# US 12,214,420 B2 · Spheroidal titanium metallic powders with custom microstructures

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- Number: US 12,214,420 B2
- Document ID: US12214420B2
- Status: Granted
- Kind: B2
- Application number: 18/061,250
- Filed: 2022-12-02
- Published: 2023-07-06
- Granted: 2025-02-04
- Earliest claimed: 2015-12-16
- Assignees: 6K Inc.
- Applicants: 6K Inc.
- Inventors: Kamal Hadidi; Gregory M. Wrobel; Makhlouf Redjdal
- Web page: https://patentgrep.com/patent/US12214420B2

## CPC

- B22F 1/00: Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F 1/065: Spherical particles
- B22F 1/142: Thermal or thermo-mechanical treatment
- B22F 9/08: by casting, e.g. through sieves or in water, by atomising or spraying (using electric discharge B22F9/14)
- B22F 9/14: using electric discharge
- B22F 9/30: with decomposition of metal compounds, e.g. by pyrolysis
- H01J 37/32192: {Microwave generated discharge (H01J37/32357, H01J37/32366, H01J37/32394, H01J37/32403 take precedence)}
- H05H 1/26: Plasma torches
- H05H 1/30: using applied electromagnetic fields, e.g. high frequency or microwave energy (H05H1/28 takes precedence)
- H05H 1/42: with provisions for introducing materials into the plasma, e.g. powder or liquid {(arc stabilising or constricting arrangements H05H1/3405; coaxial protecting fluids H05H1/341)}
- B22F 2207/11: Gradients other than composition gradients, e.g. size gradients
- B22F 2998/10: Processes characterised by the sequence of their steps
- B22F 2999/00: Aspects linked to processes or compositions used in powder metallurgy
- Y02P 10/25: Process efficiency
- B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- H01J: ELECTRIC DISCHARGE TUBES OR DISCHARGE LAMPS (spark-gaps H01T; electric arc lamps H05B31/00; particle accelerators H05H)
- H05H: PLASMA TECHNIQUE (apparatus or processes specially adapted for producing X-rays H05G2/00); PRODUCTION OF ACCELERATED ELECTRICALLY-CHARGED PARTICLES OR OF NEUTRONS; PRODUCTION OR ACCELERATION OF NEUTRAL MOLECULAR OR ATOMIC BEAMS
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## Abstract

Methodologies, systems, and devices are provided for producing metal spheroidal powder products. By utilizing a microwave plasma, control over spheriodization and resulting microstructure can be tailored to meet desired demands.

## Claims

### Claim 1

A method of modifying a particle shape and a microstructure of a feedstock, the method comprising:
melting at least a surface portion of particles of feedstock comprising titanium in a plasma to spheroidize the particles; and
setting and applying cooling processing parameters to create spheroidized particles with a microstructure,
wherein the cooling process parameters comprise one or more of a cooling gas flow rate, a residence time of the feedstock, and a cooling gas composition, and
wherein the cooling processing parameters are selected to create at least two regions in the spheroidized particles, each region having a different microstructure or crystal structure, wherein the cooling processing parameters are selected to create an equiaxed microstructure in the spheroidized particles.

### Claim 2 (depends on 1)

The method of claim 1, wherein the particles of the feedstock have a particle size of no less than 1.0 micrometers and no more than 300 micrometers.

### Claim 3 (depends on 1)

The method of claim 1, wherein setting and applying the cooling processing parameters comprises controlling a cooling gas flow rate.

### Claim 4 (depends on 1)

The method of claim 1, wherein setting and applying the selected cooling processing parameters comprises controlling a cooling gas composition.

### Claim 5 (depends on 1)

The method of claim 1, wherein the at least two regions include a core portion and a skin portion.

### Claim 6 (depends on 5)

The method of claim 5, wherein the skin portion has a microstructure that is different from the microstructure of the feedstock.

### Claim 7

A method of modifying a particle shape and a microstructure of a feedstock, the method comprising:
melting at least a surface portion of particles of the feedstock comprising titanium in a plasma to spheroidize the particles; and
setting and applying cooling processing parameters to create spheroidized particles with a microstructure,
wherein the cooling process parameters comprise one or more of a cooling gas flow rate, a residence time of the feedstock, and a cooling gas composition, and
wherein the cooling processing parameters are selected to create a martensitic microstructure, a Widmanstätten microstructure, and/or an equiaxed microstructure in the spheroidized particles.

### Claim 8 (depends on 7)

The method of claim 7, wherein the particles of the feedstock have a particle size of no less than 1.0 micrometers and no more than 300 micrometers.

### Claim 9 (depends on 7)

The method of claim 7, wherein setting and applying the selected cooling processing parameters comprises controlling a cooling gas flow rate.

### Claim 10 (depends on 7)

The method of claim 7, wherein setting and applying the selected cooling processing parameters comprises controlling a cooling gas composition.

### Claim 11 (depends on 7)

The method of claim 7, wherein the cooling processing parameters are selected to create a martensitic microstructure in the spheroidized particles.

### Claim 12 (depends on 7)

The method of claim 7, wherein the cooling processing parameters are selected to create a Widmanstätten microstructure in the spheroidized particles.

### Claim 13 (depends on 7)

The method of claim 7, wherein the cooling processing parameters are selected to create an equiaxed microstructure in the spheroidized particles.

### Claim 14 (depends on 7)

The method of claim 7, wherein the cooling processing parameters are selected to create at least two regions in the spheroidized particles.

### Claim 15 (depends on 14)

The method of claim 14, wherein each region has a different microstructure or crystal structure.

### Claim 16 (depends on 14)

The method of claim 14, wherein the at least two regions include a core portion and a skin portion.

### Claim 17 (depends on 16)

The method of claim 16, wherein the skin portion has a microstructure that is different from the microstructure of the feedstock.