Atomizing apparatuses, systems, and methods

Abstract

An atomizing system and method are disclosed. A system can include a tundish configured to hold a molten material and a nozzle in fluid communication with the tundish. The nozzle and/or the tundish can be comprised of a material having a composition that is substantially similar to the composition of the molten material. An internal channel can be defined in at least one of the tundish or the nozzle. Additionally, a pump can be configured to pump a molten heat transfer medium through the internal channel. A method of atomizing the molten material can include affecting heat transfer between the molten material and the tundish and/or the nozzle with a molten heat transfer medium in at least one internal channel in the tundish and/or the nozzle. The tundish and/or the nozzle can comprise a material that is substantially similar to the molten material.

We claim: 
     
         1 . A system for atomizing a molten material having a first material composition, wherein the system comprises:
 a tundish configured to hold the molten material;   a nozzle in fluid communication with the tundish, wherein the nozzle is comprised of a second material having a second material composition, and wherein the second material composition is substantially similar to the first material composition;   an internal channel defined in at least one of the tundish or the nozzle; and   a pump configured to pump a molten heat transfer medium through the internal channel.   
     
     
         2 . The system of  claim 1 , wherein the tundish is comprised of a third material having a third material composition, and wherein the third material composition is substantially similar to the first material composition. 
     
     
         3 . The system of  claim 1 , wherein the internal channel is defined in the tundish, and wherein a second internal channel is defined in the nozzle. 
     
     
         4 . The system of  claim 1 , wherein the molten heat transfer medium comprises a material selected from a group consisting of a salt, a metal, and an alloy. 
     
     
         5 . The system of  claim 1 , wherein the boiling point of the molten heat transfer medium is greater than the boiling point of water at atmospheric pressure. 
     
     
         6 . The system of  claim 1 , further comprising a melt chamber, wherein the tundish is positioned in the melt chamber. 
     
     
         7 . The system of  claim 6 , further comprising a melting hearth and a refining hearth positioned in the melt chamber. 
     
     
         8 . The system of  claim 7 , further comprising an atomization chamber, wherein the nozzle protrudes into the atomization chamber. 
     
     
         9 . The system of  claim 1 , wherein the molten heat transfer medium comprises a molten salt. 
     
     
         10 . A method for atomizing a molten material comprising a first material composition, wherein the method comprises:
 passing the molten material through an atomization nozzle comprised of a second material comprising a second material composition, wherein the second material composition is substantially similar to the first material composition, and wherein an internal channel is defined in the nozzle; and   pumping a molten heat transfer medium through the internal channel, wherein the molten heat transfer medium is configured to affect heat transfer to and from the atomization nozzle.   
     
     
         11 . The method of  claim 10 , further comprising providing the molten material to a tundish in fluid communication with the atomization nozzle, wherein the tundish is comprised of a third material comprising a third material composition, and wherein the third material composition is substantially similar to the first material composition. 
     
     
         12 . The method of  claim 11 , wherein a second internal channel is defined in the tundish, and wherein the method further comprises pumping the molten heat transfer medium through the second internal channel. 
     
     
         13 . The method of  claim 10 , wherein the molten heat transfer medium comprises a material selected from a group consisting of a salt, a metal, and an alloy. 
     
     
         14 . The method of  claim 10 , further comprising melting the molten material. 
     
     
         15 . The method of  claim 14 , further comprising refining the molten material. 
     
     
         16 . A method for regulating temperature in an atomizing system, wherein the atomizing system comprises a nozzle, and wherein the method comprises:
 pumping a molten heat transfer medium through an internal channel in the nozzle to heat the nozzle; and   pumping the molten heat transfer medium through the internal channel in the nozzle to cool the nozzle.   
     
     
         16 . od of  claim 16 , further comprising obtaining a nozzle comprised of a first material having a first material composition, and wherein the first material composition is substantially similar to the material composition of the atomized powder exiting the atomizing system. 
     
     
         18 . The method of  claim 16 , wherein the atomizing system further comprises a tundish, and wherein the method further comprises pumping the molten heat transfer medium through a second internal channel in the tundish to cool the tundish. 
     
     
         19 . The method of  claim 18 , wherein the tundish is comprised of a second material having a second material composition, wherein the second material composition is substantially similar to the material composition of the atomized powder exiting the atomizing system. 
     
     
         20 . The method of  claim 16 , wherein heating of the nozzle occurs during a pre-atomizing stage, and wherein cooling of the nozzle occurs during an atomizing operation.