Disclosed herein are embodiments of mechanically alloyed powder feedstock and methods for spheroidizing them using microwave plasma processing. The spheroidized powder can be used in metal injection molding processes, hot isostatic processing, and additive manufacturing. In some embodiments, mechanical milling, such as ball milling, can be used to prepare high entropy alloys for microwave plasma processing.

A process for manufacturing metal-ceramic composite material powder comprising ball milling metal powder and ceramic nanoparticles to yield a metal-ceramic composite powder comprising ceramic nanoparticles embedded in a metal matrix powder particles; wherein the ball milling is performed using a ceramic milling media and a milling vessel having a ceramic interior surface. Metal matrix nanocomposite powders comprising ceramic nanoparticles imbedded in metal matrix powder particles; wherein the metal matrix powder particles have a spherical shape; wherein there is uniform distribution the ceramic nanoparticles; wherein the nanocomposite powders have good flowability.

A process for manufacturing metal-ceramic composite material powder comprising ball milling metal powder and ceramic nanoparticles to yield a metal-ceramic composite powder comprising ceramic nanoparticles embedded in a metal matrix powder particles; wherein the ball milling is performed using a ceramic milling media and a milling vessel having a ceramic interior surface. Metal matrix nanocomposite powders comprising ceramic nanoparticles imbedded in metal matrix powder particles; wherein the metal matrix powder particles have a spherical shape; wherein there is uniform distribution the ceramic nanoparticles; wherein the nanocomposite powders have good flowability.

A powder production method includes providing an elongated workpiece and repeatedly contacting an outer surface of the elongated workpiece with a reciprocating cutter according to a predetermined at least one frequency to produce a powder. The powder includes a plurality of particles, wherein at least 95% of the produced particles have a diameter or maximum dimension ranging from about 10 μm to about 200 μm. A system for producing powders having a plurality of particles including a cutter and at least one controller is also provided herein.

A powder production method includes providing an elongated workpiece and repeatedly contacting an outer surface of the elongated workpiece with a reciprocating cutter according to a predetermined at least one frequency to produce a powder. The powder includes a plurality of particles, wherein at least 95% of the produced particles have a diameter or maximum dimension ranging from about 10 μm to about 200 μm. A system for producing powders having a plurality of particles including a cutter and at least one controller is also provided herein.

A powder production method includes providing an elongated workpiece and repeatedly contacting an outer surface of the elongated workpiece with a reciprocating cutter according to a predetermined at least one frequency to produce a powder. The powder includes a plurality of particles, wherein at least 95% of the produced particles have a diameter or maximum dimension ranging from about 10 μm to about 200 μm. A system for producing powders having a plurality of particles including a cutter and at least one controller is also provided herein.

The invention provides an iron-based metallic glass alloy powder including: Fe as the main component; a metalloid element group including Si, B, and C; a small amount of Mo to improve the degree-of-supercooling; and the addition of Cr and Ni to increase corrosion resistance, where the total amount of the metalloid element group, the amount of the degree-of-supercooling improvement element and the total amount of the elements to increase corrosion resistance are set within predetermined ranges.

A soft magnetic alloy including an internal area having a soft magnetic type alloy composition including Fe and Co, a Co concentrated area existing closer to a surface side than the internal area and having a higher Co concentration than in the internal area, and a SB concentrated area existing closer to the surface side than the Co concentrated area and having a higher concentration of at least one element selected from Si and B than in the internal area.

A composition including a three-dimensional metal printing powder; an organic polymeric additive on at least a portion of an external surface of the three-dimensional metal printing powder; and optionally, an inorganic additive on at least a portion of an external surface of the three-dimensional metal printing powder. A process for preparing a three-dimensional metal printing powder having an organic polymeric additive disposed thereon. A process for employing the three-dimensional metal printing powder including selective laser sintering.

A composition including a three-dimensional metal printing powder; an organic polymeric additive on at least a portion of an external surface of the three-dimensional metal printing powder; and optionally, an inorganic additive on at least a portion of an external surface of the three-dimensional metal printing powder. A process for preparing a three-dimensional metal printing powder having an organic polymeric additive disposed thereon. A process for employing the three-dimensional metal printing powder including selective laser sintering.