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In a high-speed fabrication process for producing highly uniform ultra-small metallic micro-spheres, a molten metal is passed through a small orifice, producing a stream of molten metal therefrom. A series of molten metal droplets forms from the break up of the capillary stream. Applied harmonic dis

In a high-speed fabrication process for producing highly uniform ultra-small metallic micro-spheres, a molten metal is passed through a small orifice, producing a stream of molten metal therefrom. A series of molten metal droplets forms from the break up of the capillary stream. Applied harmonic disturbances are used to control and generate satellite and parent droplets. Significantly, the satellite droplets formed are smaller than the orifice, allowing for the production of smaller metal balls with larger orifices. The satellite droplets are separated from the parent droplets by electrostatic charging and deflection or by aerodynamic or acoustic sorting. Preferably, the satellite droplets are cooled before being collected to avoid defects and achieve high uniformity of the resulting metal balls.

대표청구항 ▼

1. A method of manufacturing ultra-small metallic spheres comprising the steps of:forming parent and satellite droplets from a capillary stream of molten metal; separating the satellite droplets from the parent droplets; cooling the satellite droplets to solidify the balls; and collecting the satell

1. A method of manufacturing ultra-small metallic spheres comprising the steps of:forming parent and satellite droplets from a capillary stream of molten metal; separating the satellite droplets from the parent droplets; cooling the satellite droplets to solidify the balls; and collecting the satellite balls.