METHODS OF FORMING SPHERICAL METALLIC PARTICLES

• US 20190218650A1
• Filed: 01/12/2018
• Published: 07/18/2019
• Est. Priority Date: 01/12/2018
• Status: Abandoned Application

• Current Assignee: General Electric Company
• Original Assignee: General Electric Company
• Inventors: Subramanian, Pazhayannur Ramanathan, Vinciquerra, Anthony Joseph, Bewlay, Bernard Patrick
• Application Number:
  US15/869,064
• Publication Number:
  US 20190218650A1
• Time in Patent Office: Days
• CPC Class Codes: B22F 1/065 Spherical particles
• CPC Class Codes: B22F 1/14 Treatment of metallic powder mixing with lubricating or binding agents or with organic material B22F1/10
• CPC Class Codes: B22F 1/142 Thermal or thermo-mechanical treatment
• CPC Class Codes: B22F 10/20 Direct sintering or melting
• CPC Class Codes: B22F 2202/13 Use of plasma
• CPC Class Codes: B22F 2301/052 Aluminium
• CPC Class Codes: B22F 2301/205 Titanium, zirconium or hafnium
• CPC Class Codes: B22F 2998/10 Processes characterised by the sequence of their steps
• CPC Class Codes: B22F 2999/00 Aspects linked to processes or compositions used in powder metallurgy
• CPC Class Codes: B22F 3/11 Making porous workpieces or articles
• CPC Class Codes: B22F 9/023 Hydrogen absorption
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: C22C 1/08 Alloys with open or closed pores
• CPC Class Codes: C22F 1/183 of titanium or alloys based thereon
• CPC Class Codes: Y02P 10/25 Process efficiency

Abstract

A method of forming titanium-based spherical metallic particles includes performing a hydride-dehydride process on a meltless metallic sponge to form a feedstock material including a metallic powder. The method further includes introducing the feedstock material into a microwave plasma discharge to form the titanium-based spherical metallic particles.

Claims

1. A method of forming spherical metallic particles, comprising:

performing a hydride-dehydride process on a meltless metallic sponge to form a feedstock material comprising a metallic powder; and

introducing the feedstock material into a microwave plasma discharge to form the spherical metallic particles, wherein the spherical metallic particles comprise titanium.

2. The method of claim 1, wherein the meltless metallic sponge comprises elemental titanium.

3. The method of claim 1, wherein the meltless metallic sponge comprises a metal alloy comprising titanium.

4. The method of claim 3, wherein the metal alloy further comprises aluminum, vanadium, or a combination thereof.

5. The method of claim 1, wherein the meltless metallic sponge has a packing density less than 10%.

6. The method of claim 1, wherein the feedstock material comprises acicular metallic powder.

7. The method of claim 6, wherein the acicular metallic powder has a packing density greater than 50%.

8. The method of claim 1, wherein the feedstock material is introduced into the microwave plasma discharge in the presence of a non-reactive gas.

9. The method of claim 1, wherein the spherical metallic particles comprise an elemental metal, a metal alloy, or a combination thereof.

10. The method of claim 1, wherein the spherical metallic particles comprise a metal alloy comprising titanium.

11. The method of claim 10, wherein the metal alloy further comprises aluminum, vanadium, or a combination thereof.

12. A plurality of spherical metallic particles comprising titanium, formed by:

performing a hydride-dehydride process on a meltless metallic sponge to form a feedstock material comprising a metallic powder; and

introducing the feedstock material into a microwave plasma discharge to form the spherical metallic particles.

13. The plurality of spherical metallic particles of claim 12, wherein the plurality of spherical metallic particles comprises elemental titanium, a titanium alloy, or a combination thereof.

14. The plurality of spherical metallic particles of claim 12, wherein the plurality of spherical metallic particles comprises a titanium alloy.

15. The plurality of spherical metallic particles of claim 14, wherein the titanium alloy further comprises aluminum, vanadium, or a combination thereof.

16. A method of forming spherical titanium alloy particles, comprising:

performing a hydride-dehydride process on a meltless titanium alloy sponge to form a feedstock material comprising acicular titanium alloy powder; and

introducing the feedstock material into a microwave plasma discharge to form the spherical titanium alloy particles.

17. The method of claim 16, wherein the feedstock material is introduced into the microwave plasma discharge in the presence of a non-reactive gas.