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 comprising:
a raw reactive metal powder of Ti-6Al-4V particles, each of the Ti-6Al-4V particles comprising a diffused component beneath a surface of a respective Ti-6Al-4V particle of the Ti-6Al-4V particles, the diffused component imparted from an additive gas during an atomization process, wherein a flowability of the raw reactive metal powder is less than 40 s, measured according to ASTM B213; and
wherein the raw reactive metal powder displays an improved visual compaction characteristic compared to raw reactive metal powder of Ti-6Al-4V particles formed by an atomization process without the additive gas.
190 . The reactive metal powder of claim 189 , wherein a concentration profile for the diffused component is such that a flowability of the raw reactive metal powder is less than 40 s, measured according to ASTM B213.
191 . The reactive metal powder of claim 190 , wherein the concentration profile for the diffused component defines a maximum concentration at a first depth and decreasing to 50% of the maximum concentration at a diffusion depth deeper than the first depth.
192 . The reactive metal powder of claim 191 , wherein the first depth is greater than 5 nm.
193 . The reactive metal powder of claim 189 , wherein the additive gas is air, and the diffused component is oxygen.
194 . The reactive metal powder of claim 189 , wherein the additive gas is O 2 , and the diffused component is oxygen.
195 . The reactive metal powder of claim 189 , wherein the diffused component contains oxygen, and wherein the raw reactive metal powder comprises less than 1800 ppm of oxygen according to AMS 4998.
196 . The reactive metal powder of claim 189 , wherein the diffused component contains nitrogen, and wherein the raw reactive metal powder comprises less than 400 ppm of nitrogen according to AMS 4998.
197 . The reactive metal powder of claim 189 , wherein the diffused component contains carbon, and wherein the raw reactive metal powder comprises less than 1000 ppm of carbon according to AMS 4998.
198 . The reactive metal powder of claim 189 , wherein the diffused component contains hydrogen, and wherein the raw reactive metal powder comprises less than 120 ppm of hydrogen according to AMS 4998.
199 . The reactive metal powder of claim 189 , wherein the diffused component contains chlorine, and wherein the raw reactive metal powder comprises less than 1000 ppm of chlorine according to AMS 4998.
200 . The reactive metal powder 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.
201 . The reactive metal powder 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 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 of claim 189 , wherein the raw reactive metal powder has a flowability less than 28 s, measured according to ASTM B213.