Making Smaller Microshells From Refractory Metals

Tendency toward gas porosity exploited. Falling through drop tube, fine drops of molten metal lose heat to surroundings, forming hard shells around precipitated gas. Second heating/cooling cycle in drop tube of lower pressure lets gas expand. Process produces smaller shells in greater variety of materials than possible with such current processes as based on hollow-jet instability, dry-chemical blowing or fluid-droplet drying. Shell aspect ratio (ratio of radius to wall thickness) controllable. New process makes shells having diameters smaller than 100 micrometer. There are several candidate shell materials including refractory metals.