US 12,226,827 B2
Spherical tantalum powder, products containing the same, and methods of making the same
Craig M. Sungail, Chadds Ford, PA (US); and Aamir Dawood Abid, Spring City, PA (US)
Assigned to GLOBAL ADVANCED METALS USA, INC., Wellesley Hills, MA (US)
Filed by Global Advanced Metals USA, Inc., Wellesley Hills, MA (US)
Filed on May 17, 2023, as Appl. No. 18/198,300.
Application 18/198,300 is a continuation of application No. 16/286,683, filed on Feb. 27, 2019, granted, now 11,691,197.
Claims priority of provisional application 62/793,418, filed on Jan. 17, 2019.
Claims priority of provisional application 62/638,328, filed on Mar. 5, 2018.
Prior Publication US 2023/0286043 A1, Sep. 14, 2023
Int. Cl. B22F 3/11 (2006.01); B22F 1/052 (2022.01); B22F 1/065 (2022.01); B22F 1/142 (2022.01); B22F 10/12 (2021.01); B22F 10/14 (2021.01); B22F 10/25 (2021.01); B22F 10/28 (2021.01); B22F 10/32 (2021.01); B22F 10/34 (2021.01); B22F 10/36 (2021.01); B22F 10/64 (2021.01); B22F 12/13 (2021.01); B33Y 70/00 (2020.01); B33Y 80/00 (2015.01)
CPC B22F 3/11 (2013.01) [B22F 1/052 (2022.01); B22F 1/065 (2022.01); B22F 1/142 (2022.01); B22F 10/34 (2021.01); B33Y 70/00 (2014.12); B22F 10/12 (2021.01); B22F 10/14 (2021.01); B22F 10/25 (2021.01); B22F 10/28 (2021.01); B22F 10/32 (2021.01); B22F 10/36 (2021.01); B22F 10/64 (2021.01); B22F 12/13 (2021.01); B22F 2301/20 (2013.01); B22F 2304/10 (2013.01); B33Y 80/00 (2014.12)] 38 Claims
OG exemplary drawing
 
1. A method for forming an article or a part thereof, said method comprising additive manufacturing said article or said part thereof by utilizing a powder that is a tantalum powder to form the shape of said article or said part thereof, wherein the powder comprises at least the following properties:
a. a spherical shape wherein the powder has an average aspect ratio of from 1.0 to 1.25;
b. a purity of tantalum of at least 99.99 wt % Ta based on total weight of tantalum present in the powder, excluding gas impurities;
c. an average particle size of from about 0.5 micron to about 250 microns;
d. an apparent density from about 4 g/cc to about 12.3 g/cc;
e. a true density of from 16 g/cc to 16.6 g/cc; and
f. a Hall flow rate of 20 sec or less,
and wherein one or more of the following properties is achieved in forming said article or said part thereof: a) ultimate tensile strength (UTS) is at least 50% greater than wrought Ta of the same shape, b) the UTS is over 50 KSI, c) a Yield Stress that is at least 50% greater than wrought Ta of the same shape, d) the Yield Stress is over 35 KSI, e) an elongation from about 1% to about 50%.