Abstract
Microspheres of pure aluminum and Al-7wt%Si alloy were successfully fabricated by ultrasonic irradiating the molten NaCl-KCl-Al and NaCl-KCl-(Al-Si) systems respectively. Ultrasonic cavitation is mainly responsible for the formation of metal microspheres. A minimum diameter of ∼15 μm of the microspheres can be achieved. The final morphology and size of the metal spheres are determined by both the irradiation process and the subsequent solidification condition. Under the protection of molten salt, this process provides a novel way to fabricate spherical metal powder that has relative high activity and melting point.
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