Methods of forming spherical metallic particles

Abstract

A method of forming titanium-based spherical metallic particles includes performing a hydride-dehydride process on a meltless metallic sponge to form a feedstock material including a metallic powder. The method further includes introducing the feedstock material into a microwave plasma discharge to form the titanium-based spherical metallic particles.

1 . A method of forming spherical metallic particles, comprising:
 performing a hydride-dehydride process on a meltless metallic sponge to form a feedstock material comprising a metallic powder; and   introducing the feedstock material into a microwave plasma discharge to form the spherical metallic particles, wherein the spherical metallic particles comprise titanium.   
     
     
         2 . The method of  claim 1 , wherein the meltless metallic sponge comprises elemental titanium. 
     
     
         3 . The method of  claim 1 , wherein the meltless metallic sponge comprises a metal alloy comprising titanium. 
     
     
         4 . The method of  claim 3 , wherein the metal alloy further comprises aluminum, vanadium, or a combination thereof. 
     
     
         5 . The method of  claim 1 , wherein the meltless metallic sponge has a packing density less than 10%. 
     
     
         6 . The method of  claim 1 , wherein the feedstock material comprises acicular metallic powder. 
     
     
         7 . The method of  claim 6 , wherein the acicular metallic powder has a packing density greater than 50%. 
     
     
         8 . The method of  claim 1 , wherein the feedstock material is introduced into the microwave plasma discharge in the presence of a non-reactive gas. 
     
     
         9 . The method of  claim 1 , wherein the spherical metallic particles comprise an elemental metal, a metal alloy, or a combination thereof. 
     
     
         10 . The method of  claim 1 , wherein the spherical metallic particles comprise a metal alloy comprising titanium. 
     
     
         11 . The method of  claim 10 , wherein the metal alloy further comprises aluminum, vanadium, or a combination thereof. 
     
     
         12 . A plurality of spherical metallic particles comprising titanium, formed by:
 performing a hydride-dehydride process on a meltless metallic sponge to form a feedstock material comprising a metallic powder; and   introducing the feedstock material into a microwave plasma discharge to form the spherical metallic particles.   
     
     
         13 . The plurality of spherical metallic particles of  claim 12 , wherein the plurality of spherical metallic particles comprises elemental titanium, a titanium alloy, or a combination thereof. 
     
     
         14 . The plurality of spherical metallic particles of  claim 12 , wherein the plurality of spherical metallic particles comprises a titanium alloy. 
     
     
         15 . The plurality of spherical metallic particles of  claim 14 , wherein the titanium alloy further comprises aluminum, vanadium, or a combination thereof. 
     
     
         16 . A method of forming spherical titanium alloy particles, comprising:
 performing a hydride-dehydride process on a meltless titanium alloy sponge to form a feedstock material comprising acicular titanium alloy powder; and   introducing the feedstock material into a microwave plasma discharge to form the spherical titanium alloy particles.   
     
     
         17 . The method of  claim 16 , wherein the feedstock material is introduced into the microwave plasma discharge in the presence of a non-reactive gas.