Osprey Metals Limited

Olin Corporation

United Kingdom Atomic Energy Authority

Behr South Africa (Pty) Ltd.

Fhe Technology Limited

Jeffrey S Coombs

Alan George Leatham

James Burnett Forrest

Peter F Chesney

Reginald G Brooks

Gordon R Dunstan

Harvey P Cheskis

Charles R Pratt

Eric A Feest

Andrew Josef Widawski Ogilvy

Robert Ross

Alan Leathman

Luis Gerardo Elias

WGary Watson

A method of producing a silicon based alloy is described which comprises melting a silicon alloy containing greater than 50 wt. % silicon and preferably including aluminium. The melted alloy is then inert gas atomized to produce powder or a spray formed deposit in which the silicon forms a substantially continuous phase made up of fine, randomly oriented crystals in the microstructure. The alloy produced by the method has particularly useful application in electronics packaging materials and a typical example comprises an alloy of 70 wt. % silicon and 30 wt. % aluminium. Such an alloy is an engineering material which, for example, is machinable.

Silicon alloys for electronic packaging

A method of producing coated powder material is provided. In the method, molten metal or metal alloy is caused to fall in a stream (3) and is then atomized into a spray. A liquid or solid material of different composition is introduced and caused to contact the stream or spray so that a coating is formed over all or part of the surface of the atomized droplets. The coating may be the introduced material or a reaction product.

Production of powder

A method and apparatus for the production of a deposit such as a bar (1) is provided. The deposit has a longitudinal outer surface (2) and a front face deposition surface (3). The spray deposition comprises atomized droplets produced by outer and inner sprays (4 and 5). The outer and inner sprays (4 and 5) are both directed such that, during deposition, a substantial proportion of droplets from both sprays are deposited on the front face (3) of the forming deposit. The inner spray (5) has a higher gas to metal ratio than the outer spray allowing an increase of both deposition and final product yield.

Production of spray deposits

A method of forming a deposit in which a spray of gas atomized molten metal or metal alloy is generated and directed at a substrate. The substrate is rotated about an axis of rotation and a controlled amount of heat is extracted from the molten metal or metal alloy in flight and/or on deposition. The spray is oscillated relative to the substrate, preferably along the axis of the substrate. With continuous production techniques involving a single pass, base porosity can be considerably reduced and in the formation of thicker deposits of discrete length, base porosity can be minimized and reciprocation lines can be eliminated or reduced in intensity.

Production of metal spray deposits

Metal is spray cast onto a moving substrate using at least two sprays, the first of which has a solid fraction greater than 20% at the time the spray contacts the substrate, but less than the solid fraction of the second spray.

Metal spray forming using multiple nozzles

Apparatus for the production of powders or spray deposits is provided in which a metal or metal alloy stream is broken up into atomized droplets by primary jets of atomizing gas. In order to remove further heat from the atomized droplets, secondary jets are positioned adjacent the primary jets for directing cooling fluid in the form of cryogenic liquified gas at the atomized droplets. The apparatus permits the formation of coarser powders, powders from alloys with a wide solidus/liquidus gap in a shorter atomizing chamber, or spray deposits with increased yield of deposited material.

Atomizing apparatus and process

A method of forming a deposit in which a spray of gas atomized molten metal or metal alloy is generated and directed at a substrate. The substrate is rotated aobut an axis of rotation and a controlled amount of heat is extracted from the molten metal or metal alloy in flight and/or on deposition. The spray is oscillated relative to the substrate, preferably along the axis of the substrate. With continuous production techniques involving a single pass, base porosity can be considerably reduced and in the formation of thicker deposit of discrete length base porosity can be minimized and reciprocation lines can be eliminated or reduced in intensity.

A metal, e.g. in the form of a shaped article, is made by atomizing a stream of molten metal and directing the atomized stream at a collecting surface to form a deposit of the metal. Fine, solid particulate material of different composition from the metal, e.g., nonmetallic particles, and of mean particle size less than 20 micrometers, preferably less than 10 micrometers, is applied to the stream or spray so that it becomes incorporated into the deposit. The particulate material is applied by generating a fluidized bed thereof and feeding it from the bed into the stream or spray. Uniform dispersion of material such as SiC at a high volume percentage (e.g. greater than 15%) may be achieved.

Metal matrix composite manufacture

A stream of molten metal is atomized to form a spray and additional cooling is achieved by applying to the stream or spray relatively cold solid particles. The solid particles are preferably injected into the spray and may be formed from overspray particles recycled from the deposition process.

Deposition method including recycled solid particles

A stream of molten metal is atomized to form a spray and additional cooling is provided by applying to the stream or spray relatively cold solid particles. The solid particles are preferably injected into the spray and may be formed from overspray particles recycled from the deposition process.

Deposition of metallic products using relatively cold solid particles

A device for gas atomising a liquid stream, such as a stream of molten metal or metal alloy, has an atomising device including, for example, an annular opening for receiving the stream. The atomising device is arranged for applying atomising gas to the stream so as to form a spray of atomised particles. At least a part of the atomising gas, and preferably all, is applied by means movable relative to the stream whereby movement is imparted to the spray to achieve improved uniformity or control of deposition by moving the spray either by moving the atomising device with a symmetric gas flow field relative to the stream or by oscillating or rotating a rotor mounted within the atomising device and arranged to produce an asymmetric gas flow field.

Atomisation of metals

A device for gas atomizing a liquid stream, such as a stream of molten metal or metal alloy, has an atomizing device including, for example, an annular opening for receiving the stream. The atomizing device is arranged for applying atomizing gas to the stream so as to form a spray of atomized particles. At least a part of the atomizing gas, and preferably all, is applied by means movable relative to the stream whereby movement is imparted to the spray. This movement leads to improved uniformity or control of deposition.

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West Glamorgan, United Kingdom

Jeffrey S Coombs