A process for making full dense components of a carbon-containing steel, comprises the steps of: a) making a powder of the carbon-containing steel by gas atomization wherein the carbon content is low, less than 0.15 wt %, b) agglomerating the powder from step a) with at least one hydrocolloid and elemental carbon, c) compacting the agglomerated powder from step b) to a density of at least 80% of theoretical density, with the proviso that the compacted agglomerated powder still is porous allowing transport of gas to and from its interior, and d) sintering the compacted powder to a density of more than 98% of theoretical density, preferably more than 99% of theoretical density, wherein a gas comprising carbon is added during sintering and finally subjecting the component to HVC. Advantages include that it is possible to manufacture a dense component of powders which otherwise are difficult to compact.

A process for making full dense components of a carbon-containing steel, comprises the steps of: a) making a powder of the carbon-containing steel by gas atomization wherein the carbon content is low, less than 0.15 wt %, b) agglomerating the powder from step a) with at least one hydrocolloid and elemental carbon, c) compacting the agglomerated powder from step b) to a density of at least 80% of theoretical density, with the proviso that the compacted agglomerated powder still is porous allowing transport of gas to and from its interior, and d) sintering the compacted powder to a density of more than 98% of theoretical density, preferably more than 99% of theoretical density, wherein a gas comprising carbon is added during sintering and finally subjecting the component to HVC. Advantages include that it is possible to manufacture a dense component of powders which otherwise are difficult to compact.

A method to achieve full densification and grain size control for sintering metal materials, wherein raw material powder is deagglomerated to obtain deagglomerated powder with dispersion. The deagglomerated powder is granulated by spray granulation. The granulated particles are processed by high-pressure die pressing and cold isostatic pressing. The powder compact is sintered by two-step pressureless sintering. The first step is to heat up the powder compact to a higher temperature and hold for a short time to obtain 75-85% theoretical density; the second step is to cool down powder compact to a lower temperature and hold for a long time. The two-step sintering can decrease the sintering temperature, so that the powder compact can be densified at a lower temperature. Thus, the obtained refractory metal product is densified, with ultrafine grains, uniform grain size distribution, and outstanding mechanical properties.

A method for producing agglomerated tantalum particles, comprising: a step for grinding secondary tantalum particles, which are obtained by reducing a tantalum salt, and adding water thereto to give a water-containing mass; a step for drying said water-containing mass to give a dry mass; a step for sieving said dry mass to give spherical particles; and a step for heating said spherical particles. A mixed tantalum powder comprising a mixture of agglomerated tantalum particles (X) with agglomerated tantalum particles (Y), wherein said agglomerated tantalum particles (X) show a cumulative percentage of particles with particle size of 3 μm or less of 5 mass % or less after 25 W ultrasonic radiation for 10 min, while said agglomerated tantalum particles (Y) show a cumulative percentage of particles with particle size of 3 μm or less of 10 mass % or more after 25 W ultrasonic radiation for 10 min.

A method for producing agglomerated tantalum particles, comprising: a step for grinding secondary tantalum particles, which are obtained by reducing a tantalum salt, and adding water thereto to give a water-containing mass; a step for drying said water-containing mass to give a dry mass; a step for sieving said dry mass to give spherical particles; and a step for heating said spherical particles. A mixed tantalum powder comprising a mixture of agglomerated tantalum particles (X) with agglomerated tantalum particles (Y), wherein said agglomerated tantalum particles (X) show a cumulative percentage of particles with particle size of 3 μm or less of 5 mass % or less after 25 W ultrasonic radiation for 10 min, while said agglomerated tantalum particles (Y) show a cumulative percentage of particles with particle size of 3 μm or less of 10 mass % or more after 25 W ultrasonic radiation for 10 min.

Included is a method of preparing a compound for bonded magnets, the method including: coating a magnetic material having an average particle size of 10 μm or less with a thermosetting resin and a curing agent at a ratio of the equivalent weight of the curing agent to the equivalent weight of the thermosetting resin of 2 or higher and 10 or lower to obtain a coated material; granulating the coated material by compression to obtain a granulated product; milling the granulated product to obtain a milled product; and surface treating the milled product with a silane coupling agent to obtain a compound for bonded magnets, the method either including, between the granulation and the milling, heat curing the granulated product to obtain a cured product, or including, between the milling and the surface treatment, heat curing the milled product to obtain a cured product.

Included is a method of preparing a compound for bonded magnets, the method including: coating a magnetic material having an average particle size of 10 μm or less with a thermosetting resin and a curing agent at a ratio of the equivalent weight of the curing agent to the equivalent weight of the thermosetting resin of 2 or higher and 10 or lower to obtain a coated material; granulating the coated material by compression to obtain a granulated product; milling the granulated product to obtain a milled product; and surface treating the milled product with a silane coupling agent to obtain a compound for bonded magnets, the method either including, between the granulation and the milling, heat curing the granulated product to obtain a cured product, or including, between the milling and the surface treatment, heat curing the milled product to obtain a cured product.

A method for manufacturing metal powder is provided. The method includes preparing first metal powder, agglomerating the first metal powder to manufacture second metal powder in which the first metal powder is agglomerated, coating the second metal powder with an organic binder, and agglomerating and coarsening the second metal powder coated with the organic binder to manufacture third metal powder having higher flowability than the second metal powder coated with the organic binder.

A method for manufacturing metal powder is provided. The method includes preparing first metal powder, agglomerating the first metal powder to manufacture second metal powder in which the first metal powder is agglomerated, coating the second metal powder with an organic binder, and agglomerating and coarsening the second metal powder coated with the organic binder to manufacture third metal powder having higher flowability than the second metal powder coated with the organic binder.

Systems and methods of synthesizing nanoparticles on substrates using rapid, high temperature thermal shock. A method involves depositing micro-sized particles or salt precursors on a substrate, and applying a rapid, high temperature thermal pulse or shock to the micro-sized particles or the salt precursors and the substrate to cause the micro-sized particles or the salt precursors to become nanoparticles on the substrate. A system may include a rotatable member that receives a roll of a substrate sheet having micro-sized particles or salt precursors; a motor that rotates the rotatable member so as to unroll consecutive portions of the substrate sheet from the roll; and a thermal energy source that applies a short, high temperature thermal shock to consecutive portions of the substrate sheet that are unrolled from the roll by rotating the first rotatable member. Some systems and methods produce nanoparticles on existing substrate. The nanoparticles may be metallic, ceramic, inorganic, semiconductor, or compound nanoparticles. The substrate may be a carbon-based substrate, a conducting substrate, or a non-conducting substrate. The high temperature thermal shock process may be enabled by electrical Joule heating, microwave heating, thermal radiative heating, plasma heating, or laser heating.