US4762553A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Method for making rapidly solidified powder
Assignee: United States Department of the Air Force
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Filing: 1987-04-24
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Granted: 1988-08-09
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Expires: 2007-04-24
Abstract
Abstract System and method for producing metal or alloy powder are described comprising an electromagnetic levitating coil having an outlet for supporting a molten source of the metal or alloy and controllably discharging a molten stream thereof, an electromagnetic confining coil disposed at the outlet of the levitating coil and surrounding the molten stream for controlling the diameter of the molten stream, and either an atomization die and associated pressurized fluid source for disintergrating the confined molten stream into molten droplets for subsequent cooling to powder, or a controllable electromagnetic coil surrounding the confined molten stream for generating a downwardly and radially outwardly directed electromagnetic force interacting with the molten stream to form the droplets.
Inventors
- 👤 Steven J. Savage
- 👤 Daniel Eylon
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-03 08:52
CPC Classifications
B; B22; B22F; B22F9/00; B22F9/02; B22F9/06; B22F9/08; B22F9/082; B22F2009/0836; B22F2009/0892
Claims Analysis
Total Claims: 26
Claim 1
Independent Claim
84 words
A method for producing powder of metal or alloy material comprising the steps of: (a) providing a source of molten said material; (b) electromagnetically levitating said molten said material, on a levitating coil having an outlet, and forming a molten stream of said material directed from said outlet of said levitating coil; (c) electromagnetically confining said molten stream to preselected stream diameter; (d) disintegrating the confined said moltens stream into droplets of molten said material; and (e) cooling said droplets to form said powder.
Claim 2
Independent Claim
84 words
A method for producing powder of metal or alloy material comprising the steps of: (a) providing a source of molten said material; (b) electromagnetically levitating said molten said material, on a levitating coil having an outlet, and forming a molten stream of said material directed from said outlet of said levitating coil; (c) electromagnetically confining said molten stream to preselected stream diameter; (d) disintegrating the confined said moltens stream into droplets of molten said material; and (e) cooling said droplets to form said powder.
Claim 3
Dependent Claim
22 words
The method of claim 1 wherein said disintegrating step includes impacting said molten stream with a fluid stream in an atomization die.
Claim 4
Dependent Claim
39 words
The method of claim 1 wherein said disintegrating step includes directing said molten stream through a controllable electromagnetic coil generating a downwardly and radially outwardly directed electromagnetic force interacting with said molten stream and thereby disintegrating said molten stream.
Claim 5
Dependent Claim
33 words
The method of claim 1 wherein said material comprises a metal selected from the group consisting of iron, cobalt, nickel, aluminum, hafnium, zinc, titanium, niobium, zirconium, tin, copper, tungsten, molybdenum, tantalum, and magnesium.
Claim 6
Dependent Claim
30 words
The method of claim 1 wherein said material comprises an alloy selected from the group consisting of titanium-aluminum, magnesium-lithium, nickel-aluminum, molybdenum-titanium, tungsten-hafnium, stainless steel, bronze, brass, and nickel/cobalt based superalloys.
Claim 7
Dependent Claim
25 words
The method of claim 2 wherein said fluid is a material selected from the group consisting of nitrogen, argon, helium, methane, carbon dioxide, and hydrogen.
Claim 8
Independent Claim
54 words
A method for producing powder of metal or alloy material comprising the steps of: (a) forming a molten stream of said material; (b) electromagnetically confining said molten stream and controlling the diameter of said molten stream; and (c) disintegrating said molten stream into droplets of molten said material for subsequent cooling to said powder.
Claim 9
Independent Claim
54 words
A method for producing powder of metal or alloy material comprising the steps of: (a) forming a molten stream of said material; (b) electromagnetically confining said molten stream and controlling the diameter of said molten stream; and (c) disintegrating said molten stream into droplets of molten said material for subsequent cooling to said powder.
Claim 10
Dependent Claim
22 words
The method of claim 7 wherein said disintegrating step includes impacting said molten stream with a fluid stream in an atomization die.
Claim 11
Dependent Claim
39 words
The method of claim 7 wherein said disintegrating step includes directing said molten stream through a controllable electromagnetic coil generating a downwardly and radially outwardly directed electromagnetic force interacting with said molten stream and thereby disintegrating said molten stream.
Claim 12
Dependent Claim
33 words
The method of claim 7 wherein said material comprises a metal selected from the group consisting of iron, cobalt, nickel, aluminum, hafnium, zinc, titanium, niobium, zirconium, tin, copper, tungsten, molybdenum, tantalum, and magnesium.
Claim 13
Dependent Claim
30 words
The method of claim 7 wherein said material comprises an alloy selected from the group consisting of titanium-aluminum, magnesium-lithium, nickel-aluminum, molybdenum-titanium, tungsten-hafnium, stainless steel, bronze, brass, and nickel/cobalt based superalloys.
Claim 14
Dependent Claim
25 words
The method of claim 8 wherein said fluid is a material selected from the group consisting of nitrogen, argon, helium, methane, carbon dioxide, and hydrogen.
Claim 15
Independent Claim
120 words
A system for producing powder of metal or alloy material comprising: (a) a source of molten said material; (b) electromagnetic levitating means for supporting said molten said material, said levitating means including an outlet for discharging from said levitating means a molten stream of said material; (c) electromagnetic confining means disposed at said outlet of said levitating means and surrounding said molten stream for controlling the diameter of said molten stream, said confining means including an inlet and an outlet for conducting said molten stream therethrough; and (d) atomization means disposed near said molten stream and adjacent said outlet of said confining means for disintegrating said molten stream into droplets of molten said material for subsequent cooling to said powder.
Claim 16
Independent Claim
120 words
A system for producing powder of metal or alloy material comprising: (a) a source of molten said material; (b) electromagnetic levitating means for supporting said molten said material, said levitating means including an outlet for discharging from said levitating means a molten stream of said material; (c) electromagnetic confining means disposed at said outlet of said levitating means and surrounding said molten stream for controlling the diameter of said molten stream, said confining means including an inlet and an outlet for conducting said molten stream therethrough; and (d) atomization means disposed near said molten stream and adjacent said outlet of said confining means for disintegrating said molten stream into droplets of molten said material for subsequent cooling to said powder.
Claim 17
Dependent Claim
45 words
The system of claim 13 wherein said atomization means comprises a source of pressurized fluid and an atomization die disposed adjacent said outlet of said confining means and operatively connected to said source of pressurized fluid for directing a fluid stream against said molten stream.
Claim 18
Dependent Claim
50 words
The system of claim 13 wherein said atomization means comprises a controllable electromagnetic coil disposed near the outlet of said confining means and surrounding said molten stream and generating a downwardly and radially outwardly directed electromagnetic force for interaction with said molten stream and disintegration of said molten stream thereby.
Claim 19
Independent Claim
120 words
A system for producing powder of metal or alloy material comprising: (a) an electromagnetic levitating first coil for melting said material and supporting molten said material, said first coil including an outlet for discharging from said first coil a molten stream of said material; (b) an electromagnetic confining second coil disposed at said outlet of said first coil and surrounding said molten stream for controlling the diameter of said molten stream, said second coil including an inlet and an outlet for conducting said molten stream therethrough; and (c) atomization means disposed near said molten stream and adjacent said outlet of said second coil for disintegrating said molten stream into droplets of molten said material for subsequent cooling to said powder.
Claim 20
Independent Claim
120 words
A system for producing powder of metal or alloy material comprising: (a) an electromagnetic levitating first coil for melting said material and supporting molten said material, said first coil including an outlet for discharging from said first coil a molten stream of said material; (b) an electromagnetic confining second coil disposed at said outlet of said first coil and surrounding said molten stream for controlling the diameter of said molten stream, said second coil including an inlet and an outlet for conducting said molten stream therethrough; and (c) atomization means disposed near said molten stream and adjacent said outlet of said second coil for disintegrating said molten stream into droplets of molten said material for subsequent cooling to said powder.
Claim 21
Dependent Claim
45 words
The system of claim 16 wherein said atomization means comprises a source of pressurized fluid and an atomization die disposed adjacent said outlet of said second coil and operatively connected to said source of pressurized fluid for directing a fluid stream against said molten stream.
Claim 22
Dependent Claim
51 words
The system of claim 16 wherein said atomization means comprises a controllable electromagnetic third coil disposed near the outlet of said second coil and surrounding said molten stream and generating a downwardly and radially outwardly directed electromagnetic force for interaction with said molten stream and disintegration of said molten stream thereby.
Claim 23
Independent Claim
90 words
A system for producing powder of metal or alloy material comprising: (a) means for forming a molten stream of said material; (b) an electromagnetic confining first coil disposed for surrounding said molten stream and controlling the diameter of said molten stream, said first coil including an inlet and an outlet for conducting said molten stream therethrough; and (c) atomization means disposed near said molten stream and adjacent said outlet of said first coil for disintegrating said molten stream into droplets of molten said material for subsequent cooling to said powder.
Claim 24
Independent Claim
90 words
A system for producing powder of metal or alloy material comprising: (a) means for forming a molten stream of said material; (b) an electromagnetic confining first coil disposed for surrounding said molten stream and controlling the diameter of said molten stream, said first coil including an inlet and an outlet for conducting said molten stream therethrough; and (c) atomization means disposed near said molten stream and adjacent said outlet of said first coil for disintegrating said molten stream into droplets of molten said material for subsequent cooling to said powder.
Claim 25
Dependent Claim
45 words
The system of claim 19 wherein said atomization means comprises a source of pressurized fluid and an atomization die disposed adjacent said outlet of said second coil and operatively connected to said source of pressurized fluid for directing a fluid stream against said molten stream.
Claim 26
Dependent Claim
51 words
The system of claim 19 wherein said atomization means comprises a controllable electromagnetic second coil disposed near the outlet of said first coil and surrounding said molten stream and generating a downwardly and radially outwardly directed electromagnetic force for interaction with said molten stream and disintegration of said molten stream thereby.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1991-08-09 | 1992-02-08 | 1992-08-09 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1995-08-09 | 1996-02-08 | 1996-08-09 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1999-08-09 | 2000-02-08 | 2000-08-09 | $7700.00 | Window Closed / Lapsed |