MANUFACTURING

REFERENCE TO RELATED APPLICATIONS This application claims the priority benefit under 35 U.S.C. § 119(e) of U.S. Provisional Application No. 62/937054, filed November 18, 2019, the entire disclosure of which is incorporated herein by reference.

BACKGROUND

Field

[0001] The present disclosure is generally directed in some embodiments towards producing spherical or spheroidal powder products from unique feedstock materials.

Description of the Related Art

[0002] An important aspect of preparing some forms of industrial powders is the spheroidization process, which transforms irregularly shaped or angular powders produced by conventional crushing methods, into spherical low-porosity particles. Spherical powders are homogenous in shape, denser, less porous, have a high and consistent flowability, and high tap density. Such powders exhibit superior properties in applications such as injection molding, thermal spray coatings, additive manufacturing, etc.

[0003] Conventional spheroidization methods employ thermal arc plasma described in U.S. Patent 4,076,640 issued February 28, 1978 and radio-frequency generated plasma described in U.S. Patent 6,919,527 issued July 19, 2005. However, these two methods present limitations inherent to the thermal non-uniformity of radio-frequency and thermal arc plasmas.

[0004] In the case of thermal arc plasma, an electric arc is produced between two electrodes generates a plasma within a plasma channel. The plasma is blown out of the plasma channel using plasma gas. Powder is injected from the side, either perpendicularly or at an angle, into the plasma plume, where it is melted by the high temperature of the plasma. Surface tension of the melt pulls it into a spherical shape, then it is cooled, solidified and is collected in filters. An issue with thermal arc plasma is that the electrodes used to ignite the plasma are exposed to the high temperature causing degradation of the electrodes, which contaminates the plasma plume and process material. In addition, thermal arc plasma plume inherently exhibit large temperature gradient. By injecting powder into the plasma plume from the side, not all powder particles are exposed to the same process temperature, resulting in a powder that is partially spheroidized, non-uniform, with non-homogeneous porosity.

[0005] In the case of radio-frequency inductively coupled plasma spheroidization, the plasma is produced by a varying magnetic field that induces an electric field in the plasma gas, which in turn drives the plasma processes such as ionization, excitation, etc. to sustain the plasma in cylindrical dielectric tube. Inductively coupled plasmas are known to have low coupling efficiency of the radio frequency energy into the plasma and a lower plasma temperature compared to arc and microwave generated plasmas. The magnetic field responsible for generating the plasma exhibits a non-uniform profile, which leads to a plasma with a large temperature gradient, where the plasma takes a donut-like shape that exhibiting the highest temperature at the edge of the plasma (close to the dielectric tube walls) and the lowest temperature in the center of the donut. In addition, there is a capacitive component created between the plasma and the radio frequency coils that are wrapped around the dielectric tube due to the RF voltage on the coils. This capacitive component creates a large electric field that drives ions from the plasma towards the dielectric inner walls, which in turn leads to arcing and dielectric tube degradation and process material contamination by the tube’s material.

SUMMARY

[0006] Disclosed herein are embodiments for spheroidizing unique feedstock materials using microwave plasma processing. In one aspect, a method for producing a spheroidized powder from a feed material including Yttrium Stabilized Zirconia (YSZ) is provided. The method includes: introducing a feed material including YSZ particles into a microwave plasma torch; and melting and spheroidizing the particles within a plasma generated by the microwave plasma torch to form spheroidized powder.

[0007] In another aspect, a method for producing a spheroidized powder from a feed material including Aluminum (Al) or A1 alloy is provided. The method includes: introducing a feed material including Al or Al alloy particles into a microwave plasma torch; and melting and spheroidizing the particles within a plasma generated by the microwave plasma torch to form spheroidized powder. In some embodiments, the A1 or A1 alloy includes A16000 series or Aluminum Silicon Magnesium (AlSiMg). The AlSiMg can be AlSilOMg.

[0008] In another aspect, a method for producing a spheroidized powder from a feed material including water atomized alloy is provided. The method including: introducing a feed material including water atomized alloy into a microwave plasma torch; and melting and spheroidizing the particles within a plasma generated by the microwave plasma torch to form spheroidized powder. In some embodiments, the water atomized alloy includes metal injection molded (MIM) 17-4 Stainless Steel. In some embodiments, the water atomized alloy includes Inconel Alloy 625 (IN625).

[0009] In another aspect, a method for producing a spheroidized powder from a feed material including Tantalum (Ta) is provided. The method includes: introducing a feed material including Ta particles into a microwave plasma torch; and melting and spheroidizing the particles within a plasma generated by the microwave plasma torch to form spheroidized powder.

[0010] In another aspect, a method for producing a spheroidized powder from a feed material including Titanium Nitride (TiN) is provided. The method includes: introducing a feed material including TiN particles into a microwave plasma torch; and melting and spheroidizing the particles within a plasma generated by the microwave plasma torch to form spheroidized powder.

[0011] In another aspect, a method for producing a spheroidized powder from a feed material including Rhenium (Re) is provided. The method including: introducing a feed material including Re particles into a microwave plasma torch; and melting and spheroidizing the particles within a plasma generated by the microwave plasma torch to form spheroidized powder.

[0012] In another aspect, a method for producing a spheroidized powder from a feed material including Tungsten (W) is provided. The method including: introducing a feed material including W particles into a microwave plasma torch; and melting and spheroidizing the particles within a plasma generated by the microwave plasma torch to form spheroidized powder.

[0013] In another aspect, a method for producing a spheroidized powder from a feed material including Molybdenum (Mo) is provided. The method includes: introducing a feed material including Mo particles into a microwave plasma torch; and melting and spheroidizing the particles within a plasma generated by the microwave plasma torch to form spheroidized powder.

[0014] In various embodiments, the introducing the feed material into the microwave plasma torch can include introducing the feed material into an exhaust of the microwave plasma torch or into a plume of the microwave plasma torch.

[0015] In various embodiments, the collective average or median aspect ratio of the feed material may be between 5:1 to 20:1. In various embodiments, the method further includes sieving the feed material before introducing the feed material into the microwave plasma torch. In various embodiments, the spheroidized powder may have a medium sphericity of at least 0.75. In various embodiments, the spheroidized powder may have a medium sphericity of at least 0.91. In various embodiments, the spheroidized powder may have a particle size distribution of 15 to 45 microns. In various embodiments, the spheroidized powder may have a particle size distribution of 45 to 105 microns.

[0016] Further disclosed is a method of producing spheroidized powder as disclosed herein and a spheroidized powder as disclosed herein.

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] FIG. 1 illustrates an example embodiment of a method of producing spheroidal particles according to the present disclosure.

[0018] FIG. 2 illustrates an embodiment of a microwave plasma torch that can be used in the production of spheroidal powders, according to embodiments of the present disclosure.

[0019] FIGS. 3A-B illustrate embodiments of a microwave plasma torch that can be used in the production of spheroidal powders, according to a side feeding hopper embodiment of the present disclosure.

APPENDIX

[0020] This specification includes Appendix A provided herewith in 11 pages. Any suitable combination of features described in Appendix A can be implemented in combination with the subject matter described herein. DETAILED DESCRIPTION

[0021] Disclosed herein are embodiments of methods, devices, and assemblies for spheroidization of feedstock materials using microwave plasma processing. The feedstocks disclosure herein are a number of metals and ceramics, each of which have their own critical, specialized, and unique requirements for the initial feedstock as well as the processing in a microwave plasma torch in order to achieve a desired spheroidization.

[0022] As disclosed herein, processing in a microwave plasma torch can include feeding the feedstock into a microwave plasma torch, a plasma plume of the microwave plasma torch, and/or an exhaust of the microwave plasma torch. The location may vary depending on the type of feedstock used. Further the feedstock can be selected based on different requirements. Examples of requirements are aspect ratio, particle size distribution (PSD), chemistry, density, diameter, sphericity, oxygenation, hardness, and ductility.

[0023] The feedstock can then be used as a feedstock for a microwave plasma process to form a final spheroidized powder, which can then be used in different processes, such as additive manufacturing processes. However, the particular feedstock materials disclosed herein are extremely difficult to process into a proper feedstock for microwave plasma processing.

[0024] In some embodiments, the powders may be pre-processed before they are introduced into the plasma process. For example, the powders may be sieved to remove large agglomerations and selected the desired size to be processed in the plasma. In some embodiments, the powders may be cleaned with water, surfactant, detergent, solvent or any other chemical such as acids to remove contamination. In some embodiments, the powders may be magnetically cleaned if they are contaminated with any magnetic material. In some embodiments, the powder can be pre-treated to de-oxidize it. In some embodiments, other elements or compounds can be added to compensate or modify the chemistry of the powder. In some embodiments, the powder can be de-dusted to remove fines. In some embodiments, no pre-processing may be performed.

[0025] In some embodiments, particle size distribution (PSD) is with a minimum diameter of 1 micrometers (μm) and a maximum diameter of 22 (or about 22) μm, or a minimum of 5 (or about 5) μm and a maximum of 15 (or about 15) μm, or a minimum of 15 (or about 15) mih and a maximum of 45 (or about 45) mih or a minimum of 22 (or about 22) μm and a maximum of 44 (or about 44) μm, or a minimum of 20 (or about 20) μm to a maximum of 63 (or about 63) μm, or a minimum of 44 (or about 44) μm and a maximum of 70 (or about 70) μm, or a minimum of 70 (or about 70) μm and a maximum of 106 (or about 106) μm, or a minimum of 105 (or about 105) μm to a maximum of 150 (or about 150) μm, or a minimum of 106 (or about 106) μm and a maximum of 300 (or about 300) μm. In some embodiments, the PSD can be expressed as the D50 of the particles in the feedstock. As will be appreciated, these upper and lower values are provided for illustrative purposes only, and alternative PSD values may be used in other embodiments.

[0026] In some embodiments, the powder feedstock can have be angular or have a high aspect ratio before plasma processing. In some embodiments, the average aspect ratio of the powder feedstock is 2:1 (or about 2:1), 3:1 (or about 3:1), 5:1 (or about 5:1), 10:1 (or about 10:1), 20:1 (or about 20:1), 100:1 (or about 100:1), or 200:1 (or about 200:1). In some embodiments, the average aspect ratio of the powder feedstock is greater than 1:1 (or about 1:1), 3:1 (or about 3:1), 5:1 (or about 5:1), greater 10:1 (or about 10:1), greater 20:1 (or about 20:1), greater 100: 1 (or about 100:1), or greater 200: 1 (or about 200:1). In some embodiments, the average aspect ratio of the powder feedstock is less than, 3:1 (or about 3:1), 5:1 (or about 5:1), greater 10:1 (or about 10:1), greater 20:1 (or about 20:1), greater 100:1 (or about 100:1), or greater 200: 1 (or about 200:1).

Tantalum (Ta) Feedstock

[0027] Tantalum (Ta) or Ta alloy powder can be used in various applications. Applications of Ta or Ta alloy powder can benefit from a narrow particle size distribution and a high sphericity. It has been observed that microwave plasma processing of Ta or Ta alloy powder feedstock can yield a narrow particle size distribution and a high sphericity Ta or Ta alloy powder. Before plasma processing, the feedstock can be sieved to remove large agglomerations and selected the desired size to be processed in the plasma. Ta7300 is high purity Tantalum spherical powder that may be synthesized according to the embodiments herein for use in various applications including additive manufacturing. Ta has high electrical and thermal conductivity, biocompatibility and high corrosion resistance. In some embodiments, as an example, a Ta or TA alloy powder may comprise an apparent density of about 9 g/cc, a flow of about 7s/50g, a D10 of about 15 mm, a D50 of about 30 mm, and D90 of about 55 mm.

Yttrium Stabilized Zirconia (YSZ) Feedstock

[0028] Yttrium Stabilized Zirconia (YSZ) powder can be used in various applications. Applications of YSZ powder can benefit from a narrow particle size distribution and a high sphericity. It has been observed that microwave plasma processing of YSZ powder feedstock can yield a narrow particle size distribution and a high sphericity. Before plasma processing, the feedstock can be sieved to remove large agglomerations and selected the desired size to be processed in the plasma. In some embodiments, 8% YSZ may be synthesized, which is a high purity yttria stabilized zirconia spherical powder. In some embodiments, a microwave plasma treatment produces highly spherical powder with substantially no satellites. In some embodiments, YSZ powder synthesized according to the embodiments herein may comprise a composition about 8 mol% Y2O3 and about 92 mol% ZrO2, with particle sizes ranging from about 15 microns to about 45 microns. In some embodiments, as an example, the apparent density may be about 3.12 g/cc and the flow may be about 23 s/50g

Titanium Nitride (TiN) Feedstock

[0029] Titanium Nitride (TiN) powder can be used in various applications. Applications of TiN powder can benefit from a narrow particle size distribution and a high sphericity. It has been observed that microwave plasma processing of TiN powder feedstock can yield a narrow particle size distribution and a high sphericity. Before plasma processing, the feedstock can be sieved to remove large agglomerations and selected the desired size to be processed in the plasma. In some embodiments, TiN powder may be synthesized with substantially no satellites, high Sphericity, high flowability, high bulk density, and low interstitials. In some embodiments, as an example, TiN powder synthesized according to the embodiments herein may comprise an apparent density of about 2.7g/cc, a flow of about 31 s/50s, a D10 of about 18 mm, a D50 of about 35 mm, and a D90 of about 52mm.

Aluminum Feedstock [0030] Aluminum (Al) or A1 alloy powders can be used in various applications. Specifically, Al 6000 series and Aluminum Silicon Magnesium (AlSiMg) powder has been demonstrated to be useful in various applications. Applications of Al 6000 series or AlSiMg powder can benefit from a narrow particle size distribution and a high sphericity. It has been observed that microwave plasma processing of AlSiMg powder feedstock can yield a narrow particle size distribution and a high sphericity. Before plasma processing, the feedstock can be sieved to remove large agglomerations and selected the desired size to be processed in the plasma. AlSiMg powder can be AlSilOMg powder which includes a Silicon content of about 9% to about 11%. AlSilOMg is a lightweight Aluminum alloy designed specifically for use in Additive Manufacturing. This alloy has a high strength to weight ratio and excellent corrosion resistance. In some embodiments, a Al or Al alloy powders synthesized according to the embodiments herein may comprise a composition of about 9.0 - 11.0% Si, about 0.25 -0.45% Mg, about 0.25% or less Fe, about 0.20% or less N, about 0.20% or less O, about 0.15% or less Ti, about 0.10% or less Zn, about 0.10% or less Mn, and the balance Al. As an example, an Al or Al alloy powder according to the embodiments herein may comprise a particle size of about 20 - 63 microns, an apparent density of about 1.4 g/cc, and a flow of about 40s/50g.

Water Atomized Alloy Feedstock

[0031] Water atomized alloy powders can be used in various applications. Specifically, water atomized metal injection molded (MIM) 17-4 Stainless Steel powder and water atomized Inconel Alloy 625 (IN625) powder has been demonstrated to be useful is various applications. Applications of water atomized alloy powders can benefit from a narrow particle size distribution and a high sphericity. It has been observed that microwave plasma processing of water atomized MIM 17-4 Stainless Steel powder feedstock and water atomized IN625 powder feedstock can yield a narrow particle size distribution and a high sphericity. Before plasma processing, the feedstock can be sieved to remove large agglomerations and selected the desired size to be processed in the plasma. As an example, in some embodiments, a MIM 17-4 powder may comprise an apparent density of about 4.2 .g/cc, a flow of about 17 s/50g, a D10 of about 18 mm, a D50 of about 32 mm, and a D90 of about 56 mm. In some embodiments, a MIM 17-4 powder synthesized according to the embodiments herein may comprise about 17% Cr, about 4.5% Ni, about 4% Cu, about 0.30% of Nb and Ta combined, about 0.07% or less C, and the balance Fe.

[0032] As an example, in some embodiments, IN625 powder may comprise about 0.10% or less C, about 0.015% or less P, about 0.50% or less Si, about 0.50% or less Cu, about 0.40% Ti, about 0.40% Al, about 0.03% or less O, about 3.15%-4.15% Ni and Ta combined, about 0.50% or less Mn, about 20.0%-23.0% Cr, about 8.00-10.00% Mo, about 1.00% or less Co, about 0.02% or less Ni, about 5.0% or less Fe, and the balance Nickel. As an example, in some embodiments, IN625 powder may comprise an apparent density of about 4.3 g/cc, a tap density of about 5 g/cc, a flow of about 15 s/50g, a D10 of about 16-26 mm, a D50 of about 26-37 mm, and a D90 of about 37-49 mm.

Rhenium Feedstock

[0033] Rhenium (Re) or Re alloy powder can be used in various applications. Applications of Re or Re alloy powder can benefit from a narrow particle size distribution and a high sphericity. It has been observed that microwave plasma processing of Re or Re alloy powder feedstock can yield a narrow particle size distribution and a high sphericity Re or Re alloy powder. Before plasma processing, the feedstock can be sieved to remove large agglomerations and selected the desired size to be processed in the plasma. In some embodiments, the Re or Re alloy powder may comprise Re7500. As an example, in some embodiments, an Re or Re alloy powder may comprise over 99.9% Re, particle sizes between 20-63 microns, an apparent density of about 11.4 g/cc, a flow of about 4.3 s/50g, a D10 of about 29 microns, a D50 of about 39 microns, and a D90 of about 55 microns.

Tungsten Feedstock

[0034] Tungsten (W) or W alloy powder can be used in various applications. Applications of W or W alloy powder can benefit from a narrow particle size distribution and a high sphericity. It has been observed that microwave plasma processing of W or W alloy powder feedstock can yield a narrow particle size distribution and a high sphericity W or W alloy powder. Before plasma processing, the feedstock can be sieved to remove large agglomerations and selected the desired size to be processed in the plasma. In some embodiments, the W or W alloy powder may comprise W7400. As an example, in some embodiments, a W or W alloy powder may comprise over 90.9% W, or preferably over 99.9% W. As an example, in some embodiments, a W or W alloy powder may comprise particle sizes between 20-63 microns, an apparent density of about 11.2 g/cc, a flow of about 5.16 s/50g, a D10 of about 29 microns, a D50 of about 39 microns, and a D90 of about 55 microns.

Molybdenum Feedstock

[0035] Molybdenum (Mo) or Mo alloy powder can be used in various applications. Applications of Mo or Mo alloy powder can benefit from a narrow particle size distribution and a high sphericity. It has been observed that microwave plasma processing of Mo or Mo alloy powder feedstock can yield a narrow particle size distribution and a high sphericity Mo or Mo alloy powder. Before plasma processing, the feedstock can be sieved to remove large agglomerations and selected the desired size to be processed in the plasma. In some embodiments, the Mo or Mo alloy powder may comprise Mo4200. As an example, in some embodiments, the Mo or Mo alloy powder may comprise over 99.9% Mo. As an example, in some embodiments, the Mo or Mo alloy powder may comprise particle sizes between 15-45 microns, an apparent density of about 5.5 g/cc, and a flow of about 11.7 s/50g.

Sphericity

[0036] In some embodiments, the final particles achieved by the plasma processing can be spherical or spheroidal, terms which can be used interchangeably. Advantageously, by using the critical and specific disclosure relevant to each of the different feedstocks disclosed, all of the feedstocks can be transformed into the spherical powders.

[0037] Embodiments of the present disclosure are directed to producing particles that are substantially spherical or spheroidal or have undergone significant spheroidization. In some embodiments, spherical, spheroidal or spheroidized particles refer to particles having a sphericity greater than a certain threshold. Particle sphericity can be calculated by calculating the surface area of a sphere A _s, ideal with a volume matching that of the particle, V using the following equation:

[0038] The idealized surface area can be compared with the measured surface area of the particle,

[0039] In some embodiments, particles can have a sphericity of greater than 0.5, 0.6, 0.7, 0.75, 0.8, 0.9, 0.91, 0.95, or 0.99 (or greater than about 0.5, about 0.6, about 0.7, about 0.75, about 0.8, about 0.8, about 0.91, about 0.95, or about 0.99). In some embodiments, particles can have a sphericity of 0.75 or greater or 0.91 or greater (or about 0.75 or greater or about 0.91 or greater). In some embodiments, particles can have a sphericity of less than 0.5, 0.6, 0.7, 0.75, 0.8, 0.9, 0.91, 0.95, or 0.99 (or less than about 0.5, about 0.6, about 0.7, about 0.75, about 0.8, about 0.8, about 0.91, about 0.95, or about 0.99). In some embodiments, a particle is considered to be spherical, spheroidal or spheroidized if it has a sphericity at or above any of the aforementioned sphericity values, and in some preferred embodiments, a particle is considered to be spherical if its sphericity is at or about 0.75 or greater or at or about 0.91 or greater.

[0040] In some embodiments, a median sphericity of all particles within a given powder can be greater than 0.5, 0.6, 0.7, 0.75, 0.8, 0.9, 0.91, 0.95, or 0.99 (or greater than about 0.5, about 0.6, about 0.7, about 0.75, about 0.8, about 0.8, about 0.91, about 0.95, or about 0.99). In some embodiments, a median sphericity of all particles within a given powder can be less than 0.5, 0.6, 0.7, 0.75, 0.8, 0.9, 0.91, 0.95, or 0.99 (or less than about 0.5, about 0.6, about 0.7, about 0.75, about 0.8, about 0.8, about 0.91, about 0.95, or about 0.99). In some embodiments, a powder is considered to be spheroidized if all or a threshold percentage (as described by any of the fractions below) of the particles measured for the given powder have a median sphericity greater than or equal to any of the aforementioned sphericity values, and in some preferred embodiments, a powder is considered to be spheroidized if all or a threshold percentage of the particles have a median sphericity at or about 0.75 or greater or at or about 0.91 or greater.

[0041] In some embodiments, the fraction of particles within a powder that can be above a given sphericity threshold, such as described above, can be greater than 50%, 60%, 70%, 80%, 90%, 95%, or 99% (or greater than about 50%, about 60%, about 70%, about 80%, about 90%, about 95%, or about 99%). In some embodiments, the fraction of particles within a powder that can be above a given sphericity threshold, such as described above, can be less than 50%, 60%, 70%, 80%, 90%, 95%, or 99% (or less than about 50%, about 60%, about 70%, about 80%, about 90%, about 95%, or about 99%).

[0042] Particle size distribution and sphericity may be determined by any suitable known technique such as by SEM, optical microscopy, dynamic light scattering, laser diffraction, manual measurement of dimensions using an image analysis software, for example from about 15-30 measures per image over at least three images of the same material section or sample, and any other techniques.

[0043] Embodiments of the disclosed process can include feeding the powders using a powder feeder into a microwave generated plasma where the power density, gas flows and residence time are controlled. The process parameters such as power density, flow rates and residence time of the powder in the plasma can depend on the powder material’s physical characteristics, such as the melting point and thermal conductivity. The power density can range from 20 W/cm ³ to 500 W/cm ³ (or about 20 W/cm ³ to about 500 W/cm ³ ). The total gas flows can range from 0.1 cfm to 50 cfm (or about 0.1 cfm to about 50 cfm), and the residence time can be tuned from 1 ms to 10 sec (or about 1 ms to about 10 sec). This range of process parameters will cover the required processing parameters for materials with a wide range of melting point and thermal conductivity.

[0044] In some embodiments, the ability to control oxygen can provide advantages. In some embodiments where the material is milled, the milling can be done in water. Different environmental gasses can be used for different applications. As an example, nitrogen gas can be used.

[0045] In some embodiments, the feedstock could be of various morphology such as angular powder, angular chips, irregular powder, and sponge powders. The feedstock can be processed to meet certain criteria for size, gas content, purity contamination and chemistry by processing such as but not limited to grinding, milling, cleaning, washing, drying and screening. The cleaning includes removing organic, ceramic, or other contaminants.

Microwave Plasma Processing

[0046] The process parameters can be optimized to obtain maximum spheroidization depending on the feedstock initial condition. For each feedstock characteristic, process parameters can be optimized for a particular outcome. U.S. Pat. Pub. No. 2018/0297122, US 8748785 B2, and US 9932673 B2 disclose certain processing techniques that can be used in the disclosed process, specifically for microwave plasma processing. Accordingly, U.S. Pat. Pub. No. 2018/0297122, US 8748785 B2, and US 9932673 B2 are incorporated by reference in its entirety and the techniques describes should be considered to be applicable to the feedstock described herein.

[0047] One aspect of the present disclosure involves a process of spheroidization using a microwave generated plasma. The powder feedstock is entrained in an inert and/or reducing gas environment and injected into the microwave plasma environment. Upon injection into a hot plasma (or plasma plume or exhaust), the feedstock is spheroidized and released into a chamber filled with an inert gas and directed into hermetically sealed drums where is it stored. This process can be carried out at atmospheric pressure, in a partial vacuum, or at a slightly higher pressure than atmospheric pressure. In alternative embodiments, the process can be carried out in a low, medium, or high vacuum environment. The process can run continuously and the drums are replaced as they fill up with spheroidized particles.

[0048] Cooling processing parameters include, but are not limited to, cooling gas flow rate, residence time of the spheroidized particles in the hot zone, and the composition or make of the cooling gas. For example, the cooling rate or quenching rate of the particles can be increased by increasing the rate of flow of the cooling gas. Residence time of the particles within the hot zone of the plasma can also be adjusted to provide control. That is, the length of time the particles are exposed to the plasma determines the extent of melting of the particle (i.e., surface of the particle melted as compared to the inner most portion or core of the particle). Consequently, the extent of melting effects the extent of cooling needed for solidification and thus it is a cooling process parameter. Residence time can be adjusted by adjusting such operating variables of particle injection rate and flow rate (and conditions, such as laminar flow or turbulent flow) within the hot zone. Equipment changes can also be used to adjust residence time. For example, residence time can be adjusted by changing the cross- sectional area of the hot zone.

[0049] Another cooling processing parameter that can be varied or controlled is the composition of the cooling gas. Certain cooling gases are more thermally conductive than others. For example helium is considered to be a highly thermally conductive gas. The higher the thermal conductivity of the cooling gas, the faster the spheroidized particles can be cooled/quenched. By controlling the composition of the cooling gas (e.g., controlling the quantity or ratio of high thermally conductive gasses to lesser thermally conductive gases) the cooling rate can be controlled.

[0050] In one exemplary embodiment, inert gas is continually purged surrounding a powdered feed to remove oxygen within a powder-feed hopper. A continuous volume of powder feed is then entrained within an inert gas and fed into the microwave generated plasma for dehydrogenation or for composition/maintaining purity of the spheroidized particles. In one example, the microwave generated plasma may be generated using a microwave plasma torch, as described in U.S. Patent Publication No. US 2013/0270261, and/or U.S. Patent Nos. 8,748,785, 9,023,259, 9,259,785, and 9,206,085, each of which is hereby incorporated by reference in its entirety. In some embodiments, the particles are exposed to a uniform temperature profile at between 4,000 and 8,000 K within the microwave generated plasma. In some embodiments, the particles are exposed to a uniform temperature profile at between 3,000 and 8,000 K within the microwave generated plasma. In some embodiments, the microwave generated plasma may be generated by using an argon and hydrogen (H ₂ ) mixture. In some embodiments, the microwave generated plasma may be generated by using a nitrogen (N ₂ ) gas. At times, the microwave generated plasma using N ₂ gas may be larger, more stable, and more laminar than the microwave generated plasma using an argon and H ₂ mixture which can allow for a higher plasma temperature to be achieved. For certain feedstocks, a higher temperature plasma can be beneficial due to their high melting temperature. For example, YSZ, W, and Mo have high melting temperatures and therefore can benefit from a higher temperature plasma. For these feedstocks, it could be advantageous to use a microwave generated plasma using N2 gas. [0051] Within the plasma torch, the powder particles are rapidly heated and melted. As the particles within the process are entrained within an inert gas, such as argon, generally contact between particles is minimal, greatly reducing the occurrence of particle agglomeration. The need for post-process sifting is thus greatly reduced or eliminated, and the resulting particle size distribution could be practically the same as the particle size distribution of the input feed materials. In exemplary embodiments, the particle size distribution of the feed materials is maintained in the end products.

[0052] Within the plasma, plasma plume, or exhaust, the materials are inherently spheroidized due to liquid surface tension. As the microwave generated plasma exhibits a substantially uniform temperature profile, more than 90% spheroidization of particles could be achieved (e.g., 91%, 93%, 95%, 97%, 99%, 100%). After exiting the plasma, the particles are cooled before entering collection bins. When the collection bins fill, they can be removed and replaced with an empty bin as needed without stopping the process.

[0053] In one exemplary embodiment, inert gas is continually purged surrounding a feed to remove oxygen within a powder-feed hopper. A continuous volume of powder feed is then entrained within an inert gas and fed into the microwave generated plasma for composition/maintaining purity of the spheroidized particles. In one example, the microwave generated plasma may be generated using a microwave plasma torch, as described in U.S. Patent Publication No. US 2013/0270261, and/or U.S. Patent No. 8,748,785, each of which is hereby incorporated by reference in its entirety. In some embodiments, the particles are exposed to a uniform temperature profile at between 4,000 and 8,000 K within the microwave generated plasma. Within the plasma torch, the powder particles are rapidly heated and melted. As the particles within the process are entrained within an inert gas, such as argon, generally contact between particles is minimal, greatly reducing the occurrence of particle agglomeration. The need for post-process sifting is thus greatly reduced or eliminated, and the resulting particle size distribution could be practically the same as the particle size distribution of the input feed materials. In exemplary embodiments, the particle size distribution of the feed materials is maintained in the end products.

[0054] Within the plasma, the feedstock is inherently spheroidized due to liquid surface tension. As the microwave generated plasma exhibits a substantially uniform temperature profile, more than 90% spheroidization of particles could be achieved (e.g., 91%, 93%, 95%, 97%, 99%, 100%). In embodiments, both spheroidization and tailoring (e.g., changing, manipulating, controlling) microstmcture are addressed or, in some instances, partially controlled, by treating with the microwave generated plasma. After exiting the plasma, the particles are cooled before entering collection bins. When the collection bins fill, they can be removed and replaced with an empty bin as needed without stopping the process.

[0055] FIG. 1 is a flow chart illustrating an exemplary method (250) for producing spherical powders, according to an embodiment of the present disclosure. In this embodiment, the process (250) begins by introducing a feed material into a plasma torch (255). In some embodiments, the plasma torch is a microwave generated plasma torch or an RF plasma torch. Within the plasma torch, the feed materials are exposed to a plasma causing the materials to melt, as described above (260). The melted materials are spheroidized by surface tension, as discussed above (260b). After exiting the plasma, the products cool and solidify, locking in the spherical shape and are then collected (265).

[0056] As discussed above, the plasma torch can be a microwave generated plasma or an RF plasma torch. In one example embodiment, an AT-1200 rotating powder feeder (available from Thermach Inc.) allows a good control of the feed rate of the powder. In an alternative embodiment, the powder can be fed into the plasma using other suitable means, such as a fluidized bed feeder. The feed materials may be introduced at a constant rate, and the rate may be adjusted such that particles do not agglomerate during subsequent processing steps. In another exemplary embodiment, the feed materials to be processed are first sifted and classified according to their diameters, with a minimum diameter of 1 micrometers (μm) and a maximum diameter of 22 μm, or a minimum of 5 μm and a maximum of 15 μm, or a minimum of 15 μm and a maximum of 45 μm or a minimum of 22 μm and a maximum of 44 μm, or a minimum of 20 μm to a maximum of 63 μm, or a minimum of 44 μm and a maximum of 70 μm, or a minimum of 70 μm and a maximum of 106 μm, or a minimum of 105 μm to a maximum of 150 μm, or a minimum of 106 μm and a maximum of 300 μm. As will be appreciated, these upper and lower values are provided for illustrative purposes only, and alternative size distribution values may be used in other embodiments. This eliminates recirculation of light particles above the hot zone of the plasma and also ensures that the process energy present in the plasma is sufficient to melt the particles without vaporization. Pre-screening allows efficient allocation of microwave power necessary to melt the particles without vaporizing material.

[0057] In some embodiments, the environment and/or sealing requirements of the bins are carefully controlled. That is, to prevent contamination or potential oxidation of the powders, the environment and or seals of the bins are tailored to the application. In one embodiment, the bins are under a vacuum. In one embodiment, the bins are hermetically sealed after being filled with powder generated in accordance with the present technology. In one embodiment, the bins are back filled with an inert gas, such as, for example argon. Because of the continuous nature of the process, once a bin is filled, it can be removed and replaced with an empty bin as needed without stopping the plasma process.

[0058] FIG. 2 illustrates an exemplary microwave plasma torch that can be used in the production of spheroidal powders, according to embodiments of the present disclosure. As discussed above, feed materials 9, 10 can be introduced into a microwave plasma torch 3, which sustains a microwave generated plasma 11. In one example embodiment, an entrainment gas flow and a sheath flow (downward arrows) may be injected through inlets 5 to create flow conditions within the plasma torch prior to ignition of the plasma 11 via microwave radiation source 1. In some embodiments, the entrainment flow and sheath flow are both axis- symmetric and laminar, while in other embodiments the gas flows are swirling. The feed materials 9 are introduced axially into the microwave plasma torch, where they are entrained by a gas flow that directs the materials toward the plasma. As discussed above, the gas flows can consist of a noble gas column of the periodic table, such as helium, neon, argon, etc. Within the microwave generated plasma, the feed materials are melted in order to spheroidize the materials. Inlets 5 can be used to introduce process gases to entrain and accelerate particles 9, 10 along axis 12 towards plasma 11. First, particles 9 are accelerated by entrainment using a core laminar gas flow (upper set of arrows) created through an annular gap within the plasma torch. A second laminar flow (lower set of arrows) can be created through a second annular gap to provide laminar sheathing for the inside wall of dielectric torch 3 to protect it from melting due to heat radiation from plasma 11. In exemplary embodiments, the laminar flows direct particles 9, 10 toward the plasma 11 along a path as close as possible to axis 12, exposing them to a substantially uniform temperature within the plasma. In some embodiments, suitable flow conditions are present to keep particles 10 from reaching the inner wall of the plasma torch 3 where plasma attachment could take place. Particles 9, 10 are guided by the gas flows towards microwave plasma 11 were each undergoes homogeneous thermal treatment. Various parameters of the microwave generated plasma, as well as particle parameters, may be adjusted in order to achieve desired results. These parameters may include microwave power, feed material size, feed material insertion rate, gas flow rates, plasma temperature, residence time and cooling rates. In some embodiments, the cooling or quenching rate is not less than 10 ⁺³ degrees C/sec upon exiting plasma 11. As discussed above, in this particular embodiment, the gas flows are laminar; however, in alternative embodiments, swirl flows or turbulent flows may be used to direct the feed materials toward the plasma.

[0059] FIGS. 3A-B illustrates an exemplary microwave plasma torch that includes a side feeding hopper rather than the top feeding hopper shown in the embodiment of FIG. 2, thus allowing for downstream feeding. Thus, in this implementation the feedstock is injected after the microwave plasma torch applicator for processing in the “plume” or “exhaust” of the microwave plasma torch. Thus, the plasma of the microwave plasma torch is engaged at the exit end of the plasma torch to allow downstream feeding of the feedstock, as opposed to the top-feeding (or upstream feeding) discussed with respect to FIG. 2. This downstream feeding can advantageously extend the lifetime of the torch as the hot zone is preserved indefinitely from any material deposits on the walls of the hot zone liner. Furthermore, it allows engaging the plasma plume downstream at temperature suitable for optimal melting of powders through precise targeting of temperature level and residence time. For example, there is the ability to dial the length of the plume using microwave powder, gas flows, and pressure in the quenching vessel that contains the plasma plume.

[0060] Generally, the downstream spheroidization method can utilize two main hardware configurations to establish a stable plasma plume which are: annular torch, such as described in U.S. Pat. Pub. No. 2018/0297122, or swirl torches described in US 8748785 B2 and US 9932673 B2. Both FIG. 3A and FIG. 3B show embodiments of a method that can be implemented with either an annular torch or a swirl torch. A feed system close-coupled with the plasma plume at the exit of the plasma torch is used to feed powder axisymmetrically to preserve process homogeneity. Other feeding configurations may include one or several individual feeding nozzles surrounding the plasma plume. The feedstock powder can enter the plasma from any direction and can be fed in 360° around the plasma. The feedstock powder can enter the plasma at a specific position along the length of the plasma plume where a specific temperature has been measured and a residence time estimated for sufficient melting of the particles. The melted particles exit the plasma into a sealed chamber where they are quenched then collected.

[0061] The feed materials 314 can be introduced into a microwave plasma torch 302. A hopper 306 can be used to store the feed material 314 before feeding the feed material 314 into the microwave plasma torch 302, plume, or exhaust. The feed material 314 can be injected at any angle to the longitudinal direction of the plasma torch 302. 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, or 55 degrees. In some embodiments, the feedstock can be injected an angle of greater than 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, or 55 degrees. In some embodiments, the feedstock can be injected an angle of less than 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, or 55 degrees. In alternative embodiments, the feedstock can be injected along the longitudinal axis of the plasma torch. The microwave radiation can be brought into the plasma torch through a waveguide 304. The feed material 314 is fed into a plasma chamber 310 and is placed into contact with the plasma generated by the plasma torch 302. When in contact with the plasma, plasma plume, or plasma exhaust, the feed material melts. While still in the plasma chamber 310, the feed material 314 cools and solidifies before being collected into a container 312. Alternatively, the feed material 314 can exit the plasma chamber 310 while still in a melted phase and cool and solidify outside the plasma chamber. In some embodiments, a quenching chamber may be used, which may or may not use positive pressure. While described separately from FIG. 2, the embodiments of FIGS. 3A-B are understood to use similar features and conditions to the embodiment of FIG. 2.

[0062] In some embodiments, implementation of the downstream injection method may use a downstream swirl, extended spheroidization, or quenching. A downstream swirl refers to an additional swirl component that can be introduced downstream from the plasma torch to keep the powder from the walls of the tube. An extended spheroidization refers to an extended plasma chamber to give the powder longer residence time. In some implementations, it may not use a downstream swirl, extended spheroidization, or quenching. In some embodiments, it may use one of a downstream swirl, extended spheroidization, or quenching. In some embodiments, it may use two of a downstream swirl, extended spheroidization, or quenching. [0063] Injection of powder from below may results in the reduction or elimination of plasma-tube coating in the microwave region. When the coating becomes too substantial, the microwave energy is shielded from entering the plasma hot zone and the plasma coupling is reduced. At times, the plasma may even extinguish and become unstable. Decrease of plasma intensity means decreases in spheroidization level of the powder. Thus, by feeding feedstock below the microwave region and engaging the plasma plume at the exit of the plasma torch, coating in this region is eliminated and the microwave powder to plasma coupling remains constant through the process allowing adequate spheroidization.

[0064] Thus, advantageously the downstream approach may allow for the method to run for long durations as the coating issue is reduced. Further, the downstream approach allows for the ability to inject more powder as there is no need to minimize coating.

[0065] From the foregoing description, it will be appreciated that inventive processing methods for converting unique feedstocks to spheroidized powder are disclosed. While several components, techniques and aspects have been described with a certain degree of particularity, it is manifest that many changes can be made in the specific designs, constructions and methodology herein above described without departing from the spirit and scope of this disclosure.

[0066] Certain features that are described in this disclosure in the context of separate implementations can also be implemented in combination in a single implementation. Conversely, various features that are described in the context of a single implementation can also be implemented in multiple implementations separately or in any suitable subcombination. Moreover, although features may be described above as acting in certain combinations, one or more features from a claimed combination can, in some cases, be excised from the combination, and the combination may be claimed as any subcombination or variation of any subcombination.

[0067] Moreover, while methods may be depicted in the drawings or described in the specification in a particular order, such methods need not be performed in the particular order shown or in sequential order, and that all methods need not be performed, to achieve desirable results. Other methods that are not depicted or described can be incorporated in the example methods and processes. For example, one or more additional methods can be performed before, after, simultaneously, or between any of the described methods. Further, the methods may be rearranged or reordered in other implementations. Also, the separation of various system components in the implementations described above should not be understood as requiring such separation in all implementations, and it should be understood that the described components and systems can generally be integrated together in a single product or packaged into multiple products. Additionally, other implementations are within the scope of this disclosure.

[0068] Conditional language, such as “can,” “could,” “might,” or “may,” unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments include or do not include, certain features, elements, and/or steps. Thus, such conditional language is not generally intended to imply that features, elements, and/or steps are in any way required for one or more embodiments.

[0069] Conjunctive language such as the phrase “at least one of X, Y, and Z,” unless specifically stated otherwise, is otherwise understood with the context as used in general to convey that an item, term, etc. may be either X, Y, or Z. Thus, such conjunctive language is not generally intended to imply that certain embodiments require the presence of at least one of X, at least one of Y, and at least one of Z.

[0070] Language of degree used herein, such as the terms “approximately,” “about,” “generally,” and “substantially” as used herein represent a value, amount, or characteristic close to the stated value, amount, or characteristic that still performs a desired function or achieves a desired result. For example, the terms “approximately”, “about”, “generally,” and “substantially” may refer to an amount that is within less than or equal to 10% of, within less than or equal to 5% of, within less than or equal to 1% of, within less than or equal to 0.1% of, and within less than or equal to 0.01% of the stated amount. If the stated amount is 0 (e.g., none, having no), the above recited ranges can be specific ranges, and not within a particular % of the value. For example, within less than or equal to 10 wt./vol. % of, within less than or equal to 5 wt./vol. % of, within less than or equal to 1 wt./vol. % of, within less than or equal to 0.1 wt./vol. % of, and within less than or equal to 0.01 wt./vol. % of the stated amount.

[0071] The disclosure herein of any particular feature, aspect, method, property, characteristic, quality, attribute, element, or the like in connection with various embodiments can be used in all other embodiments set forth herein. Additionally, it will be recognized that any methods described herein may be practiced using any device suitable for performing the recited steps.

[0072] While a number of embodiments and variations thereof have been described in detail, other modifications and methods of using the same will be apparent to those of skill in the art. Accordingly, it should be understood that various applications, modifications, materials, and substitutions can be made of equivalents without departing from the unique and inventive disclosure herein or the scope of the claims.

APPENDIX A