Methods of forming spherical metallic particles

Abstract

A method of forming titanium-based spherical metallic particles includes contacting a feedstock material including a metal halide with a reductant in the presence of a microwave plasma discharge.

1 . A method of forming spherical metallic particles, comprising:
 contacting a feedstock material comprising a metal halide with a reductant in the presence of a microwave plasma discharge to form the spherical metallic particles, wherein the spherical metallic particles comprise titanium.   
     
     
         2 . The method of  claim 1 , wherein the spherical metallic particles comprise an elemental metal, a metal alloy, or a combination thereof. 
     
     
         3 . The method of  claim 1 , wherein the spherical metallic particles comprise a metal alloy comprising titanium. 
     
     
         4 . The method of  claim 3 , wherein the metal alloy further comprises aluminum, vanadium, or a combination thereof. 
     
     
         5 . The method of  claim 1 , wherein the metal halide comprises a titanium halide. 
     
     
         6 . The method of  claim 5 , wherein the metal halide comprises titanium chloride. 
     
     
         7 . The method of  claim 1 , wherein the feedstock material comprises a metal halide mixture. 
     
     
         8 . The method of  claim 7 , wherein the metal halide mixture comprises a titanium halide and one or both of a vanadium halide and an aluminum halide. 
     
     
         9 . The method of  claim 1 , wherein the feedstock material is a liquid. 
     
     
         10 . The method of  claim 1 , wherein the reductant comprises hydrogen. 
     
     
         11 . The method of  claim 1 , wherein the reductant comprises hydrogen gas. 
     
     
         12 . A plurality of spherical metallic particles comprising titanium, formed by contacting a feedstock material comprising a titanium halide with a reductant in the presence of a microwave plasma discharge. 
     
     
         13 . The plurality of spherical metallic particles of  claim 12 , wherein the plurality of spherical metallic particles comprises elemental titanium, a titanium alloy, or a combination thereof. 
     
     
         14 . The plurality of spherical metallic particles of  claim 12 , wherein the plurality of spherical metallic particles comprises a titanium alloy. 
     
     
         15 . The plurality of spherical metallic particles of  claim 14 , wherein the titanium alloy further comprises aluminum, vanadium, or a combination thereof. 
     
     
         16 . A method of forming spherical titanium-based particles, comprising:
 contacting a feedstock material comprising a titanium halide with a hydrogen gas in the presence of a microwave plasma discharge to reduce the titanium halide and form the spherical titanium-based particles.   
     
     
         17 . The method of  claim 16 , wherein the feedstock material further comprises a vanadium halide, an aluminum halide, or a combination thereof. 
     
     
         18 . The method of  claim 16 , wherein the spherical titanium-based particles comprise particles of a titanium alloy.