US 11,780,012 B1
Powder satellite-reduction apparatus and method for gas atomization process
Iver E. Anderson, Ames, IA (US); Jordan A. Tiarks, Ames, IA (US); Timothy E. Prost, Ames, IA (US); Bo Kong, Ames, IA (US); Emma H. White, Ames, IA (US); Trevor M. Riedemann, Ames, IA (US); Eric J. Deaton, Ames, IA (US); Ross Anderson, Ames, IA (US); David Byrd, Ames, IA (US); and Franz Hugolino Hernandez Gaitan, Ames, IA (US)
Assigned to Iowa State University Research Foundation, Inc., Ames, IA (US)
Filed by Iowa State University Research Foundation, Inc., Ames, IA (US)
Filed on Jun. 23, 2021, as Appl. No. 17/304,586.
Claims priority of provisional application 62/705,347, filed on Jun. 23, 2020.
Int. Cl. B22F 9/08 (2006.01)
CPC B22F 9/082 (2013.01) 16 Claims
OG exemplary drawing
 
1. A method for production of metal powder for particle size control and satellite suppression in close-coupled gas atomization comprising:
(a) selecting a gas atomization spray chamber having a top, a bottom, and a sidewall defining an internal space with a diameter adapted for gas atomization of molten or semi-molten metal inserted in the chamber and formation of metal powder particles from atomized melted metal droplets moving in the internal space of the chamber;
(b) identifying a critical region for satellite formation in the chamber based on an analysis of the selected chamber, atomization gas, and metal powder;
(c) close-coupled guiding of the molten or semi-molten metal and atomization gas in a central metal droplet/gas stream guided into the top of the chamber and towards the bottom of the chamber; and
(d) during operation deterring upward circulation and attachment of one or more of fines and ultra-fines that create satelliting into the central metal droplet/gas stream at the critical region in the chamber by intervening in the circulation radially or concentrically around and along the central metal droplet/gas stream at the identified critical region-effective to reduce satelliting by external satellite recirculation and attachment to molten or semi-molten droplets at least relative to operation without intervention.