Disclosed herein are systems and methods for synthesis of spheroidized metal or metal alloy powders using microwave plasma processing. In some embodiments, the metal or metal alloy may comprise a highly ductile, soft, and/or malleable metal or metal alloy such that machining of the metal or metal alloy is difficult or impossible. In some embodiments, a volatile material is dispersed within the metal or metal alloy feedstock to enable machining and pre-processing of the feedstock. In some embodiments, the dispersed volatile material alters the physical properties of the feedstock, such that the metal or metal alloy, which is difficult to machine due to high ductility, softness, and/or malleability, is easily machined in a pre-processing step. In some embodiments, the pre-processed feedstock, can be fed into a plasma processing apparatus. In some embodiments, the volatile material dispersed within the feedstock material may be vaporized upon exposure to the microwave plasma apparatus. In some embodiments, plasma processing of the pre-processed feedstock material may synthesize pure, spheroidized metal or metal alloy particles, with substantially no contamination of the volatile material ion the final product.

Disclosed herein are systems and methods for synthesis of spheroidized metal or metal alloy powders using microwave plasma processing. In some embodiments, the metal or metal alloy may comprise a highly ductile, soft, and/or malleable metal or metal alloy such that machining of the metal or metal alloy is difficult or impossible. In some embodiments, a volatile material is dispersed within the metal or metal alloy feedstock to enable machining and pre-processing of the feedstock. In some embodiments, the dispersed volatile material alters the physical properties of the feedstock, such that the metal or metal alloy, which is difficult to machine due to high ductility, softness, and/or malleability, is easily machined in a pre-processing step. In some embodiments, the pre-processed feedstock, can be fed into a plasma processing apparatus. In some embodiments, the volatile material dispersed within the feedstock material may be vaporized upon exposure to the microwave plasma apparatus. In some embodiments, plasma processing of the pre-processed feedstock material may synthesize pure, spheroidized metal or metal alloy particles, with substantially no contamination of the volatile material ion the final product.

Disclosed herein are systems and methods for synthesis of spheroidized metal or metal alloy powders using microwave plasma processing. In some embodiments, the metal or metal alloy may comprise a highly ductile, soft, and/or malleable metal or metal alloy such that machining of the metal or metal alloy is difficult or impossible. In some embodiments, a volatile material is dispersed within the metal or metal alloy feedstock to enable machining and pre-processing of the feedstock. In some embodiments, the dispersed volatile material alters the physical properties of the feedstock, such that the metal or metal alloy, which is difficult to machine due to high ductility, softness, and/or malleability, is easily machined in a pre-processing step. In some embodiments, the pre-processed feedstock, can be fed into a plasma processing apparatus. In some embodiments, the volatile material dispersed within the feedstock material may be vaporized upon exposure to the microwave plasma apparatus. In some embodiments, plasma processing of the pre-processed feedstock material may synthesize pure, spheroidized metal or metal alloy particles, with substantially no contamination of the volatile material ion the final product.

The present disclosure provides a method for preparing a powder material and an application thereof. The preparation method includes: obtaining an initial alloy ribbon including a matrix phase and a dispersed particle phase by solidifying an alloy melt, and then removing the matrix phase in the initial alloy ribbon while retaining the dispersed particle phase, so as to obtain a powder material composed of original dispersed particle phase. The preparation method of the present disclosure is simple in process and can prepare multiple powder materials of nano-level, sub-micron-level and micro-level. The powder materials have good application prospects in the fields such as catalytic materials, powder metallurgy, composite materials, wave-absorbing materials, sterilization materials, metal injection molding, 3D printing and coating.

The present disclosure provides a method for preparing a powder material and an application thereof. The preparation method includes: obtaining an initial alloy ribbon including a matrix phase and a dispersed particle phase by solidifying an alloy melt, and then removing the matrix phase in the initial alloy ribbon while retaining the dispersed particle phase, so as to obtain a powder material composed of original dispersed particle phase. The preparation method of the present disclosure is simple in process and can prepare multiple powder materials of nano-level, sub-micron-level and micro-level. The powder materials have good application prospects in the fields such as catalytic materials, powder metallurgy, composite materials, wave-absorbing materials, sterilization materials, metal injection molding, 3D printing and coating.

The present disclosure provides a method for preparing a powder material and an application thereof. The preparation method includes: obtaining an initial alloy ribbon including a matrix phase and a dispersed particle phase by solidifying an alloy melt, and then removing the matrix phase in the initial alloy ribbon while retaining the dispersed particle phase, so as to obtain a powder material composed of original dispersed particle phase. The preparation method of the present disclosure is simple in process and can prepare multiple powder materials of nano-level, sub-micron-level and micro-level. The powder materials have good application prospects in the fields such as catalytic materials, powder metallurgy, composite materials, wave-absorbing materials, sterilization materials, metal injection molding, 3D printing and coating.

The invention includes apparatus and methods for instantiating precious metals in a nanoporous carbon powder.

The invention includes apparatus and methods for instantiating precious metals in a nanoporous carbon powder.

A powder material includes: an atomized powder of an Ni-based alloy containing inclusions, in which a number of particles of the contained inclusions is 100 particles or less per 10,000 particles of the atomized powder. The Ni-based alloy may include at least one additive element selected from Al, Ti and Nb, and the inclusions include at least one of oxide and carbonitride of the additive element.

Described herein are embodiments directed to additive manufacturing (AM), including three-dimensional (3D) printing, of metal nitride ceramics. In some embodiments herein, AM may comprise powder bed fusion (PBF) techniques. Also described herein are metal nitride ceramic components formed by AM techniques and methods for forming metal nitrides capable of being used in AM processes.