There are provided reactive metal powder atomization manufacturing processes. For example, such processes include providing a heated metal source and contact the heated metal source with at least one additive gas while carrying out the atomization process. Such processes provide raw reactive metal powder having improved flowability. The at least one additive gas can be mixed together with an atomization gas to obtain an atomization mixture, and the heated metal source can be contacted with the atomization mixture while carrying out the atomization process. Reactive metal powder spheroidization manufacturing processes are also provided.

A process for producing metals, alloys and metal powders includes providing a feed material; heating the feed material in a melting hearth into a molten metal; and reducing oxygen in the molten metal using a reactive gas in an ionized or unionized state and an oxygen scavenging reaction wherein reaction sites in the molten metal containing oxygen react with the reactive gas. A first system configured to perform a process for producing metals and alloys includes a melting hearth and a heat source system in a melting chamber configured to melt a feed material into a molten metal for atomization, casting or further processing. A second system configured to perform a process for producing metal powders includes a foundry system configured to melt a feed material into a molten metal and an atomization system configured to atomize the molten metal into a metal powder comprised of metal particles.

A soft magnetic alloy particle including Fe and Si. One to twenty nitride phases are observed in a cross-section of the soft magnetic alloy particle, an area per each of the nitride phases is within a range of 0.0005 to 10 m.sup.2, and an area ratio of the observed nitride phases occupying the cross-section of the soft magnetic alloy particle is within a range of 0.1 to 2%.

In some embodiments, a coating applied to steel reinforcement bar (e.g., steel rebar) that could considerably extend the lifetime of concrete structures by reducing steel rebar corrosion is disclosed. The coating includes a thin, passivating steel (e.g., stainless steel) layer that is applied to the outside of conventional steel rebar. The coating can be applied in-line through metal cold spray manufacturing, which is a high throughput coating technique that can be integrated into existing steel manufacturing plants. Furthermore, a novel, high performance ferritic steel with tailored resistance to corrosion from chlorides is described. The new ferritic steel is distinct from other commercial and experimental steels, and is better suited for coating low-cost steel structures like rebar. Multiple alloying elements including Cr, Al, and Si will each form protective oxides independently, increasing the total amount of protection and extending it over much wider ranges of pH and electrical potential.

The present disclosure provides a brake disc coating and a method for preparing the brake disc coating. The brake disc coating is prepared from a high-entropy alloy powder, a preparation material of the high-entropy alloy powder includes an Al powder, a Co powder, a Ni powder, a Cu powder, and a Ti powder, a molar ratio of metal elements Al, Co, Ni, Cu, and Ti in the high-entropy alloy powder is in a range of 1:1:1:1:(1.1-1.3), and the high-entropy alloy powder has a single body-centered cubic (BCC) crystal structure.

A preparation process for preparing powder from a first material and a second material, having a step of melting the first and second materials using an electric arc, a step of spraying the first and second molten materials in such a way as to form droplets, a step of cooling the droplets using a carrier gas so as to form solid particles, and a step of separating the solid particles from the carrier gas and collecting the solid particles so as to form the powder, the electric current applied to form the electric arc being a short circuit current.

A load lock system for manufacturing a metal alloy using a feed material includes a process chamber having a controlled atmosphere, a feed chamber in flow communication with the process chamber having controlled atmosphere capabilities configured to contain a quantity of the feed material, and a collection chamber in flow communication with the process chamber having controlled atmosphere capabilities configured to collect the metal alloy manufactured in the process chamber. The system also includes a gate valve between the process chamber and the feed chamber configured to either allow passage of the feed material between the chambers, or to seal the process chamber from the feed chamber. The system also includes a discharge valve between the process chamber and the collection chamber configured to either allow passage of the metal alloy between the chambers, or to seal the process chamber from the collection chamber.

Provided are reactive metal powder atomization manufacturing processes. For example, such processes include providing a heated metal source and contact the heated metal source with at least one additive gas while carrying out the atomization process. Such processes provide raw reactive metal powder having improved flowability. The at least one additive gas can be mixed together with an atomization gas to obtain an atomization mixture, and the heated metal source can be contacted with the atomization mixture while carrying out the atomization process. Reactive metal powder spheroidization manufacturing processes are also provided.

A load lock system for manufacturing a metal alloy using a feed material includes a process chamber having a controlled atmosphere, a feed chamber in flow communication with the process chamber having controlled atmosphere capabilities configured to contain a quantity of the feed material, and a collection chamber in flow communication with the process chamber having controlled atmosphere capabilities configured to collect the metal alloy manufactured in the process chamber. The system also includes a gate valve between the process chamber and the feed chamber configured to either allow passage of the feed material between the chambers, or to seal the process chamber from the feed chamber. The system also includes a discharge valve between the process chamber and the collection chamber configured to either allow passage of the metal alloy between the chambers, or to seal the process chamber from the collection chamber.

A metal powder for additive manufacturing having a composition including the following elements, expressed in content by weight 15%Mn35%, 6%Al15%, 0.5%C1.8%, 0.4%Ti4.5%, 0Si3.5%, P0.013%, S0.015%, N0.100%, and optionally containing Ni8.5 wt. % and/or Cr2.5 wt. % and/or B0.1 wt. % and/or one or more elements chosen among Ta, Zr, Nb, V, Ti, Mo, and W in a cumulated amount of up to 2.0 wt. %, the balance being iron and unavoidable impurities resulting from the elaboration. It also deals with a process for manufacturing such powder and for manufacturing a printed part out of it.