Abstract: A process for producing sintered pellets made from blends of refractory metal and refractory metal nitride powders were found to have a higher fraction of intra-agglomerate pores than those made from the refractory metal or refractory metal nitride alone resulting in improved capacitor grade powders, anodes and finished capacitors therefrom. The pellet porosity and total intrusion volume maximizes when the mixture is in the 50-75 W/W % refractory metal nitride range. The total pellet pore surface area was found to be relatively independent of refractory metal nitride concentration above 50%. A substrate consisting of a 50/50 or 25/75 W/W % refractory metal/refractory metal nitride powder mixture should produce solid capacitors with higher capacitance recovery and lower ESR.

Abstract: A sintered iron-based powder metal body with lower re-compacting load and having a high density and a method of manufacturing an iron-based sintered component with fewer pores of a sharp shape and having high strength and high density.

Abstract: Low-nickel austenitic steel which contains iron and the following components: Manganese: less than 17.0% by weight; Chromium: more than 21.0 and not more than 26.0% by weight; Molybdenum: less than 1.50% by weight; Nitrogen: more than 0.70 and not more than 1.70% by weight; and Carbon: more than 0.11 and not more than 0.70% by weight and its production and use.

Abstract: A sintered sprocket is provided in which surface pressure resistance can be improved without using a forging processing. An Fe-based sintered alloy which contains C at 0.2 to 0.5% by weight, Mo at 0.2 to 1.0% by weight, and Ni at 0.2 to 1.0% by weight, and which exhibits a metallic structure in which an internal base layer comprises ferrite and bainite and in which the ferrite adjoins voids, is subjected to a rolling and is then subjected to carburizing and hardening.

Abstract: A method for manufacturing a sliding part for a hermetic compressor is disclosed. Since the abrasion resistance and corrosion resistance of the sliding part is increased, the energy consumption efficiency is improved and the performance of the compressor can be enhanced. In addition, since the manufacturing process is shortened, the production cost can be reduced and the manufacturing time can be reduced. Moreover, since the thickness change of the sliding part is minimized, the defective rate of the part size can be reduced and its quality can be improved.

Abstract: Hard sintered moldings having a nickel- and cobalt-free, nitrogen-containing steel as a binder of the hard phase, processes for the powder metallurgical production of these hard sintered moldings, in particular by powder injection molding, and powder injection molding materials for the production of these hard sintered moldings by powder injection molding.

Abstract: A coated cemented carbide tool, and a method for making the same, wherein the as-sintered substrate is formed by sintering in an atmosphere having at least a partial pressure and for a part of the time a nitrogen partial pressure.

Abstract: A method of producing a gear from a metallurgical powder includes molding at least a portion of the powder to provide a gear preform. The gear preform is sintered and hot formed, and subsequently may be carburized. The gear preform is resintered and cooled at a cooling rate suitable to provide a bainitic microstructure in at least a surface region of the preform. The gear teeth of the preform may be shaved to, for example, adjust dimensions, and enhance dimensional uniformity.

Abstract: A method for metal processing is provided in which a cooling atmosphere comprising hydrogen is used for accelerated cooling of a processed metal part in a furnace, resulting in improved properties for the metal part. A sintering furnace is also provided and comprises a means for inhibiting gas flows between a heating zone and a cooling zone of the furnace.

Abstract: A method of making a tire mold segment with a porous metal tread surface for a tire mold wherein an annular segmental tire model of refractory material is formed with tire model segments which are used to shape and form each tire mold segment from powdered metal by applying heat and pressure to sinter the powdered metal as it is shaped by the tire model segment. Blades may be mounted in the tire model segments for transfer to the tire mold segments for molding slits a tire tread.

Abstract: The invention relates to a method for producing a sintered material offering improved corrosion protection by activation and coating of the surface with a metal, followed by a heat treatment. Said method is characterized in that during activation and before coating with said metal the following steps are carried out: removal of particles adhering to the surface of the sintered material by treating said surface with a stripper; passivation of the surface; and drying of the sintered material. The invention also relates to a magnetic body with greater corrosion resistance.

Abstract: The residual stresses that are experienced in polycrystalline diamond cutters, which lead to cutter failure, can be effectively modified by selectively thinning the carbide substrate subsequent to high temperature, high pressure (sinter) processing, by selectively varying the material constituents of the carbide substrate, by subjecting the PDC cutter to an annealing process during sintering, by subjecting the formed PDC cutter to a post-process stress relief anneal, or a combination of those means.

Abstract: A method for metal processing is provided in which a cooling atmosphere comprising hydrogen is used for accelerated cooling of a processed metal part in a furnace, resulting in improved properties for the metal part. A sintering furnace is also provided and comprises a means for inhibiting gas flows between a heating zone and a cooling zone of the furnace.

Abstract: A method for forming dresser of chemical mechanical polishing pad, firstly to make a stainless steel bottom seat. Then preparing metal welding powder and organic glue, mixing the aforesaid metal welding powder, organic glue and adequate ratio of water to welding thick liquid and uniformly distributing or pasting it on the aforesaid dresser bottom seat to form the sintering layer. The aforesaid metal welding material includes the active metal with diamond can form metal carbonate. Then using the computer visual inspection system to proceed the diamond powder distribution, uniformly distributing them for 60 to 2500 grains per square centimeter. Proceeding the sintering process to make the friction layer of chemical mechanical polishing pad dresser.

Abstract: The residual stresses that are experienced in polycrystalline diamond cutters, which lead to cutter failure, can be effectively modified by selectively thinning the carbid substrate subsequent to a high-temperature, high-pressure (sinter) processing, by selectively varying the material constituents of the carbide substrate, by subjecting the PDC cutter to an annealing process during sintering, by subjecting the formed PDC cutter to a post-process stress relief anneal, or by a combination of those means.

Abstract: Parts made from powder use a material that originates from a salt to bind powder particles together. The salt may be provided dissolved in a solution, as molten salt, or as a dry powder. The figure is an electron micrograph of a cross section of a silver nitrate bound product with a skeleton of steel powder.

Abstract: The present invention provides a process for the hardening treatment of sintered members which can impart sufficient wear resistance thereto at low cost without causing a reduction in dimensional accuracy due to heat distortion. This process for the hardening treatment of sintered members comprises the steps of coating an iron-based sinterable member with a Ni—P alloy powder containing 7 to 13% by weight of phosphorus so as to give a coating weight of 0.1 to 1.2 mg/mm2; sintering the iron-based sinterable member coated with the Ni—P alloy powder at a temperature in the range of 1,000 to 1,300° C.; and hardening the iron-based sintered member by cooling it at a cooling rate of not less than 10° C./min. until a temperature of 200° C. is reached.

Abstract: A method of the present invention manufactures a watch-bracelet component through step (1A) of producing a green body containing a raw material powder by extrusion molding, step (2A) of cutting the green body, step (3A) of debinding the cut green body, and step (4A) of sintering the debound body to yield a sintered body. Subsequently, the method can easily manufacture even a product having a complicated shape, and the invention can provide a method of manufacturing a watch-bracelet component with a wide range of materials to choose from.

Abstract: The present invention relates to a coated cemented carbide insert with a binder phase enriched surface zone. The WC-grains have an average grain size in the range 1.0-3.5 &mgr;m, preferably 1.3-3.0 &mgr;m and the number of WC-grains larger than 2 times the average grain size is less than 10 grains/cm2 measured on a representative polished section 0.5 cm2 large, preferably less than 5 grains/cm2, and the number larger than 3 times the average grain size is less than 5 grains/cm2, preferably less than 3 grains/cm2. The cemented carbide is made by powder metallurgical methods and is in particular characterized in that the cooling rate, CR, from the sintering temperature, ST, exhibits the relationship 10<CR·(ST-1300)/1000<17.

Abstract: A metal foam object results from the mixing of a gasifier with metal powder and subjecting the mixture to an elevated temperature T1 and pressure P1 to form a sintered sheet placing at least a portion of the sintered sheet into a mold and subjecting the mold to a temperature T2 where T2 is greater than T1 at which the metal melts and the gas is released from the gasifier and quenching the metal foam object thus formed in the mold. The quenching is carried out by applying a cryogen to the object as a high velocity mixture of gas and liquid droplets.

Abstract: A Cobalt-containing tungsten-carbide sintered product includes first and second sintered compacts of Cobalt-containing tungsten-carbide which are integrally formed via a sintering process. One of the first and second sintered compacts has a hardness greater than that of the other one of the first and second sintered compacts.

Abstract: An object of the present invention is to provide a method of producing an Ag—ZnO electric contact material which can uniformly disperse ZnO micrograms in Ag; which maintains low contact resistance; which exhibits enhanced welding resistance and wear resistance; and which is suitable in view of production costs. The method of producing an Ag—ZnO electrical contact material comprises casting Ag and Zn at predetermined proportions and subjecting the resultant Ag—ZnO alloy to internal oxidation so as to disperse ZnO in Ag, the method being characterized in that an Ag—Zn alloy comprising 5-10 wt. % (as reduced to weight of metal) Zn, the balance being Ag, is formed into chips; the chips are subjected to internal oxidation; the internally oxidized chips are compacted to thereby form billets; the billets are pressed and sintered; and subsequently, the sintered billets are extruded, to thereby yield uniform dispersion, in Ag, of ZnO micrograms.

Abstract: There are disclosed copper-base and/or iron-base contact materials which contain a Pb intermetallic compound dispersedly precipitated therein and which have highly improved sliding properties. Double layered contact elements improved in oil impregnation and lubricity are formed by sinter bonding the above contact materials to an iron-base metal backing, respectively. Economical producing methods for such double layered contact materials are also disclosed. In the copper-base and/or iron-base contact materials, one or more kinds of Pb intermetallic compounds are dispersedly precipitated.

Abstract: A high strength spongy sintered metal composite sheet comprising a porous spongy sintered metal layer having continuous holes, and a high strength sintered, dense metal reinforcing layer having a porosity smaller than the porosity of the spongy sintered metal layer, laminated thereon, wherein the sintered, dense metal reinforcing layer has a thickness of 0.5-30% thickness with respect to the entire high strength spongy sintered metal composite sheet.

Abstract: A sintered powder metal part is prepared for machining by injecting grease into the surface of the part to be machined to a depth at least equal to the depth of machining. The grease is injected under very high pressure using repressing tooling by applying a certain volume of grease between the surface to be machined and the mating tool surface and applying pressure sufficient to uniformly inject the grease into the surface. A rim may be formed in the part adjacent to the surface which acts as a seal during grease injection and is compressed into the part.

Abstract: The invention concerns a process for the preparation of a compressed soft magnetic powder core comprising the steps of compacting an iron based powder the particles of which are insulated by a chromium containing layer, at a pressure between 300 and 1500 Mpa. The compacted body is then heated to a temperature sufficient for achieving stress relief and recrystallization of the iron base material.

Abstract: An ingot is made from a used target of 30 weight % or more, and new metals of the same components, and recycled alloy powder is made by a gas atomizing process. Magnetic permeability is controlled not to exceed 2 by adjusting the content of rare earth metals in rare earth alloy powder to be at least 35 weight %. By blending the recycled alloy powder with other powder to produce alloy powder containing at least 50 weight % of rare earth alloy powder having a magnetic permeability not higher than 2 and containing at least 65 weight % of rare earth alloy powder. By sintering the alloy powder under pressure and thereafter cutting top, bottom and side surfaces of the sintered material, a target having a magnetic permeability not higher than 2 and having a thickness not less than 8 mm is fabricated.

Abstract: The present invention concern a method using powder metallurgy for producing molded parts intended to be assembled by self-brazing to metal parts capable of receiving them and said receiving parts. The method comprises forming a homogenous mixture of a basic metal powder, brazing powder and a liquid binding agent which is injection molded to form a self-brazing part.

Abstract: A method of manufacturing a sintered anode unit for a solid electrolytic capacitor is provided. According to this method, a press-molded or compacted pellet of a valve-action metal powder is sintered at a predetermined high temperature and in a predetermined primary vacuum. The pellet is naturally cooled in this primary vacuum, and is cooled by force cooling in an inert gas atmosphere. Thereafter, the sintered pellet is subjected to a repeated cycle processing of vacuum, atmospheric leakage, and vacuum in a gradual-oxidizing chamber. The atmospheric leakage level is increased step by step to set the vacuum level in the gradual-oxidizing chamber to the atmospheric pressure. Then, the sintered pellet having the restricted content of oxygen is taken out from the gradual-oxidizing chamber into the atmosphere.

Abstract: The present invention relates to s a sintered alloy having an excellent wear resistance for a valve seat and a method of producing the same. More particularly, the present invention relates to the sintered alloy having an excellent wear resistance for a valve seat, which is produced by a sub-zero treatment for a metal powder comprising Fe(iron) as a main component, C(carbon), Si (silicon), Cr(chromium), Mo(molybdenum), Co(cobalt), Mn(Manganese), Pb(lead), V(vanadium) and W(tungsten) so that amount of metallic particles separated from a base matrix decreases and a size of the separated metallic particle becomes small when an abrasion of the sintered alloy is in proceed, thereupon a wear resistance and an impact resistance are improved and a self-lubricity and a machinability are enhanced, and a method of producing the same.

Abstract: A method for fabricating cylindrical sputter targets for rotary cylindrical cathodes used in depositing a dielectric layer of desired alloy on non-planar substrates during sputtering. The method includes forming a cooling tube having a passage within to receive a cooling medium, then fabricating multiple annular rings including each of the basic metal constituents of the desired alloy and attaching the annular rings to the cooling tube such the exposed outer portions of the annular rings provide a homogeneous layer of the desired alloy on the non-planar substrates during sputtering.

Abstract: Organic acid-based binders are efficiently removed from powder metallurgy compacts, such as tantalum capacitor anode bodies, by immersion in a heated aqueous alkanolamine solution followed by rinsing in warm water. This method results in lower residual carbon and oxygen levels than are found with thermal binder removal methods.

Abstract: Nanoscale aluminum alloy powder is synthesized by mechanical alloying/milling techniques without significant oxidation, nitridation, or contamination with foreign materials. These powders are consolidated into a very dense billet form without a high temperature sintering step. The desired microstructure and properties were obtained by post hot isostatic pressing, extrusion, and/or forging of the nanoscale material billet made from the powders.

Abstract: A high temperature Nb-base alloy material which contains a ductile Nb-base metal phase to secure the toughness of the alloy at a normal temperature, and yet it can provide a dense oxide film in a high temperature oxidative atmosphere, thereby it can maintain excellent oxidation resistance even when the coating is broken, i.e. it has self repairing function, is provided. The high temperature oxidation resistant alloy material is constructed by adding a trace amount of metal Mg which is necessary to form a dense oxide film comprising MgO as a main component on the surface in an elevated temperature oxidative atmosphere, to a composite phase alloy comprising not less than 10% by volume of a Nb-base solid solution metal phase represented by atomic ratio as Nb—(15-40%)Ti—(5-20%)Al and the remainder of one or more kinds of intermetallic compound phases or ceramic phases having high oxidation resistance.

Abstract: The present invention relates to method of making a cemented carbide insert, comprising a cemented carbide substrate and a coating. The substrate contains WC and cubic carbonitride phase in a binder phase based of Co and/or Ni and has a binder phase enriched surface zone essentially free of cubic phase. The binder phase enriched surface zone prevails over the edge. By sintering in an atmosphere essentially consisting of nitrogen the thickness of the binder phase enriched zone can be controlled.

Abstract: A method is provided for fabricating Cu/Cr sputter targets having a density of at least about 90% of theoretical density and an oxygen content of less than about 1000 ppm. According to the principles of the present invention, Cu and Cr powders, each having particles in the size range of about 20 &mgr;m to about 150 &mgr;m and having oxygen contents preferably less than about 1200 ppm and 600 ppm, respectively, are blended and pressed by hot pressing. A low-oxygen content, high-density Cu/Cr target is thereby achieved for the sputtering of thin films having a defect generation of about 0%.

Abstract: In order to keep the losses of a pump caused by oil return flow between the gears and the housing as low as possible at high operating temperatures, the oil pump gears are manufactured from a powdered Al/Si alloy formed by spray compacting, to which approximately 30 weight percent pure aluminum powder is admixed, by pressing and subsequent sintering.

Abstract: A metal/ferrite laminate magnet has perforations forming apertures in the magnet. The magnet is formed of outside metal plates surrounding a sandwich of two layers of ferrite material. The outside metal plates allow the perforations to be made in the magnet before sintering of the magnet and maintain the alignment of the holes during sintering. The metal plates also provide the magnet with mechanical robustness and rigidity and prevent cracking occurring between adjacent apertures.

Abstract: There is provided a sintered metallic alloy having toughness capable of supporting stress at a point by distributing structure portions having different values of rigidity approximately uniformly without separation of layers different in brashiness. A method of manufacturing the sintered metallic alloy and a sintered alloy gear employing the sintered metallic alloy are also provided. Metallic materials are formed into a predetermined configuration. Then, the metallic materials is sintered in a sintering furnace (14) to make a sintered metallic alloy. Next, the sintered metallic alloy is cooled gradually to an ambient atmosphere of room temperature. Finally, the temperature of the cooled metallic alloy is raised and a toughness stabilizing process is performed in a low-temperature furnace (18) so that structures with high toughness are distributed approximately uniformly.

Abstract: The present invention relates to a sintered cemented carbide consisting of 50 to 90 wt-% submicron WC in a hardenable binder phase. The binder phase comprises, in addition to Fe, 10-60 wt-% Co, <10 wt-% Ni, 0.2-0.8 wt-% C, Cr, W, Mo and/or V in amounts satisfying the relations 2xC<xW+xCr+xMo+xV<2.5xC where x denotes mol fraction elements in the binder phase and the following relation for the total Cr content 0.03<wt-% Cr/(100-wt-% WC)<0.05 In addition, the binder phase consists of martensite with a fine dispersion, a few percent, of coherent carbides, preferably of M2C type, with a size of the order of 10 nm.

Abstract: A method for manufacturing machining tools out of composite powdered metal which is first formed to approximate the desired shape of the machining tool; then bonded metallurgically; and machined to the desired finished shape. Desirably, the forming step employs at least two distinct powdered metals, the first formed to the outer shape over the portion of the tool that interfaces with the work piece and selected to exhibit the desired hardness and wear-resistance properties. The second material supports the hollow form of the first material and includes a shank to interface with the machine that the tool will be employed with. The second material is chosen to exhibit the desired ductility, surface hardness, abrasion resistance and reduced cost. Additional materials can be used for different facets of the tool to obtain an optimum balance of long life, efficient operation and low cost.

Abstract: A method for producing compacted, fully dense articles from atomized tool steel alloy particles by placing the particles in a deformable container, and isostatically pressing the particles at an elevated temperature to produce a precompact having an intermediate density. The precompact is heated to a temperature above the elevated temperature used to produce the precompact. The precompact is isostatically pressed to produce the fully-dense article.

Abstract: A densified sintered product, such as a rolling cutter adapted for use in a steel tooth rolling cutter earth boring bit, has a layer of a metal powder applied to the external surface of the unsintered compact, the metal powder being melted to form a thin glaze of the melted metal powder on the external surface of the sintered compact, and the sintered compact may then be pneumatically isostatically forged.

Abstract: A high density, non-magnetic alloy is described along with a process for manufacturing it. The preferred composition for the alloy is approximately 95% by weight of tungsten and 5% of austenitic stainless steel. The process for manufacturing the alloy begins with blending tungsten and stainless steel powders which are then mixed with an organic binder to form a feedstock. The latter is then molded into the form of compacted items, such as a hard drive counterweight balance, and then sintered in either vacuum or a hydrogen atmosphere. The tungsten heavy alloys of the present invention can be easily manufactured in large volume economically in many intricate shapes with excellent control of weight and dimensions.

Abstract: A method of densifying the wall of an opening in a powder metal preform includes forcibly extending a densification tool through the opening having a plurality of radially enlarged forming portions arranged in axially spaced succession from smallest to largest which act to enlarge and densify the preform material and impart beneficial compressive stresses. The space between successive forming portions enables the preform material to recover elastically between adjacent forming sections to maximize induced compressive stresses.

Abstract: An uncoated titanium-based carbonitride cutting tool insert with superior plastic deformation resistance and wear resistance is provided. This is accomplished by heat treating the material in nitrogen atmosphere under conditions to obtain a nitrogen rich surface zone, also containing substantial amounts of binder phase.

Abstract: An indexable cutting insert for metal machining comprises an upper rake surface, a bottom surface and side surfaces that extend between the upper and bottom surfaces. Cutting edges are formed at the transitions between the side surfaces and the upper surface. Disposed along the cutting edges on the upper surface are elongated primary lands. Disposed inside of the lands is a chip-breaking depression. A raised land area to be ground is situated in the chip-breaker, so that the total grinding area of the upper surface becomes about as large as the total grinding area of the bottom surface. The insert can thus be ground by upper and lower grinding wheels which rotate simultaneously in opposite directions.

Abstract: A cutting insert that has a flank face and a rake face and a cutting edge at the juncture thereof. The substrate presents a bulk region that contains a metallic binder, as well as one or more of Group IVB, Group VB, and Group VIB metal carbides and/or carbonitrides. The substrate further includes a flank surface region near the flank face of the substrate that has a solid solution metal carbide and/or carbonitride content greater than that of the bulk region. The substrate includes a rake surface region near the rake face of the substrate with a solid solution metal carbide content that is less than that of the flank surface region.

Abstract: A method of manufacturing high-temperature-resistant shaped parts of an iron-chromium-aluminum alloy containing 2-10 wt % aluminum, 10-40 wt % chromium, and the balance basically iron is provided. According to this method, the composition in powdered form is hot isostatically pressed to a predetermined shape to form a product. Optionally, the product may be pre-oxidized to form a protective layer of aluminum oxide on a surface thereof.

Abstract: A method for making dies or molds from powdered metals is disclosed. The method includes the steps of: providing a pattern of a desired shape to define the mold or die cavity configuration; providing a canister; placing the pattern in the canister and filling the canister with a selected powdered metal; hot isostatic pressing the canister and powdered metal to produce a consolidated and densified compact; and sectioning the compact along a plane to enable removal of the pattern and thus providing the desired die or mold cavity in the fully densified powdered metal die or mold set so formed.