CPC B22F 9/082 (2013.01) | 16 Claims |
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.
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