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 said heated reactive metal source with an atomizing gas and an additive gas, wherein the atomizing gas is at a greater temperature than the heated reactive metal source;
imparting a component from the additive gas on particles of the raw reactive metal powder; and
controlling an amount of the additive gas contacting said heated reactive metal source during the atomizing of the heated reactive metal source to control an amount of the component from the additive gas imparted on the particles of the raw reactive metal powder.
190 . The reactive metal powder atomization manufacturing process of claim 189 , wherein controlling the amount of the additive gas contacting said heated reactive metal source during the atomizing of the heated reactive metal source comprises maintaining a concentration of additive gas in an atomization mixture at or below 80 ppm.
191 . The reactive metal powder atomization manufacturing process of claim 189 , wherein controlling the amount of the additive gas further comprises controlling the amount of additive gas as a function of an operating parameter of an atomization system.
192 . The reactive metal powder atomization manufacturing process of claim 189 , wherein controlling the amount of the additive gas further comprises controlling the amount of additive gas as a function of data indicative of a surface temperature of the particles.
193 . The reactive metal powder atomization manufacturing process of claim 189 , wherein controlling the amount of the additive gas contacting said heated reactive metal source during the atomizing of the heated reactive metal source comprises intermittently injecting the additive gas.
194 . The reactive metal powder atomization manufacturing process of claim 189 , wherein the heated reactive metal source is a titanium or titanium alloy, wherein the additive gas comprises an oxygen-containing gas, and wherein the oxygen within the raw reactive metal powder is below 1800 ppm according to AMS 4998.
195 . The reactive metal powder atomization manufacturing process of claim 194 , wherein the particles are Ti-6Al-4V particles.
196 . 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 the nitrogen within the raw reactive metal powder is below 400 ppm according to AMS 4998.
197 . 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 the carbon within the raw reactive metal powder is below 1000 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 hydrogen, and wherein the hydrogen within the raw reactive metal powder is below 120 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 chlorine, and wherein the chlorine within the raw reactive metal powder is below 1000 ppm according to AMS 4998.
200 . 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.
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 10 to 53 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 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.
203 . 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.
204 . 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.
205 . The reactive metal powder atomization manufacturing process of claim 189 , wherein the atomizing gas is provided from at least one plasma source.
206 . 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 said heated reactive metal source with an atomizing gas and an additive gas, wherein the atomizing gas is provided from at least one plasma source;
imparting a component from the additive gas on particles of the raw reactive metal powder; and
controlling an amount of the additive gas contacting said heated reactive metal source during the atomizing of the heated reactive metal source to control an amount of the component from the additive gas imparted on the particles of the raw reactive metal powder.