Process for producing spheroidized powder from feedstock materials
First Claim
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1. A method for manufacturing a spheroidized powder from scrap metal or used metal parts, the method comprising:
- providing scrap metal or used metal parts comprising a material selected from the group consisting of metal and metal alloys;
milling the scrap metal or used metal parts to produce metallic particles within a range of particle volumes suitable for use as feedstock in a microwave plasma process; and
applying the microwave plasma process to the metallic particles within the range of particle volumes to form spheroidized powder;
wherein the scrap metal or used metal parts comprise a work hardened microstructure that is retained in the spheroidized powder after applying the microwave plasma process.
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Abstract
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.
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Citations
28 Claims
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1. A method for manufacturing a spheroidized powder from scrap metal or used metal parts, the method comprising:
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providing scrap metal or used metal parts comprising a material selected from the group consisting of metal and metal alloys; milling the scrap metal or used metal parts to produce metallic particles within a range of particle volumes suitable for use as feedstock in a microwave plasma process; and applying the microwave plasma process to the metallic particles within the range of particle volumes to form spheroidized powder; wherein the scrap metal or used metal parts comprise a work hardened microstructure that is retained in the spheroidized powder after applying the microwave plasma process. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
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10. A method for manufacturing a spheroidized powder having a desired particle size distribution between about x and about y, wherein x represents a low end of the particle size distribution and having a value of 5 microns and y represents a high end of the particle size distribution and having a value of 45 microns, the method comprising:
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introducing metallic particles obtained by milling or crushing scrap metal or used metal parts into a microwave plasma torch, a majority of said introduced metallic particles having a volume between about 4/3π
(x/2)3 and about 4/3π
(y/2)3, and wherein said introduced metallic particles having at least one of a collective average or median aspect ratio between 2;
1 and 200;
1; andmelting and spheroidizing the metallic particles within the microwave plasma torch to form spheroidized powder having the desired particle size distribution of about x to about y; wherein the scrap metal or used metal parts comprise a work hardened microstructure that is retained in the spheroidized powder after applying the microwave plasma process. - View Dependent Claims (11, 12, 13)
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14. A method for producing a spheroidized powder from a feed material comprising dehydrogenated or non-hydrogenated titanium or titanium alloy, the method comprising:
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introducing a feed material comprising dehydrogenated or non-hydrogenated titanium or titanium 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 being made of spheroidized particles having a martensitic microstructure. - View Dependent Claims (15, 16, 17, 18, 19, 20, 21)
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22. A method for producing a spheroidized powder from a feed material comprising dehydrogenated or non-hydrogenated titanium or titanium alloy, the method comprising:
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introducing a feed material comprising dehydrogenated or non-hydrogenated titanium or titanium 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, the spheroidized powder having at least two regions, each region having a different microstructure. - View Dependent Claims (23, 24, 25, 26, 27, 28)
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Specification