Patent ID: 7431750

Claim:
A method of fabricating a metal powder, comprising the steps of: using metal wire as feedstock; using two wires as electrodes; performing a twin-wire electric arc process to melt the wire tips to form a metal melt, and simultaneously, breaking the metal melt into melt droplets by an atomizing device, wherein an operating temperature of the electric arc process is controlled between melting point and boiling point of the wire, to avoid vaporization of the melt droplets; and performing a quenching process to cool the melt droplets by means of a cooling medium, wherein the quenching process is performed by a cyclonic device immediately adjacent to the wire tips such that each melt droplet is rapidly solidified to form the metal powder, wherein the metal powder is spherical, has an average diameter of 1˜500 μm, and comprises a plurality of nano-grains.