Metal powder with nano-composite structure and its production method using a self assembling technique

A process for producing extremely small metal spherical particles having a crystalline structure and of high uniform size and high sphericity, comprising the following steps:

• melting metal starting material;
• rotating a disk at 50,000 rpm to 100,000 rpm using a motor in a vacuum chamber, wherein an inside of the vacuum chamber is vacuumed;
• discharging the molten starting material through a nozzle toward the rotating disk in the vacuum chamber;
• dispersing said molten metal starting material into tiny spherical droplets by the rotating disk in the vacuum chamber, wherein the vacuum chamber includes oxygen at a concentration of 0.3 to 0.7 ppm;
• cooling said dispersed metal droplets by directing a cooling-reaction gas to contact the dispersed metal spherical droplets and thus solidify the droplets into tiny spherical particles and form an anti-adhesion coating on the particles in the vacuum chamber, whereby the tiny spherical particles comprise a crystalline composition having a size of 1-300 μm and precise spherical shape of less than or equal to ±10%, whereby the crystalline composition comprises a nanocomposite structure of metals including an aggregate of nano-sized metal components separated within the particles by layers or discrete nano-sized bodies having composition selected from the group consisting of metal oxides, metal nitrides and metal silicides.

A process for producing extremely small metal spherical particles having an amorphous structure and of high uniform size and high sphericity, comprising the following steps:

• melting metal starting material;
• rotating a disk at a speed of 50,000 to 100,000 rpm using a motor in a vacuum chamber, wherein an inside of the vacuum chamber is vacuumed;
• discharging the molten starting material through a nozzle toward the rotating disk in the vacuum chamber;
• dispersing said molten metal starting material into tiny spherical droplets by the rotating disk in the vacuum chamber, wherein the surrounding atmosphere has a temperature of 10-30° C.;
• cooling said dispersed metal droplets by directing a cooling-reaction gas to contact the dispersed metal spherical droplets and thus solidify the droplets into tiny spherical particles and form an anti-adhesion coating on the particles in the vacuum chamber, whereby the tiny spherical particles comprise a crystalline composition having a size of 1-300 μm and precise spherical shape of less than or equal to ±10%, whereby the crystalline composition comprises a nanocomposite structure of metals including an aggregate of nano-sized metal components separated within the particles by layers or discrete nano-sized bodies having composition selected from the group consisting of metal oxides, metal nitrides and metal silicides.

A process for producing extremely small metal spherical particles having a porous structure and of high uniform size and high sphericity, comprising the following steps:

• melting metal starting material;
• rotating a disk using a motor in a vacuum chamber, wherein an inside of the vacuum chamber is vacuumed;
• discharging the molten starting material through a nozzle toward the rotating disk in the vacuum chamber;
• dispersing said molten metal starting material into tiny spherical droplets by the rotating disk in the vacuum chamber, wherein the vacuum chamber include oxygen at a concentration of 0.8 to 1.2 ppm;
• cooling said dispersed metal droplets by directing a cooling-reaction gas to contact the dispersed metal spherical droplets and thus solidify the droplets into tiny spherical particles and form an anti-adhesion coating on the particles in the vacuum chamber.