Disclosed herein are embodiments of methods, devices, and assemblies for processing feedstock materials using microwave plasma processing. Specifically, the feedstock materials disclosed herein pertains to unique powder feedstocks such as Tantalum, Yttrium Stabilized Zirconia, Aluminum, water atomized alloys, Rhenium, Tungsten, and Molybdenum. Microwave plasma processing can be used to spheroidize and remove contaminants. Advantageously, microwave plasma processed feedstock can be used in various applications such as additive manufacturing or powdered metallurgy (PM) applications that require high powder flowability.

The invention relates to a compacted and densified metal material having one or more phases formed of an agglomerate of grains, the cohesion of the material being provided by bridges formed between grains, said material having a relative density higher than or equal to 95% and preferably higher than or equal to 98%.

The invention relates to a compacted and densified metal material having one or more phases formed of an agglomerate of grains, the cohesion of the material being provided by bridges formed between grains, said material having a relative density higher than or equal to 95% and preferably higher than or equal to 98%.

A metal powder for additive manufacturing includes: not less than 0.2 mass % and not more than 1.3 mass % of aluminum; and a balance including copper and an incidental impurity.

A metal powder for additive manufacturing includes: not less than 0.2 mass % and not more than 1.3 mass % of aluminum; and a balance including copper and an incidental impurity.

There are provided high melting point metal or alloy powder atomization manufacturing processes comprising providing a melt of the high melting point metal or alloy through a feed tube; diverting the melt at a diverting angle with respect to a central axis of the feed tube to obtain a diverted melt; directing the diverted melt to an atomization area; and providing at least one atomization gas stream to the atomization area. The atomization process can be carried out in the presence of water within an atomization chamber used for the atomization process.

A soft magnetic powder, including an Fe alloy, and containing 0.1 to 15 mass % of Si, wherein a ratio (Si/Fe) of an atomic concentration of Si and an atomic concentration of Fe is from 4.5 to 30 at a depth of 1 nm from a particle surface of the soft magnetic powder.

A soft magnetic powder, including an Fe alloy, and containing 0.1 to 15 mass % of Si, wherein a ratio (Si/Fe) of an atomic concentration of Si and an atomic concentration of Fe is from 4.5 to 30 at a depth of 1 nm from a particle surface of the soft magnetic powder.

The present invention is an atomization device for manufacturing metal powder by spraying a fluid to molten metal, said device comprising: a tundish into which the molten metal is poured and discharged from a discharge nozzle installed on a bottom part; fluid spray nozzles disposed below the tundish and spraying the fluid to the molten metal dropping from the tundish; a means for measuring a molten-metal surface height inside the tundish from an image obtained by imaging the inside of the tundish; and a means for, upon calculating an amount of the molten metal to be poured into the tundish from the molten-metal surface height, discharging the molten metal in such a manner that the height is maintained substantially constant. The interior of the tundish is formed in such a shape that the area of the molten-metal surface of the poured molten metal increases with height in the vertical direction.

A magnetic bead contains: a Fe-based magnetic metal powder; and a coating layer with which a particle surface of the Fe-based magnetic metal powder is coated. The Fe-based magnetic metal powder contains a crystal grain having a grain diameter of 1 nm or more and 60 nm or less in a ratio of 30% by volume or more and 100% by volume or less. In addition, the coating layer may contain an oxide and has an average thickness of 10 nm or more and 200 nm or less.