6k Inc.

Amastan Technologies LLC

University of Connecticut

Makhlouf Redjdal

Kamal Hadidi

Scott Joseph Turchetti

Michael C Kozlowski

Gregory M Wrobel

Ning Duanmu

John Barnes

Saurabh Ullal

Sunil Bhalchandra Badwe

Aaron Bent

Eric H Jordan

Pawel Matys

Zongren Shang

Joseph Robert Caruso

Sudip Bhattacharya

Disclosed herein are embodiments of methods, devices, and assemblies for processing feedstock materials using microwave plasma processing. Specifically, the feedstock materials disclosed herein pertains to scrap materials, dehydrogenated or non-hydrogenated feed material, and recycled used powder. Microwave plasma processing can be used to spheroidize and remove contaminants. Advantageously, microwave plasma processed feedstock can be used in various applications such as additive manufacturing or powdered metallurgy (PM) applications that require high powder flowability.

Process for producing spheroidized powder from feedstock materials

Methodologies, systems, and devices are provided for producing metal spheroidal powder products. By utilizing a microwave plasma, control over spheriodization and resulting microstructure can be tailored to meet desired demands.

Spheroidal titanium metallic powders with custom microstructures

Disclosed herein are embodiments of systems and method for processing feedstock materials using microwave plasma processing. Specifically, the feedstock materials disclosed herein pertain to metal powders. Microwave plasma processing can be used to spheroidize the metal powders and form metal nitride or metal carbide powders. The stoichiometry of the metal nitride or metal carbide powders can be controlled by changing the composition of the plasma gas and the residence time of the feedstock materials during plasma processing.

Systems and methods for synthesis of spheroidized metal powders

Methodologies, systems, and devices are provided for producing metal spheroidal powder products. Dehydrogenated and spheroidized particles are prepared using a process including introducing a metal hydride feed material into a plasma torch. The metal hydride feed material is melted within a plasma in order to dehydrogenate and spheroidize the materials, forming dehydrogenated and spheroidized particles. The dehydrogenated and spheroidized particles are then exposed to an inert gas and cooled in order to solidify the particles into dehydrogenated and spheroidized particles. The particles are cooled within a chamber having an inert gas.

Spheroidal dehydrogenated metals and metal alloy particles

An apparatus for providing material feedstock into a plasma of a plasma torch includes a material feeding device having an input end and an output end. The output end of the material feeding device extends at least partially around the periphery of a plasma generated near the output end of the plasma torch. The material feeding device is oriented at an angle with respect to a central axis of the plasma torch.

Method and apparatus for feeding material into a plasma

Disclosed herein are embodiments of methods, devices, and assemblies for processing feedstock materials using microwave plasma processing. Specifically, the feedstock materials disclosed herein pertains to unique powder feedstocks such as Tantalum, Yttrium Stabilized Zirconia, Aluminum, water atomized alloys, Rhenium, Tungsten, and Molybdenum. Microwave plasma processing can be used to spheroidize and remove contaminants. Advantageously, microwave plasma processed feedstock can be used in various applications such as additive manufacturing or powdered metallurgy (PM) applications that require high powder flowability.

Unique feedstocks for spherical powders and methods of manufacturing

Disclosed herein are embodiments of mechanically alloyed powder feedstock and methods for spheroidizing them using microwave plasma processing. The spheroidized powder can be used in metal injection molding processes, hot isostatic processing, and additive manufacturing. In some embodiments, mechanical milling, such as ball milling, can be used to prepare high entropy alloys for microwave plasma processing.

Mechanically alloyed powder feedstock

Disclosed herein are embodiments of methods, devices, and assemblies for processing feedstock materials using microwave plasma processing. Specifically, the feedstock materials disclosed herein pertains to scrap materials, dehydrogenated or non-hydrogenated feed material, recycled used powder, and gas atomized powders. Microwave plasma processing can be used to spheroidize and remove contaminants. Advantageously, microwave plasma processed feedstock can be used in various applications such as additive manufacturing or powdered metallurgy (PM) applications that require high powder flowability.

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Storrs-Mansfield, CT, United States of America

Makhlouf Redjdal