US 11,717,886 B2
Unique feedstocks for spherical powders and methods of manufacturing
Sunil Bhalchandra Badwe, Export (PA); Scott Joseph Turchetti, Newburyport, MA (US); and Makhlouf Redjdal, Melrose, MA (US)
Assigned to 6K Inc., North Andover, MA (US)
Filed by 6K Inc., North Andover, MA (US)
Filed on Nov. 17, 2020, as Appl. No. 16/950,729.
Claims priority of provisional application 62/937,054, filed on Nov. 18, 2019.
Prior Publication US 2021/0146432 A1, May 20, 2021
Int. Cl. B22F 1/065 (2022.01); B33Y 70/00 (2020.01); B22F 9/08 (2006.01); C04B 35/58 (2006.01); C04B 35/626 (2006.01)
CPC B22F 1/065 (2022.01) [B22F 9/082 (2013.01); B33Y 70/00 (2014.12); C04B 35/58014 (2013.01); C04B 35/62665 (2013.01); B22F 2009/0828 (2013.01); B22F 2202/13 (2013.01); B22F 2301/052 (2013.01); B22F 2301/15 (2013.01); B22F 2301/20 (2013.01); B22F 2301/35 (2013.01); C04B 2235/3225 (2013.01)] 13 Claims
OG exemplary drawing
 
1. A method for producing a spheroidized powder from a feed material comprising Tungsten (W), the method comprising:
introducing a W powder feed material into a microwave plasma torch via a powder feeder downstream of an applicator of the microwave plasma torch; and
melting and spheroidizing the feed material within a plasma generated by the microwave plasma torch to form spheroidized powder,
wherein the spheroidized powder has a minimum particle size of 20 microns and a maximum particle size of 63 microns, with a D10 of at least 20 microns and a D90 of at most 55 microns.