METAL POWDER ATOMIZATION MANUFACTURING PROCESSES
There are provided reactive metal powder atomization manufacturing processes. For example, such processes include providing a heated metal source and contact the heated metal source with at least one additive gas while carrying out the atomization process. Such processes provide raw reactive metal powder having improved flowability. The at least one additive gas can be mixed together with an atomization gas to obtain an atomization mixture, and the heated metal source can be contacted with the atomization mixture while carrying out the atomization process. Reactive metal powder spheroidization manufacturing processes are also provided.
1 - 188 . (canceled)
189 . A reactive metal powder atomization manufacturing process comprising:
atomizing a heated reactive metal source to produce a raw reactive metal powder, wherein atomizing the heated reactive metal source comprises contacting the heated reactive metal source with an atomizing gas, wherein the atomizing gas is at a greater temperature than the heated reactive metal source;
mixing an additive gas with a non-additive gas to dilute the additive gas; and
exposing the raw reactive metal powder to the diluted additive gas within an atomization zone to impart a component from the additive gas on particles of the raw reactive metal powder and maintain a chemical composition of the raw reactive metal powder, the raw reactive metal powder comprises a powder having a particle size distribution of 10 to 53 μm having a flowability less than 40 s, measured according to ASTM B213.
190 . The reactive metal powder atomization manufacturing process of claim 189 , wherein exposing the raw reactive metal powder comprises exposing the raw reactive metal powder to the diluted additive gas within the atomization zone.
191 . The reactive metal powder atomization manufacturing process of claim 189 , wherein the non-additive gas is the atomizing gas.
192 . The reactive metal powder atomization manufacturing process of claim 189 , wherein the non-additive gas is a sheath gas.
193 . The reactive metal powder atomization manufacturing process of claim 189 , wherein mixing the additive gas with the non-additive gas to dilute the additive gas comprises maintaining a concentration of the additive gas at a concentration of 80 parts per million (ppm) or less within the atomization zone.
194 . The reactive metal powder atomization manufacturing process of claim 193 , wherein mixing the additive gas with the non-additive gas to dilute the additive gas further comprises maintaining the concentration of the additive gas at a concentration of at least 50 parts per million (ppm).
195 . The reactive metal powder atomization manufacturing process of claim 189 , wherein the heated reactive metal source is a titanium or titanium alloy, and wherein the additive gas comprises an oxygen-containing gas, and wherein maintaining the chemical composition of the raw reactive metal powder comprises maintaining the oxygen within the raw reactive metal powder below 1800 ppm according to AMS 4998.
196 . The reactive metal powder atomization manufacturing process of claim 195 , wherein the particles are Ti-6Al-4V particles.
197 . The reactive metal powder atomization manufacturing process of claim 189 , wherein the particles are Ti-6Al-4V particles, wherein the additive gas contains nitrogen, and wherein maintaining the chemical composition of the raw reactive metal powder comprises maintaining the nitrogen within the raw reactive metal powder below 400 ppm according to AMS 4998.
198 . The reactive metal powder atomization manufacturing process of claim 189 , wherein the particles are Ti-6Al-4V particles, wherein the additive gas contains carbon, and wherein maintaining the chemical composition of the raw reactive metal powder comprises maintaining the carbon within the raw reactive metal powder below 1000 ppm according to AMS 4998.
199 . The reactive metal powder atomization manufacturing process of claim 189 , wherein the particles are Ti-6Al-4V particles, wherein the additive gas contains hydrogen, and wherein maintaining the chemical composition of the raw reactive metal powder comprises maintaining the hydrogen within the raw reactive metal powder below 120 ppm according to AMS 4998.
200 . The reactive metal powder atomization manufacturing process of claim 189 , wherein the particles are Ti-6Al-4V particles, wherein the additive gas contains chlorine, and wherein maintaining the chemical composition of the raw reactive metal powder comprises maintaining the chlorine within the raw reactive metal powder below 1000 ppm according to AMS 4998.
201 . The reactive metal powder atomization manufacturing process of claim 189 , wherein the raw reactive metal powder comprises a powder having a particle size distribution of 25 to 45 μm having a flowability less than 40 s, measured according to ASTM B213.
202 . The reactive metal powder atomization manufacturing process of claim 189 , wherein the raw reactive metal powder has a flowability less than 30 s, measured according to ASTM B213.
203 . The reactive metal powder atomization manufacturing process of claim 189 , wherein the raw reactive metal powder has a flowability less than 28 s, measured according to ASTM B213.
204 . The reactive metal powder atomization manufacturing process of claim 189 , wherein the atomizing gas is provided from at least one plasma source.