CA1038652A - High surface area valve metal powder - Google Patents

Abstract

HIGH SURFACE AREA VALVE METAL POWDER
Abstract of the Disclosure Solid particles of potassium fluotantalate are tho-roughly dried and then coated with molten form sodium reducing agent, the coating being accomplished under temperature condi-tions controlled to remain below a temperature which will ini-tiate the exothermic reduction reaction between these materials.
After completion of the coating, the charge of premixed double salt and reducing agent is then heated through the temperature at which the exothermic reduction reaction is initiated. The initiation of the exothermic reaction causes a rapid tempera-ture rise. Over 90% of the tantalum values of the salt charge are formed as elemental tantalum in particle form in the course of the exothermically driven temperature rise. The charge temperature is then stabilized in the range of 700°-1100°C, held for a time at this elevated temperature and then slowly cooled. During the temperature rise, tantalum metal particles nucleate throughout the mass of the premixed charge to form a coherent skeletal structure. This skeleton resists settling as the temperature is raised above the melting temperature of the salt mass, and a substantially homogeneous distribution of tantalum values throughout the reduction charge is formed and maintained. Tantalum metal particles, so formed are highly structured and can be separated as a high yield of high sur-face area - high capacitance tantalum powder.

Description

BACKGROI~ND OF THE INVENTION
The present invention relates generally to metal powder production and more particularly to producing high sur-face area valve metal powders for sintering into capacitor electrodes in an economical, high yield process.
It is well known in the art to produce tantalum metal, for use in making capacitors, in powder forms of high purity through reduction of a purified potassium fluotantalate double salt tK2TaF7). This is done by adding any of various reducing agents including liquid sodium, magnesium and calcium to a melt of the salt to reduce the tantalum values therein.
Separation of tantalum from the reacted mass by pulverizing and leaching to complete the metal powder production process.
The practice i9 described in U.S.Pa~ent 2,350,185 to Hellier and Martin. Such processing, using sodium reducing agent, is in large scale production use today for producing high purity, high aurface area tantalum powders. After classification to desired size cuts, the pouders are usable in manufacture of sintered anodes for electrolytic capacitors. It is also known in connection with such processes to dilute the tantalum con-taining salt with alkali metal halide salt -- including sodium chloride, potassium chloride, sodium bromi~e, potassium bromide, sodium iodide, potassium iodide, or m~xturea thereof and the like -- as taught in U.S. Patent 2,994,603 to Greenberg and Fooa. Increasing the structure of tantalum powders produced is desirable because more highly structured particles generally yield more surface area per unit of weight or volume and therefore more capacitance per unit of weight or volume in the usual case.
Related criteria for the tantalum powders so produced are high purity to avoid high leakage, good flow properties for reliable usage in pelleting dies and automated production -- 2 . .

io3~6sz equipment and good pelleting properties to permit pressing anodes at low green densities. Low sinter density after sinter-firing produces a capacitor anode with low dissipation factor in the finished capacitor. It is also necessary to take into account, in evaluating tantalum powders for capacitor use, the shrinkage characteristics of the powder. When the powders are pressed and sintered, they may have the vulnerability that they can only receive a very light sinter. V~ry high capaci-tance powders, generally made by taking finer and finer cuts of the powders, are particularly vulnerable in this regard.
When sintered at 1800C, they tend to undergo substantial shrinkage which ~eads to loss of capacitance, and worse, un-predictability as to electrical and mechanical properties. Yet, the high temperature sinter is per se desired for its strengthen-ing and cleaning benefits. Therefore it is desirable to pro-vide a low shrinkage powder with high surface area.
To enhance the ability of the reduction run to afford such properties, several process changes have been utilized or proposed. Canadian Patent number 657,596 to Kelley, Rees and 2a Mettler discloses critical temperatures for the sodium reduction of potassium fluotantalate to optimize crystalline tantalum production, which is less sensitive to oxygen pickup than amor-phous, spongy metal. The art has also used thoroug~ presinter-ing of powders to increase the degree of natural agglomeration generally present in powder produced by sodium reduction, en-hancing powder pelleting and flow properties.
British Patent No. 694,921 of Titan Company, Inc., teaches the method of producing titanium metal by partially reducing titanium tetrachloride by forming 200 gram p~llets 3a thereof, dipping such pellets into a molten alkali metal bath to cause a reduction of the pellets to a lower chloride of titanium and then further pelletizing the partially-reacted 103E~652 lumps into smaller masses and putting them into a reducing agent bath to complete the reduction to free titanium metal.
Recently introduced commercial products include a very high capacitance powder whic~ is highly structured and has good flow properties. The highly structured products are commercially sold under the trademarks SGV and SGVR, said pro-ducts and trademarks being those o~ the Norton Company of Worcester, Massachusetts, U.S.A. These products afford an enhanced uti~ization of tantalum values in a given salt source by producing high surface-high capacitance p~wders over a broader size range, in contrast to the prior state-of-the-art which involved taking finer SiSQeCUtS of reduction product powder at lower yields.
It is an important object of the present invention to produce tantalum and other valve metal powders in the form of high surface area, high capacitance powders of adequate purity, flowability, and pelletability, in high yield.
It is a further object of the invention to produce such powders as a chemical reduction product uniformly distri-buted through the reduction charge, consistent with thepreceding object.
It is a further object of the invention to produce valve metal po~ders which have improved pelleting~properties, as measured by the ability to be pressed into a binderless compact having, in the case of tantalum, a green~density of 5.0 grams per cc. with a crush strength of at least 100 pounds for a 1.8 gram compact and, in the case of other valve metals, a similarly low percent of theoretical density as green density.
It is a further object of the invention to produce a valve metal powder having a Scott Bulk Density of less than 35 grams per cubic inch (2.14 gm/cc) and distinctly advanta-geously less than 25 grams per cubic inch (1.53 gm/cc) lQ3~65Z
consistent with an oxygen content of no greater than 0.2 weight percent and consistent ~ith one or more of the preceding objects.
SUMMARY OF THE INVENTION
The objects of the invention are achieved by a re-duction process in which the valve metal -- preferably tantalum --is produced at uniformly dispersed locations throughout the main mass of a reduction charge and, due to processing conditions specifically adjusted to that end, remains in such location without substantial settling or segregation into distinct valve metal rich and valve metal poor layers. It is believed that the prior art processes of reduction do involve the initial formation of highly structured metal particles, with the struc-ture being sacrificed at later stages of the reduction as the particles grow together in separate regions. The normal re-duction process ~hether utilizing stirring or omitting such stirringl is vulnerable to layering because the reaction takes place only after formation of a molten salt pool.
In accordance with the present invention, a salt source of the desiredvvalve metal values is divided into solid particles of minus 10 Meqh and these particles are thoroughly dried or otherwise treated to ~nsu-re the substantial absence of alternative reactants to the reagents of the reduction re-action. The dried salt charge is coated ~ith reducing agent applied in molten form. The salt and reducing agent are inti~-mately mixed to provide coating throughout the salt charge. The coatings of adjacent particles are preferably in bridge con-tacting relation to form a matrix throughout the charge mass.
The drying, coating and reduction can take place in a single vessel or can be done in separate vessels at separate locations.
The reduction charge is heated to cause a reduction reaction wherein the valve metal values are reduced from their 1~38652 salt source by the reducing agent. The reducing agent can be maintain~d molten from the time of introduction to the charge until initiation of the reaction or it can be solidified after coating the salt particles. Although it is preferred to com-plete addition of reducing agent to the salt charge and coating thereof prior to initiation of the ~eduction reaction, these steps can alternatively overlap. The reduction reaction is 5p% or more completed, ppeferably over 90% complete, before temperature of the reduction charge is raised to reach the lQ liquidasoQf hhe salt-charge and_preferably before reaching its solidus temperature level. A solid, coherent but porous, metal skeleton of bridging valve metal particles is thus formed with salt in the pores and the salt's melting in whole or in part does not lead to collapse of the skelton.
The salt and reducing agent are selected for their ability to produce an exothermic reduction reaction below the salt liquidus and preferably below its solidus.
The heating of the charge for reduction reaction preferably includes a high temperature hold at a temperature preferably above the metal salt mixtures freezing point (li-quidus) and in any event above its solidus to redissolve overly fine valve metal particles in the molten salt and re-precipitate such valve metal values on the valve metal skeleton as extensions of nucleating sites formed by the larger highly structured particles therein, which are optimal for use as electrolytic anodes or the like. The elimination in part of fine particles also reduces vulnerability to oxygen contamina-tion.
The reduction reaction takes place in confined con-ditions which avoid the presence of water, oxygen,or otheralternative reactants for the reducing agent. However, the reduction reaction charge can be diluted with inert salt to enhance the formation of high structure and high surface area powder. ~ith no dilution at all, there is less surface area of powder produced; but the ppwder turns out as a low oxygen powder with characteristics which make it especidlly suitable as what is known in the industry as melting grade or metal-lurgical grade or sinter grade powder for making mill products and fabricated parts. When dilution is used, the melting of the diluent absorbs energy from the exothermic reaction to stabilize temperature rise rate and the diluent also acts as a barrier to internal pore closing within the metal mass during the time the diluent is solid. The amount of such dilution, if used, i5 limited only, as a practical matter, by hhe desire for higher throughput and the danger of introducing oxygen or other contaminants with the diluting material. The diluting materials are selected from the class consisting of alkali metal halide salts.
The source of valve metal values to be reduced may be halides of the valve metal, either as single or double salts thereof. The composItïonsinvolved are encompassed by the formula: RXM~x+5 where R is one or more of the alkali metals, M is valve metal, preferably tantalum or columbium, H is one ~r more h~logen~,but including fluorine alone or in combination with other halogens,Ax is 0 to 3 x + 5. The reducing agents are selected from the class consisting of sodium, potassium, lithium, magnesium, aluminum and mixtures, alloys, compounds and amalgams thereof, such as NaK or NaBH4 or NaAlH4.
Preferably -- and with distinct advahtage -- the charge is a mixture of K2TaF7 diluted with NaCl in a weight ratio of NaCl to K2TaF7 up to 2.Q:l and the reducing agent is reagent grade sodium, potassium or NaK, preferably sodium.
Preferred dilution ratios are in the ragne of 0.1:1 to 0.5:1.

103865~
~ he K2TaF7 is provided in a size range of no greater than 10 Mesh for a majority of the particles thereof and no greater than 4 Mesh in any event, and the NaCl is provided in a size range of no greater than 4 Mesh for the majority thereof. Appropriate size limitations will apply to other metal source salts and diluent salts. The particles are charged into a ~é-~ctarvessel in the proportions above stated. They may be charged in a repeating pattern of alternating layers thereof, or as t~o discrete masses, or as a mixture. The reactor is la sealed and evacuated. The charge is heated to a temperature belo~ the spontaneous ignition temperature for the exothermic reduction reaction and stirred 50 as to avoid unmixed pockets.
This stirring enhances heat transfer and uniformity and also helps dry the charge. In this way ~ater vapor is removed which would other~ise be a troublesome source of oxygen or water in a later stage of the process. After the charge has reached the desired temperature the vacuum is removed and the atmos-phere is changed to a slight positive pressure such as 2 psig of inert gas such aa argon or helium. Molten sodium is 2Q added to the stirred charge in an amount corresponding to between 95~ and lQ5% of the stoichiometric amount needed for the reduction reaction. The continuing of stirring coats the particles of charge ~ith molten sodium so as to essentially disperse at least 9Q~ of the liquid sodium uniformly through the particulate charge as coating and coating matrix. Stirring is then stopped and heat applied with an external furnace. A't around 300C the reaction starts and quickly permeates the charge due to the high thermal conductance from the imbued sodium. This exothermic reaction itself is very rapid and 3Q results in ai~ea~y adiabatic rise in temperature to between 600C and lQ00C depending on the degree of NaCl dilution.
External heating is maintained during the exothermic reaction 10386S~
to attempt to have the reactor wall temperature follow the time temperature profile of the charge. This attenuates the degree of solidification and remelting which might otherwise occur in the course of temperature rise. Temperature of the charge is stabilized in the range of 700-1100C, for ~.5 to 2 hours.
During the;~ to the melting point of the salt ~i~ut~e;(over the range 6Q0-900C depending on dilution~ and d~ring the actual melting process, the reduction reaction initially produces small nucleating particles uniformly dispersed throughout the charge.
These particles grow laterally to coalesce with adjacent nucleated particles to form a skeleton metal structure through-out the main mass of slight coherence, ~hich is sufficient to prevent collapse of the metal values into distinct layers, as occurs in stireed reactor, prior art,pro-ce~sses. Durin~ the temperature rise period, over 90% of the tantalum values in the salt charge are reduced therefrom and collected in the porous skeletal metal structure. During the high temperature hold some restructuring of the skel~onooccnrs by mass transfer through the liquid phase to remove ultrafine particles and remaining tantalum values in the salt source are reduced there-from and added to the skeletal metal structure which remains porous.
After holding at the elevated temperature, unreacted sodium is boiled off and condensed in a separate storage zone, the reactor vessel is cooled to ambient temperature and then opened~add the solidified reacted mass intermediate product is chipped out and leached according to prior art procedures known per se to produce powder or other particulate form of the reduced metal.
The resultant tantalum powder product is characterized by a very lo~ Scott Bult Density rS.B.D.], low oxygen, and coarse particle size, the degrees of which are dependent on dilution and hold temperature and time, but preferably in the range of 103~65Z
20--30 gms/in3 Cl.2-1.8 gm/cc2 S.B.D; oxygen content of 200 tp 2000 parts per million; and a distribution with 60-~90% of the total weight of product in the size range of -40 Mesh and +5 Microns, 1-2% of -5 Microns fine particles and the balance of +40 Mesh particles. The -325 Mesh +5 Micron portion of the yield ranges from 25-35%/ and has a low Scott Bulk Density which tends to govern the Scott Bulk Density of the yield as a whole.
Various particle size cuts of the reduction product could have Fisher Average Particle Diameters ~in microns) as follows:
Side Cut FAPD
A -40M +5 micron -- 3.7 microns B -lOOM +5 micron -- 3.2 microns C --325M +5 micron -- 2.4 microns Metal contaminants derived from the vessel are low because the present process does not require stirring a high temperature molten mass in the reaction vessel.
Crush strengths for the A & B fractions described above, when formed into compacts with a green density of 7.0 grams per cubic centimeter by binderless pressing, are over 500 psi and the crush strength of size cut C similarly formed into a compact is over 300 psi. All of these size fractions can be formed into compacts with binderless pressing having a green density of 5.0 gm/cc ~hich is resistant to 100 psi crush-ing pressure applied to a 1.8 gram cylindrical form compact of 0.25 inch diameter. Flowability characteristics, as determined through Angle of Repose measurements, and specific capacitance by weight and volume of these products approximate the flow-ability and specific capacitance properties of the commercial SGVR product cited above.
As used herein, the following terms have the following meanings and/or standards.
Mesh size of particles is U.S. standard (rather than Tyler standard2 in accordance with specification STP-447A of the ~ r`

American Society for Testlng Material ~ASTN]. In this speci-fication 325 Mesh corresponds to 44 microns. Scott Bulk Density is expressed in grams per cubic inch and measured in accordance - with ASTM B329-5BT. Angle of Repose is defined in the Dictionary of Geological Terms (American Geological Institute, Doubleday, 196~) as corresponding to the angle between a horizontal plane through a cone vertex and a cone side and is taken with respect to sample tantalum powders poured through a Carney flowmeter funnel, with an agitated tantalum wire arranged centrally in the funnel as a stirrer, into a cup. The pouring is continued until the powder overflows to form a cone. B.E.T. surface area measurement in square cm. per gram is taken according to a modification of the procedure described in the article by Brunauer, Emmet and Teller, 60 Jl. American Chem. Soc'y 309-19 (1938) and Fisher porosity measurements and calculations of FAPD
(diameter in microns) and FPR (%) are in accordance with the article at 12 Jl. Ind'l. Eng'g. Chem. (Anal. Ed'n) 479-482 (1940).
According to its broadest aspect, the present invention provides a process for making powders of a metal selected from the class consisting of tantalum and columbium from metal salt comprising chemically reducing a particulate charge of a halide salt, a majority of particles of which are minus 10 mesh of said metal with a reducing agent in an exothermic reduction reaction, utilizing a salt with a liquidus line above the initiation temperature for said exothermic reaction and a reducing agent selected from the class consisting of sodium, potassium, lithium, magnesium, aluminum and mixtures, alloys, compounds and amalgams thereof with a melting temperature below said salt liquidus, coating said salt with molten reducing agents, heating the coated particles to initiate said exothermic reaction and forming porous valve metal skeleton during a period of essentially adiabatic temperature rise of the exothermic reduction process, the - - ~.03~6SZ ., .
skeleton having nucleating valve metal sites dispersed throughout the charge, the skeleton being formed to a coherent state while the salt charge temperature is below the liquidus temperature level of the salt charge.
Numerous other objects, features and advantages and uses of the present invention will be apparent to those skilled in the art from the foregoing general description and from the following specific description describing best known modes of practicing and using the invention, and some but not all of the variations thereof, with reference to the accompanying drawings and table inserts in which:
Brief Description of the Drawings and Inserts FIG. 1 is a cross-section view of a reactor containing a full charge for the beginning of processing in accordance with the present invention;
FIG. 2 is a cross-section view of a reactor according to a second embodiment with separate coating and reacting compartments;

1038~5Z
FIG. 3 is a temperature-time plot showing the tempera-ture changes of reactor walls and reduction charge according to a process embodiment hereof; and FIG. 4 is a plot of specific capacitance values of anodes formed as described in the Examples hereof, compared with SGVR data.
Detailed Description of Preferred Embodiments of the Invention Referring now to FIG. 1 there is sho~n a reactor vessel 10 which i5 of the general type de~crihed in the above cited patent of Hellier et al, ~ith the exception that the side ribs thereof are removed, the stirrer blades 40 are modified to be of low height and afford high shear and that the power of the driving motor is stepped up to allo~ the stirrer to work solid particles in lieu of the molten mass stirring requireme~t of the prior device. The vessel has a cover 14. The blades are angled with respect to a diametral vertical plane through the vessel, and all the blades have an aggregate height which occupies a lower half of the vessel uhere the salt charge is handled. After charge stirring, the blade assembly can be left in the charge or, preferably, lifted out of the charge to occupy the upper half of the vessel and be clear of the charge during subsequent heating thereof and reduction reaction therein. The vessel is in a furnace 16 with heaters 18 and an insulation mantle 17. Sodium is fed from a supply 2a in molten form through port 21. A reflux condenser 30, e~acuation line 28, vacuum pump 32, inert gas (e.g. argon~ source 34, and valve system 36 are provided for gas handling at various stages of the process.
During sodium feed pressure is held at 2 psig.
At the end of a cycle, a separate portion of the reflux condenser 30 can be used to condense boiled off unreacted sodium into an auxiliary storage tank 35.
A pressure relief valve 36 in the form of a mercury filledbbarometric leg, or the like, is provided for venting argon overpressure through ~u~bling without breaking the hermetic seal of the system during heating.
FIG. 2 shows a second em~odiment of the reactor with separate coating and reactmon sec~ions of the vessel. An upper hopper 101 with a motor-driven stirrer paddle 14a therein has a salt charge 111 therein and can utilize a vacuum source 132 and inert gas source 134, via piping 128, and a sodium feed source la9. The upper vessel has a heater la8 for heating it to a maximum of 25QC.
Particles of the salt charge are dried and coated.
Then the coated particles are passed through valve 102 into reaction chamber lOa which is Cinifially or subsequently) sur-rounded by heaters 118 and insul~ting ~alls 116. The reaction charge 112 in ves~el lQQ can be agitated if necessary for a short time b~fore heat-up by rotating vessel 100 on a turn-table before inserting into a furnace jacket 116/118. Thevvessel 100 is provided with radiant heat shields and at the end of a reaction, sodium vapor c~n be pumped out by vacuum pump 132 using the same gas handling apparatus as in the FIG. 1 embodi-ment. A reflux condenser 130 conde~ses the sodium for storage in a separate vessel (not shounl. The central baffles 103 can be moved aside ~or salt charge filling. Annular baffles 104 complete the cover array protecting cover 114. Vessel 101 can be made of stainless steel and vessel laO should be made of Inconel ~
FIG. 3 is a temperature-time plot of typical reduction run conditions to be prescribed in accordance with the present invention. The solid line curve indicates charge temperature and 3a the dashed line curve, reactor wall temperature. At point A the charge is put into the reactor and stirring and heating begun to thoroughly dry the aharge. At B-C, temperature is held at about Registered Trademark 100-150C while stirring continues to dry the charge. The stirrer is off from C to D, a hold period varia~le from zero to any convenient time. Molten sodium is added to the charge at D and mixed into the charge. The addition and mixing is carried out slowly and co~tinued from point D to point E when all the sodium has been added. Stirring is carried out from F to G and preferably continued for at least mo minu~e~after the last sodium addition. Reactor heating is increased after G and approximately, at point H, the exothermic reduction 1~ reaction is initiated, and charge temperature rises ~a~idly.
Charge temperature rises rapidly and passes through the charge solidus and liquidus temperature ranges, which for various possible charges are indicated by S and L, respectively. Power put into the reactor wall heaters is incEeased at the maximu~
rate to limit temperature gradient from the charge center to the reactor ~all. The molten sodium is highly conductive and trahsfers heat to th~ walls. The exothermically driven rise of charga temperature carries charge temperature up to about point X and continuing charge temperature rise is caused by heat transfer thereto from the external~y heated reactor walls.
Reactor and charge temperatures nre stabilized between I and J
and held. Then the reactor is cooled between J and K to ambient temperature.
~ hile the exact mechanisms of particle formation are not entirely understood, it is believed that 90% of the tantalum values are reduced from double salt between H and I, and probably below S, and that between I and J, the balance of tantalum values are reduced. From I to J, fine tantalum particles are re-dissolved in the molten salt bath and reprecipitated as exten-sions of the skeletal structure of tantalum in the bath made upof linked coarser, highly structured particles.

103E~65 Example 1 635 grams of Na were fused in a 6-inch diameter Inconel reactor vessel located in a laboratory glove ~ox. The vessel was then filled withaa dried particulate salt mixture com-prising K2TaF7 C2167 gmi of -10 Mesh size and particulate ~aCl (646 gm) of -10 Mesh which had been intimately premixed outside the vessel by hand stirring. The salt mixture was added slowly to the molten sodium with stirring. The Na/sa~t mixture tempera-ture ~as maintained between lOQ and 150C during mixing. After the salt particles were thoroughly coated with sodium, the vessel was sealed and transferred to a furnace. The charge was heated to about 30QC at which temperature the exothermic reaction was initiated.
The temperature of the reaction products rapidly rose to 900C, as measured by an inserted thermocouple. The reactor walls were simultaneously being rapidly heated by the furnace, the objective being to have the wall temperature not lag the charge temperature or to minimize such lag. The charge temp-erature was sta~ilized in the range of 950-1050C, and held

2~ for one hour. The reactor was cooled to room temperature in amhient air, opened and the reaction products were crushed, leached and classified to produce tantalum powder. The powder yields of this and a similar experiment [lumped to provide testing quantities] were classified and tested in various size fractions. The corresponding porosity and Scott Bulk Density of ~uch powders are~given in Table 1. The fractions are identified as (1~, (2) and (3~. Powder samples of the various fractions were pressed into 1/4 inch diameter 1.8 gram compacts of 6.0 and 7.0 gram/cc green density which had crush strengths as indicated in Table 1.
Fractions (1~ and C21 had the capability of forming 7.0 gram/cm3 green density compacts ~ith crush strengths of 500 psi. The 6.Q gram green density compacts of the various fractions ~ -- 15 --were sintered at 160QC, 1700C, 180QC, l~QQC for 8a minutes.
The resultant anodes were formed~to lOQ ~olts and wet tested in accordance with the procedures described in Example 2 below.

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_ lQ3B652 The specific capacitances(microfarad - volts per gram~ of the various anodes identified by their ~prticle fraction numbers ~l~
(2) and (3) are plotted in FIG. 4 for the various sinter tempera-tures involved overlying ànline marked S~VR-4 which indicates corresponding results for the commercial product SGVR-4 when tested under similar condîtions. Shrinkages tvolume percentages) of the ~intered compacts at 1600C and 190QC are given in Table l.
Example 2 A reactor vessel, as shown in FIG. 1, was charged with lQ8.4 lb. of K2TaF7, 48.4 lb. of NaCl and heated to the point that the reactor walls were at 350C temperature and the~charge temperature was about 200-300C. The charge was under vacuum (less than 500 microns pressurel during the heating. The con-tent~ were stirred during this heating. This charge tempera-ture range was held for 1 hour ~ith stirring. Then the vessel was back-filled ~ith argon to a pressure of 10 mm. Hg. above atmospheric pressure. Then, while holding temperature and con-tinuing stirring, 10 lh. of molten sodium were added over the course of 5 minutes. This mixture ~as stirred for five more minutes. 20.8 lb. of additional molten Na were then added over 10 minutes ~ith continued stirring. The stirrer was turned off 2 minutes later. The furnace and.charge were rapidly heated to 950C where the charge temperature was thus held for 1.0 hours.
The vessel was then cooled by ambient air cooling for a day.
The vessel was then open~d and the solid reduction products com-prising K2TaF7, NaCl, KCl, NaF, Ta were chipped out, milled and leached in accordance with conventional practice of the art.
A 94% yield of the theoretical weight of tantalum was obtained.
The tantalum powder produced from this metal had the size ranges given in Table 2A below. Its -40M +5~fraction had the Fisher porosity ratings and Scott Bulk Density indicated in Table 2B and the chemical~Lmp ~ t~les listed in Table 2C.
The powder fractLon was pressed to 6.0 gm/cc. gyeen density 1.6 gram anodes of 1/4 inch diameter and sintered at 1650C and formed to 100 volts in 0.1% H3~04 solution at 92C. The anodes were wet tested in 30% ~y vol.~ ~2SO4 at 70V. for D.C. leakage and at 0.5V.A.C. tl20 cps) for capacitance and dissipation.
The measured and calculated electrical c~aracteristics thereof are given in Table 2B.

Powder Fraction Yield C~eight percent) for Example 2 Powder Fraction ~eight Percent +12M .20 -12M+40M 2.8 -40M+6QM 2.7 -60M+lOaM 5.2 -laOM+325M 32.4 -325M+5~ 56.2 -5~+0~ 0.5 ao Physical and Electrical Properties of -40M+5~Fraction (96.5w/o) for Example 2 Powder Anodes FAPDPR SBD L L/C C DF ESR
~(%~ (g/cc) (~a/g~a/~f~ ~f/g) (%) (ohm)

4.778.8 3916 16.4.22 74.7 11.2 1.99 Chemical Analysis of -40M+5~ Fraction for Example 2 Element: Al Ca Cr Cu Fe Mg Mn Ni Si 2 N2 ppm: <10 75 65 ~1 55 7 <1 29 <10 886 42 3~ Example 3 A reactor vessel, as shown in FIG. 1, was charged with 108.4 lb. of K2TaF7, 48.4 lb. of NaCl, mixed by stirring and then heated to about 100C while vacuum pumping on the vessel and without stirring during the heat-up. Then the vessel was back-filled ~ith argon to a pressure of lQ mm. Hg. above atmos-pheric pressure. Then 10 lb. of molten sodium was added over the course of 2 minutes ~ith the charge at about 100C. Then the stirrer was initiated ~hile adding an additional 20.8 lb.
sodium over the course of 3 minutes. Stirring was continued for

5 more minute~ after sodium addition. Then the stirrer was turned off. The furnace was then set for 95QC,~t~ increase the temperature of the reaction mixture. A rapid rise in temperature to 5~QC, indicative of an exothermic reaction, occurred when the reaction mass ~eached 270C; as measured by a thermocouple placed in the reaction mass and adjacent to the reactor wall. Charge temperature was brought to 950C and held for 1.O hours. A 92% yield of the theoretical weight of tanta-lum uas obtained.
The tantalum powder produced from this metal had the size ranges given in Table 3A, po~der physical properties given in Table 3B and impurity levels given in Table 3C, and (when pressed into anodes and processed as in Example 2~ the electri-cal properties given in Table 3B helou.

Powder Fraction Yield (weight percent~ for Example 3 Powder Fraction~eight ~ercent +12M .2a -12~+40M lQ.9 -40M+60M 1~.5 -60M+lOOM 11.9 IQQM+325M 27.7 . .
-325M+5~ 37-3 -5~ 1.5 Physical and Electrical Properties of -40M+5~1Fraction t88.9w/o~
for Exam~le 3 Po~derAnodes _ FAPD FPR SBD~J L L/C C DF ESR
~k~ C%~ (g/cc~Cua/g~ (ua~fl (uf/g) (~) (ohm) 3.0 80 28.314.6 .20 73.1 11.2 2.03 Chemical Analysis for -40M+5~UFraction for Example 3 Element:Al Ca Cr Cu Fe Mg Mn Ni Si 2 N2 H2 C
ppm~10 80 11 5 18 5 < 1 25 20 3172 50 323 147 Example 4-i A number of reaction initiation and power cut off runs were made ~ith proce~sing as in Examp~e 1, save t~at external heating was cutloff upon initiation of the exothermic reaction (as indicated by a temperature rise rate of 30C. per/10 seconds, or fasterl. In adding NaCl and K2TaF7 to the molten-sodium-containing crucible, the NaCl ~as added first and stirred in and K2TaF7 was added second and s~irred in. Both NaCl and K2TaF7 were prehetted to over 100C before adding.
These runs were at various dilution weight ratios of NaCl:K2TaF7 and reached respective initiation temperatures (Ti), maximum temperatures tTml and yielded, after leaching their reduction products, total tantalum yields ~YT, given in weight per cent in relation to theoretical maximum yield] and yields of minus 40 Mesh, plus 5 micron powder ~Y40/s] as shown in Table 4A. In each case, about 10-25 w/o of yield was in the minus 5 micron size range.
A further series of similar runs was made without cutting off furnace power and with elevated temperature holds (hold temperatures TH for times t) as shown in Table 4B giving YT and ~Y40/s] as shown.
The runs ~ith high temperature hold increased -40 mesh + 5 micron yield compared to the runs without holds.

-~03&652 (w/o ~
Dilution Ratio Ti~C.~ TmtC.l YT~W/0) Y40/5(W/~) .298 335+35gO0+10 96.0 72.9 .597 365+20825+20 93.4 66.2 113~2 31~+30 725+5 93.7 66.7 ._ TABLE 4B - ExANæLE 4 tw/o~
10Dilution Ratio TH ~Ct~minl X~ Y40/5 .298 1050 30 97.8 88.3 .597 1050 30 96.6 77.2 1.342 1050 30 97.0 73.2 .298 1050 60 97.2 88.4 .547 losa 6a 97.3 77.9 1.342 1050 60 97.4 73.1 .298 1050 240 98.3 90.0 .547 lQ50 240 98.6 78.1 201.342 1050 240 96.8 67.2 It is evident that those skilled in the art may now make numerous uses and modifications of, and departures from the specific embodiments described ~erein without departing from the invention concepts. Consequently, the invention is to be construed a~ embracing each and every novel feature and novel combination of features present in, or possessed by the apparatus and techniques herein disclosed and limited sole-ly by the scope and spirit of the appended claims.

3a

Claims (22)

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:

1. A process for making powders of a metal selected from the class consisting of tantalum and columbium from metal salt comprising chemically reducing a particulate charge of a halide salt, a majority of particles of which are minus 10 mesh of said metal with a reducing agent in an exothermic reduction reaction, utilizing a salt with a liquidus line above the initiation temperature for said exothermic reaction and a reducing agent selected from the class consisting of sodium, potassium, lithium, magnesium, aluminum and mixtures, alloys, compounds and amalgams thereof with a melting temperature below said salt liquidus, coating said salt with molten reducing agents, heating the coated particles to initiate said exothermic reaction and forming porous valve metal skeleton during a period of essentially adiabatic temperature rise of the exothermic reduction process, the skeleton having nucleating valve metal sites dispersed throughout the charge, the skeleton being formed to a coherent state while the salt charge temperature is below the liquidus temperature level of the salt charge.

2. Process in accordance with claim 1 wherein the salt charge is intimately premixed with at least part of the total amount of reducing agent to be used prior to initiating said exothermic reaction and the said reducing agent coats the salt particles.

3. Process in accordance with claim 2 wherein the salt charge is intimately mixed with all the reducing agents prior to initiating the exothermic reaction.

4. Process in accordance with claim 2 wherein, the reducing agent and charge are mixed at a temperature above the exothermic reaction temperature.

5. Process in accordance with claim 2 wherein, the average particle size of said coated particles is minus ten Mesh.

6. The process of claim 1 further comprising adding an inert diluent salt to the charge.

7. Process in accordance with claim 6 wherein, said diluent salt is also coated with reducing agent, the total weight of reducing agent coating both said salt species being within the range of 90-105% of stoichiometric quantity for reducing all the metal contained in the valve metal salt source.

8. Process in accordance with claim 1 wherein, the said valve metal containing salt is potassium fluotantalate and the reducing agent is sodium.

9. Process in accordance with claim 1 wherein, the charge/reduction-agent mass is further heated above its solidus.

10. Process in accordance with claim 9 wherein, the charge/reduction-agent mass is further heated above its liquidus.

11. Process in accordance with claim 10 wherein, the reaction conditions are controlled to maintain the skeletal structure intact with settling or breakage-thereof limited throughout the processing to produce a composite of a metal skeleton matrix with interconnected pores filled at least in part with frozen salt reduction products.

12. Process in accordance with claim 9 wherein, said further heating includes a hold of temperature for a time and at a level effective to dissolve fine metal particles in molten salt within the skeleton to transport tantalum values to nucleating sites in the skeleton and recrystallized tantalum at said sites.

13. Process in accordance with claim 12 wherein, the said valve metal salt is potassium fluotantalate and the reducing agent is sodium, the said further heating includes a hold of temperature in the range of 700-1100°C for at least 0.5 hours.

14. Process in accordance with claim 1 wherein, reducing agent in excess of 100% of stoichiometric quantity for the complete reduction of valve metal values in the charge is used and remaining reducing agent is boiled off at completion of the process.

15. Process in accordance with claim 1 wherein, the salt charge comprises RxTaFx+5 where R is an alkali metal and x is 0 to 3.

16. Process for making capacitor grade tantalum powder from potassium fluotantalate in accordance with claim 15 comprising the steps of forming a dried charge of said fluotantalate in a mixing vessel, adding a reducing agent selected from the class consist-ing of sodium, potassium, and alloys thereof, to said vessel and agitating the vessel contents at a temperature between the melting point of the reducing agent and 300°C therein, heating the mixture in a reaction vessel above 300°C.

17. Process in accordance with claim 16 wherein, the reducing agent is sodium.

18. Process in accordance with claim 16 wherein, said mixing vessel and reaction vessels are different vessels.

19. Process in accordance with claim 16 wherein, a diluent selected from the class consisting of sodium chloride, potassium chloride, sodium fluoride, potassium fluoride and mixtures thereof salt is added to said charge.

20. Process in accordance with claim 19 wherein, the quantity of diluent is such that the weight ratio of diluent to potassium fluotantalate is no greater than 2.0:1.

21. Process in accordance with claim 20 wherein, said ratio is no greater than 0.5:1Ø

22. Process in accordance with claim 19 wherein, said diluent is in the form of -10 Mesh average size particles and all the said diluent and fluotantalate salt particles are coated with sodium, the total quantity of all sodium in the reactor vessel being within 90-105% of stoichiometric quantity for freeing all tantalum in said fluotantalate salt in the reactor vessel.