Metal powder and sponge and processes for the production thereof

Claim 2

A powder metal consisting of a Zinc Soluble Metal-Based Metal particles of less than 30 mesh having less than about 50 PPM by weight halide, an internal porosity of from about 5% to about 40% by volume, and the powder comprising angular shaped particles.

Claim 3

The powder metal of claim 1 wherein the Zinc Soluble Base Metal is selected from the group consisting of Ti, Mn, Fe, Co, Ni, Cu, Ge, Y, Zr, Rh, Pd, Ag, Sb, Hf, Pt, Au, Pr, U and mixtures thereof.

Claim 4

The powdered metal of claim 2 wherein the Zinc Soluble Metal-Based Metal has less than 5000 PPM of H, N, O, C and S.

Claim 5

The powdered metal of claim 2 wherein the powder metal has an average particle size of about 100 mesh.

Claim 6

Zinc Soluble Metal-Based Metal particles which are substantially free of halides, zinc, hydrogen, oxygen, nitrogen and carbon, and which are suitable for powder metallurgy usage, prepared from Zinc Soluble Metal-Based Metal-zinc alloy by: (a) heating a Zinc Soluble Metal-Based 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 Zinc Soluble Metal-Based Metal values which are substantially free of zinc and halide; (b) sintering said Metal values at a sintering temperature between about 850° and about 1250° C. under conditions operative to sinter said Metal values; (c) cooling said sintered Metal values to a temperature between about 300° and about 700° C. and simultaneously contacting said sintered Metal values with hydrogen under conditions operative to hydride and embrittle said sintered Metal values, thereby forming embrittled Metal values; (d) comminuting said embrittled 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 said Metal values; (e) dehydriding said particles of said Metal values at a temperature between about 400° and about 700° C. under conditions operative to remove essentially all hydrogen values from said particles to produce dehydrided particles of said 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 Zinc Soluble Metal-Based Metal particles which are substantially free of halides, zinc, hydrogen, oxygen, nitrogen and carbon.

Claim 7

Zinc Soluble Metal-Based Metal particles which are substantially free of halides, zinc, hydrogen, oxygen, nitrogen and carbon, and which are suitable for powder metallurgy usage, prepared from Zinc Soluble Metal-Based Metal-zinc alloy by: (a) heating a Zinc Soluble Metal-Based 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 Zinc Soluble Metal-Based Metal values which are substantially free of zinc and halide; (b) sintering said Metal values at a sintering temperature between about 850° and about 1250° C. under conditions operative to sinter said Metal values; (c) cooling said sintered Metal values to a temperature between about 300° and about 700° C. and simultaneously contacting said sintered Metal values with hydrogen under conditions operative to hydride and embrittle said sintered Metal values, thereby forming embrittled Metal values; (d) comminuting said embrittled 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 said Metal values; (e) dehydriding said particles of said Metal values at a temperature between about 400° and about 700° C. under conditions operative to remove essentially all hydrogen values from said particles to produce dehydrided particles of said 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 Zinc Soluble Metal-Based Metal particles which are substantially free of halides, zinc, hydrogen, oxygen, nitrogen and carbon.

Claim 8

The metal particles of claim 5 wherein said Zinc Soluble Metal-Based Metal consists essentially of Ti, Mn, Fe, Co, Ni, Cu, Ge, Y, Zr, Rh, Pd, Ag, Sb, Hf, Pt, Au, Pr, U and mixtures thereof.

Claim 9

The metal particles of claim 5 wherein said Zinc Soluble Metal-Based Metal-zinc alloy heated in step (a) is an alloy consisting essentially of zinc and a Zinc Soluble Metal-Based Metal.

Claim 10

Passified Zinc Soluble Metal-Based Metal particles which are substantially free of halides, zinc, hydrogen, oxygen, nitrogen and carbon, and which are suitable for powder metallurgy usage, prepared from Zinc Soluble Metal-Based Metal-zinc alloy by the following steps: (a) forming particles of a Zinc Soluble Metal-Based Metal-zinc alloy, which is substantially free of halides, hydrogen, oxygen, nitrogen and carbon, into particles having a particle size of less than 30 mesh by particle forming means; (b) heating said particles of Zinc Soluble Metal-Based Metal-zinc alloy in a zone maintained at a temperature between about 500° and about 1150° C., and simultaneously introducing into said zone a continuous flow of a nondeleteriously-reactive sweep gas, said zone being maintained under conditions operative to vaporize and separate zinc from said Metal-zinc alloy particles and to produce first particles of Zinc Soluble Metal-Based Metal values which are substantially free of zinc and halides and have an internal porosity of from about 5% to about 40% by volume; (c) sintering said first particles at a sintering temperature between about 850° and 1250° C. under conditions operative to sinter said first particles; (d) contacting said sintered first particles at a temperature between about ambient temperature and about 200° C. 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 first particles thereby producing Zinc Soluble Metal-Based Metal particles which are substantially free of halides, zinc, hydrogen, oxygen, nitrogen and carbon; and (e) said forming of said Metal-zinc alloy particles in step (a), and said heating of said first particles in step (c) being operative to cause said passified Zinc Soluble Metal-Based Metal particles produced in step (d) to have a particle size distribution such that a significant amount by weight of said passified Zinc Soluble Metal-Based Metal particles are suitable for powder metallurgy usage without additional particle size reduction.

Claim 11

Passified Zinc Soluble Metal-Based Metal particles which are substantially free of halides, zinc, hydrogen, oxygen, nitrogen and carbon, and which are suitable for powder metallurgy usage, prepared from Zinc Soluble Metal-Based Metal-zinc alloy by the following steps: (a) forming particles of a Zinc Soluble Metal-Based Metal-zinc alloy, which is substantially free of halides, hydrogen, oxygen, nitrogen and carbon, into particles having a particle size of less than 30 mesh by particle forming means; (b) heating said particles of Zinc Soluble Metal-Based Metal-zinc alloy in a zone maintained at a temperature between about 500° and about 1150° C., and simultaneously introducing into said zone a continuous flow of a nondeleteriously-reactive sweep gas, said zone being maintained under conditions operative to vaporize and separate zinc from said Metal-zinc alloy particles and to produce first particles of Zinc Soluble Metal-Based Metal values which are substantially free of zinc and halides and have an internal porosity of from about 5% to about 40% by volume; (c) sintering said first particles at a sintering temperature between about 850° and 1250° C. under conditions operative to sinter said first particles; (d) contacting said sintered first particles at a temperature between about ambient temperature and about 200° C. 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 first particles thereby producing Zinc Soluble Metal-Based Metal particles which are substantially free of halides, zinc, hydrogen, oxygen, nitrogen and carbon; and (e) said forming of said Metal-zinc alloy particles in step (a), and said heating of said first particles in step (c) being operative to cause said passified Zinc Soluble Metal-Based Metal particles produced in step (d) to have a particle size distribution such that a significant amount by weight of said passified Zinc Soluble Metal-Based Metal particles are suitable for powder metallurgy usage without additional particle size reduction.

Claim 12

The metal particles of claim 8 wherein said Zinc Soluble Metal-Based Metal sintered particles of step (d) consists essentially of Ti, Mn, Fe, Co, Ni, Cu, Ge, Y, Zr, Rh, Pd, Ag, Sb, Hf, Pt, Au, Pr, U and mixtures thereof.

Claim 13

The metal particles of claim 8 wherein said Zinc Soluble Metal-Based Metal-zinc alloy particles formed in step (a) have an average particle size of about 100 mesh.

Claim 14

The metal particles of claim 8 wherein said forming of particles in step (a) comprises comminuting said Zinc Soluble Metal-Based Metal-zinc alloy.

Claim 15

The metal particles of claim 8 wherein said forming of particles in step (a) comprises casting said alloy.

Claim 16

A process to produce passified Zinc Soluble Metal-Based Metal particles which are substantially free of halides, and which are suitable for powder metallurgy usage, from a Zinc Soluble Metal-Based Metal-zinc alloy comprising: (a) heating a Zinc Soluble Metal-Based 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 Zinc Soluble Metal-Based Metal values which are substantially free of zinc and halides; (b) contacting said Metal values at a temperature between about 300° and about 700° C., with hydrogen under conditions operative to hydride and embrittle said Metal values, thereby forming embrittled Metal values; (c) comminuting said embrittled Metal values under a nondeleteriously-reactive atmosphere, to a predetermined particle size of less than 30 mesh thereby forming particles of Metal values; (d) dehydriding said particles of Metal values at a temperature between about 400° and 700° C. under conditions operative to remove essentially all hydrogen values from said particles of Metal values and to produce dehydrided particles of 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 Zinc Soluble Metal-Based Metal particles which are substantially free of halides, zinc, hydrogen, oxygen and carbon.

Claim 17

A process to produce passified Zinc Soluble Metal-Based Metal particles which are substantially free of halides, and which are suitable for powder metallurgy usage, from a Zinc Soluble Metal-Based Metal-zinc alloy comprising: (a) heating a Zinc Soluble Metal-Based 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 Zinc Soluble Metal-Based Metal values which are substantially free of zinc and halides; (b) contacting said Metal values at a temperature between about 300° and about 700° C., with hydrogen under conditions operative to hydride and embrittle said Metal values, thereby forming embrittled Metal values; (c) comminuting said embrittled Metal values under a nondeleteriously-reactive atmosphere, to a predetermined particle size of less than 30 mesh thereby forming particles of Metal values; (d) dehydriding said particles of Metal values at a temperature between about 400° and 700° C. under conditions operative to remove essentially all hydrogen values from said particles of Metal values and to produce dehydrided particles of 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 Zinc Soluble Metal-Based Metal particles which are substantially free of halides, zinc, hydrogen, oxygen and carbon.

Claim 18

The process of claim 13 wherein said heating step (a) is conducted under a partial vacuum.

Claim 19

The process of claim 13 wherein said heating step (a) is conducted under a continuous flow of a non-deleteriously-reactive sweep gas.

Claim 20

The process of claim 13 wherein said non-deleteriously-reactive sweep gas is selected from the group consisting of hydrogen, an inert gas, and mixtures thereof.

Claim 21

The process of claim 13 wherein said dehydriding step (d) is conducted under a partial vacuum.

Claim 22

A process to produce passified Zinc Soluble Metal-Based Metal particles which are substantially free of halides, zinc, hydrogen, oxygen and carbon and which are suitable for powder metallurgy usage, from a Zinc Soluble Metal-Based Metal-zinc alloy comprising: (a) forming a Zinc Soluble Metal-Based Metal-zinc alloy, which is substantially free of halides, into irregular shaped particles having particle size of less than 30 mesh; (b) heating said Zinc Soluble Metal-Based 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 Metal-zinc alloy particles and to produce particles of Zinc Soluble Metal-Based Metal values which are substantially free of zinc and halides; (c) contacting said particles of Metal values at a temperature below about 200° C. 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 Zinc Soluble Metal-Based Metal particles which are substantially free of halides; and (d) said forming of particles in step (a), said heating of said particles in step (b) being operative to cause said passified particles produced in step (c) to have a particle size distribution such that at least a substantial amount by weight of said Zinc Soluble Metal-Based Metal particles are suitable for powder metallurgy ussage without further particle size reduction.

Claim 23

A process to produce passified Zinc Soluble Metal-Based Metal particles which are substantially free of halides, zinc, hydrogen, oxygen and carbon and which are suitable for powder metallurgy usage, from a Zinc Soluble Metal-Based Metal-zinc alloy comprising: (a) forming a Zinc Soluble Metal-Based Metal-zinc alloy, which is substantially free of halides, into irregular shaped particles having particle size of less than 30 mesh; (b) heating said Zinc Soluble Metal-Based 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 Metal-zinc alloy particles and to produce particles of Zinc Soluble Metal-Based Metal values which are substantially free of zinc and halides; (c) contacting said particles of Metal values at a temperature below about 200° C. 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 Zinc Soluble Metal-Based Metal particles which are substantially free of halides; and (d) said forming of particles in step (a), said heating of said particles in step (b) being operative to cause said passified particles produced in step (c) to have a particle size distribution such that at least a substantial amount by weight of said Zinc Soluble Metal-Based Metal particles are suitable for powder metallurgy ussage without further particle size reduction.

Claim 24

The process of claim 18 wherein the particles of Zinc Soluble Metal-Based Metal produced in heating step (b) are sintered 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 Zinc Soluble Metal-Based Metal prior to passifying said particles in passification step (c).

Claim 25

The process of claim 18 wherein said heating step (b) is conducted under a partial vacuum.

Claim 26

The process of claim 18 wherein said heating step (b) is conducted under a continuous flow of a non-deleteriously-reactive sweep gas.

Claim 27

The process of claim 21 wherein said non-deleteriously-reactive sweep gas is selected from the group consisting of hydrogen, an inert gas, and mixtures thereof.

Claim 28

A process to produce passified Zinc Soluble Metal-Based Metal particles which are substantially free of halides, zinc, hydrogen, oxygen, nitrogen and carbon, and which are suitable for powder metallurgy usage, from a passified Zinc Soluble Metal-Based Metal, substantially free of zinc and halides, comprising: (a) contacting passified Zinc Soluble Metal-Based Metal values with hydrogen at a temperature between 300° and 700° C. under conditions operative to hydride and embrittle Metal values, thereby forming embrittled Metal values; (b) comminuting said embrittled Metal values under a nondeleteriously-reactive atmosphere, to a predetermined particle size of less than 30 mesh, thereby forming particles of hydrided Zinc Soluble Metal-Based Metal values; (c) dehydriding said particles at a temperature between about 400° and about 700° C. under conditions operative to remove essentially all hydrogen values from said particles to produce dehydrided particles of Zinc Soluble Metal-Based Metal values; (d) 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 Zinc Soluble Metal-Based Metal particles which are substantially free of halides, zinc, hydrogen, oxygen, nitrogen and carbon; and (e) said comminuting of said embrittled Metal values to predetermined particle size in step (b) being operative to cause said passified Zinc Soluble Metal-Based Metal particles produced in step (d) to have a particle size such that at least a substantial amount by weight of said passified Zinc Soluble Metal-Based Metal particles are suitable for powder metallurgy usage without further particle size reduction.

Claim 29

A process to produce passified Zinc Soluble Metal-Based Metal particles which are substantially free of halides, zinc, hydrogen, oxygen, nitrogen and carbon, and which are suitable for powder metallurgy usage, from a passified Zinc Soluble Metal-Based Metal, substantially free of zinc and halides, comprising: (a) contacting passified Zinc Soluble Metal-Based Metal values with hydrogen at a temperature between 300° and 700° C. under conditions operative to hydride and embrittle Metal values, thereby forming embrittled Metal values; (b) comminuting said embrittled Metal values under a nondeleteriously-reactive atmosphere, to a predetermined particle size of less than 30 mesh, thereby forming particles of hydrided Zinc Soluble Metal-Based Metal values; (c) dehydriding said particles at a temperature between about 400° and about 700° C. under conditions operative to remove essentially all hydrogen values from said particles to produce dehydrided particles of Zinc Soluble Metal-Based Metal values; (d) 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 Zinc Soluble Metal-Based Metal particles which are substantially free of halides, zinc, hydrogen, oxygen, nitrogen and carbon; and (e) said comminuting of said embrittled Metal values to predetermined particle size in step (b) being operative to cause said passified Zinc Soluble Metal-Based Metal particles produced in step (d) to have a particle size such that at least a substantial amount by weight of said passified Zinc Soluble Metal-Based Metal particles are suitable for powder metallurgy usage without further particle size reduction.

Claim 30

The process of claim 23 wherein said nondeleteriously-reactive atmosphere used in step (b) is an inert gas.

Claim 31

The process of claim 23 wherein said dehydriding step (c) is conducted under a nondeleteriously-reactive sweep gas.

Claim 32

The process of claim 23 wherein said dehydriding in step (c) is conducted under a partial vacuum.

Claim 33

A metal sponge consisting essentially of a Zinc Soluble Metal-Based Metal useful for metallurgical applications characterized as having less than about 50 PPM by weight halide, less than 5000 PPM hydrogen, oxygen, nitrogen and carbon, and an internal porosity of from about 5% to about 40% by volume.

Claim 34

A metal sponge consisting essentially of a Zinc Soluble Metal-Based Metal useful for metallurgical applications characterized as having less than about 50 PPM by weight halide, less than 5000 PPM hydrogen, oxygen, nitrogen and carbon, and an internal porosity of from about 5% to about 40% by volume.

Claim 35

The metal sponge of claim 27 wherein the Zinc Soluble Metal-Based Metal is selected from the group consisting of Mn, Fe, Co, Ni, Cu, Ge, Y, Rh, Pd, Ag, Sb, Pt, Au, Pr, U and mixtures thereof.

Claim 36

The metal sponge of claim 28 wherein the metal is an alloy of titanium and nickel.

Claim 37

The metal sponge of claim 27 wherein the metal has less than about 10 PPM by weight halide and an internal porosity of about 10% to about 20%.

Claim 38

The metal sponge of claim 27 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 39

The metal sponge of claim 27 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 40

The metal sponge of claim 27 wherein the metal has less than about 10 PPM by weight halide.

Claim 41

A process to produce passified Zinc Soluble Metal-Based Metal particles which are substantially free of halides, zinc, hydrogen, nitrogen, oxygen and carbon and which are suitable for powder metallurgy usage, from Zinc Soluble Metal-Based Metal-zinc alloy comprising: (a) heating a Zinc Soluble Metal-Based 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 Zinc Soluble Metal-Based Metal values which are substantially free of zinc and halides; (b) sintering said Metal values at a sintering temperature between about 850° and about 1150° C. under conditions operative to sinter said Metal values; (c) contacting said sintered transition metal values at a temperature between about 300° and about 700° C. with hydrogen under conditions operative to hydride and embrittle said sintered Metal values, thereby forming embrittled Metal values; (d) comminuting said embrittled Metal values under a nondeleteriously-reactive atmosphere, to a predetermined particle size thereby forming particles of embrittled metal values; (e) dehydriding said particles of embrittled 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 Metal values and to produce dehydrided particles of Metal values; (f) 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 Zinc Soluble Metal-Based Metal particles which are substantially free of halides, zinc, hydrogen, nitrogen, oxygen and carbon; and (g) said comminuting of said embrittled Metal values to predetermined particle size distribution in step (d) being operative to cause said passified Zinc Soluble Metal-Based Metal particles produced in step (f) to have a particle size such that at least a substantial amount by weight of said passified particles are suitable for powder metallurgy usage without further particle size reduction.

Claim 42

A process to produce passified Zinc Soluble Metal-Based Metal particles which are substantially free of halides, zinc, hydrogen, nitrogen, oxygen and carbon and which are suitable for powder metallurgy usage, from Zinc Soluble Metal-Based Metal-zinc alloy comprising: (a) heating a Zinc Soluble Metal-Based 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 Zinc Soluble Metal-Based Metal values which are substantially free of zinc and halides; (b) sintering said Metal values at a sintering temperature between about 850° and about 1150° C. under conditions operative to sinter said Metal values; (c) contacting said sintered transition metal values at a temperature between about 300° and about 700° C. with hydrogen under conditions operative to hydride and embrittle said sintered Metal values, thereby forming embrittled Metal values; (d) comminuting said embrittled Metal values under a nondeleteriously-reactive atmosphere, to a predetermined particle size thereby forming particles of embrittled metal values; (e) dehydriding said particles of embrittled 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 Metal values and to produce dehydrided particles of Metal values; (f) 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 Zinc Soluble Metal-Based Metal particles which are substantially free of halides, zinc, hydrogen, nitrogen, oxygen and carbon; and (g) said comminuting of said embrittled Metal values to predetermined particle size distribution in step (d) being operative to cause said passified Zinc Soluble Metal-Based Metal particles produced in step (f) to have a particle size such that at least a substantial amount by weight of said passified particles are suitable for powder metallurgy usage without further particle size reduction.

Claim 43

The process of claim 34 wherein said Zinc Soluble Metal-Based Metal-zinc alloy is produced from Zinc Soluble Metal-Based Metal sponge and zinc.

Claim 44

The process of claim 34 wherein said Zinc Soluble Metal-Based Metal-zinc alloy is produced from the reduction of a Zinc Soluble Metal-Based Metal halide with a metal alloy which comprises a reductant metal and zinc.

Claim 45

The process of claim 34 wherein said Zinc Soluble Metal-Based Metal-zinc alloy is an alloy of zinc and a Zinc Soluble Metal-Based Metal selected from the group consisting of Ti, Mn, Fe, Co, Ni, Cu, Ge, Y, Zr, Rh, Pd, Ag, Sb, Hf, Pt, Au, Pr, U and mixtures thereof.

Claim 46

A process to produce passified Zinc Soluble Metal-Based Metal particles which are substantially free of halides, and which are suitable for powder metallurgy usage, from a Zinc Soluble Metal-Based Metal-zinc alloy comprising: (a) forming a Zinc Soluble Metal-Based Metal-zinc alloy, which is substantially free of halides, into particles having a particle size of less than 30 mesh; (b) heating said particles in a zone maintained at a temperature between about 500° and about 1150° C., and simultaneously introducing into said zone a continuous flow of a nondeleteriously-reactive sweep gas, said zone being maintained under conditions operative to vaporize and separate zinc from said Zinc Soluble Metal-Based Metal-zinc alloy particles and to produce first particles of Zinc Soluble Metal-Based Metal values which are substantially free of zinc and halides; (c) sintering said first particles at a sintering temperature between about 850° and 1150° C. under conditions operative to sinter said first particles; (d) contacting said sintered first particles with a small amount of a gas selected from the group consisting of oxygen, nitrogen and mixtures thereof at a temperature between ambient temperature and about 200° C. under conditions operative to passify said cooled sintered first particles, thereby producing passified Zinc Soluble Metal-Based Metal particles which are substantially free of halides, zinc, hydrogen, nitrogen, oxygen and carbon; and (e) said forming of particles in step (a), and said heating of said first particles in step (c) being operative to cause said passified particles produced in step (d) to have a particle size distribution such that a significant amount by weight of said passified Zinc Soluble Metal-Based Metal particles are suitable for powder metallurgy usage without additional particle size reduction.

Claim 47

A process to produce passified Zinc Soluble Metal-Based Metal particles which are substantially free of halides, and which are suitable for powder metallurgy usage, from a Zinc Soluble Metal-Based Metal-zinc alloy comprising: (a) forming a Zinc Soluble Metal-Based Metal-zinc alloy, which is substantially free of halides, into particles having a particle size of less than 30 mesh; (b) heating said particles in a zone maintained at a temperature between about 500° and about 1150° C., and simultaneously introducing into said zone a continuous flow of a nondeleteriously-reactive sweep gas, said zone being maintained under conditions operative to vaporize and separate zinc from said Zinc Soluble Metal-Based Metal-zinc alloy particles and to produce first particles of Zinc Soluble Metal-Based Metal values which are substantially free of zinc and halides; (c) sintering said first particles at a sintering temperature between about 850° and 1150° C. under conditions operative to sinter said first particles; (d) contacting said sintered first particles with a small amount of a gas selected from the group consisting of oxygen, nitrogen and mixtures thereof at a temperature between ambient temperature and about 200° C. under conditions operative to passify said cooled sintered first particles, thereby producing passified Zinc Soluble Metal-Based Metal particles which are substantially free of halides, zinc, hydrogen, nitrogen, oxygen and carbon; and (e) said forming of particles in step (a), and said heating of said first particles in step (c) being operative to cause said passified particles produced in step (d) to have a particle size distribution such that a significant amount by weight of said passified Zinc Soluble Metal-Based Metal particles are suitable for powder metallurgy usage without additional particle size reduction.

Claim 48

The process of claim 38 wherein Zinc Soluble Metal-Based Metal-zinc alloy is produced from Zinc Soluble Metal-Based Metal sponge and zinc.

Claim 49

The process of claim 38 wherein said Zinc Soluble Metal-Based Metal-zinc alloy is produced from the reduction of a Zinc Soluble Metal-Based Metal halide with a metal alloy which comprises a reductant metal and zinc.

Claim 50

The process of claim 38 wherein said Zinc Soluble Metal-Based Metal-zinc alloy is an alloy of zinc and a Zinc Soluble Metal-Based Metal selected from the group consisting of Ti, Mn, Fe, Co, Ni, Cu, Ge, Y, Zr, Rh, Pd, Ag, Sb, Hf, Pt, Au, Pr, U and mixtures thereof.

Claim 51

The process of claim 38 wherein said nondeletoriously-reactive sweep gas used in step (b) is an inert gas.

Claim 52

The process of claim 38 wherein said heating in step (b) is conducted under a partial vacuum.

Claim 53

The process of claim 38 wherein said forming of particles in step (a) comprises comminuting of said Metal-zinc alloy.

Claim 54

The process of claim 38 wherein said forming of particles in step (a) comprises casting said Metal-zinc alloy.

Claim 55

A process to produce passified Zinc Soluble Metal Based Metal particles which are substantially free of halides, and which are suitable for powder metallurgy usage, from a Zinc Soluble Metal-Based Metal-zinc alloy comprising: (a) forming a Zinc Soluble Metal-Based Metal-zinc alloy, which is substantially free of halides, into particles having a particle size of less than 30 mesh; (b) heating said particles in a zone maintained at a temperature between about 500° and about 1150° C., and simultaneously introducing into said zone a continuous flow of a nondeleteriously-reactive sweep gas, said zone being maintained under conditions operative to vaporzie and separate zinc from said Metal-zinc alloy particles and to produce first particles of Zinc Soluble Metal-Based Metal values which are substantially free of zinc and halides; (c) sintering said first particles of a sintering temperature between about 850° and 1150° C. under conditions operative to sinter said first particles; (d) contacting said first particles with hydrogen at a temperature between about 300° and about 700° C. under conditions operative to hydride and embrittle said first particles, thereby forming embrittled Zinc Soluble Metal-Based Metal values; (e) comminuting said embrittled Metal values under a nondeleteriously-reactive atmosphere, to a predetermined particle size thereby forming second particles of Zinc Soluble Metal-Based Metal values; (f) dehydriding said second particles at a temperature between about 400° and 700° C. under conditions operative to remove essentially all hydrogen values from said second particles to produce dehydrided particles of Zinc Soluble Metal-Based Metal values; and (g) 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 Zinc Soluble Metal-Based Metal particles which are substantially free of halides, zinc, hydrogen, nitrogen, oxygen and carbon; and (h) said forming of particles in step (a), said heating of said first particles in step (c), and said comminuting of said embrittled Metal values to predetermined particle size distribution in step (e) being operative to cause said passified Zinc Soluble Metal-Based Metal particles produced in step (g) to have a particle size distribution such that at least a substantial amount by weight of said particles are suitable for powder metallurgy usage with further particle size reduction.

Claim 56

A process to produce passified Zinc Soluble Metal Based Metal particles which are substantially free of halides, and which are suitable for powder metallurgy usage, from a Zinc Soluble Metal-Based Metal-zinc alloy comprising: (a) forming a Zinc Soluble Metal-Based Metal-zinc alloy, which is substantially free of halides, into particles having a particle size of less than 30 mesh; (b) heating said particles in a zone maintained at a temperature between about 500° and about 1150° C., and simultaneously introducing into said zone a continuous flow of a nondeleteriously-reactive sweep gas, said zone being maintained under conditions operative to vaporzie and separate zinc from said Metal-zinc alloy particles and to produce first particles of Zinc Soluble Metal-Based Metal values which are substantially free of zinc and halides; (c) sintering said first particles of a sintering temperature between about 850° and 1150° C. under conditions operative to sinter said first particles; (d) contacting said first particles with hydrogen at a temperature between about 300° and about 700° C. under conditions operative to hydride and embrittle said first particles, thereby forming embrittled Zinc Soluble Metal-Based Metal values; (e) comminuting said embrittled Metal values under a nondeleteriously-reactive atmosphere, to a predetermined particle size thereby forming second particles of Zinc Soluble Metal-Based Metal values; (f) dehydriding said second particles at a temperature between about 400° and 700° C. under conditions operative to remove essentially all hydrogen values from said second particles to produce dehydrided particles of Zinc Soluble Metal-Based Metal values; and (g) 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 Zinc Soluble Metal-Based Metal particles which are substantially free of halides, zinc, hydrogen, nitrogen, oxygen and carbon; and (h) said forming of particles in step (a), said heating of said first particles in step (c), and said comminuting of said embrittled Metal values to predetermined particle size distribution in step (e) being operative to cause said passified Zinc Soluble Metal-Based Metal particles produced in step (g) to have a particle size distribution such that at least a substantial amount by weight of said particles are suitable for powder metallurgy usage with further particle size reduction.

Claim 57

A power metal consisting of a zinc soluble base metal selected from the group consisting of Ti, Mn, Fe, Co, Ni, Cu, Ge, Y, Zr, Rh, Pd, Ag, Sb, Hf, Pt, Au, Pr, U and mixtures thereof having an average particle size of about 100 mesh and having less than about 50 PPM of halide and an internal porosity of more than 20% by volume, said powder comprising angular shaped particles.

Claim 58

A power metal consisting of a zinc soluble base metal selected from the group consisting of Ti, Mn, Fe, Co, Ni, Cu, Ge, Y, Zr, Rh, Pd, Ag, Sb, Hf, Pt, Au, Pr, U and mixtures thereof having an average particle size of about 100 mesh and having less than about 50 PPM of halide and an internal porosity of more than 20% by volume, said powder comprising angular shaped particles.

Claim 59

Passified Zinc Soluble Metal-Based Metal particles which are substantially free of halides, zinc, hydrogen, oxygen, nitrogen and carbon and which are suitable for powder metallurgy usage prepared from zinc soluble metal-based metal alloy comprising: (a) forming particles of a Zinc Soluble Metal-Based Metal-zinc alloy, substantially free of halides, hydrogen, oxygen, nitrogen and carbon, into particles having an average particle size of about 100 mesh; (b) heating said particles in a zone maintained at a temperature between about 900° and about 950° C., and simultaneously introducing into said zone a continuous flow of a nondeleteriously reactive sweep gas, said zone being maintained under conditions operative to vaporize and separate zinc from said particles and to produce particles of Zinc Soluble Metal-Based Metal which are substantially free of zinc and have an internal porosity of more than about 20% by volume; (c) heating said Zinc Soluble Metal-Based Metal particles at a sintering temperature between about 1020° and 1060° C. under conditions operative to sinter said particles; (d) contacting said sintered particles at a temperature between about ambient temperature and about 60 C. 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 Zinc Soluble Metal-Based Metal particles which are substantially free of halides, zinc, hydrogen, oxygen, nitrogen and carbon; and (e) said forming of said Zinc Soluble Metal-Based Metal-zinc alloy particles in step (a) and said heating of said Zinc Soluble Metal-Based Metal particles in step (c) being operative to cause said passified Zinc Soluble Metal-Based Metal particles produced in step (d) to have a particle size distribution such that a significant amount by weight of said passified Zinc Soluble Metal-Based Metal particles are suitable for powder metallurgy usage without additional particle size reduction.

Claim 60

Passified Zinc Soluble Metal-Based Metal particles which are substantially free of halides, zinc, hydrogen, oxygen, nitrogen and carbon and which are suitable for powder metallurgy usage prepared from zinc soluble metal-based metal alloy comprising: (a) forming particles of a Zinc Soluble Metal-Based Metal-zinc alloy, substantially free of halides, hydrogen, oxygen, nitrogen and carbon, into particles having an average particle size of about 100 mesh; (b) heating said particles in a zone maintained at a temperature between about 900° and about 950° C., and simultaneously introducing into said zone a continuous flow of a nondeleteriously reactive sweep gas, said zone being maintained under conditions operative to vaporize and separate zinc from said particles and to produce particles of Zinc Soluble Metal-Based Metal which are substantially free of zinc and have an internal porosity of more than about 20% by volume; (c) heating said Zinc Soluble Metal-Based Metal particles at a sintering temperature between about 1020° and 1060° C. under conditions operative to sinter said particles; (d) contacting said sintered particles at a temperature between about ambient temperature and about 60 C. 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 Zinc Soluble Metal-Based Metal particles which are substantially free of halides, zinc, hydrogen, oxygen, nitrogen and carbon; and (e) said forming of said Zinc Soluble Metal-Based Metal-zinc alloy particles in step (a) and said heating of said Zinc Soluble Metal-Based Metal particles in step (c) being operative to cause said passified Zinc Soluble Metal-Based Metal particles produced in step (d) to have a particle size distribution such that a significant amount by weight of said passified Zinc Soluble Metal-Based Metal particles are suitable for powder metallurgy usage without additional particle size reduction.

Claim 61

A process to produce passified Zinc Soluble Metal-Based Metal particles which are substantially free of halides, zinc, hydrogen, oxygen and carbon and suitable for powder metallurgy usage, from a Zinc Soluble Metal-Based Metal-zinc alloy comprising: (a) forming a Zinc Soluble Metal-Based Metal-zinc alloy, which is substantially free of halides, hydrogen, oxygen and carbon, into irregular shaped particles having an average particle size of about 100 mesh; (b) heating said Zinc Soluble Metal-Based Metal-zinc alloy particles in a zone maintained at a temperature between about 900° and about 950° C. under conditions operative to vaporize and separate zinc from said particles and to produce particle of Zinc Soluble Metal-Based Metal which are substantially free of zinc; (c) contacting said Zinc Soluble Metal-Based Metal particles at a temperature between ambient temperature and about 60° C. 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 Zinc Soluble Metal-Based Metal particles; and (d) said forming of Zinc Soluble Metal-Based Metal-zinc alloy particles in step (a), and said heating of said particles in step (b) being operative to cause said passified Zinc Soluble Metal-Based Metal particles produced in step (c) to have a particle size distribution such that at least a substantial amount by weight of said Zinc Soluble Metal-Based Metal particles are suitable for powder metallurgy usage without further particle size reduction.

Claim 62

A process to produce passified Zinc Soluble Metal-Based Metal particles which are substantially free of halides, zinc, hydrogen, oxygen and carbon and suitable for powder metallurgy usage, from a Zinc Soluble Metal-Based Metal-zinc alloy comprising: (a) forming a Zinc Soluble Metal-Based Metal-zinc alloy, which is substantially free of halides, hydrogen, oxygen and carbon, into irregular shaped particles having an average particle size of about 100 mesh; (b) heating said Zinc Soluble Metal-Based Metal-zinc alloy particles in a zone maintained at a temperature between about 900° and about 950° C. under conditions operative to vaporize and separate zinc from said particles and to produce particle of Zinc Soluble Metal-Based Metal which are substantially free of zinc; (c) contacting said Zinc Soluble Metal-Based Metal particles at a temperature between ambient temperature and about 60° C. 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 Zinc Soluble Metal-Based Metal particles; and (d) said forming of Zinc Soluble Metal-Based Metal-zinc alloy particles in step (a), and said heating of said particles in step (b) being operative to cause said passified Zinc Soluble Metal-Based Metal particles produced in step (c) to have a particle size distribution such that at least a substantial amount by weight of said Zinc Soluble Metal-Based Metal particles are suitable for powder metallurgy usage without further particle size reduction.

Claim 63

A metal sponge consisting of a Zinc Soluble Metal-Based Metal useful for metallurgical application characterized as having less than 10 PPM by weight halide, 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, and an internal porosity of about 10% to about 20% by volume, said Zinc Soluble Metal-Based Metal being selected from the group consisting of Mn, Fe, Co, Ni, Cu, Ge, Y, Rh, Pd, Ag, Sb, Pt, Au, Pr, U and mixtures thereof.

Claim 64

A metal sponge consisting of a Zinc Soluble Metal-Based Metal useful for metallurgical application characterized as having less than 10 PPM by weight halide, 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, and an internal porosity of about 10% to about 20% by volume, said Zinc Soluble Metal-Based Metal being selected from the group consisting of Mn, Fe, Co, Ni, Cu, Ge, Y, Rh, Pd, Ag, Sb, Pt, Au, Pr, U and mixtures thereof.

Claim 65

A metal alloy sponge consisting of titanium and nickel useful for metallurgical applications characterized as having less than 10 PPM by weight halide, less than about 2500 PPM by weight oxygen, less than about 400 PPM by weight nitrogen, less than about 800 PPM by weight carbon, and an internal porosity of about 10 to about 20% by volume.

Claim 66

A metal alloy sponge consisting of titanium and nickel useful for metallurgical applications characterized as having less than 10 PPM by weight halide, less than about 2500 PPM by weight oxygen, less than about 400 PPM by weight nitrogen, less than about 800 PPM by weight carbon, and an internal porosity of about 10 to about 20% by volume.

Claim 67

A process to produce passified Zinc Soluble Metal-Based Metal particles which are substantially free of halides, and which are suitable for powder metallurgy usage, from a Zinc Soluble Metal-Based Metal-Zinc alloy comprising: (a) forming a Zinc Soluble Metal-Based Metal-zinc alloy, which is substantially free of halides, into particles having an average particle size of about 100 mesh; (b) heating said particles in a zone maintained at a temperature between about 900° and 950° C. and simultaneously introducing into said zone a continuous flow of a nondeleteriously-reactive sweep gas, said zone being maintained under conditions operative to vaporize and separate zinc from said particles and to produce particles of Zinc Soluble Metal-Based Metal which are substantially free of zinc and halides; (c) sintering said first particles at a sintering temperature between about 1020° and 1060° C. under conditions operative to sinter said particles; (d) contacting said sintered particles with a small amount of a gas selected from the group consisting of oxygen, hydrogen and mixtures thereof at a temperature between ambient temperature and about 60° C. under conditions operative to passify said sintered particles, thereby producing passified Zinc Soluble Metal-Based Metal particles which are substantially free of halides and zinc; and (e) said forming of Zinc Soluble Metal-Based Metal-zinc alloy particles in step (a), and said heating of said particles in step (b) being operative to cause said passified particles produced in step (d) to have particle size distribution such that a significant amount of weight of said passified Zinc Soluble Metal-Based Metal particles are suitable for powder metallurgy usage without additional particle size reduction.

Claim 68

A process to produce passified Zinc Soluble Metal-Based Metal particles which are substantially free of halides, and which are suitable for powder metallurgy usage, from a Zinc Soluble Metal-Based Metal-Zinc alloy comprising: (a) forming a Zinc Soluble Metal-Based Metal-zinc alloy, which is substantially free of halides, into particles having an average particle size of about 100 mesh; (b) heating said particles in a zone maintained at a temperature between about 900° and 950° C. and simultaneously introducing into said zone a continuous flow of a nondeleteriously-reactive sweep gas, said zone being maintained under conditions operative to vaporize and separate zinc from said particles and to produce particles of Zinc Soluble Metal-Based Metal which are substantially free of zinc and halides; (c) sintering said first particles at a sintering temperature between about 1020° and 1060° C. under conditions operative to sinter said particles; (d) contacting said sintered particles with a small amount of a gas selected from the group consisting of oxygen, hydrogen and mixtures thereof at a temperature between ambient temperature and about 60° C. under conditions operative to passify said sintered particles, thereby producing passified Zinc Soluble Metal-Based Metal particles which are substantially free of halides and zinc; and (e) said forming of Zinc Soluble Metal-Based Metal-zinc alloy particles in step (a), and said heating of said particles in step (b) being operative to cause said passified particles produced in step (d) to have particle size distribution such that a significant amount of weight of said passified Zinc Soluble Metal-Based Metal particles are suitable for powder metallurgy usage without additional particle size reduction.