US 11,919,071 B2
Systems and methods for synthesis of spheroidized metal powders
Sunil Bhalchandra Badwe, Export, PA (US); Scott Joseph Turchetti, Newburyport, MA (US); Sudip Bhattacharya, Billerica, 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 Oct. 21, 2021, as Appl. No. 17/451,716.
Claims priority of provisional application 63/108,118, filed on Oct. 30, 2020.
Prior Publication US 2022/0134431 A1, May 5, 2022
Int. Cl. B22F 1/065 (2022.01); B22F 9/14 (2006.01); B22F 1/05 (2022.01)
CPC B22F 1/065 (2022.01) [B22F 1/05 (2022.01); B22F 9/14 (2013.01); B22F 2202/13 (2013.01); B22F 2302/20 (2013.01); B22F 2304/10 (2013.01)] 9 Claims
OG exemplary drawing
 
1. A method for manufacturing a spheroidized powder, the method comprising:
providing a feedstock to a microwave plasma torch, the feedstock comprising titanium powder;
introducing the feedstock into a microwave plasma generated by the microwave plasma torch, the microwave plasma generated by subjecting a reactive plasma gas to microwaves from a microwave power source, the reactive plasma gas comprising at least nitrogen-containing gas; and
forming the spheroidized powder, the spheroidized powder formed by at least partially melting the feedstock and initiating a chemical reaction between the feedstock and the reactive plasma gas within the microwave plasma torch, and the spheroidized powder comprising one or more particles, the one or more particles comprising titanium nitride throughout a complete mass of the one or more particles,
wherein the one or more particles comprise a pre-determined concentration of nitrogen to form a TiN, Ti2N, or TiN2 phase within the one or more particles by controlling an amount of the nitrogen-containing gas and a residence time of the feedstock in the reactive plasma gas.