The present invention may comprise processes, methods, and systems for powder processing aimed at and characterized in reduction of adsorbed gases, vapors, particulates, and moisture through high-temperature vacuum out-gassing by disintegrating the powder bulk or flow into separate particles. Heat may be transferred to powder particles in vacuum by multiple interactions during intimate contact with heated metal balls within a tube or other container.

The present invention may comprise processes, methods, and systems for powder processing aimed at and characterized in reduction of adsorbed gases, vapors, particulates, and moisture through high-temperature vacuum out-gassing by disintegrating the powder bulk or flow into separate particles. Heat may be transferred to powder particles in vacuum by multiple interactions during intimate contact with heated metal balls within a tube or other container.

A powder production method includes providing an elongated workpiece and repeatedly contacting an outer surface of the elongated workpiece with a reciprocating cutter according to a predetermined at least one frequency to produce a powder. The powder includes a plurality of particles, wherein at least 95% of the produced particles have a diameter or maximum dimension ranging from about 10 μm to about 200 μm. A system for producing powders having a plurality of particles including a cutter and at least one controller is also provided herein.

A powder production method includes providing an elongated workpiece and repeatedly contacting an outer surface of the elongated workpiece with a reciprocating cutter according to a predetermined at least one frequency to produce a powder. The powder includes a plurality of particles, wherein at least 95% of the produced particles have a diameter or maximum dimension ranging from about 10 μm to about 200 μm. A system for producing powders having a plurality of particles including a cutter and at least one controller is also provided herein.

A coated soft magnetic alloy particle includes a soft magnetic alloy particle containing an amorphous phase, and a first film containing at least one compound selected from the group consisting of an inorganic compound having a hexagonal, trigonal, or monoclinic crystal structure and a layered silicate mineral. The first film coats a surface of the soft magnetic alloy particle, and an outer peripheral contour of a section of the coated soft magnetic alloy particle has an average smoothness ζ_ave of 0.92 or more and 1.00 or less (i.e., from 0.92 or more and 1.00).

A coated soft magnetic alloy particle includes a soft magnetic alloy particle containing an amorphous phase, and a first film containing at least one compound selected from the group consisting of an inorganic compound having a hexagonal, trigonal, or monoclinic crystal structure and a layered silicate mineral. The first film coats a surface of the soft magnetic alloy particle, and an outer peripheral contour of a section of the coated soft magnetic alloy particle has an average smoothness ζ_ave of 0.92 or more and 1.00 or less (i.e., from 0.92 or more and 1.00).

A supply module (2) for supplying additive manufacturing powder comprises: a main hopper (29) for storing additive manufacturing powder, the main hopper (29) being designed to be connected to a manufacturing module (4) configured to additively manufacture an object from the powder; an inlet (211) of the supply module (2) designed to be connected to the manufacturing module (4) and to receive powder located in the manufacturing module (4); a glovebox (25) being able to be closed in a sealed manner; a provisioning circuit configured to transfer powder located in the glovebox (25) to the main hopper (29); and a circulation system designed to set powder in motion according to a circulation loop closed on itself, the circulation system comprising a suction system (21) designed to evacuate gas present in the circulation loop, the circulation loop passing through the main hopper (29) and the suction system (21).

A supply module (2) for supplying additive manufacturing powder comprises: a main hopper (29) for storing additive manufacturing powder, the main hopper (29) being designed to be connected to a manufacturing module (4) configured to additively manufacture an object from the powder; an inlet (211) of the supply module (2) designed to be connected to the manufacturing module (4) and to receive powder located in the manufacturing module (4); a glovebox (25) being able to be closed in a sealed manner; a provisioning circuit configured to transfer powder located in the glovebox (25) to the main hopper (29); and a circulation system designed to set powder in motion according to a circulation loop closed on itself, the circulation system comprising a suction system (21) designed to evacuate gas present in the circulation loop, the circulation loop passing through the main hopper (29) and the suction system (21).

A supply module (2) for supplying additive manufacturing powder comprises: a main hopper (29) for storing additive manufacturing powder, the main hopper (29) being designed to be connected to a manufacturing module (4) configured to additively manufacture an object from the powder; an inlet (211) of the supply module (2) designed to be connected to the manufacturing module (4) and to receive powder located in the manufacturing module (4); a glovebox (25) being able to be closed in a sealed manner; a provisioning circuit configured to transfer powder located in the glovebox (25) to the main hopper (29); and a circulation system designed to set powder in motion according to a circulation loop closed on itself, the circulation system comprising a suction system (21) designed to evacuate gas present in the circulation loop, the circulation loop passing through the main hopper (29) and the suction system (21).

The present disclosure discloses a method for coating a magnetic powder core with sodium silicate, including: using polyoxyethylene laurylether phosphate as a dispersant for sodium silicate and lignosulfonate as a dispersant for a metal magnetic powder, mixing a dispersed sodium silicate solution and a dispersed metal magnetic powder, coating the dispersed metal magnetic powder, and drying: adding an insulating adhesive and a lubricant, subjecting the resulting mixture to a compression molding, and finally, carrying out a high-temperature annealing treatment to obtain a sodium silicate coated magnetic powder core.