Manufacturing and applications of metal powders and alloys

1. A process to reduce mixtures of at least one metal halide by molten metal reduction of the liquid phase of a metal halide in an alkali or alkaline earth metal to form a reaction product comprising at least one metal mixture and a halide salt coating,

wherein the molten metal reductant is in stoichiometric excess to the metal halide, and wherein the reductant is consumed in the reaction and does not need to be removed at the end of the reaction;

wherein the at least one metal halide mixture comprises a mixture of metal chlorides and the molten metal reductant comprises metallic sodium; and

wherein the reaction temperature is selected from the group consisting of:

(a) a reaction temperature of 275° C., wherein the particle size of the reaction product primary particle size ranges from 10 to 50 nm, and wherein the aggregate particle sizes range from 0.2 to 1 micron;

(b) a reaction temperature of 550° C. and the particle size of the reaction product primary particle size ranges from 20 to 100 nm, and wherein the aggregate particle sizes range from 0.4 to 5 microns; and

(c) a reaction temperature is 775° C. and the particle size of the reaction product primary particle size ranges from 50 to 500 nm, and wherein the aggregate particle sizes range from 0.6 to 25 microns.

2. The process of claim 1 wherein the sodium in the molten metal reductant is obtained from NaK.

3. The process of claim 2 wherein the reaction temperature is 275° C. and the particle size of the reaction product primary particles ranges from 10 to 50 nm.

4. The process of claim 2 wherein the reaction temperature is 550° C. and the particle size of the reaction product primary particles range from 20 to 100 nm.

5. The process of claim 2 wherein the reaction temperature is 775° C. and the particle size of the reaction product primary particles range from 50 to 500 nm.