The International Nickel Company, Inc.

Ian Sidney Clark

John K Pargeter

Benjamin Joseph Baltrukovicz

Jay Michael Larson

Robert C Gibson

John Oliver Ward

Apparatus and method for water atomizing molten metal to provide a low oxygen metal powder. A molten metal stream is introduced to an atomization vessel containing a pressurized inert gas. The metal stream is atomized by impingement of high pressure water within the atomization vessel. The atomization vessel has an exit aperture located so that the slurry of water and metal powder can exit from the atomization vessel only after deflection within the atomization vessel. Inert gas contained within the atomization vessel and entrapped within the slurry during atomization begins to leave the slurry during deflection, the inert gas returning to the atomization vessel atmosphere. The inert gas removal process continues after passage through the exit aperture and entrance into a closed degassing vessel. In this vessel, substantially all of the inert gas is removed from the slurry by gravity separation for return to the atmosphere of the atomization vessel, and the turbulent conditions initially present in the slurry are substantially dissipated prior to passage of the slurry from the closed degassing vessel.

Process for producing metal powders having low oxygen content

The invention is directed to a process for producing metal powder through atomizing in which a molten metal stream is subjected to the influence of a plurality but correlated sets of atomization jets by virtue of which a disintegrating medium exits from the jets at a velocity of at least Mach No. 1, the medium from one set of jets being angled to strike the falling molten body at a point below and at an angle less than the medium dispensed from the other set of jets, whereby less flake and filigree are formed, a higher powder yield obtains, lower medium pressure can be used, etc.

Process for producing metal powder

Apparatus and method for water atomizing molten metal to provide a low oxygen metal powder. A molten metal stream is introduced to an atomization vessel containing a pressurized inert gas. The metal stream is atomized, by impingement of high pressure water within the atomization vessel. The atomization vessel has an exit aperture located so that the slurry of water and metal powder can exit from the atomization vessel only after deflection within the atomization vessel. Inert gas contained within the atomization vessel and entrapped within the slurry during atomization begins to leave the slurry during deflection, the inert gas returning to the atomization vessel atmosphere. The inert gas removal process continues after passage through the exit aperture and entrance into a closed degassing vessel. In this vessel, substantially all of the inert gas is removed from the slurry by gravity separation for return to the atmosphere of the atomization vessel, and the turbulent conditions initially present in the slurry are substantially dissipated prior to passage of the slurry from the closed degassing vessel.

Water atomizer for low oxygen metal powders

A process is disclosed for producing a high density spray cast metal body from a highly energetic atomized metal stream by directing said atomized stream into the interior of a mold and causing said stream to scan and fill said mold interior by effecting relative movement between said atomized metal stream and said mold, thereby producing a fine grained spray cast metal body of high density.

Spray casting of gas atomized molten metal to produce high density ingots

Thermally induced porosity, which can lead to cracking in metal powders after consolidation, is believed to be caused by the entrapment of the inert gas used for atomization within the metal powders. The addition of an activating agent to the molten alloy prior to atomization with an inert gas, such as argon, serves to substantially reduce the porosity of metal powders. Suitable activating agents are characterized by an ability to rapidly diffuse to the surface of a molten metal particle and an affinity for oxygen. Activating agents that are useful for high nickel alloys and highly alloyed steels include magnesium, calcium, lithium, silicon, and rare earths.

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Greenwood Lake, NY, United States of America

Ian Sidney Clark