US5707419A
Expired / Lapsed
US
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Method of production of metal and ceramic powders by plasma atomization
Assignee: Hydro-Québec
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Filing: 1995-08-15
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Granted: 1998-01-13
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Expires: 2015-08-15
Abstract
Abstract A metal or an alloy thereof, or a ceramic that has a liquid phase is introduced in the form of a rod or a wire or as a liquid stream into the apex formed by a plurality of converging plasma jets. Atomization takes place and upon controlled cooling good quality spheroidal powders are obtained whose size varies generally between about 10 and 300 μm.
Inventors
- 👤 Peter G. Tsantrizos
- 👤 François Allaire
- 👤 Majid Entezarian
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-08 06:47
CPC Classifications
B; B01; B01J; B01J19/00; B01J19/26; B01J19/08; B01J19/087; B01J19/088; B22; B22F; B22F9/00; B22F9/02; B22F9/06; B22F9/08; B22F9/082; B01J2219/00; B01J2219/00049; B01J2219/00051; B01J2219/08; B01J2219/0803; B01J2219/0805; B01J2219/0807; B01J2219/0809; B01J2219/0824; B01J2219/0826; B01J2219/083; B01J2219/0832; B01J2219/0845; B01J2219/0847; B01J2219/0873; B01J2219/0881; B01J2219/0883; B01J2219/0894; B22F2998/00; B22F2999/00
Claims Analysis
Total Claims: 22
Claim 1
Independent Claim
134 words
Method for the production of substantially spheroidal powders of at least one material selected from the group consisting of metals, alloys and ceramics having a liquid phase, which comprises: (a) providing a plurality of plasma torches each delivering a jet; (b) causing said jets to converge into an apex; (c) directing a continuous feed of said at least one material into said apex; (d) providing said jets with sufficient kinetic energy in said apex to cause atomization of said at least one material into particles having a particle size of from 10 to 300 μm by said jets; (e) controlling cooling of atomized material as it exits from said apex at a rate of at least about 10 3 K/sec. to cause spheroidization of said atomized material and to produce said substantially spheroidal powders.
Claim 2
Dependent Claim
134 words
Method for the production of substantially spheroidal powders of at least one material selected from the group consisting of metals, alloys and ceramics having a liquid phase, which comprises: (a) providing a plurality of plasma torches each delivering a jet; (b) causing said jets to converge into an apex; (c) directing a continuous feed of said at least one material into said apex; (d) providing said jets with sufficient kinetic energy in said apex to cause atomization of said at least one material into particles having a particle size of from 10 to 300 μm by said jets; (e) controlling cooling of atomized material as it exits from said apex at a rate of at least about 10 3 K/sec. to cause spheroidization of said atomized material and to produce said substantially spheroidal powders.
Claim 3
Dependent Claim
18 words
Method according to claim 1, which comprises providing three plasma torches wherein the jets converge into said apex.
Claim 4
Dependent Claim
38 words
Method according to claim 2, wherein said jets are equally distributed around a central axis to define angles of about 120° between one another and each forming an angle of about 30° with respect to the central axis.
Claim 5
Dependent Claim
24 words
Method according to claim 1, which comprises feeding said at least one material into said apex in the form of a molten stream thereof.
Claim 6
Dependent Claim
44 words
Method according to claim 4, which comprises melting said at least one material in a furnace to produce a molten material and pouring said molten material through a nozzle provided in said furnace to give said molten stream of said at least one material.
Claim 7
Dependent Claim
12 words
Method according to claim 5, wherein said nozzle is made of graphite.
Claim 8
Dependent Claim
25 words
Method according to claim 1, which comprises feeding said at least one material into said apex in the form of a continuous elongated shape thereof.
Claim 9
Dependent Claim
34 words
Method according to claim 7, which comprises pressing ceramic powders whose size is about 1 μm into a rod, feeding said rod into said apex, and melting and atomizing said rod to form powders.
Claim 10
Dependent Claim
22 words
Method according to claim 7, wherein the continuous elongated shape is a wire which is fed into said apex for spheroidization thereof.
Claim 11
Dependent Claim
21 words
Method according to claim 7, wherein said continuous elongated shape is fed into said apex by means of a reeling device.
Claim 12
Dependent Claim
14 words
Method according to claim 1, wherein said material consists of one or more metals.
Claim 13
Dependent Claim
25 words
Method according to claim 11, wherein said one or more metals are selected from the group consisting of aluminum, copper, nickel, titanium and alloys thereof.
Claim 14
Dependent Claim
23 words
Method according to claim 1, wherein momentum of the plasma jet is adjusted to give particle sizes between about 50 and 100 μm.
Claim 15
Dependent Claim
13 words
Method according to claim 1, wherein said material comprises one or more ceramics.
Claim 16
Dependent Claim
25 words
Method according to claim 14, wherein said ceramics are selected from the group consisting of oxides, carbides, borides and nitrides which have a liquid phase.
Claim 17
Dependent Claim
36 words
Method according to claim 1, wherein said material is selected from the group consisting of metal and ceramic powders of irregular morphology, and atomized metal and ceramic powders are converted into spheroidal powders of regular morphology.
Claim 18
Dependent Claim
27 words
Method according to claim 16, wherein agglomerated metal and ceramic powders are fed into the apex under conditions to produce fully dense spherical particles of said material.
Claim 19
Dependent Claim
28 words
Method according to claim 1, wherein said plasma torches are each provided with a high velocity nozzle to increase momentum of the plasma jets and facilitate said atomization.
Claim 20
Dependent Claim
18 words
The method according to claim 1, wherein said method consists of steps a, b, c, d and e.
Claim 21
Dependent Claim
112 words
Method for the production of consolidated shapes of at least one material selected from the group consisting of metals, alloys and ceramics having a liquid phase, which comprises: a) providing a plurality of plasma torches each delivering a jet; b) causing said jets to converge into an apex; c) directing a continuous feed of said at least one material into said apex; d) providing said jets with sufficient kinetic energy in said apex to cause atomization of said at least one material into particles having a particle size of from 10 to 300 μm by said jets; e) directing said atomized material against a cool substrate to form said consolidated shapes thereon.
Claim 22
Dependent Claim
112 words
Method for the production of consolidated shapes of at least one material selected from the group consisting of metals, alloys and ceramics having a liquid phase, which comprises: a) providing a plurality of plasma torches each delivering a jet; b) causing said jets to converge into an apex; c) directing a continuous feed of said at least one material into said apex; d) providing said jets with sufficient kinetic energy in said apex to cause atomization of said at least one material into particles having a particle size of from 10 to 300 μm by said jets; e) directing said atomized material against a cool substrate to form said consolidated shapes thereon.
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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) | 2001-01-12 | 2001-07-14 | 2002-01-13 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2005-01-12 | 2005-07-14 | 2006-01-13 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2009-01-12 | 2009-07-14 | 2010-01-13 | $7700.00 | Window Closed / Lapsed |