Method for making ultrafine metal powder

Claim 2

A fine amorphous metallurgical powder suitable for compacting and sintering into densified articles consisting essentially of a major portion by weight of a metal selected from the group consisting of transition metals or mixtures thereof and less than a minor amount of an additional component for enhancing the amorphous characteristics of said fine amorphous metallurgical powder, said fine amorphous metallurgical powder further consisting essentially of smooth surfaced plasma densified particles being solidifed from molten particles rebounding from a repellanht surface wherein at least 80 percent of the particles have a size of less than about ten micrometers.

Claim 3

A process for producing fine amorphous metallurgical powder suitable for producing a densified amorphous powdered metallurgical article comprising forming a flowable agglomerated powder consisting essentially or a major portion by weight of a metal selected from the group consisting of a transistion metals or mixtures thereof and less than a minor amount of an additional component for enhancing the amorphous characteristic of said fine amorphous metallurgical powder, entraining said agglomerated powder in a high pressure gas for transporting said powder to a plasma torch, creating a plasma in said gas and heating entrained powder to a molten condition to form a high velocity stream of molten metal droplets, said stream being discharged from said torch at a speed greater than 200 meters per second, directing said stream toward a repellant surface, impacting said molten droplets against said repellant surface to form fragmented portions, and cooling said fragmented portions at a rate to form an amorphous powder comprising particles less than about ten micrometers with smooth surfaces, said amorphous powder being capable of being compacted and sintered to form a powdered metallurgical artice.

Claim 4

A process for producing fine amorphous metallurgical powder suitable for producing a densified amorphous powdered metallurgical article comprising forming a flowable agglomerated powder consisting essentially or a major portion by weight of a metal selected from the group consisting of a transistion metals or mixtures thereof and less than a minor amount of an additional component for enhancing the amorphous characteristic of said fine amorphous metallurgical powder, entraining said agglomerated powder in a high pressure gas for transporting said powder to a plasma torch, creating a plasma in said gas and heating entrained powder to a molten condition to form a high velocity stream of molten metal droplets, said stream being discharged from said torch at a speed greater than 200 meters per second, directing said stream toward a repellant surface, impacting said molten droplets against said repellant surface to form fragmented portions, and cooling said fragmented portions at a rate to form an amorphous powder comprising particles less than about ten micrometers with smooth surfaces, said amorphous powder being capable of being compacted and sintered to form a powdered metallurgical artice.

Claim 5

A process according to claim 2 wherein said stream of molten metal droplets is formed by entraining a metal powder in a carrier gas said metal powder comprising flowable agglomerated particles, feeding said entrained metal powder through a high temperature reactor to form a stream of entrained molten metal droplets.

Claim 6

A process according to claim 2 wherein said metal powder consisting essentially of a major portion by weight a transistion metal or combinations thereof and a suitable amount of an additional component for enhancing the amorphous characteristics of densified articles.

Claim 7

A process according to claim 3 wherein said metal powder consists essentially of a major portion by weight a metal selected from Fe, Co, Ni, or Mo, W, Cr and V or combinations thereof and a suitable amount of an additional component selected from the group consisting of Si, C, B, P, Al, Sn, Sb, Ce, In and Be for enhancing the amorphous characteristics hardness of densified articles.