Provided is a flaky soft magnetic powder including an FeSiAl alloy having an oxygen content of 0.6 mass % or less, a manganese content of 0.1 mass % to 1.0 mass %, and the balance incidental impurities. The flaky soft magnetic powder has an average particle size of 43 to 60 m and exhibits a coercive force Hc of 106 A/m or less as measured under application of a magnetic field in an in-plane direction of the flaky soft magnetic powder. The ratio of the tap density to the true density of the flaky soft magnetic powder is 0.17 or less. Also provided is a method of producing the flaky soft magnetic powder. The use of the flaky soft magnetic powder can produce a magnetic sheet having particularly high magnetic permeability.

Provided is a flaky soft magnetic powder including an FeSiAl alloy having an oxygen content of 0.6 mass % or less, a manganese content of 0.1 mass % to 1.0 mass %, and the balance incidental impurities. The flaky soft magnetic powder has an average particle size of 43 to 60 m and exhibits a coercive force Hc of 106 A/m or less as measured under application of a magnetic field in an in-plane direction of the flaky soft magnetic powder. The ratio of the tap density to the true density of the flaky soft magnetic powder is 0.17 or less. Also provided is a method of producing the flaky soft magnetic powder. The use of the flaky soft magnetic powder can produce a magnetic sheet having particularly high magnetic permeability.

Provided is a flaky soft magnetic powder including an FeSiAl alloy having an oxygen content of 0.6 mass % or less, a manganese content of 0.1 mass % to 1.0 mass %, and the balance incidental impurities. The flaky soft magnetic powder has an average particle size of 43 to 60 m and exhibits a coercive force Hc of 106 A/m or less as measured under application of a magnetic field in an in-plane direction of the flaky soft magnetic powder. The ratio of the tap density to the true density of the flaky soft magnetic powder is 0.17 or less. Also provided is a method of producing the flaky soft magnetic powder. The use of the flaky soft magnetic powder can produce a magnetic sheet having particularly high magnetic permeability.

A spray forming method for producing a metallic ingot and metallic powder from a metallic source of metal or metal alloy includes: forming one or more streams of metal or alloy from the source, gas atomizing one or more streams of metal or alloy to form one or more sprays of atomized droplets, directing the spray(s) of droplets through a spray nozzle to a rotatable hot body, depositing the droplets to the hot body to form the ingot, controlling the process parameters 1) temperature of metal or alloy, 2) inlet and outlet pressure of the spray nozzle, 3) rotation speed of the hot body, and/or 4) distance between the hot body and the spray(s) of droplets, and collecting the metallic powder having a predefined size distribution. The process parameters are controlled such that the ingot yield is 60-80% and the metallic powder yield is 40-20%, relative to the metallic source.

A spray forming method for producing a metallic ingot and metallic powder from a metallic source of metal or metal alloy includes: forming one or more streams of metal or alloy from the source, gas atomizing one or more streams of metal or alloy to form one or more sprays of atomized droplets, directing the spray(s) of droplets through a spray nozzle to a rotatable hot body, depositing the droplets to the hot body to form the ingot, controlling the process parameters 1) temperature of metal or alloy, 2) inlet and outlet pressure of the spray nozzle, 3) rotation speed of the hot body, and/or 4) distance between the hot body and the spray(s) of droplets, and collecting the metallic powder having a predefined size distribution. The process parameters are controlled such that the ingot yield is 60-80% and the metallic powder yield is 40-20%, relative to the metallic source.

A production method of particulate materials, through centrifugal atomization (CA) is disclosed. The method is suitable for obtaining fine spherical powders with exceptional morphological quality and extremely low content, or even absence of non-spherical-shape particles and internal voids. A appropriate cost effective method for industrial scale production of metal, alloy, intermetallic, metal matrix composite or metal like material powders in large batches is also disclosed. The atomization technique can be extended to other than the centrifugal atomization with rotating element techniques.

A production method of particulate materials, through centrifugal atomization (CA) is disclosed. The method is suitable for obtaining fine spherical powders with exceptional morphological quality and extremely low content, or even absence of non-spherical-shape particles and internal voids. A appropriate cost effective method for industrial scale production of metal, alloy, intermetallic, metal matrix composite or metal like material powders in large batches is also disclosed. The atomization technique can be extended to other than the centrifugal atomization with rotating element techniques.

A metal powder manufacturing apparatus for a metal 3-dimensional (3D) printer includes a driving unit which generates a rotational force, a metal beam connected to the driving unit to receive the rotational force from the driving unit and having one end disposed in a vacuum chamber, and a shaft support which supports an outer circumference of the metal beam using a magnetic force for relative movement of the metal beam in a lengthwise direction of the metal beam, wherein the shaft support is disposed such that an inner side is spaced apart a predetermined distance from the outer circumference of the metal beam, and can support the metal beam at an adjusted relative distance from the metal beam.

A metal powder manufacturing apparatus for a metal 3-dimensional (3D) printer includes a driving unit which generates a rotational force, a metal beam connected to the driving unit to receive the rotational force from the driving unit and having one end disposed in a vacuum chamber, and a shaft support which supports an outer circumference of the metal beam using a magnetic force for relative movement of the metal beam in a lengthwise direction of the metal beam, wherein the shaft support is disposed such that an inner side is spaced apart a predetermined distance from the outer circumference of the metal beam, and can support the metal beam at an adjusted relative distance from the metal beam.

A nozzle, a tundish arrangement used for the production of granulated material, and a method and apparatus for the production of a granulated material with an improved size distribution are provided. The grain size and grain size distribution is controlled by a nozzle having a specific design. The nozzle comprises an upper inlet opening, sidewalls forming a channel, a bottom and at least one outlet opening or at least one row of outlet openings at the lower end of the channel. The outlet opening(s) in the channel have a size of at least 5 mm in the smallest dimension. A cross sectional area of the channel at the inlet A.sub.C is at least 3 times bigger than the total area of the outlet openings A.sub.T.