Apparatus and method for clean, rapidly solidified alloys

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.

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.

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.

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.

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.