A device for producing metal powder. This includes a melting chamber, a downstream atomization tower, and a nozzle assembly for atomizing a melt jet. The device further includes an induction coil disposed within the melting chamber and operated at a melting frequency f.sub.melt, the induction coil is adapted to locally melt a material rod at least section-wise received therein, to produce the melt jet to be atomized, and a separate intermediate coil disposed within the melting chamber and operated at a base frequency f.sub.base, wherein said intermediate coil is disposed downstream of the induction coil and aligned coaxially with the induction coil. The intermediate coil is configured to superheat the melt jet in a region between the induction coil and the nozzle assembly. The following applies to a frequency ratio F.sub.BS of the base frequency f.sub.base to the melting frequency f.sub.melt, 1F.sub.BS=f.sub.base/f.sub.melt500.

A device for producing metal powder. This includes a melting chamber, a downstream atomization tower, and a nozzle assembly for atomizing a melt jet. The device further includes an induction coil disposed within the melting chamber and operated at a melting frequency f.sub.melt, the induction coil is adapted to locally melt a material rod at least section-wise received therein, to produce the melt jet to be atomized, and a separate intermediate coil disposed within the melting chamber and operated at a base frequency f.sub.base, wherein said intermediate coil is disposed downstream of the induction coil and aligned coaxially with the induction coil. The intermediate coil is configured to superheat the melt jet in a region between the induction coil and the nozzle assembly. The following applies to a frequency ratio F.sub.BS of the base frequency f.sub.base to the melting frequency f.sub.melt, 1F.sub.BS=f.sub.base/f.sub.melt500.

The present invention addresses the problem of providing a method for continuously producing eutectic alloy fine particles, the method enabling the production of eutectic alloy particles, the particle diameters of which are easily controlled. The present invention provides a method for producing eutectic alloy fine particles that have a particle diameter of 0.1 m to 50 m, wherein: a fluid to be processed containing at least a melt of a eutectic alloy, the melt that serves as a dispersoid, and a solvent that serves as a dispersion medium is used; the fluid to be processed is continuously introduced an atomizer which atomizes the fluid to be processed between at least two processing surfaces that are arranged to face each other; the fluid to be processed goes through a dispersion state in which the melt of a eutectic alloy and the solvent are both in a liquid state within the atomizer; and solid eutectic alloy fine particles are obtained by cooling the fluid discharged from the atomizer. With respect to this method for producing eutectic alloy fine particles, the melt of a eutectic alloy is dispersed in the solvent in the form of droplets between the at least two processing surfaces; and the particle diameters of the melt of a eutectic alloy in the form of droplets are controlled by changing the viscosity of the solvent to be introduced between the at least two processing surfaces.

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.

An atomization unit (1) for atomizing metal melts, in particular for powder-metallurgical purposes, includes a crucible (2) having a base outlet (4). A melt nozzle (16) is arranged below the base outlet (4) and a gas nozzle (9) is preferably arranged concentrically with respect to the melt nozzle (16). The melt nozzle (16) is formed in multiple parts and comprises a casing body along with a nozzle core (17). The nozzle core (17) passes through a conical seat within the casing body.

The present disclosure is directed to methods of preparing substantially spherical metallic alloyed particles, having micron and sub-micron (i.e., nanometer)-scaled dimensions, and the powders so prepared, as well as articles derived from these powders. In particular embodiments, these metallic alloyed particles, comprising rare earth metals, can be prepared in sizes as small 80 nm in diameter with size variances as low as 2-5%.