Abstract: The present invention provides water atomized copper powder comprising substantially irregular shaped copper particles having at least a median D50 particle size of from about 10 ?m to about 50 ?m. The powders of the present invention are suitable for use in electrically conductive compositions, such as copper-based adhesives. The present invention also provides methods of making these copper powders.

Abstract: Improved frangible bullets comprising powder particles of one metal bonded together by another metal wherein the metals have substantially different melting points or an alloying metal is diffused between the metal particles are manufactured by compacting the metal particles and heating under conditions to create brittle bonds.

Abstract: The invention relates to bullets having increased frangibility (or which can be easily fragmented) and to materials and processes for the manufacture of such bullets. The bullets of the present invention are typically made from copper or copper alloy powders (including brass, bronze and dispersion strengthened copper) which are pressed and then sintered under conditions so as to obtain bullets with the desired level of frangibility. In preferred embodiments of the invention, the bullets also contain several additives that increase or decrease their frangibility.

Abstract: The invention concerns a material for the powder-metallurgical production from a powder mixture containing at least approximately 50 wt. % copper in particular of valve seat rings or valve guides with high resistance to wear and corrosion and high heat conductivity. The starting powder mixture consists of between 50 and 90 wt. % of a basic powder, containing the copper portion, and between 10 and 50 wt. % of a powdery molybdenum-containing alloy flux. The basic powder is a copper powder which is dispersion-hardened by Al.sub.2 O.sub.3, has an Al.sub.2 O.sub.3 content of between 0.1 and 1.1 wt. %, and is produced by pulverizing a Cu--Al melt followed by heating in an oxidizing atmosphere. The invention further concerns the use of a dispersion-hardened powder of this type for the powder-metallurgical production in particular of wear and corrosion-resistant valve seat rings or valve guides with high heat conductivity. Finally, the invention concerns a method of producing such valve seat rings or valve guides.

Abstract: A composite material comprising a pure copper or dispersion strengthened copper matrix and a boron rich species, such as, but not limited to, elemental boron or boron carbide, for use in the fabrication of baskets that support spent nuclear fuel in nuclear waste containers. A method for manufacturing the composite material using powder metallurgy and hot extrusion.

Abstract: This invention relates to substantially full-dense, near-net shape bodies made of dispersion strengthened copper (D.S.C.) powder and products which are cold formed and/or machined from these bodies, such as resistance welding electrodes. The invention includes processes for manufacturing substantially full-dense, near-net shape, substantially equiaxed bodies from D.S.C. powder.

Abstract: This invention relates to substantially full-dense, near-net shape bodies made of dispersion strengthened copper (D.S.C.) powder and products which are cold formed and/or machined from these bodies, such as resistance welding electrodes. The invention includes processes for manufacturing substantially full-dense, near-net shape, substantially equiaxed bodies from D.S.C. powder.

Abstract: There is provided a substantially fully dense powdered metal composite comprising a highly conductive metal or metal alloy matrix having dispersed therein discrete microparticles of a refractory metal oxide and discrete macroparticles of an additive metal or metal alloy, such as a nickel/iron alloy. The respective components undergo minimal alloying because sintering is not utilized in forming the composite. These composites are characterized by high thermal or electrical conductivity and a desired property attributable to the composite forming additive metal or metal alloy. The composites are useful in forming lead frames for integrated circuit chips, electric lamp lead wires, and electrical contact members.

Abstract: An improved resistance welding electrode cap adapted to being internally cooled with a flow of coolant has a main body portion with a nose root at one end and an electrical and coolant connection projecting from the other, the area of the root being substantially smaller than that of the direct projection of the main body portion, a pronounced nose projecting from the root. The whole nose is of dispersion-strengthened copper, as is at least the main body portion. Such cap provides astonishingly improved performance for resistance welding, even of galvanized steel, and particularly of double-sided, galvanized cold-rolled steel sheet.

Abstract: A process and a product produced thereby, for forming rod or bar or tube stock or strip, comprising a sheath and a densified dispersion strengthened metal core. Powdered dispersion strengthened copper is put into a metal can and compressively reduced to size and density. The relationship between the tensile strength of the core when fully densified and the cold worked tensile strength of the can is important to the nature of the product.

Abstract: Substantially completely deoxidized, consolidated dispersion-strengthened copper stock of sizable cross section and particulates capable of being thus consolidated into such stock are shown. The stock exhibits ductility substantially greater than that of otherwise corresponding stock which contains about 100-500 ppm of available oxygen. Also shown is a staged powder deoxidation process using hydrogen or like reducing gas followed by the sequestration of remaining available oxygen with a minute proportion of diffusible, normally solid oxygen getter.

Abstract: A process for making a novel alloy of a dispersion strengthened copper by blending dispersion strengthened copper powder and a powdered modifying metal, heat treating the blend to form the alloy, and the compacting and working the compact to densify it.

Abstract: This invention relates to dispersion strengthening of metals. A coherent mass comprising an intimate blend of alloy powder and oxidant is formed prior to dispersion strengthening. Said coherent mass is easily formed because the alloy powder is not yet strengthened, and undergoes internal oxidation rapidly because of the intimate blend of alloy powder and oxidant.

Abstract: A process for dispersion strengthening of atomized alloy particles by internal oxidation is substantially improved by providing atomized particles substantially free of oxide surface film to enhance the efficiency of the internal oxidation step. The atomized alloy particles can be produced by dry collection to prevent oxide film formation, or alternatively, the oxide surface film can be removed by mechanical action removal or by chemical leaching.

Abstract: A process for dispersion strengthening metal alloys comprising the steps of separating metal powder particles larger than about 180 microns, flattening the particles to provide flake particles having a thickness less than 180 microns, and then internally oxidizing the flake particles. The flaked particles can be combined and consolidated with atomized particles less than about 180 microns on a 20% to 80% and preferably 40% to 60% weight basis to provide improved dispersion strengthened metal products.

Abstract: Welding electrodes and welding wheels can be hot forged from powdered dispersion strengthened metal wherein the powder is pressed into a preform, heated, and then hot forged to form a full density workpiece to produce a desirable grain structure.

Abstract: A dispersion-strengthened metal wherein the improvement comprises recrystallizing alloy powder prior to internal oxidation to increase the grain size of the alloy to at least about ASTM (E-112) Grain Size No. 6 to reduce the grain boundary area in the alloy powder whereby the recrystallized alloy powder provides substantially improved structural properties in the dispersion-strengthened metal product.

Abstract: A welding electrode made of dispersion strengthened metal wherein the electrode tip is pressure formed or forged to reorientate and/or destroy the coaxial fiber structure and form a non-axial grain structure in the electrode tip portion. The electrode is produced in a method for pressure flowing a blank by applying axial pressure to pressure flow the blank transverse to the axially applied pressure whereby the overall strength of workpieces such as welding electrode rods is substantially increased.

Abstract: A process for dispersion strengthing of atomized alloy particles by internal oxidation is substantially improved by providing atomized particles substantially free of oxide surface film to enhance the efficiency of the internal oxidation step. The atomized alloy particles can be produced by dry collection to prevent oxide film formation, or alternatively, the oxide surface film can be removed by mechanical action removal or by chemical leaching.