A method and an apparatus for manufacturing a metallic article involve providing a non-metallic feedstock, for example in the form of an oxide of a desired metal or a mixture of oxides of the components of a desired metal alloy. A manufacturing apparatus has a reduction apparatus for electrochemically reducing the feedstock to a metallic product and a processor for converting the metallic product to a metallic powder. The powder is fed into an additive-manufacturing apparatus for fabricating the metallic article from the metallic powder. At least the reduction apparatus and the processor, and preferably also the additive-manufacturing apparatus, are collocated, or located in the same container, or in the same building, or on the same site.

A method (100) for producing a particulate titanium alloy product can include preparing (110) a composite particulate oxide mixture with TiO.sub.2 powder and at least one alloying element powder. The composite particulate oxide mixture can be co-reduced (120) using a metallic reducing agent under a hydrogen atmosphere at a reduction temperature for a reduction time sufficient to produce a hydrogenated titanium alloy product. The hydrogenated titanium alloy product can then be heat treated (130) under a hydrogen atmosphere and a heat treating temperature to reduce pore size and specific surface area to form a heat treated hydrogenated titanium product. The heat treated hydrogenated titanium product can be deoxygenated (140) to reduce residual oxygen to less than 0.2 wt % to form a deoxygenated hydrogenated titanium product as a particulate. The deoxygenated hydrogenated titanium product can optionally be dehydrogenated (150) to form the titanium alloy product as a particulate.

A method to extract and refine metal products from metal-bearing ores, including a method to extract and refine titanium products. Titanium products can be extracted from titanium-bearing ores with TiO.sub.2 and impurity levels unsuitable for conventional methods.

Disclosed herein is a method for reducing a metal oxide in a metal containing precursor. The method comprises providing a reaction mixture comprising the metal oxide containing precursorand an aluminium reductant; heating the reaction mixture in the presence of solid or gaseous aluminium chloride to temperature at which reactionsthatresultin the metal oxide being reduced are initiated; controlling reaction conditions whereby the reaction mixture is prevented from reaching a temperature at which thermal runaway can occur; and isolating reaction products that include reduced metal oxide.

A method to extract and refine metal products from metal-bearing ores, including a method to extract and refine titanium products. Titanium products can be extracted from titanium-bearing ores with TiO.sub.2 and impurity levels unsuitable for conventional methods.

A method for producing a particulate titanium alloy product can include preparing a composite particulate oxide mixture with TiO.sub.2 powder and at least one alloying element powder. The composite particulate oxide mixture can be co-reduced using a metallic reducing agent under a hydrogen atmosphere at a reduction temperature for a reduction time sufficient to produce a hydrogenated titanium alloy product. The hydrogenated titanium alloy product can then be heat treated under a hydrogen atmosphere and a heat treating temperature to reduce pore size and specific surface area to form a heat treated hydrogenated titanium product. The heat treated hydrogenated titanium product can be deoxygenated to reduce residual oxygen to less than 0.2 wt % to form a deoxygenated hydrogenated titanium product as a particulate. The deoxygenated hydrogenated titanium product can optionally be dehydrogenated to form the titanium alloy product as a particulate.

A method to extract and refine metal products from metal-bearing ores, including a method to extract and refine titanium products. Titanium products can be extracted from titanium-bearing ores with TiO.sub.2 and impurity levels unsuitable for conventional methods.

A smelting apparatus that includes (a) a smelting vessel (4) that is adapted to contain a bath of molten metal and slag and (b) a smelt cyclone (2) for pre-treating a metalliferous feed material positioned above and communicating directly with the smelting vessel The apparatus also includes an oft-gas duct (9) extending from the smelt, cyclone for discharging an off-gas from the smelt cyclone. The off-gas duct has an inlet section (18) that extends upwardly from the smelt cyclone and is formed to cause off-gas to undergo a substantial change of direction as it flows through the inlet section of the off-gas duct.

A method to extract and refine metal products from metal-bearing ores, including a method to extract and refine titanium products. Titanium products can be extracted from titanium-bearing ores with TiO.sub.2 and impurity levels unsuitable for conventional methods.

A method and an apparatus for manufacturing a metallic article involve providing a non-metallic feedstock, for example in the form of an oxide of a desired metal or a mixture of oxides of the components of a desired metal alloy. A manufacturing apparatus has a reduction apparatus for electrochemically reducing the feedstock to a metallic product and a processor for converting the metallic product to a metallic powder. The powder is fed into an additive-manufacturing apparatus for fabricating the metallic article from the metallic powder. At least the reduction apparatus and the processor, and preferably also the additive-manufacturing apparatus, are collocated, or located in the same container, or in the same building, or on the same site.