There are provided reactive metal powder atomization manufacturing processes. For example, such processes include providing a heated metal source and contact the heated metal source with at least one additive gas while carrying out the atomization process. Such processes provide raw reactive metal powder having improved flowability. The at least one additive gas can be mixed together with an atomization gas to obtain an atomization mixture, and the heated metal source can be contacted with the atomization mixture while carrying out the atomization process. Reactive metal powder spheroidization manufacturing processes are also provided.
B22F 9/08 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
B01J 2/02 - Processes or devices for granulating materials, in general; Rendering particulate materials free flowing in general, e.g. making them hydrophobic by dividing the liquid material into drops, e.g. by spraying, and solidifying the drops
B22F 1/052 - Metallic powder characterised by the size or surface area of the particles characterised by a mixture of particles of different sizes or by the particle size distribution
B22F 1/16 - Metallic particles coated with a non-metal
B22F 9/04 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes starting from solid material, e.g. by crushing, grinding or milling
B22F 9/14 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes using electric discharge
C22C 1/04 - Making non-ferrous alloys by powder metallurgy
2.
REACTIVE METAL POWDERS IN-FLIGHT HEAT TREATMENT PROCESSES
There are provided reactive metal powder in-flight heat treatment processes. For example, such processes comprise providing a reactive metal powder; and contacting the reactive metal powder with at least one additive gas while carrying out said in-flight heat treatment process, thereby obtaining a raw reactive metal powder.
B22F 9/08 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
B22F 1/16 - Metallic particles coated with a non-metal
B22F 1/145 - Chemical treatment, e.g. passivation or decarburisation
There are provided reactive metal powder in-flight heat treatment processes. For example, such processes comprise providing a reactive metal powder; and contacting the reactive metal powder with at least one additive gas while carrying out said in-flight heat treatment process, thereby obtaining a raw reactive metal powder.
B22F 1/00 - Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
B22F 9/08 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
B22F 1/16 - Metallic particles coated with a non-metal
B22F 1/145 - Chemical treatment, e.g. passivation or decarburisation
A plasma atomization metal powder manufacturing process includes providing a heated metal source and contacting the heated metal source with the plasma of at least one plasma source under conditions effective for causing atomization of the heated metal source. The atomization may be carried out using a gas to metal ratio of less than about 20, thereby obtaining a raw metal powder having a 0-106 μm particle size distribution yield of at least 80%. The process may further include aligning the heated metal source with the plasma of at least one plasma source. An atomizing system may include an alignment system positioned upstream of the plasma source and adapted to adjust an orientation of the metal source relative to the at least one plasma source.
B22F 9/08 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
C22C 1/04 - Making non-ferrous alloys by powder metallurgy
B22F 9/14 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes using electric discharge
B22F 9/12 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes starting from gaseous material
B22F 1/052 - Metallic powder characterised by the size or surface area of the particles characterised by a mixture of particles of different sizes or by the particle size distribution
5.
METHOD FOR FORMING HIGH QUALITY POWDER FOR AN ADDITIVE MANUFACTURING PROCESS
A powder treatment assembly and method for treating a feedstock powder of feedstock particles includes directing the feedstock powder into a plasma chamber within a reactor, exposing the feedstock powder to a plasma field generated by a plasma source to form a treated powder having treated particles with an increased average sphericity relative to the feedstock particles, and supplying a hot gas sheath flow downstream of the plasma chamber, the hot gas sheath flow substantially surrounding the treated powder.
A system and method (400) for treating additive powder (104) includes a reactor configured for receiving a large volume of additive powder (104). An evacuation subsystem (112) removes injected or residual gases from the reactor chamber (112) by purging the chamber with an inert gas or drawing a vacuum within the chamber. A heating assembly raises the reactor content temperature of the reactor chamber (112) while the additive powder (104) is continuously stirred. A gas mixture including a small amount of reactive gas is injected into the reactor chamber (112) to modify the surface (304) chemistry of the additive powder (104) before the additive powder (104) is slowly cooled down.
B22F 1/145 - Chemical treatment, e.g. passivation or decarburisation
B33Y 70/00 - Materials specially adapted for additive manufacturing
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
A system and method for treating additive powder includes a reactor configured for receiving a large volume of additive powder. An evacuation subsystem removes injected or residual gases from the reactor chamber by purging the chamber with an inert gas or drawing a vacuum within the chamber. A heating assembly raises the reactor content temperature of the reactor chamber while the additive powder is continuously stirred. A gas mixture including a small amount of reactive gas is injected into the reactor chamber to modify the surface chemistry of the additive powder before the additive powder is slowly cooled down.
A system and method (400) for treating additive powder (104) includes a reactor configured for receiving a large volume of additive powder (104). An evacuation subsystem (112) removes injected or residual gases from the reactor chamber (112) by purging the chamber with an inert gas or drawing a vacuum within the chamber. A heating assembly raises the reactor content temperature of the reactor chamber (112) while the additive powder (104) is continuously stirred. A gas mixture including a small amount of reactive gas is injected into the reactor chamber (112) to modify the surface (304) chemistry of the additive powder (104) before the additive powder (104) is slowly cooled down.
B22F 1/02 - Special treatment of metallic powder, e.g. to facilitate working, to improve properties; Metallic powders per se, e.g. mixtures of particles of different composition comprising coating of the powder
B22F 10/28 - Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
Aluminum-based metallic powders, along with their methods of production and formation, are provided. The Al-based metallic powders are formed with an increased amount of oxygen within at least a portion of the particles of the powder. The Al-based metallic powders show improved flowability.
B22F 1/00 - Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
B22F 9/08 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
10.
ALUMINUM BASED METAL POWDERS AND METHODS OF THEIR PRODUCTION
Aluminum-based metallic powders, along with their methods of production and formation, are provided. The Al-based metallic powders are formed with an increased amount of oxygen within at least a portion of the particles of the powder. The Al-based metallic powders show improved flowability.
B22F 1/00 - Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
B22F 9/14 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes using electric discharge
B22F 9/16 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using chemical processes
11.
ALUMINUM BASED METAL POWDERS AND METHODS OF THEIR PRODUCTION
Aluminum-based metallic powders, along with their methods of production and formation, are provided. The Al-based metallic powders are formed with an increased amount of oxygen within at least a portion of the particles of the powder. The Al-based metallic powders show improved flowability.
B22F 1/00 - Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
B22F 1/145 - Chemical treatment, e.g. passivation or decarburisation
B22F 9/08 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
12.
Electron beam melting additive manufacturing machine with dynamic energy adjustment
An electron beam melting machine and a method of operation are provided which maintains constant energy absorption within a build layer by adjusting an incident energy level to compensate for energy not absorbed by the additive powder. This unabsorbed energy is detected in the form of electron emissions, which include secondary electrons, backscattered electrons, and/or electrons which are transmitted through the build platform.
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B29C 64/20 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering - Details thereof or accessories therefor
B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
13.
Reactive metal powders in-flight heat treatment processes
There are provided reactive metal powder in-flight heat treatment processes. For example, such processes comprise providing a reactive metal powder; and contacting the reactive metal powder with at least one additive gas while carrying out said in-flight heat treatment process, thereby obtaining a raw reactive metal powder.
B22F 1/00 - Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
B22F 1/02 - Special treatment of metallic powder, e.g. to facilitate working, to improve properties; Metallic powders per se, e.g. mixtures of particles of different composition comprising coating of the powder
B33Y 70/00 - Materials specially adapted for additive manufacturing
B22F 9/08 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
14.
Plasma atomization metal powder manufacturing processes and system therefor
A plasma atomization metal powder manufacturing process includes providing a heated metal source and contacting the heated metal source with the plasma of at least one plasma source under conditions effective for causing atomization of the heated metal source. The atomization may be carried out using a gas to metal ratio of less than about 20, thereby obtaining a raw metal powder having a 0-106 μm particle size distribution yield of at least 80%. The process may further include aligning the heated metal source with the plasma of at least one plasma source. An atomizing system may include an alignment system positioned upstream of the plasma source and adapted to adjust an orientation of the metal source relative to the at least one plasma source.
B22F 9/08 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
B22F 9/14 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes using electric discharge
B22F 9/12 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes starting from gaseous material
B22F 1/00 - Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
C22C 1/04 - Making non-ferrous alloys by powder metallurgy
15.
REACTIVE METAL POWDERS IN-FLIGHT HEAT TREATMENT PROCESSES
There is provided a reactive metal powder in-flight heat treatment process comprising: contacting a reactive metal powder with an in-flight heat treatment process gas mixture comprising (i) at least one in-flight heat treatment process gas and (ii) at least one additive gas that is present at a concentration of less than 1000 ppm in the mixture, while carrying out the in-flight heat treatment process to obtain a raw reactive metal powder; and forming, with the at least one additive gas, a surface layer on the raw reactive metal powder, the raw reactive metal powder with the surface layer thereon, comprises less than 1000 ppm of at least one element from the at least one additive gas, the surface layer comprises a first layer and a second layer, the first layer being a depletion layer deeper and thicker than the second layer, the second layer being a native oxide layer.
16.
REACTIVE METAL POWDERS IN-FLIGHT HEAT TREATMENT PROCESSES
A reactive metal powder in-flight heat treatment process is provided comprising: contacting a reactive metal powder with an in-flight heat treatment process gas mixture comprising (i) an in-flight heat treatment process gas and (ii) an additive gas that is present at a concentration of less than 1000 ppm in the mixture, while carrying out the in- flight heat treatment process to obtain a raw reactive metal powder; and forming, with the additive gas, a surface layer on the raw reactive metal powder, the raw reactive metal powder with the surface layer thereon, comprises less than 1000 ppm of at least one element from the additive gas, after sieving, separately stirring the separated raw material powder in a liquid. The surface layer comprises a first layer and a second layer, the first layer being a depletion layer deeper and thicker than the second layer, the second layer being a native oxide layer.
There are provided reactive metal powder in-flight heat treatment processes. For example, such processes comprise providing a reactive metal powder; and contacting the reactive metal powder with at least one additive gas while carrying out said in-flight heat treatment process, thereby obtaining a raw reactive metal powder.
B22F 1/02 - Special treatment of metallic powder, e.g. to facilitate working, to improve properties; Metallic powders per se, e.g. mixtures of particles of different composition comprising coating of the powder
There are provided reactive metal powder atomization manufacturing processes. For example, such processes can include mixing together an atomizing gas and at least one additive gas to obtain an atomization mixture; contacting a heated reactive metal source with said atomization mixture while atomizing said heated reactive metal source to produce a raw reactive metal powder having a surface layer thereon; sieving said raw reactive metal powder with said surface layer thereon to obtain a powder having a predetermined particle size; and contacting said powder having said predetermined particle size with water.
B22F 9/08 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
B22F 1/05 - Metallic powder characterised by the size or surface area of the particles
B22F 1/145 - Chemical treatment, e.g. passivation or decarburisation
B22F 9/16 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using chemical processes
There are provided reactive metal powder atomization manufacturing processes. For example, such processes can include mixing together an atomizing gas and at least one additive gas to obtain an atomization mixture; contacting a heated reactive metal source with said atomization mixture while atomizing said heated reactive metal source to produce a raw reactive metal powder having a surface layer thereon; sieving said raw reactive metal powder with said surface layer thereon to obtain a powder having a predetermined particle size; and contacting said powder having said predetermined particle size with water.
B22F 9/08 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
B22F 9/16 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using chemical processes
20.
PLASMA ATOMIZATION METAL POWDER MANUFACTURING PROCESSES AND SYSTEMS THEREFORE
A plasma atomization metal powder manufacturing process includes providing a heated metal source and contacting the heated metal source with the plasma of at least one plasma source under conditions effective for causing atomization of the heated metal source. The atomization may be carried out using a gas to metal ratio of less than about 20, thereby obtaining a raw metal powder having a 0-106 µm particle size distribution yield of at least 80%. The process may further include aligning the heated metal source with the plasma of at least one plasma source. An atomizing system may include an alignment system positioned upstream of the plasma source and adapted to adjust an orientation of the metal source relative to the at least one plasma source.
B22F 9/14 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes using electric discharge
B22F 9/08 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
21.
METHODS AND APPARATUSES FOR PREPARING SPHEROIDAL POWDERS
A method for producing a spheroidal powder substantially free of contaminants by plasma atomization comprising preheating a material in the form of a wire or rod to a temperature below the melting point of the material prior to melting and atomization of the material. The method improves the productivity of the spheroidal powder. The apparatus comprises a heating means for preheating the material, a melting and atomization means including electric arc and plasma gas jet or hot gas jet, and a separating means for minimizing the contact between the atomized powder and contaminants generated in the process.
B22F 9/14 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes using electric discharge
patents
