Patents Examined by Leon Nigohosian, Jr.
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Patent number: 5035957Abstract: Disclosed are coated metal articles having protective coatings which are applied to substrate metals by coating the metal surface, e.g. by dipping the substrate metal in a molten alloy of the coating metals, and then exposing the coating at an elevated temperature to an atmosphere containing a reactive gaseous species which forms an oxide, a nitride, a carbide, a boride or a silicide. The coating material is a mixture of the metals M.sub.1 and M.sub.2, M.sub.1 being zirconium and/or titanium, which forms a stable oxide, nitride, carbide, boride or silicide under the prevailing conditions. The metal M.sub.2 does not form a stable oxide, nitride, carbide, boride or silicide. M.sub.2 serves to bond the oxide, etc. of M.sub.1 to the substrate metal. Mixtures of M.sub.1 and/or M.sub.2 metals may be employed. Eutectic alloys of M.sub.1 and M.sub.2 which melt substantially lower than the melting point of the substrate metal are preferred.Type: GrantFiled: February 23, 1990Date of Patent: July 30, 1991Assignee: SRI InternationalInventors: Robert W. Bartlett, Paul J. Jorgensen, Ibrahim M. Allam, David J. Rowcliffe
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Patent number: 5033939Abstract: Shaped parts are formed from a powder having the desired chemistry of the finished part by mixing the powder with a thermosetting condensation resin that acts as a binder. The resin may be partially catalyzed, or additives or surfactants added to improve rheology, mixing properties, or processing time. Upon heating, the inherently low viscosity mixture will solidify without pressure being applied to it. A rigid form is produced which is capable of being ejected from a mold. Pre-sintered shapes or parts are made by injection molding, by using semi-permanent tooling, or by prototyping. Binder removal is accomplished by thermal means and without a separate debinding step, despite the known heat resistance of thermosetting resins. Removal is due to the film forming characteristic of the binder leaving open the part's pores, by providing oxidizing conditions within the part's pores as the part is heated, and by insuring that the evolving resin vapor diffuses through the pores by heating the part in a vacuum.Type: GrantFiled: October 29, 1990Date of Patent: July 23, 1991Assignee: Megamet IndustriesInventor: Gregory M. Brasel
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Patent number: 5034053Abstract: A hard sintered compact for tools is a sintered compact obtained by super-high pressure sintering of 45-75% by vol. of cubic boron nitride powder and the remaining proportion of binder powder. The binder includes 5-25% by wt. of Al and the remaining proportion of at least one species of compounds represented by (Hf.sub.1-z M.sub.z) C, where M denotes elements of IVa, Va and VIa groups in a periodic table except for Hf, and 0.ltoreq.z.ltoreq.0.3 is satisfied. Because of this composition, improvements are made in strength, wear resistance and heat resisting property of the binder, and a hard sintered compact for tools having excellent strength and excellent wear resistance can be obtained.Type: GrantFiled: November 21, 1990Date of Patent: July 23, 1991Assignee: Sumitomo Electric Industries, Ltd.Inventors: Tetsuo Nakai, Mitsuhiro Goto
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Patent number: 5024902Abstract: A fiber-reinforced metal comprising glass fibers and a matrix metal, said glass fibers having a nitrogen content of at least 8 atomic %. The fiber-reinforced metal has a high tensile strength and elasticity.Type: GrantFiled: June 15, 1990Date of Patent: June 18, 1991Assignee: Shimadzu CorporationInventors: Katsuaki Suganuma, Hiroyuki Fujii, Hiroyoshi Minakuchi, Katsuhiko Kada, Haruo Osafune, Kuniaki Kanamaru
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Patent number: 5022919Abstract: A complex boride cermet having high strength and high toughness, which comprises a hard phase composed mainly of a boride of (Mo.sub.1-x W.sub.x).sub.2 NiB.sub.2 formed by substituting a part of Mo of Mo.sub.2 NiB.sub.2 by W, and a matrix alloy phase composed mainly of Ni and containing Mo, and a complex boride cermet comprising a hard phase composed mainly of Mo.sub.2 NiB.sub.2 or (Mo.sub.1-x W.sub.x).sub.2 NiB.sub.2 and a matrix of an alloy phase composed mainly of Ni and containing Mo, which is characterized in that carbon or/and nitrogen, and optionally at least one metal selected from the metals of Groups 4B and 5B and Cr, are incorporated to further improve the strength and toughness. Such complex boride cermet has high strength and high toughness and maintains such properties even at elevated temperatures of from 600.degree. to 900.degree. C.Type: GrantFiled: May 16, 1989Date of Patent: June 11, 1991Assignee: Asahi Glass Company Ltd.Inventors: Yasuo Shinozaki, Noritoshi Horie, Kazuo Hamashima, Makoto Imakawa
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Patent number: 5022803Abstract: A method for joining carbon-carbon structural elements together using a carbon-carbon pin type fastener for transfer of shear loads. A coating of powdered metal which undergoes a large expansion when reacted in the presence of a gas is used to coat the outer surfaces of a pin which extends through the structural elements to be joined, with the powdered metal coating between the body of the pin and the surfaces of the structural elements through which the pin passes. After installation through the structural elements the pin is heated in an oxygen atmosphere causing the powdered metal coating to expand up to 100% from its unheated volume binding the pin to the structural elements. A fluted or scalloped edge on the pin increases the surface area of the pin increasing its friction holding force.Type: GrantFiled: May 25, 1990Date of Patent: June 11, 1991Assignee: General Dynamics Corporation, Convair DivisionInventor: Kurt W. Swanson
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Patent number: 5022918Abstract: A heat-resistant aluminum alloy sinter comprises 5 to 12% by weight of Cr, less than 10% by weight of at least one selected from the group consisting of Co, Ni, Mn, Zr, V, Ce, Fe, Ti, Mo, La, Nb, Y and Hf, and the balance of Al containing unavoidable impurities. A silicon carbide fiber is included for reinforcing the sinter in a fiber volume fraction range of 2 to 30%.Type: GrantFiled: December 1, 1988Date of Patent: June 11, 1991Assignee: Honda Giken Kogyo Kabushiki KaishaInventors: Seiichi Koike, Hiroyuki Horimura, Masao Ichikawa, Noriaki Matsumoto
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Patent number: 5013611Abstract: A camshaft having a tubular steel shaft and a sintered cam piece joined to the shaft. The sintered cam piece has iron tetroxide film at its surface. The camshaft is produced by assembling a powder compact to the steel shaft to provide a camshaft assembly, sintering the assembly to provide an integral assembly, correcting bending to the assembly, annealing the assembly, grinding the cam piece and effecting vaporization treatment to the assembly at a temperature lower than the annealing temperature.Type: GrantFiled: January 18, 1990Date of Patent: May 7, 1991Assignee: Nippon Piston Ring Co., Ltd.Inventors: Yasuo Suzuki, Shunsuke Takeguchi
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Patent number: 5011529Abstract: A cured sintered porous metal structure comprising aluminum and aluminum alloys is presented comprising an aluminum oxide durable surface integral to the structure. The surface layer is enhanced in aluminum while the underlying structure is thereby depleted in aluminum. The structure exhibits surface and interfacial durability.Type: GrantFiled: March 14, 1989Date of Patent: April 30, 1991Assignee: Corning IncorporatedInventors: Kathryn E. Hogue, Srinivas H. Swaroop, Raja R. Wusirika
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Patent number: 5009842Abstract: High strength steel parts or articles are made from a powder alloy by compacting the powder into a preform, sintering the preform in a sintering furnace or the like under a highly-reducing atmosphere and at a temperature of at least 1150.degree. C., cooling the preform, preheating the sintered preform in a highly-reducing atmosphere, such as an inert gas-based atmosphere containing hydrogen or pure hydrogen, to a temperature of at least 1000.degree. C. and transferring the preheated preform to an impact forging device and impacting the preform at a peak averaging forging pressure of at least about 1000 MPa to obtain a forged part or article. The time period between removal of the preheated preform from the preheater and the first forging impact is no more than about 8 seconds. The sintering and preheating steps can be combined with the sintered preform being cooled to the preheating temperature in the sintering furnace and transferred directly from the sintering furnace to the impact forging device.Type: GrantFiled: June 8, 1990Date of Patent: April 23, 1991Assignee: Board of Control of Michigan Technological UniversityInventors: Alfred A. Hendrickson, Darrell W. Smith
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Patent number: 5009841Abstract: A process for dewaxing injection molded metal pieces consisting of a metal/binder mixture, wherein a metal oxide is added to the metal/binder mixture.Type: GrantFiled: April 12, 1990Date of Patent: April 23, 1991Assignee: BASF AktiengesellschaftInventors: Martin Bloemacher, Reinhold Schlegel, Dieter Weinand
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Patent number: 5009705Abstract: A microdrill bit is made of a tungsten carbide based cemented carbide which contains a binder phase of 6% by weight to 14% by weight of a cobalt alloy and a hard dispersed phase of balance tungsten carbide. The cobalt alloy contains cobalt, chromium, vanadium and tungsten and has weight ratios so as to satisfy the relationships of 0.04.ltoreq.(c+d)/(a+b+c+d).ltoreq.0.10 and 0.50.ltoreq.c/(c+d).ltoreq.0.95, where a, b, c and d denote weight ratios of tungsten, cobalt, chromium and vanadium, respectively. The drill bit is formed so as to have a Rockwell A scale hardness of 92.0 to 94.0.Type: GrantFiled: December 28, 1989Date of Patent: April 23, 1991Assignee: Mitsubishi Metal CorporationInventors: Hironori Yoshimura, Inada Shyogo
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Patent number: 5006164Abstract: A starting material for injection molding of a metal powder including from 38 to 46% by volume of an organic binder and the balance of spherical iron powder with an average particle size from 2 to 6 .mu.m, which provides a sintered part having a density ratio of higher than 94%, by conducting injection molding, debinding and sintering in a non-oxidizing atmosphere at a temperature lower than the A.sub.3 transformation point of carbon steel.Type: GrantFiled: February 26, 1990Date of Patent: April 9, 1991Assignee: Kawasaki Steel CorporationInventor: Yoshisato Kiyota
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Patent number: 5004498Abstract: A dispersion strengthened copper alloy containing a copper matrix, and dispersion particles dispersed in the copper matrix within a range of 0.5 to 6 vol %. In this alloy, an average diameter of a matrix region where the dispersion particles are not present is 0.3 .mu.m or less, and the total amount of solid solution elements contained in the copper matrix is determined such that, when this amount of the solid solution elements is added to pure copper, the electric conductivity of the matrix is lowered by 5% IACS or less.Type: GrantFiled: October 10, 1989Date of Patent: April 2, 1991Assignee: Kabushiki Kaisha ToshibaInventors: Keizo Shimamura, Kagetaka Amano, Tatsuyoshi Aisaka, Satoshi Hanai, Kohsoku Nagata
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Patent number: 5004580Abstract: A method and apparatus for packing a permanent magnet powder wherein a solenoid coil is provided near the opening of a cylindrical molding space of a mold in such a manner that the direction of the central axis of the solenoid coil substantially coincides with the central axis of the molding space, and an alternating current magnetic field is applied, so that a permanent magnet powder above the opening is packed into the molding space. A magnetic pole may be provided in the center of the solenoid coil. The method of the present invention can be applied to not only a powder for a sintered magnet but also a powder for a bonded magnet.Type: GrantFiled: April 13, 1990Date of Patent: April 2, 1991Assignee: Fuji Electrochemical Co. Ltd.Inventors: Yoshio Matsuo, Hirofumi Nakano, Masakuni Kamiya, Kezuo Matsui
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Patent number: 4999157Abstract: A method for molding powders comprises the steps of forming a mold support having at least an opening and a cavity, forming a film of latex on inner surfaces of the mold support by pouring the latex from the opening into the cavity of the mold support and discharging a substantial portion of the latex poured into the cavity, forming a thin-wall resilient mold inside the mold support by drying the film of latex formed, charging powders as materials for a compact from the opening into the thin-wall resilient mold, exhausting air out of the thin-wall resilient mold filled up with the powders through the opening and sealing the opening of the thin-wall resilient mold, separating the thin-wall resilient mold filled up with the powders from the mold support, and subjecting the thin-wall resilient mold to a cold isostatic press method treatment.Type: GrantFiled: March 5, 1990Date of Patent: March 12, 1991Assignee: NKK CorporationInventors: Hiroaki Nishio, Akira Kato, Sazo Nakamura
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Patent number: 4996022Abstract: A sintered body is produced by a process comprising the steps of mixing one or more metal powder particles with an organic binder, injection-molding the mixture to form a green body of a predetermined shape, removing the binder from the green body to form a porous body substantially made of the metal powder, and heating the porous body to a sintering temperature and holding it at that temperature to produce a sintered body, in which process the binder is removed through the sequence of the following steps: preheating the green body in an inert gas atmosphere in a temperature range that creates open pores in it; placing the green body, in which open pores have started to form, in a hydrogen gas atmosphere optionally mixed with an inert gas; holding the green body in a temperature range where the metal powder is not carburized and where the open pores will be maintained, so that the greater part of the binder is removed to form a porous body that is substantially made of the metal powder alone; and further holdType: GrantFiled: July 10, 1990Date of Patent: February 26, 1991Assignees: Juki Corporation, Nippon Piston Ring Co., Ltd.Inventors: Norikazu Shindo, Tomoyuki Sekine, Yoshikatsu Nakamura, Takashi Kawamoto
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Patent number: 4992234Abstract: An improved method is proposed for the preparation of a sintered permanent magnet of a rare earth-iron-boron alloy having remarkably improved magnetic properties and stability by the powder metallurgical process. The scope of the inventive method consists in the particle size classification of the alloy powder for compression molding into a powder compact to be sintered, by which particles having a finer particle diameter and, preferably, a coarser particle diameter than the respective critical values are removed so as to effectively prevent oxidation of the too fine particles and improving the magnetic orientation of the particles as well as the sintering behavior of the particles.Type: GrantFiled: July 19, 1990Date of Patent: February 12, 1991Assignee: Shin-Etsu Chemical Co., Ltd.Inventors: Ken Ohashi, Masanobu Shimao
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Patent number: 4992235Abstract: Thermoelectric elements with excellent thermoelectric characteristics such as Seebeck coefficient thermoelectromotive force and thermal conductivity can be produced by molding a powder of metal or metal alloy as the raw material and then sintering; by using as such raw material, ultra fine powders containing Fe and Si as main components and having a mean particle diameter of 50 to 5,000 .ANG..Type: GrantFiled: March 23, 1989Date of Patent: February 12, 1991Assignee: Idemitsu Petrochemical Co., Ltd.Inventors: Takeo Tokiai, Takashi Uesugi
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Patent number: 4992236Abstract: A method of making a golf club head and golf club heads produced by said method which involves filling a mold with material selected from the group consisting of metal powders, castings, wrought metal, and green compact metal powders and combinations thereof so as to achieve the desired properties in the particular areas of the club head, compressing the material in the mold to form a green compact of the material, removing the green compact of the material from the mold land then heating the green compact to an elevated temperature to form a sintered product. Thereafter, the sintered product may be further heated under pressure to improve its density.Type: GrantFiled: January 16, 1990Date of Patent: February 12, 1991Inventor: Chester S. Shira