Apparatus and method for the formation of uniform spherical particles

The present invention relates to an apparatus and method for atomizing a molten liquid to form particles of substantially uniform size, particularly for the formation of relatively large metal particles of substantially uniform size with an induced duplex microstructure. The present invention relates to an apparatus and method for the formation of nearly spherical particles, particularly for the formation of metal or metal alloy particles with an induced duplex microstructure. The present invention provides an atomization apparatus having a nozzle positioned at the bottom of a cooling chamber. Rayleigh wave instability may be induced by imparting vibrations to a stream of molten material, which is released under positive pressure upward into a cooling chamber where the stream breaks up into substantially spherical droplets. This produces a plurality of uniform droplets, each droplet having an initial velocity sufficient to follow a unique upward parabolic trajectory above the aperture. These parabolic trajectories carry the individual droplets to a chill body disposed within the cooling chamber, with which they impact while they are at least partially molten.