A method of forming metal spheres includes ejecting a precisely measured droplet of molten metal from a molten metal mass, buffering the molten metal droplet to reduce the internal kinetic energy of the droplet without solidifying the droplet and cooling the buffered droplet until the droplet solidi
A method of forming metal spheres includes ejecting a precisely measured droplet of molten metal from a molten metal mass, buffering the molten metal droplet to reduce the internal kinetic energy of the droplet without solidifying the droplet and cooling the buffered droplet until the droplet solidifies in the form of a metal sphere. An apparatus for fabricating metal spheres includes a droplet generator that generates a droplet from a molten metal mass, a buffering chamber that receives the droplet from the droplet generator, and diminishes internal kinetic energy of the droplet without solidifying the droplet, and a cooling drum that receives the droplet from the buffering chamber, and cools the droplet to the extent that the droplet solidifies into a metal sphere. The apparatus may further include a collector arrangement that receives the metal spheres from the cooling drum and makes the metal sphere available for collection.
대표청구항▼
What is claimed is: 1. A process for fabricating metal spheres, comprising: providing a molten metal mass within a receptacle; causing a reciprocating motion of a piston to force a droplet of the molten metal mass through an aperture in the receptacle; buffering the droplet by diminishing internal
What is claimed is: 1. A process for fabricating metal spheres, comprising: providing a molten metal mass within a receptacle; causing a reciprocating motion of a piston to force a droplet of the molten metal mass through an aperture in the receptacle; buffering the droplet by diminishing internal kinetic energy of the droplet without solidifying the droplet; and cooling the buffered droplet to the extent that the droplet solidifies into a metal sphere; wherein causing a reciprocating motion of the piston to force a droplet of the molten metal mass through the aperture in the receptacle includes imparting an impulse force by the piston on the molten metal mass within the receptacle to cause a portion of the molten metal mass to eject through the aperture as the droplet; further comprising collecting the metal sphere, wherein collecting the metal sphere includes receiving the metal sphere in a reservoir that holds a liquid; passing the metal sphere and a volume of the liquid to a pipe connected to a bottom end of the reservoir; and delivering the metal sphere from the pipe to a collection basket. 2. The process of claim 1, wherein imparting an impulse force by the piston includes causing the piston to abut a wall of the receptacle at an end of the reciprocating motion such that the piston closes off the aperture from inside of the receptacle and forces a droplet of molten metal out of the aperture. 3. The process of claim 1, further comprising positioning the piston and aperture such that the droplet is ejected from the aperture in a generally upward trajectory. 4. The process of claim 3, further comprising directing the trajectory by ejecting the droplet from the aperture through a feed tube extending from the aperture. 5. The process of claim 3, further comprising allowing the ejected droplet to reach a maximum unimpeded height in the upward trajectory. 6. The process of claim 1, wherein passing the metal sphere and a volume of the liquid to a pipe includes allowing the metal sphere to slide down a lower side of the reservoir that slopes toward an opening in the pipe. 7. The process of claim 1, wherein collecting the metal sphere further includes allowing the metal sphere to settle in a bend in the pipe. 8. The process of claim 1, wherein delivering the metal sphere from the pipe to the collection basket includes pumping the metal sphere and the volume of the liquid to a level that is higher than a level of the liquid in the reservoir, and depositing the metal sphere and the volume of the liquid into the collection basket. 9. The process of claim 8, wherein collecting the metal sphere further includes removing the collection basket. 10. The process of claim 9, wherein collecting the metal sphere further includes passing the volume of the liquid through openings in the collection basket that are smaller than the metal sphere. 11. The process of claim 10, further including returning liquid passing through the openings in the collection basket to the reservoir. 12. The process of claim 11, wherein returning the liquid to the reservoir includes providing the liquid to a return channel in fluid communication with the reservoir. 13. A process for fabricating metal spheres, comprising: providing a molten metal mass within a receptacle; causing a reciprocating motion of a piston to force a droplet of the molten metal mass through an aperture in the receptacle; buffering the droplet by diminishing internal kinetic energy of the droplet without solidifying the droplet; and cooling the buffered droplet to the extent that the droplet solidifies into a metal sphere; wherein buffering the droplet includes passing the droplet through an enclosed gaseous medium having a controlled temperature; further comprising collecting the metal sphere, wherein collecting the metal sphere includes receiving the metal sphere in a reservoir that holds a liquid; passing the metal sphere and a volume of the liquid to a pipe connected to a bottom end of the reservoir; and delivering the metal sphere from the pipe to a collection basket. 14. The process of claim 13, wherein causing a reciprocating motion of the piston to force a droplet of the molten metal mass through the aperture in the receptacle includes imparting an impulse force by the piston on the molten metal mass within the receptacle to cause a portion of the molten metal mass to eject through the aperture as the droplet. 15. The process of claim 14, wherein imparting an impulse force by the piston includes causing the piston to abut a wall of the receptacle at an end of the reciprocating motion such that the piston closes off the aperture from inside of the receptacle and forces a droplet of molten metal out of the aperture. 16. The process of claim 14, further comprising positioning the piston and aperture such that the droplet is ejected from the aperture in a generally upward trajectory. 17. The process of claim 16, further comprising directing the trajectory by ejecting the droplet from the aperture through a feed tube extending from the aperture. 18. The process of claim 16, further comprising allowing the ejected droplet to reach a maximum unimpeded height in the upward trajectory. 19. A process for fabricating metal spheres, comprising: generating a droplet from a molten metal mass, including containing the molten metal mass in a receptacle that includes a plurality of walls, an aperture through a first wall of the plurality of walls, and a piston tube, disposing a piston within the piston tube to form a substantially fluid-tight seal with the piston tube, and providing reciprocating motion of the piston within the piston tube to change pressure of the molten metal mass, causing the piston to abut the first wall at an end of the reciprocating motion such that the piston closes off the aperture from inside of the receptacle, such that an impulse force imparted on the molten metal mass causes a portion of the molten metal mass to eject through the aperture as the droplet buffering the droplet to diminish internal kinetic energy of the droplet without solidifying the droplet; and cooling the buffered droplet to the extent that the droplet solidifies into a metal sphere; wherein buffering the droplet takes place in a first medium, cooling the droplet takes place in a second medium, and the first medium is disposed above the second medium; further comprising collecting the metal sphere; wherein collecting the metal sphere includes receiving the metal sphere in a reservoir that holds a liquid; passing the metal sphere and a volume of the liquid to a pipe connected to a bottom end of the reservoir; and delivering the metal sphere from the pipe to a collection basket.
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