Abstract: An interconnector for a solid oxide fuel cell is manufactured by single-press compacting a powder blend to form a green interconnector with a desired shape of a final interconnector. The powder blend includes chromium and iron, and may include an organic lubricant. At least 50 wt % or more of an iron portion of the powder blend comprises iron particles smaller than 45 um. The green interconnector is then sintered and oxidized to form the final interconnector. The oxidation step occurs in a continuous flow furnace in which a controlled atmosphere (e.g., humidified air) is fed into the furnace in the travel direction of the interconnector. The final interconnector comprises at least 90 wt % chromium, at least 3 wt % iron, and less than 0.2 wt % nitrogen. An average density within a flow field of the final interconnector may be less than 6.75 g/cc.

Abstract: An interconnector for a solid oxide fuel cell is manufactured by single-press compacting a powder blend to form a green interconnector with a desired shape of a final interconnector. The powder blend includes chromium and iron, and may include an organic lubricant. At least 50 wt % or more of an iron portion of the powder blend comprises iron particles smaller than 45 um. The green interconnector is then sintered and oxidized to form the final interconnector. The oxidation step occurs in a continuous flow furnace in which a controlled atmosphere (e.g., humidified air) is fed into the furnace in the travel direction of the interconnector. The final interconnector comprises at least 90 wt % chromium, at least 3 wt % iron, and less than 0.2 wt % nitrogen. An average density within a flow field of the final interconnector may be less than 6.75 g/cc.

Abstract: A method of manufacturing powder metal plates comprising feeding a predetermined mass of metal powder onto a moving tape (101), restricting the metal powder by surrounding the metal powder with vibrating boundary walls (201, 202) extending parallel to the direction of movement of the tape, rolling the metal powder at an ambient temperature to form a green compact strip (GS), continuously sintering the green compact strip in a furnace (400), forming the green compact strip to a net shape part (NS) while in the furnace, and cooling the net shape part in a non-oxidizing environment (404) at a temperature in excess of 1000 degrees Celsius.

Abstract: A method of manufacturing powder metal plates comprising feeding a predetermined mass of metal powder onto a moving tape (101), restricting the metal powder by surrounding the metal powder with vibrating boundary walls (201, 202) extending parallel to the direction of movement of the tape, rolling the metal powder at an ambient temperature to form a green compact strip (GS), continuously sintering the green compact strip in a furnace (400), forming the green compact strip to a net shape part (NS) while in the furnace, and cooling the net shape part in a non-oxidizing environment (404) at a temperature in excess of 1000 degrees Celsius.

Abstract: A method of pressing a powder metal compact comprising partially filling a die cavity with powder metal, engaging a second die with the first die, extending radially inwardly punches for forming a transverse feature in the compact, filling the die cavity with powder metal, compressing the powder metal with a punch, relieving pressure on the compact, withdrawing the radially inwardly punches so as to allow axial movement of the compact, withdrawing the second die, and ejecting the compact from the die while simultaneously filling the die cavity.

Abstract: A method for producing a powder metal article having a three dimensional shape and having at least one densified surface comprising: a) providing a blend of powdered metals; b) compacting said blend to form a pre-form having a general shape of said article; c) sintering said pre-form; d) densifying at least one cylindrical surface region of said pre-form; and, e) forming said pre-form to a final density and into the three dimensional shape of said article.

Abstract: A disc protector is described for use in the field of optical data storage discs where commonly known applications are compact discs (CD), digital versatile discs (DVD) and super audio compact discs (SACD). In particular a method to improve disc-holders is described where a protective material is present between the data-access surface of the disc and the disc-holder.

Abstract: A method for forming an internal gear is provided comprising providing a powder metal preform workpiece, supporting the workpiece about its periphery, and roll forming said workpiece to produce a set of densified gear teeth of a predefined dimension.

Abstract: A method of forming a gear comprising gripping a blank to be spun formed in a spin forming machine, spin forming a gear having helical teeth disposed on an inner surface, and ejecting the gear by simultaneous extension and rotation of an ejector member and thereby rotation of the gear being ejected.

Abstract: A compaction tool assembly is provided that uses multiple die cavities and a single compaction stroke for simultaneously forming multiple discrete powdered metal components. The tooling includes a plurality of punches and corresponding die cavities, and a single compaction stroke operates the punches to compact powdered metal contained by the die cavities to form the components. Preferably the punch pairs are arranged concentrically to balance compaction forces and die stresses.

Abstract: The invention relates to methods of forming sintered compacts of low alloy steel composition to high density at ambient temperature. The invention provides for a method of forming sintered powder metal articles by forming the sintered powder metal in a die cavity having a clearance for movement of said sintered powder metal to a final shape with increased density after compaction wherein the formed sintered powder metal article has a compaction length which is approximately 3 to 30% less than the original length.

Abstract: A method for making a high density powdered metal article is provided. In one embodiment, the composition consists of iron based powder, lubricant, graphite and ferro alloy additions. Satisfactory results may also be achieved by using fully prealloyed grades of metal powders, substantially pure powder blends, fully prealloyed powder blends, partially prealloyed powder blends and powder blends containing ferro alloys. The composition is compacted in rigid tools at ambient temperature, sintering at high temperature greater than 1100.degree. C. and then formed in rigid tools at 40 to 90 tons per square inch to a density greater than 94% of theoretical. The high density article is then annealed. The final article demonstrates remarkable mechanical properties which are atypical of powdered metal components and approach those of wrought steel.

Abstract: A manufacturing method is provided for the production of high density, high carbon, sintered powder metal steels. The composition consists of iron based powder, graphite, lubricant, and possibly at least one alloying element from the group of chromium, copper, manganese, molybdenum, nickel, niobium or vanadium. The composition is compacted in rigid tools, sintered and during cooling an isothermal or slow cooling treatment is introduced between 650.degree. C. and 750.degree. C. The isothermal or slow cooling treatment may alternatively be applied during a heat treatment cycle that is carried out after a conventional sintering cycle. The material processed as described may then be formed to high density. Forming to high density is not practical with high carbon materials that have been processed by conventional methods. The high density article is then heat treated in a manner to suit specific product requirements.

Abstract: A method for making a high density powdered metal article is provided. The composition consists of iron based powder, lubricant, graphite and ferro alloy additions. The composition is compacted in rigid tools at ambient temperature, sintered at high temperature and then formed in rigid tools at 40 to 90 tons per square inch to a density greater than 94% of theoretical. The high density article is then annealed. The final article demonstrates remarkable mechanical properties which are atypical of powdered metal components and approach those of wrought steel.

Abstract: A process of coining sintered articles of powder metal comprising: blending carbon, ferro manganese, and lubricant with compressible elemental iron powder, pressing the blended mixture to form the articles, high temperature sintering of the articles in a reducing atmosphere and then coining the sintered articles to final shape so as to narrow the tolerance variability of coined articles and substantially eliminate secondary operations.