not higher than 1000° C.

Abstract: Systems and methods are presented for producing shot from molten material, in which two or more sprays of inert gas, such as an upper or primary spray followed by one or more lower or secondary sprays, are used to break apart large molten droplets into shot as the molten material is dropped from a crucible orifice. The upper or primary gas feed in one application acts to initially break the stream or droplets into initial droplets of a lesser size or to flatten the droplets, with the second spray then breaking up the intermediate droplets into yet smaller shot particles to be cooled and collected.

Abstract: Metal-carbon composite powders and methods for producing metal-carbon composite powders. The powders have a well-controlled microstructure and morphology and preferably have a small average particle size. The method includes forming the particles from an aerosol of powder precursors. The invention also includes novel devices and products formed from the composite powders.

Abstract: A crucible is formed of a cylindrical body member and a disk-shaped nozzle member fitted to the bottom portion of the body member, and the nozzle member is provided with a nozzle hole for discharging out a semiconductor molten solution dropwise therethrough. The semiconductor molten solution drops discharged out of the crucible through the nozzle hole are cooled and solidified during falling to become semiconductor grains. Silicon grains having high crystal quality can be manufactured at low cost.

Abstract: Metal-carbon composite powders and methods for producing metal-carbon composite powders. The powders have a well-controlled microstructure and morphology and preferably have a small average particle size. The method includes forming the particles from an aerosol of powder precursors. The invention also includes novel devices and products formed from the composite powders.

Abstract: A soldering ball fabrication method includes the steps of: (1) drawing a metal wire rod into the desired thickness, (2) cutting the metal wire thus obtained into pieces subject to the desired length, (3) washing the pieces of metal wire to remove dust, (4) processing the pieces of metal wire into balls, (5) washing the balls thus obtained, (6) using a screen to select the balls, (7) inspecting selected balls, and (8) obtaining approved soldering balls.

Abstract: The present invention relates to a method for preparing metal powder by means of blowing a cooling liquid toward a flowing down melt metal flow characterized that the cooling liquid is successively discharged downwardly from an annular nozzle toward the melt metal flow for surrounding it in the form of a hyperboloid of one sheet, wherein the annular nozzle is provided with a hole through which the melt metal flow may pass, and that the hyperboloid of one sheet has a pressure reduced by 50˜750 mmHg at the neighborhood of the constricted part inside the hyperboloid of one sheet. According to the present invention, there may be prepared fine and sherical metal powder which has a narrow range of a particle size distribution.

Abstract: An apparatus and a method for producing single crystal semiconductor particulate in near spherical shape and the particulate product so formed is accomplished by producing uniform, monosized, near spherical droplets; identifying the position of an undercooled droplet in a nucleation zone; and seeding the identified droplet in the nucleation zone to initiate single crystal growth in the droplet.

Abstract: The invention encompasses methods of utilizing atomization, methods for forming magnet powders, methods for forming magnets, and methods for forming bonded magnets. The invention further encompasses methods for simulating atomization conditions. In one aspect, the invention includes an atomization method for forming a magnet powder comprising: a) forming a melt comprising R.sub.2.1 Q.sub.13.9 B.sub.

Abstract: Provided are apparatus and method for the manufacture of metallic shot for use in shotguns. The apparatus and method fractionate molten shot material within a reservoir system. Subsequent descent of the molten shot material is controlled through a temperature-regulated environment producing shot of superior sphericity and uniformity.

Abstract: The present invention relates to a method for granulating a stream of molten metal which falls from a launder or the like, down into a liquid cooling bath contained in a tank. The metal stream divides into droplets in the liquid cooling bath and the droplets solidify and form solid granules. The cooling liquid has substantially uniform flow across the tank in a direction that is substantially perpendicular to the falling metal stream. The flow of cooling liquid has a velocity of less than 0.1 m/sec. The distance from the outlets of the launder to the surface of the liquid cooling bath is kept less than 100 times the diameter of the metal stream measured as the metal stream leaves the launder.

Abstract: Method for making hollow microspheres of substantially uniform diameter and of substantially uniform wall thickness is disclosed. The walls of the hollow microspheres comprise sintered together particles which define interconnecting voids within the walls and a single central cavity in the interior of the microspheres and inner and outer microsphere wall surfaces. The interconnecting voids are continuous and extend from the outer wall surface to the inner wall surface. The walls have substantially uniform void content and the interconnecting voids are substantially uniformly distributed in the walls of the hollow microspheres and the walls of the hollow microspheres are free of latent solid or liquid blowing gas materials and are substantially free of relatively thinned wall portions and bubbles. The method includes heating the microspheres for a sufficient period of time to close and seal the interconnecting void.

Abstract: A method and a device for manufacturing a powder of amorphous ceramic or metallic particles in a high pressure autoclave. The substance in the liquid state is pressed out of a nozzle (7) upwards in vertical direction. An acoustic levitation field acts on the area in front of the nozzle orifice (12) and an inert cooling gas is made to flow turbulently in this area so that the droplets sprayed out of the nozzle are rapidly cooled and get solidified to grains. The powder can be directly machined by pressing and sintering into objects of the desired shape.

Abstract: A crucible is formed of a cylindrical body member and a disk-shaped nozzle member fitted to the bottom portion of the body member, and the nozzle member is provided with a nozzle hole for discharging out a semiconductor molten solution dropwise therethrough. The semiconductor molten solution drops discharged out of the crucible through the nozzle hole are cooled and solidified during falling to become semiconductor grains. Silicon grains having high crystal quality can be manufactured at low cost.