Process for producing free flowing powder and product

Claim 1

Process for producing a free flowing flame spray powder consisting essentially of substantially spherical particles of an inorganic material having a melting point above 500°C; the particles having an apparent density of at least 40 percent of the theoretical density of the material, a particle size distribution within the range of about 60 micrometers, substantially smooth non-porous surfaces and a Hall flow within the range of from about 9 to 21 seconds; the process comprising: a. entraining powder particles in a carrier gas, said particles consisting essentially of agglomerates of a finely divided particulate of the inorganic material, the agglomerates having a size range of 60 micrometers and 80 percent of the agglomerates having a size range of 30 micrometers, b. feeding the entrained particles through a high temperature reactor having a temperature above the melting point of the highest melting component of the powder material, at a feed rate sufficient to result in the melting of at least the outer surfaces of a substantial portion of the particles, and c. cooling the at least partially melted particle to solidify at least the outer surfaces of the particles prior to their contact with a solid surface or with each other.