According to one or more embodiments presently described, metal-containing particles may be formed by a method including forming a molten material from a solid supply material, introducing the molten material into a reaction zone of a Barton reactor, and contacting the molten material with a processing gas in the reaction zone to form solid metal-containing particles comprising solid metallic particles and solid metal oxide particles. The Barton reactor may include a reaction vessel which may include a top cover and sidewalls defining the reaction zone, an agitator, a processing gas inlet, and a product outlet. The molten material may be introduced to the reaction zone in a laminar flow or as atomized molten particles. Less than 99% of the particles may include metal oxide.

According to one or more embodiments presently described, metal-containing particles may be made by a method that includes introducing a molten material into a reaction zone of a reactor system, passing a process gas into the reaction zone in a direction substantially tangential to a sidewall of the reaction zone, and contacting the process gas with the molten material in the reaction zone to form metal-containing particles. The molten material may be introduced into an upper portion of the reaction zone The reaction zone may include a substantially circular cross-section, and the molten metal may be introduced into the reaction zone in a laminar flow or as atomized particles.

According to one or more embodiments presently described, a method for processing metal-containing materials may include passing a feed stream through a first conduit of a multi-conduit reactor, the feed stream including metal-containing material in a molten phase; passing a fluid stream through a second conduit of the multi-conduit reactor; and contacting the feed stream with the fluid stream in a mixing zone downstream of the first conduit and second conduit, thereby causing a chemical or physical change in the one or more materials of the feed stream to form a product stream comprising metal-containing particles.

An aluminum alloy powder for additive manufacturing, and method for manufacturing a piece by manufacturing from this powder are disclosed. In one aspect, the alloy powder is composition by weight: Al.sub.compSi.sub.aMg.sub.bZr.sub.cR.sub.d wherein R represents one or more elements selected from the group consisting of Mn, Cr, Cu, Zn and Ti, and wherein, in percent by weight: a is between 0.2% and 1%, b is between 0.3% and 1.7%, c is between 0.4% and 5%, and d is between 0% and 1%, wherein the balance consists of aluminum and unavoidable impurities.

A nickel-based alloy powder for additive manufacturing having in weight %: C:0.09 to 0.17, Ti:3.8 to 4.5, Zr:>0.06, W:1.8 to 2.6, and Al:3.0 to 3.8 is disclosed.

A method of manufacturing a corrosion- and wear-resistant component and a corrosion- and wear-resistant component. The method includes preparing a feedstock powder that includes a stainless steel powder and a ceramic powder, sintering the feedstock powder at a first temperature to form a low porosity free-standing wear body, and bonding the wear body to an aluminum or aluminum alloy substrate at a second temperature lower than the first temperature.

An improved method of manufacturing a cast part by sand casting, permanent mold casting, investment casting, lost foam casting, die casting, or centrifugal casting, or a powder metal material by water, gas, plasma, ultrasonic, or rotating disk atomization is provided. The method includes adding at least one additive to a melted metal material before or during the casting or atomization process. The at least one additive forms a protective gas atmosphere surrounding the melted metal material which is at least three times greater than the volume of melt to be treated. The protective atmosphere prevents introduction or re-introduction of contaminants, such as sulfur (S) and oxygen (O.sub.2), into the material. The cast parts or atomized particles produced include at least one of the following advantages: less internal pores, less internal oxides, median circularity of at least 0.60, median roundness of at least 0.60 and increased sphericity of microstructural phases and/or constituents.

The copper alloy composition is a Cu.sub.comp(Al.sub.2O.sub.3).sub.aZr.sub.bCr.sub.c mass composition in which, in mass percent 1.5%a5%, 0.01%b5%, 0%c5%, the complement consisting of copper and unavoidable impurities.

Disclosed is a diffusion controlled reaction based alloying anodes through nanostructuring. The diffusion controlled reaction based alloying anode includes a carbon-alloy-based anode material nanocomposite composed of a carbon matrix and alloy-based anode material particles and formed via a diffusion-controlled induction process that is means for inducing the diffusion-controlled reaction.

A method of making dispersion-strengthened alloy particles involves melting an alloy having a corrosion and/or oxidation resistance-imparting alloying element, a dispersoid-forming element, and a matrix metal wherein the dispersoid-forming element exhibits a greater tendency to react with a reactive species acquired from an atomizing gas than does the alloying element. The melted alloy is atomized with the atomizing gas including the reactive species to form atomized particles so that the reactive species is (a) dissolved in solid solution to a depth below the surface of atomized particles and/or (b) reacted with the dispersoid-forming element to form dispersoids in the atomized particles to a depth below the surface of said atomized particles. The atomized alloy particles are solidified as solidified alloy particles or as a solidified deposit of alloy particles. Bodies made from the dispersion strengthened alloy particles, deposit thereof, exhibit enhanced fatigue and creep resistance and reduced wear as well as enhanced corrosion and/or oxidation resistance at high temperatures by virtue of the presence of the corrosion and/or oxidation resistance imparting alloying element in solid solution in the particle alloy matrix.