Method and apparatus for heat treating feedstock powder

Abstract

Disclosed are methods and apparatuses for processing a powder alloy to improve its microstructure. The methods for processing the powder alloy can include introducing the powder alloy into a powder vessel having an inert atmosphere, uniformly heat treating the powder alloy inside the powder vessel at its solutionizing temperature, and cooling the heat treated powder alloy at a rate of at least 5° C./s to form treated particles. The treated particles obtained from the methods and apparatuses disclosed herein can be used in any suitable manufacturing process, such as in cold gas dynamic spray.

1 - 19 . (canceled) 
     
     
         20 . An apparatus comprising
 a furnace,   a powder assembly vessel positioned in the furnace, wherein the powder assembly vessel comprises an inlet through which a gas or a powder enter into the powder assembly vessel,   a rotary assembly connected to the powder assembly vessel which is capable of rotating the powder assembly vessel,   a cooling system capable of cooling a powder in the powder assembly vessel at a rate of at least 5° C./s, and   a device for depositing a heat treated particle obtained from the cooling system to a surface of a substrate.   
     
     
         21 . The apparatus of  claim 20 , wherein the powder assembly vessel is configured to maintain an inert atmosphere within the powder assembly vessel while the powder is being heated. 
     
     
         22 . The apparatus of  claim 20 , wherein the powder assembly vessel further comprises a device for excluding an interior portion of the powder assembly vessel during heat treatment. 
     
     
         23 . The apparatus of  claim 22 , wherein the device is an extrusion that extends out of the rotary assembly into the powder vessel assembly. 
     
     
         24 . The apparatus of  claim 20 , wherein the powder assembly vessel is at least partially fabricated from steel. 
     
     
         25 . The apparatus of  claim 20 , wherein the cooling system is within the powder assembly vessel. 
     
     
         26 . The apparatus of  claim 20 , wherein the cooling system is external to the powder assembly vessel. 
     
     
         27 . The apparatus of  claim 26 , wherein the cooling system comprises a water bath, an oil bath, a brine bath, a molten salt, compressed air, a cooling jet, or a combination thereof. 
     
     
         28 . The apparatus of  claim 27 , wherein the cooling system comprises jet quencher. 
     
     
         29 . The apparatus of  claim 20 , wherein the cooling system capable of cooling a powder in the powder assembly vessel at a rate of at least 10° C./s. 
     
     
         30 . The apparatus of  claim 20 , wherein the cooling system capable of cooling a powder in the powder assembly vessel at a rate of at least 50° C./s. 
     
     
         31 . The apparatus of  claim 20 , wherein the cooling system capable of cooling a powder in the powder assembly vessel at a rate of at least 100° C./s. 
     
     
         32 . The apparatus of  claim 20 , wherein the powder assembly vessel comprises a sensor for monitoring and/or controlling the temperature of the powder assembly vessel. 
     
     
         33 . The apparatus of  claim 20 , wherein the device for depositing the heat treated particle is a cold gas dynamic spray assembly. 
     
     
         34 . The apparatus of  claim 20 , further comprising a pressure release valve on the powder assembly vessel. 
     
     
         35 . The apparatus of  claim 20 , further comprising an inline particle filter.