An arc reactor and a process for the production of nanoparticles are disclosed. The reactor has a crucible in a gas-tight housing having a carrier gas inlet and a spaced-apart carrier gas outlet. The carrier gas inlet is directed to the side of the crucible opposite the crucible opening. The inlet can be disposed below the crucible and directed to the side of the crucible opposite the crucible opening. The carrier gas outlet is disposed above the crucible and exits the housing above the crucible. The carrier gas outlet is formed by a hood disposed at a distance above the crucible, which is separated from the crucible and formed by an exhaust pipe that connects the hood to the carrier gas outlet of the housing. The reactor housing has at least one inlet for cooling gas. This can be directed at an interstice formed between the crucible and the hood.

A method and apparatus for producing titanium metal powder from a melt. The apparatus includes an atomization chamber having an inner wall that is coated with or formed entirely of a titanium alloy that is the same as the titanium metal powder to prevent contamination of titanium metal powder therein. The inner surfaces of some or all components of the apparatus in a flow path following the atomization chamber may also be coated with or formed entirely of the titanium alloy or CP-Ti.

A molten metal fuel to plasma to electricity power source that provides at least one of electrical and thermal power comprising (i) at least one reaction cell for the catalysis of atomic hydrogen to form hydrinos, (ii) a chemical fuel mixture comprising at least two components chosen from: a source of H.sub.20 catalyst or H.sub.20 catalyst; a source of atomic hydrogen or atomic hydrogen; reactants to form the source of H.sub.20 catalyst or H.sub.20 catalyst and a source of atomic hydrogen or atomic hydrogen; and a molten metal to cause the fuel to be highly conductive, (iii) a fuel injection system comprising an electromagnetic pump, (iv) at least one set of confinement electrodes that provide repetitive short bursts of low-voltage, high-current electrical energy to initiate rapid kinetics of the hydrin reaction and an energy gain due to forming hydrinos to form a brilliant-light emitting plasma.

An alloy powder manufacturing device with temperature control design includes: a crucible unit, for accommodating a melt; a melt delivery tube, for delivering the melt from the crucible unit; a temperature control unit, inductively heating the melt delivery tube and the melt therein, to generate an overtemperature melt, and enabling the temperature of the overtemperature melt leaving the melt delivery tube to reach a predetermined temperature; and a powder spray unit in communication with the outlet of the melt delivery tube, for impacting and atomizing the overtemperature melt having the predetermined temperature and then quickly solidifying the overtemperature melt to form alloy powders.

A method and apparatus for producing titanium metal powder from a melt. The apparatus includes an atomization chamber having an inner wall that is coated with or formed entirely of CP-Ti to prevent contamination of titanium metal powder therein. The inner surfaces of all components of the apparatus in a flow path following the atomization chamber may also be coated with or formed entirely of CP-Ti.

A tilting melting hearth system (10) includes a tilting melting hearth (12) for melting a metal (14) into a molten metal (16) and a central processing unit (CPU) (18) for controlling the tilting melting hearth (12) having an automated hearth tilting program (20) configured to select a hearth tilt profile based on a weight (66A) of the molten metal (16) in the tilting melting hearth (12). The tilting melting hearth system (10) can also include an atomization die (38) in flow communication with the tilting melting hearth (12) for receiving a stream of molten metal (40) and generating a metal powder (42), or a casting die (46) for generating a casting (48) of the metal (14). The tilting melting hearth system (10) can be used to perform a method for recycling scrap metal by automatically determining the weight of the molten metal (16) in the tilting melting hearth (12).

A method of producing iron powder by a water atomization process may include preparing a molten metal in a tundish, discharging the molten metal in a free-falling manner by opening an orifice formed on a bottom of the tundish, and producing iron powder by spraying water onto the free-falling molten metal using a pair of water spraying nozzles, an angle formed by the water spraying nozzles being at least 45.

A metal powder preparation system and method are provided. The metal powder preparation system includes a medium frequency smelting furnace, a homogeneous insulated quantitative pouring furnace, a precision-controlled liquid level temperature pouring ladle, and a plurality of groups of atomization mechanisms connected in sequence. The present application improves the preparation quality of the metal powder, so that the parameters such as the powder particle size, sphericity, fluidity, oxygen content, component distribution, and particle size distribution of the metal powder can all meet the requirements of high-quality metal additive manufacturing, achieving efficient and continuous preparation of the metal powder at the same time.

A method of making dispersion-strengthened alloy particles involves melting an alloy having a corrosion and/or oxidation resistance-imparting alloying element, a dispersoid-forming element, and a matrix metal wherein the dispersoid-forming element exhibits a greater tendency to react with a reactive species acquired from an atomizing gas than does the alloying element. The melted alloy is atomized with the atomizing gas including the reactive species to form atomized particles so that the reactive species is (a) dissolved in solid solution to a depth below the surface of atomized particles and/or (b) reacted with the dispersoid-forming element to form dispersoids in the atomized particles to a depth below the surface of said atomized particles. The atomized alloy particles are solidified as solidified alloy particles or as a solidified deposit of alloy particles. Bodies made from the dispersion strengthened alloy particles, deposit thereof, exhibit enhanced fatigue and creep resistance and reduced wear as well as enhanced corrosion and/or oxidation resistance at high temperatures by virtue of the presence of the corrosion and/or oxidation resistance imparting alloying element in solid solution in the particle alloy matrix.

An alloy structure has an arbitrary shape dimension which has high uniformity in the distribution of the element composition. The alloy structure contains Fe and at least four elements, which are selected from the group consisting of elements from atomic number 13 to atomic number 79 included in Group 3 to Group 16 of the periodic table of the elements and have a ratio of the atomic radius to an Fe atom of 0.83 or more but 1.17 or less, each of Fe and the four elements is contained in an atomic concentration range of 5 at % or more but 30 at % or less, a difference in atomic concentration between at least four elements among the at least four elements and Fe is in a range of less than 3 at %, and the alloy structure has, a column crystal in which the at least four elements and Fe are solid-dissolved.