Processes, systems, and apparatus for forming products from atomized metals and alloys

Abstract

Processes, systems, and apparatuses are disclosed for forming products from atomized metals and alloys. A stream of molten alloy and/or a series of droplets of molten alloy is atomized to produce particles of the molten alloy. The molten alloy particles are cooled to a temperature that is less than a solidus temperature of the molten alloy particles so that the molten alloy particles solidify. The solid alloy particles impact a collector and produce a solid alloy preform.

What is claimed is: 
     
         1 . A system comprising:
 a melting assembly configured to produce at least one of a stream of molten alloy and a series of droplets of molten alloy;   an atomizing assembly configured to produce electrically-charged particles of the molten alloy by impinging electrons on at least one of the stream of molten alloy and the series of droplets of molten alloy to atomize the molten alloy;   a field producing assembly configured to produce at least one of an electrostatic field and an electromagnetic field to accelerate the electrically-charged molten alloy particles;   a thermal control zone configured to cool the molten alloy particles to a temperature that is no greater than a solidus temperature of the molten alloy particles so that the molten alloy particles solidify while accelerating and form solid alloy particles; and   a collector, wherein the solid alloy particles impact the collector and produce a solid alloy preform.   
     
     
         2 . The system of  claim 1 , wherein the melting assembly comprises at least one of a vacuum arc remelting apparatus, an electroslag refining apparatus, an induction melting apparatus, a plasma arc melting apparatus, an electron beam melting apparatus, or a cold hearth melting apparatus. 
     
     
         3 . The system of  claim 1 , wherein the melting assembly comprises a cold induction guide. 
     
     
         4 . The system of  claim 1 , wherein the melting assembly substantially lacks ceramic material. 
     
     
         5 . The system of  claim 1 , wherein the melting assembly is configured to negatively precharge the molten alloy before the molten alloy enters the atomizing assembly. 
     
     
         6 . The system of  claim 1 , wherein the atomizing assembly comprises at least one of a thermo-ionic electron beam emitter and a wire-discharge ion plasma electron emitter. 
     
     
         7 . The system of  claim 1 , wherein the atomizing assembly is configured to produce a three-dimensional electron field. 
     
     
         8 . The system of  claim 7 , wherein the atomizing assembly is configured to raster an electron beam to provide a three-dimensional spatial distribution of electrons. 
     
     
         9 . The system of  claim 1 , wherein the atomizing assembly is configured to produce at least one of an electrostatic field and an electromagnetic field that directs the electrons to produce a three-dimensional electron field in a flow path of the molten alloy through the atomizing assembly. 
     
     
         10 . The system of  claim 1 , wherein the thermal control zone is configured to cool the molten alloy particles to a temperature that is no greater than the solidus temperature of the alloy and that is greater than 0.50 times the solidus temperature of the alloy. 
     
     
         11 . The system of  claim 1 , wherein the thermal control zone is configured to cool the molten alloy particles to a temperature that is no greater than 0.95 times the solidus temperature of the alloy and that is greater than 0.50 times the solidus temperature of the alloy. 
     
     
         12 . The system of  claim 1 , wherein the thermal control zone comprises a non-equilibrium plasma-producing assembly configured to produce non-equilibrium plasma that contacts molten alloy particles transporting through the thermal control zone. 
     
     
         13 . The system of  claim 1 , wherein the thermal control zone comprises a cooling coil through which the molten alloy particles are directed. 
     
     
         14 . The system of  claim 1 , wherein the collector comprises at least one of a mold, a platen, a plate, a mandrel, and a substrate. 
     
     
         15 . The system of  claim 1 , wherein the collector comprises an alloy that is the same alloy as that forming the alloy particles. 
     
     
         16 . The system of  claim 1 , wherein the collector is held at a positive potential to attract the electrically-charged alloy particles produced in the atomizing assembly. 
     
     
         17 . A system comprising:
 a melting assembly configured to produce at least one of a stream of molten alloy and a series of droplets of molten alloy;   an atomizing assembly configured to produce electrically-charged particles of the molten alloy by impinging electrons on at least one of the stream of molten alloy and the series of droplets of molten alloy to atomize the molten alloy;   a thermal control zone configured to cool the molten alloy particles to a temperature that is no greater than a solidus temperature of the molten alloy particles so that the molten alloy particles solidify while transporting through the thermal control zone; and   a collector, wherein the solid alloy particles impact the collector and produce a solid alloy preform.   
     
     
         18 . A process comprising:
 atomizing molten alloy particles;   transporting the molten alloy particles;   cooling the molten alloy particles to a temperature that is no greater than a solidus temperature of the alloy so that the molten alloy particles solidify while transporting to form solid alloy particles; and   impacting the solid alloy particles onto a collector.