Process for producing metals and metal alloys using mixing cold hearth

1. A process for producing metals and metal alloys comprising:

providing a mixing cold hearth having a melting cavity configured to hold a raw material for melting into a molten metal, an induction coil configured to generate an electromagnetic field for stirring and heating the raw material in the melting cavity into the molten metal, and a mechanical drive configured to move the mixing cold hearth for mixing the raw material in the melting cavity;

feeding the raw material into the melting cavity;

heating the raw material in the melting cavity;

stirring the raw material during the heating step using the electromagnetic field;

moving the mixing cold hearth during the heating step using the mechanical drive;

providing an electrically conductive atomization die having an orifice for receiving the molten metal from the mixing cold hearth, and an induction coil configured to generate a magnetic field for interacting with the molten metal to generate a metal powder having a desired shape and particle size, and an atomization tower configured to receive and cool the metal powder;

transferring the molten metal from the mixing cold hearth to the atomization die; and

atomizing the molten metal using the atomization die while generating the magnetic field.

2. The process of claim 1 wherein the moving step includes both oscillatory movement and rotational movement of the mixing cold hearth.

3. The process of claim 1 further comprising providing a heat removal system having a plurality of fluid cooled tiles configured to provide adjustable insulation for the molten metal; and controlling a temperature within the melting cavity using the heat removal system.

4. The process of claim 1 wherein the atomization die comprises a removable element of an assembly of interchangeable atomization dies.

5. A process for producing metals and metal alloys comprising:

providing a mixing cold hearth having a melting cavity configured to hold a raw material for melting into a molten metal, an induction coil configured to generate an electromagnetic field for stirring and heating the raw material in the melting cavity into the molten metal, and a mechanical drive configured to move the mixing cold hearth for mixing the raw material in the melting cavity;

feeding the raw material into the melting cavity;

heating the raw material in the melting cavity;

stirring the raw material during the heating step using the electromagnetic field;

providing a fluid cooled mold configured to receive the molten metal from the mixing cold hearth, a fluid cooled roll caster assembly configured to cool the molten metal into a solidified shape, and a moveable dovetail configured to adjust a size of the solidified shape;

transferring the molten metal from the mixing cold hearth to the mold;

cooling the molten metal in the mold using the roll caster assembly; and

adjusting the size of the solidified shape using the dovetail.

6. The process of claim 5 wherein the roll caster assembly comprises a removable element of an assembly of interchangeable roll caster assemblies.

7. The process of claim 5 wherein the mixing cold hearth comprises a removable element of an assembly of interchangeable mixing cold hearths.

8. The process of claim 5 further comprising providing a skull in the melting cavity containing selected alloys, and rotating the mixing cold hearth during the heating step to at least partially melt the skull and incorporate the selected alloys into the molten metal.

9. A process for producing metals and metal alloys comprising:

providing a plurality of fluid cooled mixing cold hearths as an assembly of interchangeable mixing cold hearths, with each mixing cold hearth of the assembly having a melting cavity configured to hold a raw material for melting into a molten metal, and a mechanical drive configured to move the mixing cold hearth for mixing the raw material in the melting cavity;

selecting a particular mixing cold hearth;

feeding the raw material into the melting cavity of the particular mixing cold hearth;

heating the raw material in the melting cavity of the particular mixing cold hearth using a heat source; and

oscillating and rotating the particular mixing cold hearth during the heating step using the mechanical drive.

10. The process of claim 9 further comprising providing a skull in the melting cavity containing selected alloys, and at least partially melting the skull during the heating step to incorporate the selected alloys into the molten metal.

11. The process of claim 9 further comprising providing a plurality of interchangeable atomization dies configured to atomize the molten metal as removable elements of an assembly, and selecting a particular atomization die of the assembly; and atomizing the molten metal using the particular atomization die.

12. The process of claim 9 further comprising providing a plurality of interchangeable roll caster assemblies configured to cool and shape the molten metal as removable elements of an assembly, with each roll caster assembly of the assembly configured for cooling and shaping a specific category of raw materials into a solidified shape; selecting a particular roll caster assemblies of the assembly; and cooling and shaping the molten metal using the particular roll caster assembly.