公开(公告)号：US20240399459A1

公开(公告)日：2024-12-05

申请号：US18125073

申请日：2023-03-22

Applicant: PYROGENESIS CANADA INC.

Inventor： Christopher Alex DORVAL DION ,  Ali SHAHVERDI ,  François PROULX

IPC: B22F10/34 ,  B22F1/065 ,  B22F9/08 ,  B22F9/14 ,  C22C1/04

Abstract: A high temperature process is provided, which can melt, atomize and spheroidize a coarse angular powder into a fine and spherical one. It uses thermal plasma to melt the particle in a heating chamber and a supersonic nozzle to accelerate the stream and break up the particles into finer ones.

公开(公告)号：US20240278324A1

公开(公告)日：2024-08-22

申请号：US18372685

申请日：2023-09-25

Applicant: PYROGENESIS CANADA INC.

Inventor： François PROULX ,  Christopher Alex DORVAL DION ,  Pierre CARABIN

IPC: B22F9/14 ,  B22F1/065 ,  B22F9/08 ,  H05H1/26

CPC classification number: B22F9/14 ,  B22F1/065 ,  B22F9/082 ,  H05H1/26 ,  B22F2009/0824 ,  B22F2009/0848 ,  B22F2202/13 ,  B22F2999/00

Abstract: The present application relates to a plasma atomization process and apparatus for producing metallic powders from at least one wire/rod feedstock. In the process, an electrical arc is applied between the at least one wire/rod feedstock, and a plasma torch is employed to generate a supersonic plasma stream at an apex at which the electric arc is transferred to the at least one wire/rod to melt and atomize the at least one wire/rod feedstock to produce the metallic powders. An anti-satellite diffuser is employed to prevent recirculation of the powders in order to avoid satellite formation.

公开(公告)号：US20200180034A1

公开(公告)日：2020-06-11

申请号：US16632337

申请日：2018-07-23

Applicant: PYROGENESIS CANADA INC.

Inventor： Christopher Alex DORVAL DION ,  François PROULX

IPC: B22F9/08 ,  B33Y40/10

Abstract: A metal powder plasma atomization process and apparatus comprises at least one plasma torch, a confinement chamber, a nozzle positioned downstream of the confinement chamber and a diffuser positioned downstream of the nozzle. The nozzle accelerates liquid metal particles produced by the at least one plasma torch and also plasma gas to supersonic velocity such that the liquid metal particles are sheared into finer powders. The diffuser provides a Shockwave to the plasma gas to increase temperature of the plasma in order to avoid stalactite formation at an exit of the nozzle. The process increases both production rate of the metal powder and the yield of −45 μm metal powder.

公开(公告)号：US20210229170A1

公开(公告)日：2021-07-29

申请号：US16972949

申请日：2019-06-06

Applicant: PYROGENESIS CANADA INC.

Inventor： François PROULX ,  Christopher Alex DORVAL DION ,  Pierre CARABIN

IPC: B22F1/00 ,  B22F9/08 ,  B22F9/14 ,  H05H1/26 ,  H05H1/52 ,  H05H1/46

Abstract: The present application relates to a plasma atomization process and apparatus for producing metallic powders from at least one wire/rod feedstock. In the process, an electric arc is applied to the at least one wire/rod feedstock to melt the same. A plasma torch is employed to generate a supersonic plasma stream at an apex at which the electric arc is transferred to the at least one wire/rod feedstock to atomize the molten wire/rod feedstock into particles. A downstream cooling chamber solidifies the particles into the metallic powders. An anti-satellite diffuser is employed to prevent recirculation of the powders in order to avoid satellite formation. In an apparatus where two wires are fed, one wire serves as an anode, and the other as a cathode.

公开(公告)号：US20210114104A1

公开(公告)日：2021-04-22

申请号：US16981692

申请日：2019-03-18

Applicant: PYROGENESIS CANADA INC.

Inventor： Bernard ALLARD ,  Pierre CARABIN ,  Christopher Alex DORVAL DION ,  Milad MARDAN ,  François PROULX

IPC: B22F9/14 ,  B22F1/00 ,  B22F9/08

Abstract: An apparatus for producing metallic powders from molten feedstock includes a heating source for melting a solid feedstock into a molten feed, and a crucible for containing the molten feed. A liquid feed tube is also provided to feed the molten feed as a molten stream. A plasma source delivers a plasma stream, with the plasma stream being adapted to be accelerated to a supersonic N velocity and being adapted : to then impact the molten stream for producing metallic powders. The feed tube extends from the crucible to a location where a supersonic plasma plume atomizes the molten stream. The plasma source includes at least two plasma torches provided with at least one supersonic nozzle aimed towards the molten stream. The multiple plasma torches are disposed symmetrically about the location where the supersonic plasma plumes atomize the molten stream, such as in a ring-shaped configuration