Powder Pretreatment (prior To Consolidation Or Sintering) Patents (Class 419/30)
  • Publication number: 20040118245
    Abstract: An article made of a metallic material having its constituent elements is made by furnishing at least one nonmetallic precursor compound, wherein all of the nonmetallic precursor compounds collectively include the constituent elements of the metallic material in their respective constituent-element proportions. The precursor compounds are chemically reduced to produce particles comprising the metallic material, without melting the precursor compounds and without melting the metallic material. The particles may be consolidated into a rod, which may be used as a welding rod in a welding operation. Alternatively, the nonmetallic precursor compounds may be consolidated prior to the chemical reduction.
    Type: Application
    Filed: December 23, 2002
    Publication date: June 24, 2004
    Inventors: Eric Allen Ott, Andrew Philip Woodfield, Clifford Earl Shamblen
  • Patent number: 6740287
    Abstract: A method of fabricating nanostructure bodies by integrating the steps of attriting precursor nanometer-sized particulate materials, desorbing the exposed surfaces of the attrited nanoparticulates, adsorbing a surfactant on at most 50% of the desorbed surfaces and dispersing the surfactant-coated nanoparticulates in an organic matrix to form a homogeneous thermoplastic compound from which green bodies are shaped, dewaxed and sintered.
    Type: Grant
    Filed: February 11, 2002
    Date of Patent: May 25, 2004
    Inventors: Romain Louis Billiet, Hanh T. Nguyen
  • Patent number: 6737017
    Abstract: An article of a base metal alloyed with an alloying element is prepared by mixing a chemically reducible nonmetallic base-metal precursor compound of a base metal and a chemically reducible nonmetallic alloying-element precursor compound of an alloying element to form a compound mixture. The alloying element is preferably thermophysically melt incompatible with the base metal. The method further includes chemically reducing the compound mixture to a metallic alloy, without melting the metallic alloy, and thereafter consolidating the metallic alloy to produce a consolidated metallic article, without melting the metallic alloy and without melting the consolidated metallic article.
    Type: Grant
    Filed: June 14, 2002
    Date of Patent: May 18, 2004
    Assignee: General Electric Company
    Inventors: Andrew Philip Woodfield, Clifford Earl Shamblen, Eric Allen Ott
  • Publication number: 20040052672
    Abstract: A precursor powder comprising a metal compound is formed into a sample for electro-deoxidation, for example by slip-casting. The sample is then immersed in a melt comprising a molten salt and a cathodic potential applied to remove non-metal species from the precursor powder by electro-deoxidation and dissolution in the melt. This typically forms a metallic sample which can be fragmented to form a metallic powder. In a second aspect of the invention a powdered feed material is formed into a shaped precursor and more extensive electro-deoxidation carried out so as to form a near-net shaped product.
    Type: Application
    Filed: October 2, 2003
    Publication date: March 18, 2004
    Inventors: Derek John Fray, George Zheng Chen
  • Publication number: 20040040837
    Abstract: A method of fabricating a glass containing target for sputter deposition of a glass onto a substrate. The method includes synthesizing a glass from pure chemical element materials and then forming the synthesized glass into a powder, which is then used to form a glass containing target. In accordance with one aspect of the invention, the glass containing target may be used for sputter deposition of a thin coating of glass on a substrate. In exemplary embodiments, the glass is a chalcogenide glass target useful in fabricating memory devices.
    Type: Application
    Filed: August 29, 2002
    Publication date: March 4, 2004
    Inventors: Allen McTeer, Jiutao Li, Terry L. Gilton
  • Patent number: 6676728
    Abstract: There is provided a method of making a high-melting metal powder which has high purity and excellent formability and, particularly, of a metal powder of spherical particles made of Ta, Ru, etc. having a higher melting point than iron. There is also provided a target of high-melting metal or its alloy, which is made by the sintering under pressure of these powders and which has high purity and a low oxygen concentration and shows high density and a fine and uniform structure. A powder metal material mainly composed of a high-melting metal material is introduced into a thermal plasma into which hydrogen gas has been introduced, thereby to accomplish refining and spheroidizing. Further, an obtained powder is pressed under pressure by hot isostatic pressing, etc.
    Type: Grant
    Filed: August 21, 2002
    Date of Patent: January 13, 2004
    Assignee: Hitachi Metals, Ltd.
    Inventors: Gang Han, Hideo Murata, Hideki Nakamura
  • Publication number: 20030231974
    Abstract: An article of a base metal alloyed with an alloying element is prepared by mixing a chemically reducible nonmetallic base-metal precursor compound of a base metal and a chemically reducible nonmetallic alloying-element precursor compound of an alloying element to form a compound mixture. The alloying element is preferably thermophysically melt incompatible with the base metal. The method further includes chemically reducing the compound mixture to a metallic alloy, without melting the metallic alloy, and thereafter consolidating the metallic alloy to produce a consolidated metallic article, without melting the metallic alloy and without melting the consolidated metallic article.
    Type: Application
    Filed: June 14, 2002
    Publication date: December 18, 2003
    Inventors: Andrew Philip Woodfield, Clifford Earl Shamblen, Eric Allen Ott
  • Publication number: 20030230170
    Abstract: A metallic article made of metallic constituent elements is fabricated from a mixture of nonmetallic precursor compounds of the metallic constituent elements. The mixture of nonmetallic precursor compounds is chemically reduced to produce an initial metallic material, without melting the initial metallic material. The initial metallic material is consolidated to produce a consolidated metallic article, without melting the initial metallic material and without melting the consolidated metallic article.
    Type: Application
    Filed: June 14, 2002
    Publication date: December 18, 2003
    Inventors: Andrew Philip Woodfield, Eric Allen Ott, Clifford Earl Shamblen
  • Publication number: 20030228238
    Abstract: A target for a deposition apparatus is formed by blending at least two different types of powders together and consolidating the powders with a powder metallurgy process to form a billet. The target is then formed from the billet. The target includes a first material phase having a first PTF and a second material phase having a second PTF higher than the first PTF. The second PTF is also higher than a PTF of a material having the same chemistry as the target.
    Type: Application
    Filed: June 7, 2002
    Publication date: December 11, 2003
    Inventors: Wenjun Zhang, Bernd Kunkel, Anand Deodutt, Michael Bartholomeusz
  • Patent number: 6652806
    Abstract: A sputtering target contains a target material including as constituent elements Ag, In, Te and Sb with the respective atomic percents (atom. %) of &agr;, &bgr;, &ggr; and &dgr; thereof being in the relationship of 0.5≦&agr;<8, 5≦&bgr;≦23, 17≦&ggr;≦38, 32≦&dgr;≦73, &agr;≦&bgr;, and &agr;+&bgr;+&ggr;+&dgr;=100, and a method of producing the above sputtering target is provided. An optical recording medium includes a recording layer containing a phase-change recording material which includes as constituent elements Ag, In, Te and Sb with the respective atomic percents of &agr;, &bgr;, &ggr; and &dgr; thereof being in the relationship of 1≦&agr;<6, 7≦&bgr;≦20, 20≦&ggr;≦35, 35≦&dgr;≦70, and &agr;+&bgr;+&ggr;+&dgr;=100, and is capable of recording and erasing information by utilizing the phase change of the recording material in the recording layer.
    Type: Grant
    Filed: September 19, 2001
    Date of Patent: November 25, 2003
    Assignee: Ricoh Company, Ltd.
    Inventors: Yukio Ide, Hiroko Iwasaki, Yoshiyuki Kageyama, Yujiro Kaneko, Katsuyuki Yamada, Michiaki Shinotsuka, Makoto Harigaya, Hiroshi Deguchi
  • Patent number: 6652805
    Abstract: Highly filled composite materials, e.g. comprising approximately 60 volume % or greater of finely powdered particles of filler in a polymer matrix, are made by dissolving polymer in a volatilisable solvent, adding filler and forming a homogeneous mixture by high shear mixing. Most solvent is then removed while maintaining homogeneity in the mixture, preferably by evaporation in a high shear mill. Then, extruding a thin layer of the composite material and removing remaining solvent, as by heating. Bodies are formed from the dried layer, which are heated and pressed to melt and disperse melted polymer into the interstices between filler particles. Thereby, certain polymers unusable at low solids contents become effective bonding materials at high solids contents. Filler materials are chosen to tailor electrical and physical properties of the articles, which may comprise substrates for electronic circuits. Suitable polymers are certain polyarylene ethers soluble in cyclohexanone.
    Type: Grant
    Filed: October 5, 2001
    Date of Patent: November 25, 2003
    Assignee: Holl Technologies Company
    Inventors: Richard A. Holl, Philip L. Lichtenberger, Kenneth S. Yao
  • Patent number: 6639787
    Abstract: Pressed material such as anodes are described and formed from oxygen reduced oxide powders using additives, such as binders and/or lubricants. Methods to form the pressed material are also described, such as with the use of atomizing, spray drying, fluid bed processing, microencapsulation, and/or coacervation.
    Type: Grant
    Filed: November 6, 2001
    Date of Patent: October 28, 2003
    Assignee: Cabot Corporation
    Inventors: Jonathon L. Kimmel, Randall V. Redd
  • Patent number: 6625872
    Abstract: A method for easily sintering a magnetic core while preventing damage to the magnetic core caused by deformation or other problems, includes preparing a flattened tubular compact by forming the compact to have a flattened tubular shape and a through hole. A supporting plate made from a baked porcelain material or a metal material having a dimension that allows for insertion into the through hole of the flattened tubular compact, as well as a length that is sufficiently longer than that of the flattened tubular compact, is inserted through the through hole. The flattened tubular compact is placed inside of a sintering container having highly pure alumina powder spread therein so that the axial direction of the compact is horizontal. The flattened tubular compact is then sintered in a sintering furnace to produce the magnetic core.
    Type: Grant
    Filed: December 23, 1999
    Date of Patent: September 30, 2003
    Assignee: Murata Manufacturing Co., Ltd.
    Inventors: Hideyuki Mihara, Hiroyuki Kino
  • Publication number: 20030168333
    Abstract: The invention concerns a sputter target on a metal or metal alloy base with a melting point of not more than 750° C., especially tellurium alloy, with a microstructure of powder particles compacted by means of powder metallurgy, where the primary microstructure of the powder particles is very fine as compared with their size and where the particle size is clearly greater than the grain size of the primary microstructure.
    Type: Application
    Filed: May 8, 2003
    Publication date: September 11, 2003
    Inventors: Martin Schlott, Josef Heindel
  • Publication number: 20030141187
    Abstract: The specification and drawings describe and show embodiments of the present invention in the cesium vapor emitter and the method of fabricating the same. More specifically, the cesium vapor emitter of the present invention includes a housing having at least one chamber therein and at least one channel, wherein the channel has a size wide enough to introduce a desired amount of cesium vapor, a cesium reservoir placed in the chamber, wherein the cesium reservoir is filled with a cesium pellet and a plug located between the cesium pellet and the channel, thereby emitting the cesium vapor from the cesium pellet through the channel, and a stopper securing the cesium reservoir in the chamber, so that the cesium vapor is emitted through the channel.
    Type: Application
    Filed: January 30, 2002
    Publication date: July 31, 2003
    Applicant: PLASMION CORPORATION
    Inventors: Minho Sohn, Seungdeok Kim, Steven Kim
  • Patent number: 6582493
    Abstract: A method for recycling thoriated tungsten objects such as thoriated tungsten scrap resulting from the fabrication of electrodes for lamps. The thoriated tungsten objects are oxidized, homogenized by mixing and chemically reduced under a hydrogen gas atmosphere to form thoriated tungsten. This method eliminates the need to separate the tungsten from its dopants. The thoriated tungsten obtained as the end product is returned to the production process and is preferably used as a raw material for the production of welding electrodes or thoriated tungsten discharge lamp electrodes.
    Type: Grant
    Filed: September 28, 2001
    Date of Patent: June 24, 2003
    Assignee: Patent-Treuhand-Gesellschaft für elektrische Glühlampen mbH
    Inventor: Dieter Meiss
  • Patent number: 6576038
    Abstract: A method to agglomerate metal particles such as tantalum and niobium powders is described which includes combining a volatilizable or vaporizable liquid with the particles to form wet particles; compacting the wet particles; drying the compacted wet particles to form a cake; and heat treating the cake to form the agglomerated particles. Also described are agglomerated particles obtained by this method and further, particles, preferably tantalum or niobium powder, having a flow rate of at least about 65 mg/sec and/or an improved pore size distribution, and/or a higher Scott Density. Capacitors made from tantalum powder and niobium powder are also described.
    Type: Grant
    Filed: May 19, 1999
    Date of Patent: June 10, 2003
    Assignee: Cabot Corporation
    Inventor: Bhamidipaty K. D. P. Rao
  • Publication number: 20030103858
    Abstract: The present invention provides iron-based metallurgical powder compositions and a method of making and using the same. The metallurgical powder compositions of the present invention contain certain amounts of an iron-alloy powder having iron and at least one alloying additive; substantially pure iron powder; and a carbon powder, such as graphite. The metallurgical powder compositions are prepared by admixing the iron-alloy powder with the iron powder and carbon powder. The metallurgical powder compositions thus produce and when formed into metal parts have, for example, improved machinability properties.
    Type: Application
    Filed: October 8, 2002
    Publication date: June 5, 2003
    Inventors: Michael C. Baran, K.S.V.L. Narasimhan
  • Patent number: 6537385
    Abstract: The method for manufacturing alloy powder for R—Fe—B type rare earth magnets of the present invention includes a first pulverization step of coarsely pulverizing a material alloy for rare earth magnets and a second pulverization step of finely pulverizing the material alloy. In the first pulverization step, the material alloy is pulverized by a hydrogen pulverization method. In the second pulverization step, easily oxidized super-fine powder (particle size: 1.0 &mgr;m or less) is removed to adjust the particle quantity of the super-fine powder to 10% or less of the particle quantity of the entire powder.
    Type: Grant
    Filed: July 9, 2002
    Date of Patent: March 25, 2003
    Assignee: Sumitomo Special Metals Co., Ltd.
    Inventors: Katsumi Okayama, Naoyuki Ishigaki, Shuhei Okumura
  • Patent number: 6511631
    Abstract: The present invention aims to prevent heating and ignition of a material powder of a rare-earth alloy while reducing the oxygen content thereof so as to improve the magnetic properties of the rare-earth magnet. A rare-earth alloy powder is compacted by using a powder compacting apparatus including: an airtight container capable of storing a rare-earth alloy powder therein; an airtight feeder box moved between a powder-filling position and a retracted position; and an airtight powder supply device capable of supplying the rare-earth alloy powder from the container into the feeder box without exposing the rare-earth alloy powder to the atmospheric air.
    Type: Grant
    Filed: April 20, 2001
    Date of Patent: January 28, 2003
    Assignee: Sumitomo Special Metals Co., Ltd.
    Inventors: Futoshi Kuniyoshi, Koki Tokuhara, Kunitoshi Kanno, Hitoshi Morimoto, Tomoiku Ohtani, Ryoji Ono
  • Patent number: 6506227
    Abstract: The invention relates to a process for the powder metallurgical production of objects from tool steel as well as to such an object.
    Type: Grant
    Filed: June 6, 2001
    Date of Patent: January 14, 2003
    Assignee: Bohler Edelstahl GmbH
    Inventor: Claes Tornberg
  • Publication number: 20020130041
    Abstract: A method of regenerating a phase-change sputtering target for optical storage media. First, a used powder-metallurgy sputtering target composed of a target material, an adhesion material, and a backing plate is recycled. Then, the target material is separated from the backing plate. Then, the target adhesion material is scraped from the recycled target material Thereafter, the surface of the recycled target material is processed. Finally, the backing plate, a new adhesion material, the recycled target material, and new powders are placed in a vacuum thermal-pressure furnace in sequence to perform a thermal-pressure sintering process.
    Type: Application
    Filed: March 12, 2002
    Publication date: September 19, 2002
    Inventors: Jyh-Chung Wen, Ming-Shyong Lai, Bean-Jon Li
  • Publication number: 20020122737
    Abstract: A powder compaction method in which a powder p is filled by air tapping or other suitable method into a mold 1, then while the mold 1 being filled with the powder, the powder particles are bound with each other without application of force from outside the mold to form a compact C, and then the compact C is taken out from the mold 1. This method produces a variety of shapes of the compact far greater than in conventional methods, and net shape manufacturing of products with complex shapes is made possible by this method. Because this method uses far less binder compared to MIM and PIM that are expected as methods for producing products with complicated shapes, the time needed for elimination of the binder is much shorter than in MIM and PIM.
    Type: Application
    Filed: May 3, 2002
    Publication date: September 5, 2002
    Inventors: Masato Sagawa, Tochihiro Watanabe, Hiroshi Nagata
  • Publication number: 20020094297
    Abstract: Disclosed is a method for the preparation of a sintered body of a high-chromium cast iron of a specified chemical composition having greatly improved mechanical, abrasion-resistant and corrosion-resistant properties as compared with conventional cast bodies of the same cast iron. The inventive method comprises the steps of preparing a powder of the cast iron alloy by quenching solidification of a melt, e.g., by centrifugal spray atomization, and sintering the powder under compression by the discharge plasma sintering method.
    Type: Application
    Filed: December 14, 2000
    Publication date: July 18, 2002
    Inventors: Tomio Satoh, Michiru Sakamoto, Shigeru Akiyama, Akiko Akiyama, Akira Kitahara
  • Patent number: 6409794
    Abstract: A method for producing composite powders based on silver-tin oxide, by chemically reductive precipitation of silver onto particulate tin oxide. A solution of a silver compound and a solution of a reducing agent are simultaneously added in stoichiometrically equivalent amounts, separately and continuously with intensive mixing, to an aqueous suspension of tin oxide. The resulting composite powders have very high homogeneity, and can be processed to make electrical contact materials. The method is particularly suitable for producing composite powders based on silver-tin oxide doped with indium oxide, to be used in the manufacture of electrical contact materials.
    Type: Grant
    Filed: April 4, 2001
    Date of Patent: June 25, 2002
    Assignee: DMC
    Inventors: Roger Wolmer, Mechthild Mueller, Frank Heringhaus, Dietrich Ruehlicke, Dan Goia
  • Patent number: 6409796
    Abstract: A method of treatment a metal powder to increase its surface area is presented. The metal powder to be treated is selected from a group consisting of tantalum, niobium and mixtures thereof. The method utilizes mechanical alloying applied to an initial selected metal powder and an auxiliary substance having relatively weak corrosion resistance as compared to that of the selected metal. The mechanical alloying is continued until a solid solution of the selected metal and the substance is obtained, in which the selected metal particle has a substantially developed surface area and is at least partly wetted with the substance substantially within a surface region of the selected metal particle. The substance is then removed from the obtained solid solution, thereby leaving the selected metal particles with the substantially developed surface area free of the substance.
    Type: Grant
    Filed: October 6, 2000
    Date of Patent: June 25, 2002
    Assignee: Advanced Alloy Technologies, Ltd.
    Inventor: Dina Surpin
  • Patent number: 6391083
    Abstract: A mixture for a powder metallurgy product, including iron powder, graphite powder and copper (Cu) of about 3.0 to about 5.0 weight percent. Iron powder includes iron grains which contain MnS therein. The mixture contains the MnS of about 0.65 to about 1.40 weight percent. The graphite powder is contained in the mixture such that an amount of carbon (C) in the powder metallurgy product is about 0.3 to about 0.7 weight percent. An amount (wt % C) of the carbon and an amount (wt % Cu) of the copper is determined to obtain a target fatigue strength FS (MPa) and a target hardness HR (HRB) based on a relation FS=66.63×(wt % C)+22.61×(wt % Cu)+280.84 HR=22.96×(wt % C)+2.99×(wt % Cu)+78.91.
    Type: Grant
    Filed: November 9, 2000
    Date of Patent: May 21, 2002
    Assignees: Kobeico Metal Powder of America, Inc., Kobe Steel, Ltd., Honda Giken Kogyo Kabushiki Kaisha
    Inventors: Nobuaki Akagi, Shinya Kawai, Masaaki Satoh, Yoshikazu Seki, Masaki Amano, Hideaki Ushio, Russell T. Scott
  • Publication number: 20020054824
    Abstract: A sintered rare earth magnet is produced by finely pulverizing a coarse rare earth magnet alloy powder to an average particle size of 1-10 &mgr;m in a non-oxidizing atmosphere; introducing the resultant fine rare earth magnet alloy powder into a non-oxidizing liquid comprising at least one oil selected from the group consisting of mineral oils, synthetic oils and vegetable oils, and at least one lubricant selected from the group consisting of esters of aliphatic acids and monovalent alcohols, esters of polybasic acids and monovalent alcohols, esters of aliphatic acids and polyvalent alcohols and their derivatives to prepare a slurry; molding the slurry; degreasing the resultant green body; sintering the degreased green body; and then heat-treating the green body.
    Type: Application
    Filed: September 14, 2001
    Publication date: May 9, 2002
    Applicant: HITACHI METALS, LTD.
    Inventors: Hisato Tokoro, Kimio Uchida
  • Publication number: 20020051883
    Abstract: Nanostructured non-stoichiometric materials and methods of reducing manufacturing and raw material costs through the use of nanostructured materials are provided. Specifically, use of non-stoichiometric materials of oxide, nitride, carbide, chalcogenides, borides, alloys and other compositions are taught.
    Type: Application
    Filed: November 27, 2001
    Publication date: May 2, 2002
    Inventors: Tapesh Yadav, Ming Au, Bijan Miremadi, John Freim, Yuval Avniel, Roger Dirstine, John Alexander, Evan Franke
  • Publication number: 20020034663
    Abstract: A sputtering target contains a target material including as constituent elements Ag, In, Te and Sb with the respective atomic percents (atom. %) of &agr;, &bgr;, &ggr; and &dgr; thereof being in the relationship of 0.5≦&agr;<8, 5≦&bgr;≦23, 17≦&ggr;≦38, 32≦&dgr;≦73, &agr;≦&bgr;, and &agr;+&bgr;+&ggr;+&dgr;=100, and a method of producing the above sputtering target is provided. An optical recording medium includes a recording layer containing a phase-change recording material which includes as constituent elements Ag, In, Te and Sb with the respective atomic percents of &agr;, &bgr;, &ggr; and &dgr; thereof being in the relationship of 1≦&agr;<6, 7≦&bgr;≦20, 20≦&ggr;≦35, 35≦&dgr;≦70, and &agr;+&bgr;+&ggr;+&dgr;=100, and is capable of recording and erasing information by utilizing the phase change of the recording material in the recording layer.
    Type: Application
    Filed: September 19, 2001
    Publication date: March 21, 2002
    Inventors: Yukio Ide, Hiroko Iwasaki, Yoshiyuki Kageyama, Yujiro Kaneko, Katsuyuki Yamada, Michiaki Shinotsuka, Makoto Harigaya, Hiroshi Deguchi
  • Publication number: 20020025271
    Abstract: A method and corresponding device for compacting a powder material into a homogenous article. The method includes the steps of, placing the powder material in a molding cavity connected to a gas source, blowing gas into the lower end of the molding cavity so that the particles in the powder material are suspended in a gas stream, sealing the upper end of the molding cavity by an upper pressing punch, connecting the lower end of the molding cavity to a vacuum source, sealing the connection to the vacuum source by moving a lower punch relative to the lower end portion of the molding cavity, and thereafter compacting the powder material with the help of the pressing punch.
    Type: Application
    Filed: April 23, 2001
    Publication date: February 28, 2002
    Inventor: Bo Goransson
  • Patent number: 6348081
    Abstract: A granulated powder for a high-density sintered body is provided, which has an excellent flow rate and an excellent sintered density, and a sintered body produced using the same is provided. The granulated powder is obtained by granulation using a binder and a powder material comprising small diameter particles comprised of stainless steel and having an average particle diameter of 1 to 20 &mgr;m and large diameter particles comprised of stainless steel and having an average particle diameter of 30 to 150 &mgr;m. The content of the small diameter particles in the granulated powder is 30 to 70% by weight, and at least part of the small diameter particles adheres to the surfaces of the large diameter particles to form skin particles.
    Type: Grant
    Filed: September 25, 2000
    Date of Patent: February 19, 2002
    Assignee: Daido Tokushuko Kabushiki Kaisha
    Inventors: Akira Horata, Tetsuya Kondo
  • Patent number: 6346132
    Abstract: A composite material includes a metallic second phase dispersed in a metallic matrix material. The metallic second phase has a grain structure that is at least partially martensitic. The second phase material is preferably an alloy of nickel and titanium, each present in the range from 48 to 52 atomic %, optionally in combination with further additives. The second phase particles can be present in the form of granular particles, wires, fibers, whiskers, or layers, making up 5 to 60 vol. % of the overall composite material. The matrix material is preferably an aluminum alloy. The composite material has a high damping capacity and a high tensile strength provided by the matrix, and a high damping capacity provided by the second phase. A method of making the composite material involves mixing a powdery matrix material and a powdery second phase material, and then heat and consolidating the mixture at a temperature of 400 to 700 ° C. and a pressure of 100 to 300 MPa.
    Type: Grant
    Filed: June 15, 2000
    Date of Patent: February 12, 2002
    Assignee: DaimlerChrysler AG
    Inventors: Ulrike Huber, Rainer Rauh, Eduard Arzt
  • Patent number: 6344168
    Abstract: The method of producing an R—Fe—B type sintered magnet according to the present invention includes the steps of: (a) preparing an alloy powder material in a first state, in which a first amount of lubricant has been applied to a surface of an alloy powder; (b) partially evaporating said lubricant in said alloy powder material in said first state to transform said alloy powder material into a second state, in which the amount of said lubricant has been reduced to a second amount; (c) compacting said alloy powder material in said second state to form a compact; and (d) sintering said compact.
    Type: Grant
    Filed: August 29, 2000
    Date of Patent: February 5, 2002
    Assignee: Sumitomo Special Metals Co., Ltd.
    Inventor: Futoshi Kuniyoshi
  • Publication number: 20020012600
    Abstract: The method for producing a rare-earth sintered magnet of the present invention includes the steps of: compacting alloy powder for the rare-earth sintered magnet to form a green compact; loading the green compact into a case having a structure restricting a path through which gas flows between the outside and inside of the case, and placing a gas absorbent at least near the path; and sintering the green compact by heating the case including the green compact inside in a decompressed atmosphere.
    Type: Application
    Filed: May 2, 2001
    Publication date: January 31, 2002
    Inventors: Koki Tokuhara, Akiyasu Oota, Tsuyoshi Wada, Katsumi Okayama, Tomoiku Ohtani, Kunitoshi Kanno
  • Patent number: 6338816
    Abstract: A nitrogen containing niobium powder is disclosed as well as electrolytic capacitors formed from the niobium powders. Methods to reduce DC leakage in a niobium anode are also disclosed.
    Type: Grant
    Filed: March 9, 2000
    Date of Patent: January 15, 2002
    Assignee: Cabot Corporation
    Inventor: James A. Fife
  • Publication number: 20010037938
    Abstract: A refractory metal silicide target is characterized by comprising a fine mixed structure composed of MSi2 (where M: refractory metal) grains and Si grains, wherein the number of MSi2 grains independently existing in a cross section of 0.01 mm2 of the mixed structure is not greater than 15, the MSi2 grains have an average grain size not greater than 10 &mgr;m, whereas free Si grains existing in gaps of the MSi2 grains have a maximum grain size not greater than 20 &mgr;m. The target has a high density, high purity fine mixed structure with a uniform composition and contains a small amount of impurities such as oxygen etc. The employment of the target can reduce particles produced in sputtering, the change of a film resistance in a wafer and the impurities in a film and improve yield and reliability when semiconductors are manufactured.
    Type: Application
    Filed: May 2, 2001
    Publication date: November 8, 2001
    Applicant: KABUSHIKI KAISHA TOSHIBA
    Inventors: Michio Sato, Takashi Yamanobe, Tohru Komatsu, Yoshiharu Fukasawa, Noriaki Yagi, Toshihiro Maki, Hiromi Shizu
  • Patent number: 6312642
    Abstract: A method for controlling oxygen content in valve metal materials. The method includes deoxidizing a valve metal material, typically tantalum, niobium, or alloys thereof, and leaching the material in an acid leach solution at a temperature lower than room temperature. In one embodiment of the present invention, the acid leach solution is prepared and cooled to a temperature lower than room temperature prior to leaching the deoxidized valve metal material. The method of the present invention has been found to lower both the oxygen and fluoride concentrations in valve metal materials, as the use of reduced acid leach temperatures provide lower oxygen for a given quantity of a leach acid, such as hydrofluoric acid.
    Type: Grant
    Filed: July 2, 1999
    Date of Patent: November 6, 2001
    Assignee: Cabot Corporation
    Inventor: James A. Fife
  • Patent number: 6312643
    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.
    Type: Grant
    Filed: October 24, 1997
    Date of Patent: November 6, 2001
    Assignee: The United States of America as represented by the Secretary of the Air Force
    Inventors: Kamleshwar Upadhya, Wesley P. Hoffman
  • Patent number: 6280683
    Abstract: Improved methods for coating particulate materials at low shear conditions and preferably below the melting point of the coating material are provided. In one aspect, metallurgical compositions are provided that contain a metal-based powder bound to an alloying powder or powders by way of a low melting polymer or wax binding agent, which is preferably polyethylene. The binding agent is blended with the metal-based and alloying powders at elevated temperatures preferably below the melting point of the binding agent. The bonded metallurgical composition can be used in compaction processes to manufacture compacted parts that can be sintered to impart strength.
    Type: Grant
    Filed: October 22, 1999
    Date of Patent: August 28, 2001
    Assignee: Hoeganaes Corporation
    Inventors: William Hendrickson, Sydney Luk
  • Patent number: 6280496
    Abstract: A silicon carbide based composite material includes as a first component, a metal mainly consisting of aluminum or copper, and as a second component, particles mainly consisting of silicon carbide having high purity and few defects. The material is obtained by heating a compact of the raw material powder containing the first and second components at a temperature not lower than the melting point of the metal mainly consisting of aluminum or copper, and by forging and solidifying under pressure. Preferably, the silicon carbide raw material powder is prepared to have high purity by carrying out a preliminary treatment, or the material after forging or a material obtained through a conventional infiltration process is further heated at a temperature lower than the melting point of the first component. In this manner, an improved superior thermal conductivity can be obtained.
    Type: Grant
    Filed: September 8, 1999
    Date of Patent: August 28, 2001
    Assignee: Sumitomo Electric Industries, Ltd.
    Inventors: Chihiro Kawai, Shin-ichi Yamagata, Akira Fukui, Yoshinobu Takeda
  • Patent number: 6270547
    Abstract: A hydrogen absorbing alloy electrode characterized in that the electrode consists mainly of a mixture of a first hydrogen absorbing alloy powder A formed on surfaces of particles thereof with a surface layer 22 containing metallic copper or a copper oxide and a second hydrogen absorbing alloy powder B formed on surfaces of particles thereof with a surface layer 24 containing metallic cobalt or a cobalt oxide. The copper-coated hydrogen absorbing alloy powder A affords improved electric conductivity, and the cobalt-coated hydrogen absorbing alloy powder B gives improved ability to absorb and desorb hydrogen, whereby the electrode is improved in different battery characteristics, such as cycle characteristics, high-rate discharge characteristics and infernal pressure characteristics, at the same time.
    Type: Grant
    Filed: March 29, 2000
    Date of Patent: August 7, 2001
    Assignee: Sanyo Electric Co., Ltd.
    Inventors: Teruhiko Imoto, Kikuko Kato, Yohei Hirota, Nobuyuki Higashiyama, Mamoru Kimoto, Shin Fujitani, Koji Nishio
  • Patent number: 6159308
    Abstract: A method of producing an R--Fe--B-based, sintered permanent magnet, wherein R is at least one rare earth element including Y, having a small oxygen content. A coarse alloy powder prepared by a reductive diffusion method is milled and recovered into a solvent to form a slurry. The slurry is wet-compacted to form a green body which is then sintered after removing the solvent. The milling, recovering, wet-compacting, solvent-removing and sintering steps are carried out while preventing the powder, slurry and green body from being brought into contact with air to minimize the oxygen content in the final sintered permanent magnet. The sintered permanent magnet produced has a high density and a high magnetic properties due to a low oxygen content.
    Type: Grant
    Filed: December 11, 1998
    Date of Patent: December 12, 2000
    Assignee: Hitachi Metals, Ltd.
    Inventors: Kimio Uchida, Masahiro Takahashi
  • Patent number: 6149861
    Abstract: It is an object of the present invention to provide a method for manufacturing a raw material alloy powder that can be utilized effectively in the regeneration of surplus or defective R--Fe--B type sintered magnets while leaving the main phase crystal grains alone, and a method for manufacturing an R--Fe--B type magnet. Surplus or defective R--Fe--B type sintered magnets are pulverized, acid washed, and dried, after which this product is subjected to a calcium reduction treatment and washed to remove the calcium component, which allows a raw material alloy powder composed of an Nd.sub.2 Fe.sub.14 B main phase system, which contributes the most to magnet characteristics, to be regenerated efficiently. An alloy powder for compositional adjustment that improves sintering and adjusts the composition is added to this main phase system raw material alloy powder to produce a sintered magnet, which facilitates the manufacture of a sintered magnet with superior magnet characteristics.
    Type: Grant
    Filed: April 6, 2000
    Date of Patent: November 21, 2000
    Assignee: Sumitomo Special Metals Co., Ltd.
    Inventors: Yuji Kaneko, Yasuhide Sasakawa, Katsuya Kase, Takashi Hashikawa, Kaname Takeya
  • Patent number: 6136100
    Abstract: A process for passivating rare-earth alloy powders such that magnets formed from the powders have fewer expansion defects is described. By exposing the rare-earth alloy powders to a humid atmosphere, rare-earth oxide impurities that could result in eruptions in the magnets are reduced. Magnets made from the passivated powder show fewer expansion defects than magnets made from unpassivated powder.
    Type: Grant
    Filed: September 29, 1999
    Date of Patent: October 24, 2000
    Assignee: Magnequench International, Inc.
    Inventor: Viswanathan Panchanathan
  • Patent number: 6110420
    Abstract: A composite structure and method for manufacturing same, the composite structure being comprised of metal particles and an inorganic bonding media. The method comprises the steps of coating particles of a metal powder with a thin layer of an inorganic bonding media selected from the group of powders consisting of a ceramic, glass, and glass-ceramic. The particles are assembled in a cavity and heat, with or without the addition of pressure, is thereafter applied to the particles until the layer of inorganic bonding media forms a strong bond with the particles and with the layer of inorganic bonding media on adjacent particles. The resulting composite structure is strong and remains cohesive at high temperatures.
    Type: Grant
    Filed: August 3, 1999
    Date of Patent: August 29, 2000
    Assignee: UT-Battelle, LLC
    Inventors: Arthur J. Moorhead, Hyoun-Ee Kim
  • Patent number: 6089843
    Abstract: An outer rotor and an inner rotor are formed of sintered aluminum alloy. The sintered aluminum alloy contains 0.5 wt % to 11 wt % of aluminum nitride. Porosity of the sintered aluminum alloy for outer rotor is 3 vol % to 15 vol %. Porosity of the sintered aluminum alloy for inner rotor is 2 vol % to 10 vol %. Outer rotor and inner rotor are set in a pump case. A rotary driving shaft formed of steel is inserted to a through hole of inner rotor. A press fit member is inserted at a press fit surface of inner rotor and rotary driving shaft. Accordingly, sliding members formed of sintered aluminum alloy which reduces seizure and abrasive wear of the inner and outer rotors can be provided, and in addition, an oil pump of which wear and damage at the inner rotor inner diameter surface is suppressed, can be provided.
    Type: Grant
    Filed: September 10, 1998
    Date of Patent: July 18, 2000
    Assignee: Sumitomo Electric Industries, Ltd.
    Inventor: Katsuyoshi Kondoh
  • Patent number: 5993731
    Abstract: The process for producing net shape or near net shape metal parts is improved by sintering a compact in a reducing atmosphere where the compact contains a metal and chemically-bound oxygen in the form of a metal oxide, for example, and the chemically-bound oxygen is in an amount sufficient to improve the sintering of the compact. Improved sintering is facilitated when the metal oxide forms a metal/metal oxide eutectic during reduction of the chemically-bound oxygen in a reducing atmosphere during the sintering process. The compact can contain a metal oxide and a solution compound to produce an alloy part, provided the chemically-bound oxygen is present in an amount sufficient to improve sintering. In a preferred embodiment, the compact also contains a reinforcement compound and is sintered to make a metal matrix composite. The resultant density of the near net shape metal parts made by the improved sintering process is preferably about 97% or more of the theoretical density.
    Type: Grant
    Filed: November 7, 1997
    Date of Patent: November 30, 1999
    Assignee: Brush Wellman, Inc.
    Inventors: David E. Jech, Juan L. Sepulveda, Anthony B. Traversone
  • Patent number: 5935722
    Abstract: A laminated composite structure of alternating metal powder layers, and layers formed of an inorganic bonding media powder, and a method for manufacturing same are discosed. The method includes the steps of assembling in a cavity alternating layers of a metal powder and an inorganic bonding media of a ceramic, glass, and glass-ceramic. Heat, with or without pressure, is applied to the alternating layers until the particles of the metal powder are sintered together and bonded into the laminated composite structure by the layers of sintered inorganic bonding media to form a strong composite structure. The method finds particular application in the manufacture of high performance magnets wherein the metal powder is a magnetic alloy powder.
    Type: Grant
    Filed: September 3, 1997
    Date of Patent: August 10, 1999
    Assignee: Lockheed Martin Energy Research Corporation
    Inventors: Arthur J. Moorhead, Hyoun-Ee Kim
  • Patent number: 5925463
    Abstract: The object of the invention is a method for the electrochemical preparation of metal colloids with particle sizes of less than 30 nm, characterized in that one or more metals of groups Ib, IIb, III, IV, V, VI, VIIb, VIII, lanthanoides, and/or actinoides of the periodic table are cathodically reduced in the presence of a stabilizer, optionally with a supporting electrolyte being added, in organic solvents or in solvent mixtures of organic solvents and/or water within a temperature range of between -78.degree. C. and +120.degree. C. to form metal colloidal solutions or redispersible metal colloid powders, optionally in the presence of inert substrates and/or soluble metal salts of the respective metals.The invention further relates to soluble or redispersible colloids as well as application on substrates and immobilization thereof, in particular for the preparation of catalysts.
    Type: Grant
    Filed: December 18, 1996
    Date of Patent: July 20, 1999
    Assignee: Studiengesellschaft Kohle mbH
    Inventors: Manfred T. Reetz, Wolfgang Helbig, Stefan Andreas Quaiser