Abstract: A sintering compound containing a sinterable powder and a binder removable in a debinding step is injected into a metal mold set provided with a sintering compound injecting mold, in a sintering compound molding step (S104). An add-on forming compound which becomes removable or separable from the sintering compound injection molded body in the debinding step or the sintering step is injected into the metal mold set provided with an add-on mold in an add-on forming step (S102). The sintering compound injection molded body and the add-on are formed integrally with each other in the metal mold set. The integral formation of the add-on and the sintering compound injection molded body enables to prevent damage during release from the mold and make easy to handle the injection molded body.

Abstract: A composition having high density and low toxicity suitable for use as a shotgun pellet, a bullet or armor piercing projectile and a method for manufacturing such composition is described. This material and product are developed to economically address the toxicity problems inherent in lead shot and bullets. This composition, in its present embodiment, is also suitable for use in any product requiring high-density and low toxicity. One present embodiment maintains the magnetic properties of the projectile if desired.

Abstract: Methods of forming bit bodies for earth-boring bits include assembling green components that have been infiltrated, brown components that have been infiltrated, or fully sintered components that have been infiltrated, and sintering the assembled components. Other methods include isostatically pressing a powder to form a green body substantially composed of a particle-matrix composite material, and sintering or hot isostatic pressing the green body or brown body to provide a bit body having a desired final density. Methods of forming earth-boring bits include providing a bit body substantially formed of a particle-matrix composite material and attaching a shank to the body. The body is provided by pressing a powder to form a green body and sintering the green body. Earth-boring bits include a unitary structure substantially formed of a particle-matrix composite material. The unitary structure includes a first region configured to carry cutters and a second region that includes a threaded pin.

Abstract: A method for providing a porous metal implant. A mixture of a biocompatible metal, a spacing agent, and a binder is provided. The mixture is formed into a shaped the spacing agent is removed to form a plurality of pores in the implant. A shaped porous metal implant is also provided.

Abstract: The present invention discloses a process for sintering particles using a sintering aid. The sintering aid can be brought into contact with a plurality of particles to be sintered such that a mixture of the particles and the sintering aid is provided. The mixture of particles and the sintering aid is heated and at least part of the sintering aid is vaporized. Sintering of the particles to form a sintered component followed by cooling of the sintered component can complete the process, or in the alternative, a subsequent heating step or steps can be included whereby additional vaporization of the sintering aid can occur.

Abstract: A feedstock composition and a method of forming metal articles using powder metallurgy techniques comprise mixing metal powders and a novel aromatic binder system. The composition of the novel feedstock comprises an aromatic binder system and a metal powder. The aromatic binder system comprises an aromatic species and can further comprise lubricants, surfactants, and polymers as additives. The metal powder comprises elemental metals, metal compounds, and metal alloys, particularly for highly-reactive metals. The method of forming metal articles comprises the steps of providing and mixing the metal powder and the aromatic binder system to produce a novel feedstock. The method further comprises processing the novel feedstock into a metal article using a powder metallurgy forming technique. Metal articles formed using the present invention have an increase in carbon and oxygen contents each less than or equal to 0.2 wt % relative to the metal powder used to fabricate the article.

Abstract: A shaped charge liner formed by injection molding, where the liner components include powdered metal and organic binder. The liner components are blended then processed within an injection molding device and urged from the molding device into a mold where a liner shape is formed. The liner shape is debinded, both mechanically and chemically. Mechanical debinding involves heating and chemical debinding comprises treating the liner shape with a solution to dissolve and remove the binder components. The process of forming the shaped charge liner does not include sintering. The present process can also use “green products” formed by the injection molding device that are not debinded. A shaped charge case can also be formed using the present method. The added step of sintering can be applied to the process of forming the shaped charge case.

Abstract: An ultrasonic welding tool fabricated of powder metal material includes a body and a welding tip extending axially from the body to a working end. The powder metal material can be ferrous-based and admixed with additives, such as alumina, carbide, ferro-molybdenum, ferro-nickel, chrome or tribaloy. An exposed surface of the welding tip can comprise Fe3O4 oxides. The tool is compacted to the desired shape and sintered. The body can include a different second material compacted separately from the welding tip and then joined to the tip and sintered.

Abstract: Nanotechnology methods for creating stoichiometric and non-stoichiometric substances with unusual combination of properties by lattice level composition engineering are described.

Abstract: Hollow metal spheres are heated in a high vacuum in the presence of an organic substance, at a temperature at least equal to the melting point of a eutectic between carbon and the metallic constituents of the said spheres.

Abstract: A component is produced by powder metallurgy from hard metal. The alloy includes at least one grain growth-inhibiting additive from the group consisting of V, Cr, Ti, Ta and Nb with, at least locally, a graduated concentration profile. As a result, the mechanical properties also have a graduated profile. In the fabrication process, a dispersion or solution which contains the grain growth-inhibiting additive in finely distributed or dissolved form is applied to the surface of a green compact. Penetration of this dispersion or solution along open pores leads to a graduated distribution of the grain growth-inhibiting additive in the green compact. There is also described a process in which the grain growth-inhibiting additive in the form of a solution is distributed uniformly in the green compact and is then gradually broken down from edge regions by a heat treatment or a solvent.

Abstract: A novel method is disclosed for the preparation of a sintered porous body of a metallic or ceramic powder having a closed cell texture and a porosity as high as 95% or higher. The method comprises the steps of: preparing a foamable aqueous slurried composition containing a powder of the metallic or ceramic material, a blowing agent and a binder resin which is a water-soluble polymer capable of becoming gelled; subjecting the slurried composition to gelation of the binder resin; subjecting the gelled mass of the composition to foaming by gas-evolution from the blowing agent; and heating the thus gelled and foamed body of the composition to effect drying and sintering of the particles of the metallic or ceramic powder.

Abstract: 1. High pressure nozzle and method for the manufacture of a high pressure nozzle. 2.1. The invention relates to a high pressure nozzle with a jet director within a supply channel to a discharge opening. 2.2 According to the invention in an area directly surrounding the supply channel median longitudinal axis, the jet director has a free flow cross-section. 2.3. Use e.g. for high pressure nozzles for descaling steel products.

Abstract: A process for manufacturing a sliding contact piece for medium to high current densities including a step of warm premixing of graphite and plastic binder, a step of cold mixing of the resulting premixture with copper, a step of pressing of the resulting main mixture into the sliding contact piece, and finally a step of sintering of it; and so as to improve the operating characteristics of the sliding contact piece, which is free of any environmentally harmful additives, a metal such as zinc, tin, bismuth or an alloy of such metals is added during the premixing of the graphite and plastic binder.

Abstract: A powder injection molding composition is disclosed. The composition comprises caprolactam and a plurality of particles, where that plurality of particles is selected from a metal powder, a metal hydride powder, a ceramic powder, a ferrite powder, and mixtures thereof. The composition optionally firther comprises a wax and polymeric material.

Abstract: A method of reducing the oxygen content of a powder is provided. A canister is prepared with a getter, filled with the powder to be densified, sealed and evacuated. The canister is subjected to a hydrogen atmosphere at an elevated temperature whereby hydrogen diffuses into the canister through the walls thereof. The hydroge forms moisture when reacted with the oxygen of the powder and the moisture in the reacted with the getter in order to remove oxygen from the powder to the getter. The atmosphere outside the canister is then altered to an inert atmosphere or vacuum, whereby hydrogen diffuses out of the canister. A dense body having a controlled amount of oxygen can thereafter be produced by conventional powder metallurgy techniques.

Abstract: The present invention relates to a method for manufacturing a dental scaler tip using a powder injection molding process which can produce the article in large quantities to save the manufacturing cost and forms an eccentric discharge port of a scaler tip to operate the mould using only one core pin, a mould used for the same that is provided with slide cores having the various shapes machined according to the article to enable the uniform article to be manufactured rapidly to enhance a characteristic and design of the article, and a scaler tip manufactured by the same that is more excellent in shape-reliability and injects fluid to a front end thereof along a curved section of the tip section to perform effectively an operation.

Abstract: “The present invention relates to a method for fabricating parts by an injection molding technique including preparing a feedstock—having at least one powder mixed with a polymer binder solubilized in a solvent, injecting the feedstock into the mold under pressure, debinding, and sintering where the feedstock is maintained at a temperature above a solvent vaporization temperature during the pressing.

Abstract: Novel powders or particles are formed by associating them with relatively small proportions of hydrolysable liquid material. The resulting particle/liquid mass is placed in a mold and sintered under conditions of heat and pressure that enables at least some of the hydrolysable liquid to react within the sintered mass. The sintered mass displays a controllable range of properties such as increased density, increased tensile strength, and improved natural polish finish. The hydrolysable liquid may partially hydrolyze and/or react with the powders and particles, but the liquid is not completely (not 100%) reduced to an inorganic oxide prior to introduction to the mold and performance of the sintering process.

Abstract: The invention concerns a powder metal composition comprising an iron based powder and a lubricant and/or binder comprising at least one secondary amide of the general formula: R1—NH—CO—R2, wherein R1 and R2 are the same or different, straight or branched, saturated or unsaturated aliphatic hydrocarbon groups. The invention further concerns a method of making green bodies of the powder metal composition according to the invention, a method of producing a bonded iron-based powder composition, as well as the use of the at least one secondary amide as a lubricating and/or binding agent for iron based powders and the use as a die wall lubricant.

Abstract: A controlled combustion synthesis apparatus comprises an ignition system, a pressure sensor for detecting internal pressure, a nitrogen supply, a gas pressure control valve for feeding nitrogen and exhausting reaction gas, means for detecting the internal temperature of the reaction container, a water cooled jacket, and a cooling plate. A temperature control system controls the temperature of the reaction container by controlling the flow of cooling water supplied to the jacket and the cooling plate in response to the detected temperature. By combustion synthesizing, while controlling the internal pressure and temperature, the apparatus can synthesize a silicon alloy including 30-70 wt. % silicon, 10-45 wt. % nitrogen, 1-40 wt. % aluminum, and 1-40 wt % oxygen.

Abstract: A method of making cemented carbide at which powders forming hard constituents and powders forming binder phase are wet milled together with a pressing agent is disclosed. The slurry is dried, preferably by spray drying, compacted into bodies of desired shape and sintered. A cemented carbide powder with a reduced compacting pressure at a predetermined weighing in of 18% shrinkage can be obtained by using from about 1 to about 3 wt-% pressing agent with the following composition: less than about 90 wt-% PEG and greater than about 10 wt-% of long chain C?20 fatty acids, their esters and salts, in particular, erucic acid and/or behenic acid. The invention also relates to a cemented carbide powder with low compaction pressure.

Abstract: The invention concerns a sintered metal part which has a densified surface and sintered density of at least 7.35 g/cm3 and a core structure distinguished by a pore structure obtained by single pressing to at least 7.35 g/cm3 and single sintering of a mixture of a coarse iron or iron-based powder and optional additives.

Abstract: Clutch components for automotive use usually include a pair of clutch members with operative faces. In particular, planar one way clutches include a pair of clutch members whose operative faces are enclosed spaced opposition, with each clutch face including a plurality of recessed defining respective load bearing shoulders. A plurality of struts are disposed between the coupling face of the members, and such struts are moveable between the coupling position and non coupling position. A preferable method of manufacturing such clutch components includes powder metal operations comprising die compacting a metal powder into a metal blank, sintering the metal blank to form a sintered metal blank, and cooling the sintered metal blank to form a cooled metal blank. The preferred metallic structure of the cooled metal blank is 50-80% martensite and 20-50% bainite and fine pearlite. The application is especially useful for clutches used as backing plates in clutch brake applications.

Abstract: A porous near-net-shape metallic parts with an open porosity of at least 10% by volume is made by first forming an injectable mass of a metallic powder of stainless steel, Ti, NiTi, or a titanium alloy, at least one thermoplastic binder, and at least one place holder. The mass then injection molded into the shape of the part to be produced, cooled, set in a capillary-active material, and subjected to a first-stage binder removal to produce an open porosity. The place holder is then removed at least partially from the part with a fluid, and the part is subjected to a thermal binder-removing process. Finally the part is sintered.

Abstract: A method for producing a sintered body is provided. The method for producing the sintered body comprising: forming a green body by molding a composition for forming a green body into a specified shape to obtain the green body, the composition comprising powder constituted of a metallic material and a binder containing a first resin which is decomposable by ozone; first debinding the green body by exposing the green body to a high ozone content atmosphere to decompose the first resin and remove the decomposed first resin form the green body to obtain a brown body; exposing the thus obtained brown body at least once to a low ozone content atmosphere whose ozone concentration is lower than an ozone concentration of the high ozone content atmosphere to obtain an intermediate brown body; and sintering the intermediate brown body which has been exposed to the low ozone content atmosphere to obtain the sintered body.

Abstract: Embodiments of a method for making molybdenum parts using metal injection molding are disclosed. In general, molybdenum powder is mixed or blended with a binder to form a feedstock, which is injection molded to form a green-state part. The green-state part is then sintered, such as by heating the part in a furnace for a predetermined period of time to effect consolidation and densification of the part. Desirably, the green-state part can be debound to remove at least a portion of the binder prior to sintering. In exemplary embodiments, sintering produces the final molybdenum article, and therefore the process does not require, but optionally may include, further processing of the sintered part, such as machining, cold-working, and/or hot-working.

Abstract: The invention concerns a new pre alloyed steel powder comprising in addition to iron and inevitable impurities, by wt %, 1.3-1.7% by weight of Cr, 0.15-0.3% by weight of Mo, 0.09-0.3% by weight of Mn, not larger than 0.01 by weight of C, not larger than 0.25% of O.

Abstract: This invention relates to a method of functionalising a powdered substrate. The method comprises the following steps, which method comprises passing a gas into a means for forming excited and/or unstable gas species, typically an atmospheric pressure plasma or the like and treating the gas such that, upon leaving said means, the gas comprises excited and/or unstable gas species which are substantially free of electric charge. The gas comprising the excited and/or unstable gas species which are substantially free of electric charge is then used to treat a powdered substrate and a functionalising precursor in a downstream region external to the means for forming excited and/or unstable gas, wherein neither the powdered substrate nor the functionalising precursor have been subjected to steps (i) and (ii) and wherein said functionalising precursor is introduced simultaneously with or subsequent to introduction of the powdered substrate. Preferably the method takes place in a fluidised bed.

Abstract: The invention concerns a method of controlling the dimensional change to a predetermined value including the steps of providing a first powder (A) consisting of an iron based powder (1) and copper in the form of elemental copper (2), or copper diffusion-bonded to the iron-based powder (3); providing a second powder (B) consisting of the iron-based powder (1) and a pre-alloyed iron-copper powder (4); mixing the first and second powder mixtures (A) and (B) in proportions resulting in the desired dimensional change adding graphite and lubricant and optionally hard phase materials and other alloying elements to the obtained mixture; compacting the obtained mixture; and sintering the compacted body.

Abstract: An atomised pre-alloyed iron-based powder which comprises by weight-% 10.5-30 Cr ??3-15 Al ??5-20 Cu max 0.1 C max 0.2 N max 3.0 Mn max 2.5 Si max 3.0 Mo balance essentially only iron and unavoidable impurities.

Abstract: In contrast to current industrial practice where alloying powders are added to starting powder metallurgy compositions either as powder mixtures or fully prealloyed powders, the present invention posits a diffusion bonded nickel-copper precursor additive mixture for direct one step addition to the starting powder metallurgy master blend composition. Segregation and dusting are substantially reduced and the mechanical properties of the resultant compact are improved.

Abstract: The present invention concerns a powder metal composition for producing powder metal components comprising a Co-based pre-alloyed powder, with irregularly shaped particles comprising at least 15% by weight Cr and less than 0.3% by weight C, admixed with graphite. The invention also concerns a method for producing PM components by pressing of articles to shape from the powder metal composition according to the invention and sintering them.

Abstract: High-density composite materials comprising tungsten and bronze are useful as lead replacements in the production of ammunition, weights and other high density articles. The composition of the composite, articles manufactured using the composite, and a process for making the composite are disclosed.

Abstract: A method for solid free-form fabrication of a three-dimensional metal object includes depositing a particulate blend in a defined region, the particulate blend including a number of metal or metal alloy particulates and a peroxide, and selectively ink-jetting a binder system onto a predetermined area of the particulate blend to form a green part, wherein the liquid phase binder includes a water soluble monofunctional acrylate-based monomer, a water soluble difunctional acrylate-based monomer, an amine, and water.

Abstract: Polycrystalline diamond (PCD) carbide composites of this invention have a microstructure comprising a plurality of granules formed from PCD, polycrystalline cubic boron nitride, or mixture thereof, that are distributed within a substantially continuous second matrix region that substantially surrounds the granules and that is formed from a cermet material. In an example embodiment, the granules are polycrystalline diamond and the cermet material is cemented tungsten carbide. PCD carbide composites of this invention display improved properties of fracture toughness and chipping resistance, without substantially compromising wear resistance, when compared to conventional pure PCD materials.

Abstract: An object of the present invention is to provide a low-alloyed steel powder for sintering that can yield a sintered compact with high density and uniform characteristics, and to provide a sintered compact having such characteristics. The present invention is a raw powder for sintering, comprising Fe as its primary component and also comprising 0.8 wt % or less of C, 0.05 to 1.0 wt % of Si, 1.0 wt % or less of Mn, and 1.0 to 10.0 wt % or less of Ni, wherein the mean grain size of the raw powder for sintering is 8.5 ?m or less; and is also a granulated powder for sintering obtained by granulating the raw powder for sintering by means of a binder.

Abstract: A 3D Printing Rapid Prototyping process using Al/Mg particles coated with a metal (i.e. copper, nickel, zinc, or tin) that (1) prevents oxidation of the Al/Mg particles, and (2) either alone, or when alloyed with the aluminum or magnesium core metal, melts below the liquidus temperature of the core.

Abstract: A green article comprising an A-B powder mixture and methods of manufacturing such green articles and corresponding sintered articles are disclosed. The A-B powder mixture consists of a minor volume fraction of a relatively fine powder A and a complementary major volume fraction of a relatively coarse prealloyed powder B wherein the A-B powder mean particle size ratio is at least about 1:5. Metal powder A consists of one or more elemental metals or alloys which has a melting or solidus temperature above the highest sintering temperature at which the A-B powder mixture may be sintered without slumping. Prealloyed metal powder B consists of one or more alloys which are amenable to supersolidus liquid phase sintering. Green articles made from the A-B powder have a wider sintering temperature window than do articles made from prealloyed metal powder B alone.

Abstract: A metal-made seamless pipe is provided, containing at least one metal selected from the group consisting of metals each having a melting point of 1,600° C. or more, and has a porosity of 0.3 to 25%. The porosity is defined as a ratio of the open pores present at the outer surface of the pipe to the total surface area of the outer surface of the pipe. The open pores do not include through-pores perforating to the inner surface of the pipe. A process for producing such a metal-made seamless pipe is also provided. The metal-made seamless pipe is low in processability but can be produced having a small thickness and a small inner diameter, having superior mechanical strength and gastightness, and can be suitably used as a sealing member of a translucent vessel of a high-pressure discharge lamp.

Abstract: The invention refers to a new method for preparing sintered structural parts of carbon or tool steels or high speed steel having a carbon content of up to 2% by weight, wherein an agglomerated spherical powder comprising at least 0.5% of a thermo-reversible hydrocolloid is pressed to a green body of high density which is then heated at 450–650° C. to remove the non-carbon content of the hydrocolloid and subsequently sintered at about 1100–1400° C. to structural parts having high strength properties.

Abstract: The invention relates to a method for producing metal bodies by mixing metal compound particles with a binding agent and compacting them to form shaped parts, whereby the binding agent is subsequently removed and the metal compound is reduced to metal by gassing the same with a reductive gas at high temperatures. The reduction is carried out at temperatures lower than the sintering temperature of the reduced metal compound so that the formed reduced shaped bodies, while maintaining their original dimensions to a large extent, have a density less than that of the metal compound used. The metallic matrix obtained in such a manner can be subjected to a post compaction by applying mechanical forces. High-strength steel parts having very low residual porosities and a high geometric tolerance are obtained by sintering the matrix at usual sintering temperatures after compaction.

Abstract: The present invention provides: a material, which is dense, with a density of ?90%, bulk dry self-lubricating, with a coefficient of friction of <0.3, constituted by a matrix that endows it with suitable strength, with a Rm of ?400 MPa in a medium to high temperature range of 300° C.???600° C.; said matrix including particles of solid lubricant in its volume; mechanical parts formed from said material; a method of manufacturing said material.

Abstract: The invention concerns a method of preparing an iron-based powder comprising the steps of mixing and heating an iron-based powder, at least one oligomer amide type lubricant, at least one fatty acid and optionally one or more additives to a temperature above the melting point of the lubricant and subsequently cooling the obtained mixture. The invention also comprises the mixture of the iron-based powder, the oligomer amide type lubricant and the fatty acid.

Abstract: A manufacturing method for high-density iron-based powder compacts is disclosed. The temperature of the die is adjusted at ordinary temperature or at a predetermined temperature by preheating. A lubricant for die lubrication prepared by mixing at least two different lubricants having melting points higher than a predetermined temperature of the compaction pressure is sprayed at the upper part of the die and is introduced into the die and adhered by electrification to the surface of the die. The resulting die is filled with an iron-based mixed powder including a lubricant and molding is performed at ordinary temperature or at a temperature raised by heating.

Abstract: A method of preparing an article made of a metallic material having its constituent elements includes the steps of 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, and thereafter utilizing the nonmetallic precursor compound to produce a metallic injection molded brown article. The nonmetallic precursor compounds may be processed into the metallic material by first chemically reducing them to the metallic material, and then injection molding the metallic material, or first injection molding the nonmetallic precursor compounds and then chemically reducing them to the metallic material.

Abstract: A mixture of two particulate phases used in the production of a green compact that can be sintered at higher temperatures. The first phase contains particles that consist of a metal and/or a metal allow and/or a metal compound. The second phase contains particles from the group of the inorganic compounds that do not release any decomposition products at temperatures of more than 400° C., that are interstitially soluble in the sintering metal phase, and/or that react with the second phase to stable compounds. The mixture, by providing the second phase, is effective in supporting the fine structure of the first phase against the forces of surface tensions during the sintering process. During sintering, the second phase remains thermally stable and substantially chemically inert with respect to the first phase.

Abstract: The disclosure describes an economical and environmentally benign method for using crystalline silicon metal kerf recovered from wiresaw slurries towards the fabrication of complex MEMS and MEMS components, including MEMS packages, with improved design features.

Abstract: The present invention relates generally to a method of manufacturing broadhead components utilizing a powder injection molding (PIM) process that reduces the number of operations, thus simplifying the manufacturing process required to produce a finished product while maintaining the precision essential to the function of this commodity. The method of manufacturing includes powder injection molding one or more than one components for a broadhead, sintering the component(s) at an elevated temperature to form component(s) and assembling the component(s) to form a broadhead.

Abstract: A thin arc segment magnet made of a an R-T-B based, rare earth sintered magnet substantially comprising 28-33 weight % of R and 0.8-1.5 weight % of B, the balance being substantially Fe T, wherein R is at least one rare earth element including Y, and T is Fe or Fe and Co, which has an oxygen content of 0.3 weight % or less, a density of 7.56 g/cm3 or more, a coercivity iHc of 1.1 MA/m (14 kOe) or more at room temperature, and an orientation Br/4?Imax of 96% or more in an anisotropy-providing direction at room temperature can be produced by using a slurry mixture formed by introducing fine alloy powder of the above composition into a mixture liquid comprising 99.7-99.99 parts by weight of a mineral oil, a synthetic oil or a vegetable oil and 0.01-0.3 parts by weight of a nonionic surfactant and/or an anionic surfactant.