An apparatus for producing metallic powders from molten feedstock includes a heating source for melting a solid feedstock into a molten feed, and a crucible for containing the molten feed. A liquid feed tube is also provided to feed the molten feed as a molten stream. A plasma source delivers a plasma stream, with the plasma stream being adapted to be accelerated to a supersonic N velocity and being adapted : to then impact the molten stream for producing metallic powders. The feed tube extends from the crucible to a location where a supersonic plasma plume atomizes the molten stream. The plasma source includes at least two plasma torches provided with at least one supersonic nozzle aimed towards the molten stream. The multiple plasma torches are disposed symmetrically about the location where the supersonic plasma plumes atomize the molten stream, such as in a ring-shaped configuration.

A torch stinger apparatus may comprise one or more sets of plasma generating electrodes and at least one hydrocarbon injector contained within the electrodes. The electrodes may be concentric. The at least one hydrocarbon injector may be cooled. A method of making carbon particles using the apparatus is also described.

A torch stinger apparatus may comprise one or more sets of plasma generating electrodes and at least one hydrocarbon injector contained within the electrodes. The electrodes may be concentric. The at least one hydrocarbon injector may be cooled. A method of making carbon particles using the apparatus is also described.

The present disclosure relates to a process and an apparatus for producing powder particles by atomization of a feed material in the form of an elongated member such as a wire, a rod or a filled tube. The feed material is introduced in a plasma torch. A forward portion of the feed material is moved from the plasma torch into an atomization nozzle of the plasma torch. A forward end of the feed material is surface melted by exposure to one or more plasma jets formed in the atomization nozzle. The one or more plasma jets being includes an annular plasma jet, a plurality of converging plasma jets, or a combination of an annular plasma jet with a plurality of converging plasma jets. Powder particles obtained using the process and apparatus are also described.

The present disclosure relates to a process and an apparatus for producing powder particles by atomization of a feed material in the form of an elongated member such as a wire, a rod or a filled tube. The feed material is introduced in a plasma torch. A forward portion of the feed material is moved from the plasma torch into an atomization nozzle of the plasma torch. A forward end of the feed material is surface melted by exposure to one or more plasma jets formed in the atomization nozzle. The one or more plasma jets being includes an annular plasma jet, a plurality of converging plasma jets, or a combination of an annular plasma jet with a plurality of converging plasma jets. Powder particles obtained using the process and apparatus are also described.

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.

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.

A novel, modified cathode device having partially dome shaped portion with a cathode flat surface therealong has been created, whereby arc rotational movement is significantly improved over conventional cathode designs. A complimentary cathode holder with enhanced cooling features is provided to prevent overheating of the cathode tip. The end result is an improved, more versatile plasma arc spray gun that can run at elevated power and enthalpy levels without incurring thermal damage.

A novel, modified cathode device having partially dome shaped portion with a cathode flat surface therealong has been created, whereby arc rotational movement is significantly improved over conventional cathode designs. A complimentary cathode holder with enhanced cooling features is provided to prevent overheating of the cathode tip. The end result is an improved, more versatile plasma arc spray gun that can run at elevated power and enthalpy levels without incurring thermal damage.

An inductively coupled plasma (ICP) torch is described that includes a tapered outer end. A system embodiment includes, but is not limited to, a tubular sample injector configured to receive an aerosolized sample in an interior defined by walls of the tubular sample injector; an inner tube surrounding at least a portion of the tubular sample injector to form a first annular space between the inner tube and the walls of the tubular sample injector, the inner tube defining at least one inlet port for introduction of an auxiliary gas into the first annular space; and an outer tube surrounding at least a portion of the inner tube to form a second annular space, the outer tube defining at least one inlet port for introduction of a cooling gas into the second annular space, the outer tube having a flared region at an outlet of the outer tube.