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Methods For Producing Metal Powders And Metal Masterbatches

Inactive Publication Date: 2018-02-15
BOSTON ELECTRONICS MATERIALS
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

The invention provides a way to make high purity, low oxygen content metal powders that flow well.

Problems solved by technology

However, processes for achieving metal powders having such characteristics require further development.

Method used

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  • Methods For Producing Metal Powders And Metal Masterbatches
  • Methods For Producing Metal Powders And Metal Masterbatches
  • Methods For Producing Metal Powders And Metal Masterbatches

Examples

Experimental program
Comparison scheme
Effect test

example 1 (

Theoretical Example)

[0071]Using a process flow as illustrated in FIG. 2, a storage tank containing 200 gallons of molten sodium is pumped through a continuous loop using an electromagnetic pump. There is a cold trap installed on the loop that is used to remove contaminants prior to starting up production. Once the contaminants are removed the cold trap is valved off until needed again. The electromagnetic pump pumps the molten sodium to a flow split. The flow to the cooler can be roughly 3 GPM and the flow to the heater can be roughly 17 GPM. The flows can be controlled using valves and Coriolis flow meters.

[0072]The cold sodium stream flows around a funnel. The HfCl4 powder is added to this funnel. The sodium flows around the funnel and collects the powder and it is drawn through an eductor. The eductor uses the hot sodium flow as the motive fluid sucking the HfCl4 slurry into it. The additional heat provided by the hot sodium stream initiates the reduction reaction. Feeding of the...

example 2

wder Feed Test

Instrumentation Setup

[0075]A powder trickier was used for all halide powder trials to feed the reactant powders to a beaker containing alkali metal(s). This powder feeder consists of an adjustable hopper, discharge tube, stand, and 2-speed control pad. All reactant powders flowed readily through the tube given the vibration frequency at hand, except the TaCl5 and NiCl2 50 / 50 powder blend. This powder blend packed tightly inside both the tube and the hopper base. As a result, remaining powder was fed to the reaction beaker using a “hand-add” approach with a spatula for the TaCl5 and NiCl2 50 / 50 blend.

[0076]All tests utilized an IKA 70 Watt mixer with the capability of producing speeds from 60 to 2000 rpm. A stainless steel, 1.20 inch diameter, turbine impeller blade was utilized for the first two tests performed, TaCl5 in excess sodium. All subsequent tests were performed using a stainless steel, 1.65 inch diameter, Cowles blade impeller to improve the incorporation of ...

example 3

wder and Liquid Initiation Test

Instrumentation Setup

[0101]A second set of experiments was conducted to verify the reactivity of various powder and liquid halides with sodium metal. All tests were performed in a glovebox, inerted with argon to eliminate oxygen and moisture from the atmosphere.

[0102]Powder halide transfer: Aluminum Trichloride and Zirconium (IV) Chloride powders were transferred into weighing dishes using a microspatula. The powders were then poured into the reaction cups from the weighing dishes.

[0103]Liquid halide transfer: Vanadium (IV) Chloride, Tin (IV) Chloride, Titanium (IV) Chloride, and Silicon Tetrachloride were transferred into the reaction cups using 1 mL syringes. For each liquid halide, a volume of 0.1 mL was transferred into a syringe. The syringes were then placed in the glovebox. The syringes were then used to inject drops of each liquid halide into a reaction cup containing molten sodium metal.

[0104]Reaction vessel: Stainless steel 2.5 oz. cups were ...

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Abstract

A method for producing a metal powder that combines molten reducing metal and metal halide in a space that is substantially free of oxygen and water, wherein the molten reducing metal is sodium and / or potassium, or aluminum (or magnesium or titanium) and is present in a stoichiometric excess to the metal halide which is a solid or liquid, thereby producing metal particles and salt, removing unreacted reducing metal, optionally removing the salt, and recovering the metal powder, is described. A method for producing a metal masterbatch wherein the molten reducing metal is aluminum, magnesium, and / or titanium and after combining molten aluminum (or magnesium or titanium) and metal halide in the reaction space, substantially removing the produced metal salt to obtain the metal masterbatch which comprises at least a portion of the molten aluminum (or magnesium or titanium) and at least one metal also is described.

Description

[0001]This application claims the benefit under 35 U.S.C. §119(e) of prior U.S. Provisional Patent Application No. 62 / 374,212, filed Aug. 12, 2016, which is incorporated in its entirety by reference herein.BACKGROUND OF THE INVENTION[0002]The present invention relates to methods for producing metal powders, salt-coated metal powders, and metal masterbatches.[0003]Metal powders can be used for advanced metallurgical processes, such as near net shape powder pressing, and additive manufacturing, including laser metal deposition (LMD), direct metal laser sintering (DMLS), selective laser sintering (SLS), and selective laser melting (SLM). The end products find applications in a wide variety of industries, including aerospace, medical, and electronics. Other applications include the production of wire bar stock for rolling into medical alloys (e.g., superconducting wires for MRI machines), sputtering targets in electronics manufacturing for thin film metal deposition in displays, use in ...

Claims

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Application Information

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IPC IPC(8): B22F9/24C22B34/12C22C14/00C22B34/14
CPCB22F9/24C22B34/14B22F2304/10C22C14/00B22F2301/205C22B34/1277B22F9/20B22F9/28C22B5/04C22C1/047
Inventor FINNERTY, DONALDHENDERSON, DAVIDKOENITZER, JOHNMATHESON, ANDREWVAN LIESHOUT, RICHARD
Owner BOSTON ELECTRONICS MATERIALS
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