Group IVb transition metal based metal and processes for the production thereof

Claim 2

A powder metal comprising a Group IVb transition metal useful for powdered metallurgical applications characterized as having less than about 50/ppm by weight halide, an internal porosity of from about 10% to about 30% by volume, and the powder comprising angular shaped particles.

Claim 3

The powder metal of claim 1 wherein the transition metal is selected from the group consisting of titanium, hafnium and zirconium.

Claim 4

The powdered metal of claim 2 wherein the metal is titanium.

Claim 5

The powder metal of claim 3 wherein the metal is alloyed, by weight percent, with a least one of the following alloying agents: 0 to about 5% tin, 0 to about 10% vanadium, 0 to about 10% aluminum, 0 to about 5% zirconium, 0 to 5% molybdenum, 0 to about 10% silicon, 0 to about 10% iron, 0 to about 0.5% oxygen and mixtures thereof, the metal comprising at least 90% by weight titanium.

Claim 6

The powdered metal of claim 2 wherein the Group IVb transition metal is selected from the group consisting of hafnium and zirconium.

Claim 7

The powdered metal of claim 5 wherein the metal is alloyed, by weight percent, with at least one of the following alloying agents: 0 to about 3% tin, 0 to about 0.40% iron, 0 to about 0.02% chromium, 0 to about 0.01% nickel, 0 to about 10% niobium, 0 to about 0.5% oxygen and mixtures thereof; the metal comprising at least 90% by weight hafnium or zirconium.

Claim 8

The powder metal of claim 1 wherein the metal has less than about 10 PPM by weight halide and the powder has an internal porosity of about 10% to about 20%.

Claim 9

The powder metal of claim 1 wherein the metal has less than about 2500 PPM by weight oxygen, less than about weight n and less than about 400 PPM by weight nitrogen and less than about 800 PPM by weight carbon.

Claim 10

The powder metal of claim 1 wherein the metal has less than about 50 PPM by weight oxygen, less than about 90 PPM by weight nitrogen, and less than about 150 PPM by weight carbon.

Claim 11

The powder metal of claim 9 wherein the metal has less than about 10 PPM by weight halide.

Claim 12

Passified Group IVb transition metal-based metal particles which are substantially free of halides, hydrogen, oxygen, nitrogen and carbon, and which are suitable for powder metallurgy usage, prepared from a Group IVb transition metal-zinc alloy by: (a) heating a Group IVb transition metal-zinc alloy, which is substantially free of halides, at a temperature between about 500° and about 1150° C. under conditions operative to vaporize and separate zinc therefrom and to produce Group IVb transition metal values which are substantially free of zinc and halide; (b) heating said transition metal values to, or maintaining said transition metal values at, a sintering temperature between about 850° and about 1250° C. under conditions operative to sinter said transition metal values; (c) cooling said sintered transition metal values to a lower temperature between about 300° and about 700° C., and simultaneously contacting said sintered transition metal values with hydrogen under conditions operative to hydride and embrittle said sintered transition metal values, thereby forming embrittled transition metal values; (d) comminuting said embrittled transition metal values under a nondeleteriously-reactive atmosphere, to a predetermined particle size distribution, such that at least a substantial amount by weight of said particles are suitable for powder metallurgy usage without further particle size reduction, thereby forming particles of transition metal values; (e) dehydriding said particles of transition metal values at a temperature between about 400° and about 700° C. under conditions operative to remove essentially all hydrogen values from said particles of transition metal values and to produce dehydrided particles of transition metal values; and (f) contacting said dehydrided particles with a small amount of a gas selected from the group consisting of oxygen, nitrogen, and mixtures thereof under conditions operative to passify said dehydrided particles thereby producing passified Group IVb transition metal-based metal particles which are substantially free of halides, hydrogen, oxygen, nitrogen and carbon.

Claim 13

Passified Group IVb transition metal-based metal particles which are substantially free of halides, hydrogen, oxygen, nitrogen and carbon, and which are suitable for powder metallurgy usage, prepared from a Group IVb transition metal-zinc alloy by: (a) heating a Group IVb transition metal-zinc alloy, which is substantially free of halides, at a temperature between about 500° and about 1150° C. under conditions operative to vaporize and separate zinc therefrom and to produce Group IVb transition metal values which are substantially free of zinc and halide; (b) heating said transition metal values to, or maintaining said transition metal values at, a sintering temperature between about 850° and about 1250° C. under conditions operative to sinter said transition metal values; (c) cooling said sintered transition metal values to a lower temperature between about 300° and about 700° C., and simultaneously contacting said sintered transition metal values with hydrogen under conditions operative to hydride and embrittle said sintered transition metal values, thereby forming embrittled transition metal values; (d) comminuting said embrittled transition metal values under a nondeleteriously-reactive atmosphere, to a predetermined particle size distribution, such that at least a substantial amount by weight of said particles are suitable for powder metallurgy usage without further particle size reduction, thereby forming particles of transition metal values; (e) dehydriding said particles of transition metal values at a temperature between about 400° and about 700° C. under conditions operative to remove essentially all hydrogen values from said particles of transition metal values and to produce dehydrided particles of transition metal values; and (f) contacting said dehydrided particles with a small amount of a gas selected from the group consisting of oxygen, nitrogen, and mixtures thereof under conditions operative to passify said dehydrided particles thereby producing passified Group IVb transition metal-based metal particles which are substantially free of halides, hydrogen, oxygen, nitrogen and carbon.

Claim 14

The metal particles of claim 11 wherein said Group IVb transition metal-zinc alloy is a titanium-zinc alloy.

Claim 15

The metal particles of claim 11 wherein said Group IVb transistion metal-zinc alloy and zirconium-zinc alloy.

Claim 16

Passified Group IVb transition metal-based metal particles substantially free of halides, zinc, hydrogen, oxygen, nitrogen and carbon, and suitable for powder metallurgy usage, which are produced from a transition metal-zinc alloy by a process comprising: (a) forming a Group IVb transition metal-zinc alloy, which is substantially free of halides, hydrogen, oxygen, nitrogen and carbon, into particles, at least 90% by weight of said particles having a particle size distribution between 80 mesh and about 1/4 inch; (b) heating said particles in a zone maintained at a temperature between about 500° and about 1150° C. under conditions operative to vaporize and separate zinc from said transition metal-zinc alloy particles and to produce particles of Group IVb transition metal values which are substantially free of halides, zinc, hydrogen, oxygen, nitrogen and carbon; (c) heating said particles to a sintering temperature between about 850° and 1250° C. under conditions operative to sinter said particles; (d) cooling said sintered particles to a lower temperature between about ambient temperature and about 200° C.; (e) contacting said cooled sintered particles with a small amount of a gas selected from the group consisting of oxygen, nitrogen, and mixtures thereof under conditions operative to passify said cooled sintered particles thereby producing passified Group IVb transition metal-based metal particles which are substantially free of halides, zinc, hydrogen, oxygen, nitrogen and carbon; and (f) said forming of a Group IVb transition metal-zinc alloy of a specified particle size distribution in step (a), and said heating of said first particles in step (c) being operative to cause said passified Group IVb transition metal-based metal particles produced in step (e) to have a particle size distribution such that a significant amount by weight of said passified Group IVb transition metal-based metal particles are suitable for powder metallurgy usage without additional particle size reduction.

Claim 17

Passified Group IVb transition metal-based metal particles substantially free of halides, zinc, hydrogen, oxygen, nitrogen and carbon, and suitable for powder metallurgy usage, which are produced from a transition metal-zinc alloy by a process comprising: (a) forming a Group IVb transition metal-zinc alloy, which is substantially free of halides, hydrogen, oxygen, nitrogen and carbon, into particles, at least 90% by weight of said particles having a particle size distribution between 80 mesh and about 1/4 inch; (b) heating said particles in a zone maintained at a temperature between about 500° and about 1150° C. under conditions operative to vaporize and separate zinc from said transition metal-zinc alloy particles and to produce particles of Group IVb transition metal values which are substantially free of halides, zinc, hydrogen, oxygen, nitrogen and carbon; (c) heating said particles to a sintering temperature between about 850° and 1250° C. under conditions operative to sinter said particles; (d) cooling said sintered particles to a lower temperature between about ambient temperature and about 200° C.; (e) contacting said cooled sintered particles with a small amount of a gas selected from the group consisting of oxygen, nitrogen, and mixtures thereof under conditions operative to passify said cooled sintered particles thereby producing passified Group IVb transition metal-based metal particles which are substantially free of halides, zinc, hydrogen, oxygen, nitrogen and carbon; and (f) said forming of a Group IVb transition metal-zinc alloy of a specified particle size distribution in step (a), and said heating of said first particles in step (c) being operative to cause said passified Group IVb transition metal-based metal particles produced in step (e) to have a particle size distribution such that a significant amount by weight of said passified Group IVb transition metal-based metal particles are suitable for powder metallurgy usage without additional particle size reduction.

Claim 18

The metal particles of claim 14 wherein said Group IVb transition metal-zinc alloy is a titanium-zinc alloy.

Claim 19

The metal particles of claim 14 wherein said Group IVb transition metal-zinc alloy particles formed in step (a) has a particle size distribution of about 90% by weight between about 60 mesh and about 20 mesh.

Claim 20

The metal particles of claim 14 wherein said forming of a Group IVb transition metal-zinc alloy into particles in step (a) comprises comminuting of said alloy.

Claim 21

The metal particles of claim 14 wherein said forming of a Group IVb transition metal-zinc alloy into particles in step (a) comprises casting said alloy.

Claim 22

The metal particles of claim 14 wherein said Group IVb transition metal-zinc alloy is selected from the group consisting of hafnium-zinc alloy and zirconium-zinc alloy.

Claim 23

A process to produce passified Group IVb transition metal-based metal particles which are substantially free of halides, and which are suitable for powder metallurgy usage, from a Group IVb transition metal-zinc alloy comprising: (a) heating a Group IVb transition metal-zinc alloy, which is substantially free of halides, in a distillation zone maintained at a temperature between about 500° and about 1150° C. under conditions operative to vaporize and separate zinc from said transition metal-zinc alloy and to produce Group IVb transition metal values which are substantially free of zinc and halides; (b) cooling said sintered transition metal values to a lower temperature between about 300° and about 700° C., and simultaneously contacting said sintered transition metal values with hydrogen under conditions operative to hydride and embrittle said transition metal values, thereby forming embrittled transition metal values; (c) comminuting said embrittled transition metal values under a nondeleteriously-reactive atmosphere, to a predetermined particle size distribution of about 90% by weight between about 80 mesh and about 1/4 inch thereby forming particles of transition metal values; (d) dehydriding said particles of transition metal values at a temperature between about 400° and 700° C. under conditions operative to remove essentially all hydrogen values from said particles of transition metal values and to produce dehydrided particles of transition metal values; and (e) contacting said dehydrided particles with an effective amount of a gas selected from the group consisting of oxygen, nitrogen, and mixtures thereof under conditions operative to passify said dehydrided particles thereby producing passified Group IVb transition metal-based metal particles which are substantially free of halides.

Claim 24

A process to produce passified Group IVb transition metal-based metal particles which are substantially free of halides, and which are suitable for powder metallurgy usage, from a Group IVb transition metal-zinc alloy comprising: (a) heating a Group IVb transition metal-zinc alloy, which is substantially free of halides, in a distillation zone maintained at a temperature between about 500° and about 1150° C. under conditions operative to vaporize and separate zinc from said transition metal-zinc alloy and to produce Group IVb transition metal values which are substantially free of zinc and halides; (b) cooling said sintered transition metal values to a lower temperature between about 300° and about 700° C., and simultaneously contacting said sintered transition metal values with hydrogen under conditions operative to hydride and embrittle said transition metal values, thereby forming embrittled transition metal values; (c) comminuting said embrittled transition metal values under a nondeleteriously-reactive atmosphere, to a predetermined particle size distribution of about 90% by weight between about 80 mesh and about 1/4 inch thereby forming particles of transition metal values; (d) dehydriding said particles of transition metal values at a temperature between about 400° and 700° C. under conditions operative to remove essentially all hydrogen values from said particles of transition metal values and to produce dehydrided particles of transition metal values; and (e) contacting said dehydrided particles with an effective amount of a gas selected from the group consisting of oxygen, nitrogen, and mixtures thereof under conditions operative to passify said dehydrided particles thereby producing passified Group IVb transition metal-based metal particles which are substantially free of halides.

Claim 25

The process of claim 20 wherein said heating step (a) is conducted under a partial vacuum.

Claim 26

The process of claim 20 wherein said heating step (a) is conducted under a continuous flow of a nondeleteriously-reactive sweep gas.

Claim 27

The process of claim 22 wherein said nondeleteriously-reactive sweep gas is selected from the group consisting of hydrogen, an inert gas, and mixtures thereof.

Claim 28

The process of claim 20 wherein said dehydriding step (d) is conducted under a partial vacuum.

Claim 29

The process of claim 20 wherein the entire process is conducted at temperatures which are no higher than about 1300° C.

Claim 30

The process of claim 20 wherein the entire process is conducted at temperatures which are no higher than about 1150° C.

Claim 31

The process of claim 20 wherein said Group IVb transition metal-zinc alloy is produced from Group IVb transition metal sponge and zinc.

Claim 32

The process of claim 20 wherein said Group IVb transition metal-zinc alloy is produced from the reduction of a transition metal halide with a metal alloy which comprises a reductant metal and zinc.

Claim 33

The metal particles of claim 20 wherein said Group IVb transition metal-zinc alloy is a titanium-zinc alloy.

Claim 34

The metal particles of claim 20 wherein said Group IVb transition metal-zinc alloy is selected from the group consisting of hafnium-zinc alloy and zirconium-zinc alloy.

Claim 35

A process to produce passified Group IVb transition metal-based metal particles which are substantially free of halides, and which are suitable for powder metallurgy usage, from a Group IVb transition metal-zinc alloy comprising: (a) forming a Group IVb transition metal-zinc alloy, which is substantially free of halides, into irregular shaped particles, at least 90% by weight of said particles having a particle size distribution between about 80 mesh and about 1/4 inch; (b) heating said Group IVb transition metal-zinc alloy particles in a zone maintained at a temperature between about 500° and about 1150° C., under conditions operative to vaporize and separate zinc from said transition metal-zinc alloy particles to produce particles of Group IVb transition metal-based metal which are substantially free of zinc and halides; (c) cooling said Group IVb transition metal based-metal value particles to a temperature below about 200° C.; (d) contacting said cooled Group IVb transition metal based-metal particles with a small amount of a gas selected from the group consisting of oxygen, nitrogen, and mixtures thereof under conditions operative to passify said particles thereby producing passified Group IVb transition metal-based metal particles which are substantially free of halides; and (e) said forming of a Group IVb transition metal-zinc alloy of a specified particles size distribution in step (a), and said heating of said first particles in step (b) being operative to cause said passified transition metal-based metal particles produced in step (d) to have a particle size distribution such that a significant amount by weight of said passified transition metal-based metal particles are suitable for powder metallurgy usage without additional particle size reduction.

Claim 36

A process to produce passified Group IVb transition metal-based metal particles which are substantially free of halides, and which are suitable for powder metallurgy usage, from a Group IVb transition metal-zinc alloy comprising: (a) forming a Group IVb transition metal-zinc alloy, which is substantially free of halides, into irregular shaped particles, at least 90% by weight of said particles having a particle size distribution between about 80 mesh and about 1/4 inch; (b) heating said Group IVb transition metal-zinc alloy particles in a zone maintained at a temperature between about 500° and about 1150° C., under conditions operative to vaporize and separate zinc from said transition metal-zinc alloy particles to produce particles of Group IVb transition metal-based metal which are substantially free of zinc and halides; (c) cooling said Group IVb transition metal based-metal value particles to a temperature below about 200° C.; (d) contacting said cooled Group IVb transition metal based-metal particles with a small amount of a gas selected from the group consisting of oxygen, nitrogen, and mixtures thereof under conditions operative to passify said particles thereby producing passified Group IVb transition metal-based metal particles which are substantially free of halides; and (e) said forming of a Group IVb transition metal-zinc alloy of a specified particles size distribution in step (a), and said heating of said first particles in step (b) being operative to cause said passified transition metal-based metal particles produced in step (d) to have a particle size distribution such that a significant amount by weight of said passified transition metal-based metal particles are suitable for powder metallurgy usage without additional particle size reduction.

Claim 37

The process of claim 31 wherein the particles of Group IVb transition metal-based metal produced in heating step (b) are heated to, or maintained at, a sintering temperature between about 850° and 1250° C. under conditions operative to sinter said particles in a sintering zone to produce sintered particles of Group IVb transition metal-based metal prior to cooling said particles in cooling step (c).

Claim 38

The process of claim 31 wherein said heating step (b) is conducted under a partial vacuum.

Claim 39

The process of claim 31 wherein said heating step (b) is conducted under a continuous flow of a nondeleteriously-reactive sweep gas.

Claim 40

The process of claim 34 wherein said nondeleteriously-reactive sweep gas is selected from the group consisting of hydrogen, an inert gas, and mixtures thereof.

Claim 41

The process of claim 31 wherein the entire process is conducted at temperatures which are no higher than about 1150° C.

Claim 42

The process of claim 31 wherein said Group IVb transition metal-zinc alloy is produced from Group IVb transition metal sponge and zinc.

Claim 43

The process of claim 31 wherein said Group IVb transition metal-zinc alloy is produced from the reduction of a transition metal halide with a metal alloy which comprises a reductant metal and zinc.

Claim 44

The process of claim 31 wherein said Group IVb transition metal-zinc alloy is a titanium-zinc alloy.

Claim 45

The process of claim 31 wherein said Group IVb transition metal-zinc alloy is selected from the group consisting of hafnium-zinc alloy and zirconium-zinc alloy.

Claim 46

A process to produce passified Group IVb transition metal-based metal particles which are substantially free of halides, and which are suitable for powder metallurgy usage, from passified Group IVb transition metal based-metal sponge, substantially free of zinc and halides, comprising: (a) heating a passified Group IVb transition metal based-metal sponge, which is substantially free of zinc and halides, at a temperature between about 300° and about 700° C.; (b) contacting said heated passified Group IVb transition metal based-metal sponge with hydrogen under conditions operative to hydride and embrittle said transition metal based-metal, thereby forming embrittled Group IVb transition metal values; (c) comminuting said embrittled Group IVb transition metal values under a nondeleteriously-reactive atmosphere, to a predetermined particle size distribution thereby forming particles of hydrided Group IVb transition metal values; (d) dehydriding said particles of hydrided Group IVb transition metal values at a temperature between about 400° and about 700° C. under conditions operative to remove essentially all hydrogen values from said particles of Group IVb transition metal values and to produce dehydrided particles of Group IVb transition metal values; (e) contacting said dehydrided particles of Group IVb transition metal values with a small amount of a gas selected from the group consisting of oxygen, nitrogen, and mixtures thereof under conditions operative to passify said dehydrided particles thereby producing passified Group IVb transition metal-based metal particles which are substantially free of halides; and (f) said comminuting of said embrittled transition metal values to predetermined particle size distribution in step (c) being operative to cause said passified transition metal-based metal particles produced in step (e) to have a particle size distribution such that a significant amount by weight of said passified Group IVb transition metal-based metal particles are suitable for powder metallurgy usage without additional particle size reduction.

Claim 47

A process to produce passified Group IVb transition metal-based metal particles which are substantially free of halides, and which are suitable for powder metallurgy usage, from passified Group IVb transition metal based-metal sponge, substantially free of zinc and halides, comprising: (a) heating a passified Group IVb transition metal based-metal sponge, which is substantially free of zinc and halides, at a temperature between about 300° and about 700° C.; (b) contacting said heated passified Group IVb transition metal based-metal sponge with hydrogen under conditions operative to hydride and embrittle said transition metal based-metal, thereby forming embrittled Group IVb transition metal values; (c) comminuting said embrittled Group IVb transition metal values under a nondeleteriously-reactive atmosphere, to a predetermined particle size distribution thereby forming particles of hydrided Group IVb transition metal values; (d) dehydriding said particles of hydrided Group IVb transition metal values at a temperature between about 400° and about 700° C. under conditions operative to remove essentially all hydrogen values from said particles of Group IVb transition metal values and to produce dehydrided particles of Group IVb transition metal values; (e) contacting said dehydrided particles of Group IVb transition metal values with a small amount of a gas selected from the group consisting of oxygen, nitrogen, and mixtures thereof under conditions operative to passify said dehydrided particles thereby producing passified Group IVb transition metal-based metal particles which are substantially free of halides; and (f) said comminuting of said embrittled transition metal values to predetermined particle size distribution in step (c) being operative to cause said passified transition metal-based metal particles produced in step (e) to have a particle size distribution such that a significant amount by weight of said passified Group IVb transition metal-based metal particles are suitable for powder metallurgy usage without additional particle size reduction.

Claim 48

The process of claim 41 wherein said nondeleteriously-reactive atmosphere used in step (c) is an inert gas.

Claim 49

The process of claim 41 wherein said heating step (a) is conducted under a nondeleteriously-reactive sweep gas.

Claim 50

The process of claim 41 wherein said dehydriding in step (e) is conducted under a partial vacuum.

Claim 51

The process of claim 41 wherein the entire process is conducted at temperatures which are no higher than about 1150° C.

Claim 52

The process of claim 41 wherein the Group IVb transition metal of the passified Group IVb transition metal-based metal, substantially free of zinc and halides, is selected from titanium, hafnium and zirconium.

Claim 53

A metal sponge comprising a Group IVb transition metal useful for metallurgical applications characterized as having less than about 50 PPM by weight halide and an internal porosity of from about 10% to about 30% by volume.

Claim 54

A metal sponge comprising a Group IVb transition metal useful for metallurgical applications characterized as having less than about 50 PPM by weight halide and an internal porosity of from about 10% to about 30% by volume.

Claim 55

The metal sponge of claim 47 wherein the transition metal is selected from the group consisting of titanium, hafnium and zirconium.

Claim 56

The metal sponge of claim 48 wherein the metal is titanium.

Claim 57

The metal sponge of claim 49 wherein the metal is alloyed, by weight percent, with at least one of the following alloying agents: 0 to about 5% tin, 0 to about 10% vanadium, 0 to about 10% aluminum, 0 to about 5% zirconium, 0 to 5% molybdenum, 0 to about 10% silicon, 0 to about 10% iron, 0 to about 0.5% oxygen and mixtures thereof, the metal comprising at least 90% by weight titanium.

Claim 58

The powdered metal of claim 48 wherein the Group IVb transition metal is selected from the group consisting of hafnium and zirconium.

Claim 59

The powdered metal of claim 51 wherein the metal is alloyed, by weight percent, with at least one of the following alloying agents: 0 to about 3% tin, 0 to about 0.04 iron, 0 to about 0.2% chromium, 0 to about 0.01% nickel, 0 to about 10% niobium, 0 to about 0.5% oxygen and mixtures thereof; the metal comprising at least 90% by weight hafnium or zirconium.

Claim 60

The metal sponge of claim 47 wherein the metal has less than about 10 PPM by weight halide and an internal porosity of about 10% to about 20%.

Claim 61

The metal sponge of claim 47 wherein the metal has less than about 2500 PPM by weight oxygen, less than about 400 PPM by weight nitrogen and less than about 800 PPM by weight carbon.

Claim 62

The metal sponge of claim 47 wherein the metal has less than about 50 PPM by weight oxygen, less than about 90 PPM by weight nitrogen, and less than about 150 PPM by weight carbon.

Claim 63

The metal sponge of claim 55 wherein the metal has less than about 10 PPM by weight halide.

Claim 64

A powder metal useful for powder metallurgical applications characterized as having angular shaped particles with an internal porosity of from about 10% to about 30% by volume, less than about 10 PPM by weight halide, less than about 50 PPM by weight oxygen, less than about 90 PPM by weight nitrogen, less than about 150 PPM by weight carbon, said powder metal comprising at least 90% by weight titanium and, by weight percent,: 0-5% tin, 0-10% vanadium, 0-10% aluminum, 0-5% zirconium, 0-5% molybdenum, 0-10% silicon, 0-10% iron, and 0-0.5% oxygen.

Claim 65

A powder metal useful for powder metallurgical applications characterized as having angular shaped particles with an internal porosity of from about 10% to about 30% by volume, less than about 10 PPM by weight halide, less than about 50 PPM by weight oxygen, less than about 90 PPM by weight nitrogen, less than about 150 PPM by weight carbon, said powder metal comprising at least 90% by weight titanium and, by weight percent,: 0-5% tin, 0-10% vanadium, 0-10% aluminum, 0-5% zirconium, 0-5% molybdenum, 0-10% silicon, 0-10% iron, and 0-0.5% oxygen.

Claim 66

A metal sponge useful for powder metallurgical applications characterized as having an internal porosity of from about 10% to about 30% by volume, less than about 10 PPM by weight halide, less than about 50 PPM by weight oxygen, less than about 90 PPM by weight nitrogen, less than about 150 PPM by weight carbon, said metal sponge comprising at least 90% by weight titanium and, by weight percent, 0-5% tin, 0-10% vanadium, 0-10% aluminum, 0-5% zirconium, 0-5% molybdenum, - 10% silicon, 0-10% iron, and 0-0.5% oxygen.

Claim 67

A metal sponge useful for powder metallurgical applications characterized as having an internal porosity of from about 10% to about 30% by volume, less than about 10 PPM by weight halide, less than about 50 PPM by weight oxygen, less than about 90 PPM by weight nitrogen, less than about 150 PPM by weight carbon, said metal sponge comprising at least 90% by weight titanium and, by weight percent, 0-5% tin, 0-10% vanadium, 0-10% aluminum, 0-5% zirconium, 0-5% molybdenum, - 10% silicon, 0-10% iron, and 0-0.5% oxygen.

Claim 68

A process to produce passified Group IVb transition metal-based metal particles which are substantially free of halides, and which are suitable for powder metallurgical usage, from a Group IVb transition metal-zinc alloy comprising: (a) heating a Group IVb transition metal-zinc alloy, which is substantially free of halides to a temperature between about 900° and about 950° C. under conditions operative to vaporize and separate zinc therefrom to produce Group IVb transition metal values which are substantially free of zinc and halides; (b) comminuting said transition metal values under a nondeleteriously-reactive atmosphere to a predetermined particle size distribution of from +200 to -30 mesh thereby forming particles of transition metal values; and (c) contacting said particles with an effective amount of a gas selected from the group consisting of oxygen, nitrogen and mixtures thereof under conditions operative to passify said particles thereby producing passified Group IVb transition metal-based particles which are substantially free of halides.

Claim 69

A process to produce passified Group IVb transition metal-based metal particles which are substantially free of halides, and which are suitable for powder metallurgical usage, from a Group IVb transition metal-zinc alloy comprising: (a) heating a Group IVb transition metal-zinc alloy, which is substantially free of halides to a temperature between about 900° and about 950° C. under conditions operative to vaporize and separate zinc therefrom to produce Group IVb transition metal values which are substantially free of zinc and halides; (b) comminuting said transition metal values under a nondeleteriously-reactive atmosphere to a predetermined particle size distribution of from +200 to -30 mesh thereby forming particles of transition metal values; and (c) contacting said particles with an effective amount of a gas selected from the group consisting of oxygen, nitrogen and mixtures thereof under conditions operative to passify said particles thereby producing passified Group IVb transition metal-based particles which are substantially free of halides.

Claim 70

A process to produce passified titanium metal-based metal particles comprising titanium which are substantially free of halides and which are suitable for powder metallurgy usage from a titanium zinc alloy comprising: (a) forming an alloy comprising titanium and zinc, which is substantially free of halides, into irregular shaped particles, at least 90% by weight of said particles having a particle size distribution between about 60 mesh and about 20 mesh; (b) heating said alloyed particles in a zone maintained at a temperature of between about 900° and about 950° C., under conditions operative to vaporize and separate zinc from said particles to produce particles of titanium metal based metal substantially free of zinc and halides; (c) cooling said particles to a temperature between ambient and about 60° C.; (d) contacting said cooled titanium particles with a small amount of a gas selected from the group consisting of oxygen, nitrogen and mixtures thereof under conditions operative to passify said particles thereby producing passified titanium metal-based metal particles; and (e) said forming of titanium-zinc alloy particles of a specified particle size distribution in step (a), and said heating of said particles in step (b) being operative to cause passified titanium metal-based metal particles produced in step (d) to have a particle size distribution such that significant amount by weight of said passified titanium metal-based metal particles are suitable for powder metallurgy usage without additional particle size reduction.

Claim 71

A process to produce passified titanium metal-based metal particles comprising titanium which are substantially free of halides and which are suitable for powder metallurgy usage from a titanium zinc alloy comprising: (a) forming an alloy comprising titanium and zinc, which is substantially free of halides, into irregular shaped particles, at least 90% by weight of said particles having a particle size distribution between about 60 mesh and about 20 mesh; (b) heating said alloyed particles in a zone maintained at a temperature of between about 900° and about 950° C., under conditions operative to vaporize and separate zinc from said particles to produce particles of titanium metal based metal substantially free of zinc and halides; (c) cooling said particles to a temperature between ambient and about 60° C.; (d) contacting said cooled titanium particles with a small amount of a gas selected from the group consisting of oxygen, nitrogen and mixtures thereof under conditions operative to passify said particles thereby producing passified titanium metal-based metal particles; and (e) said forming of titanium-zinc alloy particles of a specified particle size distribution in step (a), and said heating of said particles in step (b) being operative to cause passified titanium metal-based metal particles produced in step (d) to have a particle size distribution such that significant amount by weight of said passified titanium metal-based metal particles are suitable for powder metallurgy usage without additional particle size reduction.

Claim 72

A process to produce passified Group IVb transition metal-based metal particles substantially free of halides, zinc, hydrogen, oxygen, nitrogen and carbon, and suitable for powder metallurgy usage, from a Group IVb transition metal-zinc alloy comprising: (a) forming a Group IVb transition metal-zinc alloy, which is substantially free of halides, hydrogen, oxygen, nitrogen and carbon, into particles, at least 90% by weight of said particles having a particle size distribution between 80 mesh and about 1/4 inch; (b) heating said particles in a zone maintained at a temperature between about 500° and about 1150° C. under conditions operative to vaporize and separate zinc from said transition metal-zinc alloy particles and to produce particles of Group IVb transition metal values which are substantially free of halides, zinc, hydrogen, oxygen, nitrogen and carbon; (c) heating said particles to a sintering temperature between about 850° and 1250° C. under conditions operative to sinter said particles; (d) cooling said sintered particles to a lower temperature between about ambient temperature and about 200° C.; (e) contacting said cooled sintered particles with a small amount of a gas selected from the group consisting of oxygen, nitrogen, and mixtures thereof under conditions operative to passify said cooled sintered particles thereby producing passified Group IVb transition metal-based metal particles which are substantially free of halides, zinc, hydrogen, oxygen, nitrogen and carbon; and (f) said forming of a Group IVb transition metal-zinc alloy of a specified particle size distribution in step (a), and said heating of said particles in step (c) being operative to cause said passified Group IVb transition metal-based metal particles produced in step (e) to have a particle size distribution such that a significant amount by weight of said passified Group IVb transition metal-based metal particles are suitable for powder metallurgy usage without additional particle size reduction.

Claim 73

A process to produce passified Group IVb transition metal-based metal particles substantially free of halides, zinc, hydrogen, oxygen, nitrogen and carbon, and suitable for powder metallurgy usage, from a Group IVb transition metal-zinc alloy comprising: (a) forming a Group IVb transition metal-zinc alloy, which is substantially free of halides, hydrogen, oxygen, nitrogen and carbon, into particles, at least 90% by weight of said particles having a particle size distribution between 80 mesh and about 1/4 inch; (b) heating said particles in a zone maintained at a temperature between about 500° and about 1150° C. under conditions operative to vaporize and separate zinc from said transition metal-zinc alloy particles and to produce particles of Group IVb transition metal values which are substantially free of halides, zinc, hydrogen, oxygen, nitrogen and carbon; (c) heating said particles to a sintering temperature between about 850° and 1250° C. under conditions operative to sinter said particles; (d) cooling said sintered particles to a lower temperature between about ambient temperature and about 200° C.; (e) contacting said cooled sintered particles with a small amount of a gas selected from the group consisting of oxygen, nitrogen, and mixtures thereof under conditions operative to passify said cooled sintered particles thereby producing passified Group IVb transition metal-based metal particles which are substantially free of halides, zinc, hydrogen, oxygen, nitrogen and carbon; and (f) said forming of a Group IVb transition metal-zinc alloy of a specified particle size distribution in step (a), and said heating of said particles in step (c) being operative to cause said passified Group IVb transition metal-based metal particles produced in step (e) to have a particle size distribution such that a significant amount by weight of said passified Group IVb transition metal-based metal particles are suitable for powder metallurgy usage without additional particle size reduction.

Claim 74

The process of claim 61 wherein said heating step (b) is conducted under a partial vacuum.

Claim 75

The process of claim 61 wherein said heating step (b) is conducted under a continuous flow of a non-deleteriously-reactive sweep gas.

Claim 76

The process of claim 63 wherein said non-deleteriously-reactive sweep gas is selected from the group consisting of hydrogen, an inert gas, and mixtures thereof.

Claim 77

The process of claim 61 wherein said Group IVb transition metal-zinc alloy is a titanium-zinc alloy.

Claim 78

The process of claim 61 wherein said Group IVb transition metal-zinc alloy is selected from the group consisting of hafnium-zinc alloy and zirconium-zinc alloy.

Claim 79

The process of claim 61 wherein said forming of a Group IVb transition metal-zinc alloy into particles in step (a) comprises comminuting of said alloy.

Claim 80

The metal particles of claim 61 wherein said forming of a Group IVb transition metal-zinc alloy into particles in step (a) comprises casting said alloy.

Claim 81

A process to produce titanium metal-based metal particles substantially free of halides, zinc, hydrogen, oxygen, nitrogen and carbon and suitable for powder metallurgy usage, from a titanium metal-zinc alloy comprising: (a) forming a titanium metal-zinc alloy, which is substantially free of halides, hydrogen, oxygen, nitrogen and carbon, into particles, at least 90% by weight of the particles having a particle size distribution between about 60 mesh and about 20 mesh; (b) heating said particles in a zone maintained at a temperature between about 900° and 950° C. under conditions operative to vaporize and separate zinc from said titanium metal-zinc alloyed particles to produce particles of titanium metal-based metal which are substantially free of halides, zinc, hydrogen, oxygen, nitrogen and carbon; (c) heating said particles to a sintering temperature of between about 1020° and 1060° C. under conditions operative to sinter said particles; (d) cooling said sintered particles to a lower temperature between about ambient temperature and about 60° C.; (e) contacting said cooled sintered particles with a small amount of gas selected from the group consisting of oxygen, nitrogen, and mixtures thereof under conditions operative to passify said particles thereby producing passified titanium metal-based metal particles which are substantially free of halides, zinc, hydrogen, oxygen, nitrogen and carbon; and (f) said forming of titanium metal-zinc alloy of a specified particle size distribution in step (a), and said heating of said titanium metal based metal particles in step (c) being operative to cause said passified titanium metal-based metal particles produced in step (e) to have a particle size distribution such that a significant amount by weight of said passified titanium metal-based metal particles are suitable for powder metallurgy usage without additional particle size reduction.

Claim 82

A process to produce titanium metal-based metal particles substantially free of halides, zinc, hydrogen, oxygen, nitrogen and carbon and suitable for powder metallurgy usage, from a titanium metal-zinc alloy comprising: (a) forming a titanium metal-zinc alloy, which is substantially free of halides, hydrogen, oxygen, nitrogen and carbon, into particles, at least 90% by weight of the particles having a particle size distribution between about 60 mesh and about 20 mesh; (b) heating said particles in a zone maintained at a temperature between about 900° and 950° C. under conditions operative to vaporize and separate zinc from said titanium metal-zinc alloyed particles to produce particles of titanium metal-based metal which are substantially free of halides, zinc, hydrogen, oxygen, nitrogen and carbon; (c) heating said particles to a sintering temperature of between about 1020° and 1060° C. under conditions operative to sinter said particles; (d) cooling said sintered particles to a lower temperature between about ambient temperature and about 60° C.; (e) contacting said cooled sintered particles with a small amount of gas selected from the group consisting of oxygen, nitrogen, and mixtures thereof under conditions operative to passify said particles thereby producing passified titanium metal-based metal particles which are substantially free of halides, zinc, hydrogen, oxygen, nitrogen and carbon; and (f) said forming of titanium metal-zinc alloy of a specified particle size distribution in step (a), and said heating of said titanium metal based metal particles in step (c) being operative to cause said passified titanium metal-based metal particles produced in step (e) to have a particle size distribution such that a significant amount by weight of said passified titanium metal-based metal particles are suitable for powder metallurgy usage without additional particle size reduction.

Claim 83

A process to produce titanium metal-based metal particles which are substantially free of halides, zinc, hydrogen, oxygen, nitrogen and carbon, and suitable for powder metallurgy usage, from a titanium metal-zinc alloy comprising: (a) heating a titanium metal-zinc alloy, which is substantially free of halides, hydrogen, oxygen, nitrogen and carbon to a temperature between about 900° and 950° C. under conditions operative to vaporize and separate zinc therefrom to produce titanium metal-based metal which is substantially free of halides, zinc, hydrogen, oxygen, nitrogen and carbon; (b) comminuting said titanium metal-based metal under a nondeleteriously-reactive atmosphere to a predetermined particle size distribution of from +200 to -30 mesh thereby forming particles of titanium metal-based metal; and (c) contacting said titanium metal-based metal particles with an effective amount of a gas selected from the group consisting of oxygen, nitrogen and mixtures thereof under conditions operative to passify said particles thereby producing passified titanium metal-based metal particles which are substantially free of halides, zinc, hydrogen, oxygen, nitrogen and carbon.

Claim 84

A process to produce titanium metal-based metal particles which are substantially free of halides, zinc, hydrogen, oxygen, nitrogen and carbon, and suitable for powder metallurgy usage, from a titanium metal-zinc alloy comprising: (a) heating a titanium metal-zinc alloy, which is substantially free of halides, hydrogen, oxygen, nitrogen and carbon to a temperature between about 900° and 950° C. under conditions operative to vaporize and separate zinc therefrom to produce titanium metal-based metal which is substantially free of halides, zinc, hydrogen, oxygen, nitrogen and carbon; (b) comminuting said titanium metal-based metal under a nondeleteriously-reactive atmosphere to a predetermined particle size distribution of from +200 to -30 mesh thereby forming particles of titanium metal-based metal; and (c) contacting said titanium metal-based metal particles with an effective amount of a gas selected from the group consisting of oxygen, nitrogen and mixtures thereof under conditions operative to passify said particles thereby producing passified titanium metal-based metal particles which are substantially free of halides, zinc, hydrogen, oxygen, nitrogen and carbon.