[특허]Apparatus and method for clean, rapidly solidified alloys

ATI Properties, Inc.

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특허 상세정보

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내보내기 페이스북 공유 트위터 공유 카카오톡 공유

Apparatus and method for clean, rapidly solidified alloys

특허상세정보
국가/구분	United States(US) Patent 등록
국제특허분류(IPC7판)	B22F-009/14 B22F-009/02
미국특허분류(USC)	266/202; 266/237
출원번호	UP-0232702 (2005-09-22)
등록번호	US-7578960 (2009-09-08)
발명자 / 주소	Forbes Jones, Robin M. Kennedy, Richard L.
출원인 / 주소	ATI Properties, Inc.
대리인 / 주소	Kirkpatrick & Lockhart Preston Gates Ellis LLP
인용정보	피인용 횟수 : 23 인용 특허 : 81

초록
▼

One non-limiting embodiment of an apparatus for forming an alloy powder or preform includes a melting assembly, an atomizing assembly, and a field generating assembly, and a collector. The melting assembly produces at least one of a stream of a molten alloy and a series of droplets of a molten alloy, and may be substantially free from ceramic in regions contacted by the molten alloy. The atomizing assembly generates electrons and impinges the electrons on molten alloy from the melting assembly, thereby producing molten alloy particles. The field generating assembly produces at least one of an electrostatic field and an electromagnetic field between the atomizing assembly and the collector. The molten alloy particles interact with the at least one field, which influences at least one of the acceleration, speed, and direction of the molten alloy particles. Related methods also are disclosed.

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We claim: 1. An apparatus comprising: a melting assembly adapted to produce at least one of a stream of a molten alloy and a series of droplets of a molten alloy, wherein the melting assembly is substantially free from ceramic in regions contacted by the molten alloy; an atomizing assembly generating at least one electron field comprising a three-dimensional shape, the atomizing assembly impinging the at least one electron field on molten alloy from the melting assembly to atomize the molten alloy and produce molten alloy particles; a collector; and a field generating assembly generating at least one of an electrostatic field and an electromagnetic field between the atomizing assembly and the collector, wherein the field interacts with the molten alloy particles and influences at least one of the acceleration, speed, and direction of the molten alloy particles. 2. The apparatus of claim 1, wherein the melting assembly is a ceramic-less melting apparatus. 3. The apparatus of claim 1, wherein the melting assembly is selected from a vacuum double-electrode remelting device, a device comprising an electroslag remelting device and a cold induction guide, an electron beam melting device, and an electron beam cold hearth melting device. 4. The apparatus of claim 1, wherein the melting assembly is adapted to impart negative charge to the molten material. 5. The apparatus of claim 4, wherein at least a portion of the melting assembly contacted by the molten material is maintained at a negative potential to thereby impart negative charge to the molten material. 6. The apparatus of claim 1, wherein an electrically charged structure disposed adjacent an exit orifice of the melting assembly, upstream of the atomizing assembly, induces negative charge in the molten material. 7. The apparatus of claim 6, wherein the structure is one of a ring and a plate. 8. The apparatus of claim 1, wherein the collector is one of a surface, a platen, a mandrel, a mold, a chamber, and a can. 9. The apparatus of claim 1, wherein the field generating assembly comprises at least one high voltage DC power supply, and wherein one of a positive pole and a negative pole of the at least one power supply is electrically connected to the atomizing assembly and the collector is electrically grounded. 10. The apparatus of claim 1, wherein the field generating assembly comprises at least one high voltage DC power supply, and wherein one of a positive pole and a negative pole of the at least one power supply is electrically connected to the collector and the atomizing assembly is electrically grounded. 11. The apparatus of claim 1, wherein the field generating assembly comprises at least one magnetic coil electrically connected to a power supply, and wherein the coil is disposed between the atomizing means and the collector and generates an electromagnetic field. 12. The apparatus of claim 1, wherein the apparatus forms an alloy powder product. 13. The apparatus of claim 1, wherein the apparatus forms a solid preform. 14. The apparatus of claim 13, wherein the apparatus forms a solid preform by one of spray forming and nucleated casting. 15. The apparatus of claim 1, further comprising a chamber enclosing at least part of the melting assembly, atomizing assembly, collector, and field generating assembly; and a vacuum device providing vacuum to the chamber. 16. The apparatus of claim 1, wherein the collector is held at one of a ground potential and a positive potential, thereby attracting negatively charged molten alloy particles produced by the atomizing assembly. 17. The apparatus of claim 1, wherein the at least one electron field generated by the atomizing assembly comprises any combination of an energy, an intensity, and a three-dimensional shape capable of atomizing the molten alloy. 18. The apparatus of claim 1, wherein the at least one electron field generated by the atomizing assembly extends along a path of the molten alloy in the atomizing assembly for a distance suitable to atomize the molten alloy. 19. The apparatus of claim 1, wherein the atomizing assembly further comprises a rastering apparatus which controls a shape of the at least one electron field. 20. An apparatus comprising: a melting device providing at least one of a stream of molten alloy and a series of droplets of molten alloy, wherein the melting device is substantially free from ceramic in regions contacted by the molten alloy; an atomizing device generating at least one field of electrons comprising a three-dimensional shape, the atomizing device impinging the at least one field of electrons on molten alloy from the melting means to atomize the molten alloy and produce molten alloy particles; and a field generating device producing at least one of an electromagnetic field and an electrostatic field downstream of the atomizing device, wherein the field interacts with and influences the molten alloy particles. 21. The apparatus of claim 20, wherein the melting device comprises at least one of a vacuum double-electrode remelting device, a device combining an electroslag remelting device and a cold induction guide, an electron beam melting device, and an electron beam cold hearth melting device. 22. The apparatus of claim 20, wherein the field generated by the field generating device influences at least one of the acceleration, speed, and direction of the molten alloy particles. 23. The apparatus of claim 20, further comprising a collector downstream of the atomizing device, wherein the field generating device comprises at least one high voltage DC power supply, one of a positive pole and a negative pole of the at least one power supply is electrically connected to one of the atomizing device and the collector, and the other of the atomizing device and the collector is electrically grounded. 24. The apparatus of claim 20, wherein the field generating device comprises at least one magnetic coil electrically connected to a power supply, and wherein the coil is disposed downstream of the atomizing device and generates an electromagnetic field. 25. The apparatus of claim 20, further comprising a collector into which the molten alloy particles from the atomizing device are directed under influence of the field. 26. The apparatus of claim 25, wherein the collector is one of a surface, a platen, a mandrel, a mold, a chamber, and a can. 27. The apparatus of claim 25, wherein the collector is held at one of a ground potential and a positive potential and thereby attracts negatively charged molten alloy particles produced by the atomizing device. 28. The apparatus of claim 20, wherein the apparatus forms a powder product. 29. The apparatus of claim 20, wherein the apparatus forms a solid preform. 30. The apparatus of claim 20, wherein the apparatus forms a solid preform by one of spray forming and nucleated casting. 31. The apparatus of claim 20, wherein the melting device is adapted to impart negative charge to the molten material. 32. The apparatus of claim 20, further comprising a chamber enclosing at least part of the melting device, atomizing device, and field generating device; and a vacuum device providing vacuum to the chamber. 33. The apparatus of claim 20, wherein the at least one field of electrons generated by the atomizing device comprises any combination of an energy, an intensity, and a three-dimensional shape capable of atomizing the molten alloy. 34. The apparatus of claim 20, wherein the at least one field of electrons generated by the atomizing device extends along a path of the molten alloy in the atomizing device for a distance suitable to atomize the molten alloy. 35. The apparatus of claim 20, wherein the atomizing device further comprises a rastering apparatus which is used to control a shape of the at least one field of electrons. 36. An apparatus comprising: a melting assembly providing at least one of a stream of molten alloy and a series of droplets of molten alloy, wherein the melting assembly is substantially free from ceramic in regions contacted by the molten alloy; an atomizing assembly generating at least one electron field comprising a three-dimensional shape, the atomizing assembly impinging the at least one electron field on molten alloy from the melting assembly to atomize the molten alloy and produce molten alloy particles; a collector receiving one or more of the molten alloy particles; at least one of an electric coil and a plate creating an electromagnetic field influencing at least one of the acceleration, speed, and direction of the molten alloy particles in a region between the atomizing assembly and the collector. 37. The apparatus of claim 36, wherein the melting assembly comprises at least one of a vacuum double-electrode remelting device, a device combining an electroslag remelting device and a cold induction guide, an electron beam melting device, and an electron beam cold hearth melting device. 38. The apparatus of claim 36, wherein the melting assembly imparts negative charge to the molten alloy. 39. The apparatus of claim 36, further comprising: a chamber enclosing at least part of the melting assembly, the atomizing assembly, the at least one of an electric coil and a plate and the collector; and a vacuum device providing vacuum to the chamber. 40. The apparatus of claim 36, wherein the at least one electron field generated by the atomizing assembly comprises any combination of an energy, an intensity, and a three-dimensional shape capable of atomizing the molten alloy. 41. The apparatus of claim 36, wherein the at least one electron field generated by the atomizing assembly extends along a path of the molten alloy in the atomizing assembly for a distance suitable to atomize the molten alloy. 42. The apparatus of claim 36, wherein the atomizing assembly further comprises a rastering apparatus which controls a shape of the at least one electron field. 43. An apparatus comprising: a melting assembly adapted to produce at least one of a stream of a molten alloy and a series of droplets of a molten alloy, wherein the melting assembly is adapted to induce a negative charge in the molten alloy; and an atomizing assembly generating at least one field of electrons comprising a three-dimensional shape, the atomizing assembly impinging the at least one field of electrons on molten alloy from the melting assembly to atomize the molten alloy and produce molten alloy particles. 44. The apparatus of claim 43, wherein the melting assembly is substantially free of ceramic in regions of the melting assembly contacted by the molten alloy. 45. The apparatus of claim 43, wherein the at least one field of electrons generated by the atomizing assembly comprises any combination of an energy, an intensity, and a three-dimensional shape capable of atomizing the molten alloy. 46. The apparatus of claim 43, wherein the at least one electron field generated by the atomizing assembly extends along a path of the molten alloy in the atomizing assembly for a distance suitable to atomize the molten alloy. 47. The apparatus of claim 43, wherein the atomizing assembly further comprises a rastering apparatus which controls a shape of the at least one electron field. 48. An apparatus comprising: a melting assembly adapted to produce at least one of a stream of a molten alloy and a series of droplets of a molten alloy, wherein the melting assembly is substantially free from ceramic in regions contacted by the molten alloy; an atomizing assembly generating at least one electron field and impinging the at least one electron field on molten alloy from the melting assembly to atomize the molten alloy and produce molten alloy particles, wherein the at least one electron field comprises a two-dimensional transverse cross-section with respect to a direction of travel of the molten alloy through the atomizing assembly; a collector; and a field generating assembly generating at least one of an electrostatic field and an electromagnetic field between the atomizing assembly and the collector, wherein the field interacts with the molten alloy particles and influences at least one of the acceleration, speed, and direction of the molten alloy particles. 49. The apparatus of claim 48, wherein the transverse cross-section is one of a circular shape, a rectangular shape, a triangular shape, a polygonal shape, and an otherwise bounded shape. 50. The apparatus of claim 48, wherein the melting assembly is a ceramic-less melting apparatus. 51. The apparatus of claim 48, wherein the melting assembly is selected from a vacuum double-electrode remelting device, a device comprising an electroslag remelting device and a cold induction guide, an electron beam melting device, and an electron beam cold hearth melting device. 52. The apparatus of claim 48, wherein the melting assembly is adapted to impart negative charge to the molten material. 53. The apparatus of claim 52, wherein at least a portion of the melting assembly contacted by the molten material is maintained at a negative potential to thereby impart negative charge to the molten material. 54. The apparatus of claim 48, wherein an electrically charged structure disposed adjacent an exit orifice of the melting assembly, upstream of the atomizing assembly, induces negative charge in the molten material. 55. The apparatus of claim 54, wherein the structure is one of a ring and a plate. 56. The apparatus of claim 48, wherein the collector is one of a surface, a platen, a mandrel, a mold, a chamber, and a can. 57. The apparatus of claim 48, wherein the field generating assembly comprises at least one high voltage DC power supply, and wherein one of a positive pole and a negative pole of the at least one power supply is electrically connected to the atomizing assembly and the collector is electrically grounded. 58. The apparatus of claim 48, wherein the field generating assembly comprises at least one high voltage DC power supply, and wherein one of a positive pole and a negative pole of the at least one power supply is electrically connected to the collector and the atomizing assembly is electrically grounded. 59. The apparatus of claim 48, wherein the field generating assembly comprises at least one magnetic coil electrically connected to a power supply, and wherein the coil is disposed between the atomizing assembly and the collector and generates an electromagnetic field. 60. The apparatus of claim 48, further comprising a chamber enclosing at least part of the melting assembly, atomizing assembly, collector, and field generating assembly; and a vacuum device providing vacuum to the chamber. 61. The apparatus of claim 48, wherein the collector is held at one of a ground potential and a positive potential, thereby attracting negatively charged molten alloy particles produced by the atomizing assembly. 62. The apparatus of claim 48, wherein the at least one electron field generated by the atomizing assembly comprises any combination of an energy, an intensity, and a three-dimensional shape capable of atomizing the molten alloy. 63. The apparatus of claim 48, wherein the at least one electron field generated by the atomizing assembly extends along a path of the molten alloy in the atomizing assembly for a distance suitable to atomize the molten alloy. 64. The apparatus of claim 48, wherein the atomizing assembly further comprises a rastering apparatus which controls a shape of the at least one electron field. 65. An apparatus comprising: a melting device providing at least one of a stream of molten alloy and a series of droplets of molten alloy, wherein the melting device is substantially free from ceramic in regions contacted by the molten alloy; an atomizing device generating at least one field of electrons and impinging the at least one field of electrons on molten alloy from the melting device to atomize the molten alloy and produce molten alloy particles, wherein the at least one field of electrons comprises a two-dimensional transverse cross-section with respect to a direction of travel of the molten alloy through the atomizing device; and a field generating device producing at least one of an electromagnetic field and an electrostatic field downstream of the atomizing device, wherein the field interacts with and influences the molten alloy particles. 66. The apparatus of claim 65, wherein the transverse cross-section is one of a circular shape, a rectangular shape, a triangular shape, a polygonal shape, and an otherwise bounded shape. 67. The apparatus of claim 65, wherein the melting device comprises at least one of a vacuum double-electrode remelting device, a device combining an electroslag remelting device and a cold induction guide, an electron beam melting device, and an electron beam cold hearth melting device. 68. The apparatus of claim 65, wherein the field generated by the field generating device influences at least one of the acceleration, speed, and direction of the molten alloy particles. 69. The apparatus of claim 65, further comprising a collector downstream of the atomizing device, wherein the field generating device comprises at least one high voltage DC power supply, one of a positive pole and a negative pole of the at least one power supply is electrically connected to one of the atomizing device and the collector, and the other of the atomizing device and the collector is electrically grounded. 70. The apparatus of claim 65, wherein the field generating device comprises at least one magnetic coil electrically connected to a power supply, and wherein the coil is disposed downstream of the atomizing device and generates an electromagnetic field. 71. The apparatus of claim 65, further comprising a collector into which the molten alloy particles from the atomizing device are directed under influence of the field. 72. The apparatus of claim 71, wherein the collector is one of a surface, a platen, a mandrel, a mold, a chamber, and a can. 73. The apparatus of claim 71, wherein the collector is held at one of a ground potential and a positive potential and thereby attracts negatively charged molten alloy particles produced by the atomizing device. 74. The apparatus of claim 65, wherein the melting device is adapted to impart negative charge to the molten material. 75. An apparatus comprising: a melting assembly providing at least one of a stream of molten alloy and a series of droplets of molten alloy, wherein the melting assembly is substantially free from ceramic in regions contacted by the molten alloy; an atomizing assembly generating at least one electron and impinging the at least one electron field on molten alloy from the melting assembly to atomize the molten alloy and produce molten alloy particles, wherein the at least one electron field comprises a two-dimensional transverse cross-section with respect to a direction of travel of the molten alloy through the atomizing assembly; a collector receiving one or more of the molten alloy particles; at least one of an electric coil and a plate creating an electromagnetic field influencing at least one of the acceleration, speed, and direction of the molten alloy particles in a region between the atomizing assembly and the collector. 76. The apparatus of claim 75, wherein the transverse cross-section is one of a circular shape, a rectangular shape, a triangular shape, a polygonal shape, and an otherwise bounded shape. 77. The apparatus of claim 75, wherein the melting assembly comprises at least one of a vacuum double-electrode remelting device, a device combining an electroslag remelting device and a cold induction guide, an electron beam melting device, and an electron beam cold hearth melting device. 78. The apparatus of claim 75, wherein the melting assembly imparts negative charge to the molten alloy. 79. The apparatus of claim 75, further comprising: a chamber enclosing at least part of the melting assembly, the atomizing assembly, the at least one an electric coil a plate and the collector; and a vacuum device providing vacuum to the chamber. 80. The apparatus of claim 75, wherein the at least one field of electrons generated by the atomizing assembly comprises any combination of an energy, an intensity, and a three-dimensional shape capable of atomizing the molten alloy. 81. The apparatus of claim 75, wherein the at least one field of electrons generated by the atomizing assembly extends along a path of the molten alloy in the atomizing assembly for a distance suitable to atomize the molten alloy. 82. The apparatus of claim 75, wherein the atomizing assembly further comprises a rastering apparatus which is used to control a shape of the at least one field of electrons. 83. An apparatus comprising: a melting assembly adapted to produce at least one of a stream of a molten alloy and a series of droplets of a molten alloy, wherein the melting assembly is adapted to induce a negative charge in the molten alloy; and an atomizing assembly generating at least one field of electrons and impinging the at least one field of electrons on molten alloy from the melting assembly to atomize the molten alloy and produce molten alloy particles, wherein the at least one electron field comprises a two-dimensional transverse cross-section with respect to a direction of travel of the molten alloy through the atomizing assembly. 84. The apparatus of claim 83, wherein the transverse cross-section is one of a circular shape, a rectangular shape, a triangular shape, a polygonal shape, and an otherwise bounded shape. 85. The apparatus of claim 83, wherein the melting assembly is substantially free of ceramic in regions of the melting assembly contacted by the molten alloy. 86. The apparatus of claim 83, wherein the at least one field of electrons generated by the atomizing assembly comprises any combination of an energy, an intensity, and a three-dimensional shape capable of atomizing the molten alloy. 87. The apparatus of claim 83, wherein the at least one electron field generated by the atomizing assembly extends along a path of the molten alloy in the atomizing assembly for a distance suitable to atomize the molten alloy. 88. The apparatus of claim 83, wherein the atomizing assembly further comprises a rastering apparatus which controls a shape of the at least one electron field.

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