Abstract: In a method for removing a wax material from a molded part, to remove a major binder, waxes, from a molded part fabricated by a powder injection molding method or a compression molding method, a supercritical mixed fluid of carbon dioxide and propane is used as a dewaxing solvent.

Abstract: A method to form a combined enclosure and heat sink structure for a semiconductor device is achieved. A first feedstock comprising a first mixture of powdered metal materials, lubricants, and binders is prepared. A second feedstock comprising a second mixture of powdered metal materials, lubricants, and binders is prepared such that the difference between the sintering shrinkage of each of the first and second feedstocks is less than 1%. The first and second feedstocks are pressed to form a first green part having an enclosure shape and a second green part having a heat sink shape. The lubricants and the binders from said first and second green parts are removed to form a first powdered skeleton and a second powdered skeleton. The first and second powdered skeletons are sintered to complete the combined enclosure and heat sink structure. The first and second powdered skeletons are in intimate contact during the sintering.

Abstract: A binder B for inorganic powders comprises a mixture of

Abstract: The invention relates to a process for the production of metallic and metal-ceramic composite components by powder injection molding of a system comprising a metal composite powder, a binder and optionally a ceramic component, where the metal composite powder used is mixed with a protecting liquid in an inert atmosphere before the mixing with the binder. The invention furthermore relates to molybdenum/copper and tungsten/copper composite powders which have a primary metal particle size of predominantly <2 &mgr;m, an oxygen content of <0.8% by weight and optionally a ceramic component, to the use of these composite powders for the production of composite components by powder injection molding, and to a process for the preparation of composite powders in which oxides of molybdenum or tungsten and of copper are mixed, dry-ground and reduced using hydrogen at a temperature of from 800 to 1050° C., and a ceramic component is optionally admixed with the resultant metal composite powder.

Abstract: A method for manufacturing complex shape memory alloy materials is described. The method comprises generating a particulate form of a shape memory alloy, combining the particulate with a binder, molding, heating (which may include the steps of debinding and sintering), and thermo-mechanical processing. The method allows for the formation of complex shape memory alloy materials that exhibit the desirable properties of shape memory alloys, namely shape memory and superelasticity.

Abstract: A method for forming composite motor parts of two or more dissimilar materials by injection molding. Two or more different powder materials are injected under heat and pressure into cavities of a cylindrical-shaped mold and allowed to solidify to form a composite green compact. The final part may be used in machines of the type including permanent magnet, synchronous reluctance, switch reluctance and induction machines.

Abstract: Boron powders are sintered and densified utilizing a microwave environment for so doing.

Abstract: A method is provided for manufacturing a form tool used for forming threaded fasteners. The method utilizes powdered metal technology and processes to produce densified parts having at least the near net shape of the desired threaded fastener form tool.

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: A method to form a combined enclosure and heat sink structure for a semiconductor device is achieved. A first feedstock comprising a first mixture of powdered metal materials, lubricants, and binders is prepared. A second feedstock comprising a second mixture of powdered metal materials, lubricants, and binders is prepared such that the difference between the sintering shrinkage of each of the first and second feedstocks is less than 1%. The first and second feedstocks are pressed to form a first green part having an enclosure shape and a second green part having a heat sink shape. The lubricants and the binders from said first and second green parts are removed to form a first powdered skeleton and a second powdered skeleton. The first and second powdered skeletons are sintered to complete the combined enclosure and heat sink structure. The first and second powdered skeletons are in intimate contact during the sintering.

Abstract: The present invention relates to the extrusion freeform fabrication of low cost, in situ, metallic foam components having oriented microstructures and improved mechanical properties such as energy absorption and specific stiffness. The present invention relates to the freeform fabrication of metallic foams to form parts having complex geometry that demonstrate superior mechanical properties and energy absorbing capacity.

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: 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 invention concerns a method of preparing high density compacts for soft magnetic applications comprising the steps of subjecting an iron or iron-based soft magnetic powder the particles of which are electrically insulated to compaction in an uniaxial pressure operation with a ram speed of at least 2 m/s.

Abstract: There is provided a method for debindering of powder molded body, which comprises dipping, in an extracting solution composed of an aqueous surfactant solution, a ceramic powder or metal powder molded body containing a binder comprising at least two kinds of binder components, to selectively extract and remove at least one kind of binder component from the molded body, and then removing the binder components remaining in the molded body after extraction. This debindering method enables a short time and rapid debindering treatment while preventing the generation of defects such as cracks and the like, has high safety to human health and environment, and requires a low facility cost.

Abstract: This invention relates to a metal powder composition for warm compaction. According to the invention, the invention comprises metal powder, graphite, optional binding agent, optional alloying elements and a lubricant essentially consisting of ethylene-bis-stearamide, whereby the mixture before warm compaction has been subjected to treatment with an organic solvent. The invention further relates to a method for making sintered products, whereby an organic solvent is added during the mixing of the metal powder composition and is evaporated before warm compaction.

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: 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.

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: A process for preparation of molded articles, such as golf club heads, by metal injection molding and the resulting product.

Abstract: A method is provided for manufacturing an object, such as, for example, a form tool used for forming threaded fasteners. The method utilizes metal injection molding technology and processes to form densified parts having at least the near net shape of the desired object.

Abstract: A tool for chip-forming machining is made by passing first and second compounds through first and second coaxial dies, respectively, whereby the first material forms a center core of the tool, and the second material forms an outer rod of the material. The material of the core is tougher and less wear-resistant than the material of the outer rod. The coaxial first and second compounds are passed through a shaping die and then through a flute-forming structure which forms chip flutes in the outer rod.

Abstract: The present invention concerns powder compositions including iron-containing powders, additives, lubricant and flow agents. The powder compositions essentially consist of iron-containing particles having additive particles bonded thereto by a molten and subsequently solidified lubricant for the formation of aggregate particles and from about 0.005 to about 2 percent by weight of a flow agent having a particle size below 200 nanometers.

Abstract: A metal sintered part; the subject of this invention is produced by the following example processes in order to offer the metal sintered part, which has a high degree of hardness and a superior wear resistance, and, in order to offer the uncomplicated production method. Process 1A: To produce a green body, which is manufactured from a metal powder and a binding material, by the metal injection molding (MIM) method. Process 2A: To conduct the de-binding treatment to the green body. Process 3A: To sinter the de-binding body and obtain the metal sintered part. The metal powder for the production is a self-fluxing alloy, such as a nickel based self-fluxing alloy. The surface Vickers hardness Hv of this product is more than value 500.

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 NM 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.

Abstract: This invention provides a process for forming sintered, molded articles having improved dimensional stability. More particularly, this invention pertains to process for forming heat sinks. This process includes forming a substantially uniform copper composition comprising a polysaccharide binder, water, and copper particles; molding the copper composition under conditions sufficient to form a solid molded intermediate; and sintering the solid molded intermediate at a sufficient temperature and for a sufficient time to form a heat sink.

Abstract: A base metal repair tape includes a first layer formed braze alloy bonded together with fibrillated polytetrafluoroethylene, a second layer formed from powdered base metal bonded together by fibrillated polytetrafluoroethylene and a third layer comprising a brazing alloy bonded together by fibrillated polytetrafluoroethylene. This is used to repair base metal by placing the first layer on the base metal and brazing the base metal powder so that the brazing alloy melts and diffuses into the base metal powder bonding it to the surface of the article. This permits the braze powder to be bonded to the base metal surface with minimal distance between the base powder particles. The number of alternating layers of base metal and braze alloy can be increased to increase the thickness of the repair. This can also be used to form small intricate parts.

Abstract: A method for producing a metal hose coupling which is designed to be mounted permanently on the end of a hose for pressurized hydraulic oil, which hose coupling creates a fluid connection between the hose and an attachment member, the hose coupling having at least one hose nipple which, in the fitted state, projects into the hose and a connecting part, which is designed to form a connection to the attachment member, the hose coupling furthermore comprising, for each hose nipple, a deformable sleeve which, in the fitted state, rests around that part of the hose which has been pushed onto the hose nipple and, with deformation to the sleeve, holds the hose on the hose nipple, an oil passage extending through the connecting part and the at least one hose nipple. The connecting part and the hose nipple are produced as a single-piece body by means of the metal injection moulding process.

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 process for producing a thermoelectric material comprising mixing at least two of bismuth, tellurium, selenium, and antimony and, if desired, a dopant, melting the mixture, grinding the resulting alloy ingot, forming the powder, and sintering the green body under normal pressure, or hot pressing the powder, wherein the grinding and the normal sintering or hot pressing are carried out in the presence of a solvent represented by CnH2n+1OH or CnH2n+2CO (wherein n is 1, 2 or 3).

Abstract: The invention improves the thermal conductivity of the material powder to be fired and also makes it possible to produce an amorphous magnetically soft body within a shortened period of time. The amorphous magnetically soft body is produced by preforming the material powder into a body first, and heating the preformed body without pressing. Stated more specifically, an amorphous magnetically soft body is produced from a material powder comprising a powder of an amorphous magnetically soft alloy, a glass having a softening point lower than the crystallization starting temperature of the alloy and a binding resin, by pressing the material powder in a preforming die to prepare a preformed body by the binding property of the resin, and firing the preformed body without pressing at a temperature higher than the softening point of the glass and lower than the crystallization starting temperature of the alloy to join the particles of the alloy with the glass.

Abstract: A method of strengthening green form parts made from metal powder requires the use of a cross-linkable polymer which, when cross-linking has been induced, retains its mechanical properties to a degree sufficient to prevent fracture or significant deformation of the green form part when subjected to heat sufficient to induce phase transformation and carbonization. The polymer is incorporated into a green form part and cross-linking induced, giving the green part additional strength which enables it to endure the consolidation process without failing. The required polymer can be part of the powder blend used to form the green form part, and induced to cross-link with heat or radiation. Alternatively, the green form part can be dipped in a thermoset resin that cross-links when cured.

Abstract: The method of producing an R—Fe—B magnet of the present invention is characterized in that R—Fe—B alloy fine powder is molded in a magnetic field and sintered using a lubricant for molding magnets containing specific components, individually or as a mixture, of specific amounts of methyl caproate and/or methyl caprylate, which provide high crystal orientation, and lubricant comprising depolymerized polymer for improving molded article strength, or a lubricant for molding magnets wherein Ti coupling agent that improves crystal orientation is added to this lubricant for molding magnets. Each particle of the fine powder has a high degree of crystal orientation in the direction of the magnetic field, and molded article strength is markedly improved, leading to improved mass-productivity and yield. Moreover, the above-mentioned lubricants do not react with this magnet powder during sintering and are emitted as a gas.

Abstract: A method for producing high performance components by the consolidation of powdered materials under conditions of hot isostatic pressure. The method uses the inclusion of reactive materials mixed into pressure-transmitting mold materials and into the powder to be consolidated to contribute to in-situ materials modification including purification, chemical transformation, and reinforcement. The method also uses encapsulation of the mold in a sealed container to retain the mold material in position, and to exclude air and contaminants.

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.

Abstract: A composite molding compound comprising a combination of metal and ceramic powders is disclosed. The powders are combined with a binder, a liquid carrier and other processing additives in a manner to provide uniform distribution of two phases in a material format that facilitates the molding of complex parts at relatively low pressures and temperatures using conventional injection molding machines. The products formed from these molding compounds may be designed with tailored physical and mechanical properties such as thermal conductivity, thermal expansion coefficient, density, elastic modulus and wear properties.

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.

Abstract: A process for shaping threaded metal and ceramic parts from powders and molding compositions therefor is disclosed. Parts produced by this process are formed net shape without the need for machining or other finishing operations. The process comprises forming a mixture containing metal powders, ceramic powders or mixtures thereof, a gel-forming material and an aqueous gel-forming material solvent, and molding the mixture in a mold containing internal and/or external threads under conditions of temperature and pressure to produce a self-supporting threaded article.

Abstract: Metal materials are sintered using microwave energy to provide high strength dental restorations. The metal materials used to manufacture the dental restorations herein are sintered to high density to provide high strength products that have a density close to the density achieved when the same materials are cast. A dense solid having a fine microstructure is achieved using microwave heating. Through the process described herein, higher heating rates may be achieved, reducing the time necessary for sintering the materials. The process is faster than conventional processes used in the manufacture of dental restorations, eliminates time-consuming steps typically involved in the lost wax process and provides materials with better grain-size control and properties. It is possible to produce high strength dental restorations at lower temperatures having high hardness and density and small grain size.

Abstract: Molded green parts are fused together to form a bond or joint during the sintering process. The molded green parts are held in intimate contact with each other and sintered at temperatures sufficient to fuse the parts together. The process may entail dry fusing of part-to-part or it may include the use of a flux between the parts being fused together to enhance the bond.

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: Metal powders are pressed into compacts more readily through the addition of a minor percentage of dimethyl sulfone binder. Dimethyl sulfone may be dry-blended with the metal powder by mixing it in the form of a powder, or it may be wet-blended by first dissolving it in a suitable solvent, then adding it to the metal powder and evaporating the solvent. Dimethyl sulfone may be almost completely removed from compacts pressed from tantalum, etc., either by vacuum distillation or by water leaching, to leave compacts uncontaminated by the binder and suitable for further processing into capacitor anodes, etc.

Abstract: A process for molding metal knife blades from powders and molding compositions therefor are disclosed. Parts produced by this process are formed near net shape without the need for machining or other finishing operations. The process comprises forming a mixture containing metal powders, a gel-forming material and an aqueous gel-forming material solvent, and molding the mixture in an injection molding machine under conditions of temperature and pressure to produce a self-supporting knife blade having a sharp edge.

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 thin arc segment magnet made of a rare earth sintered magnet substantially comprising 28-33 weight % of R and 0.8-1.5 weight % of B, the balance being substantially Fe, 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&pgr;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.

Abstract: A process for molding flat tableware from powders and molding compositions therefor are disclosed. Parts produced by this process are formed near net shape without the need for machining or other finishing operations. The process comprises forming a mixture containing a metal powder, a gel-forming material and an aqueous gel-forming material solvent, and molding the mixture in an injection molding machine under conditions of temperature and pressure to produce a self-supporting flat tableware article.

Abstract: A hydrogen storage material is disclosed with no collapse due to pulverization of hydrogen storage alloy particles by repeated hydrogen absorption and desorption thereby permitting repeated use while manifesting excellent electric and thermal conductivities. Pressure molding of hydrogen storage alloy particles, each being covered with a plated metal film having microgranules of a thermoplastic resin, at a temperature higher than a glass transition temperature or a melting point of and below a thermal decomposition temperature of the thermoplastic resin can produce a porous hydrogen storage material of hydrogen storage alloy particles being bonded to each other via the thermoplastic resin. The hydrogen storage material can become firm and strong because the plated metal films covering the hydrogen storage alloy particles are clasped with each other complexly.

Abstract: The present invention relates generally to a monolithic broadhead including a ferrule and a blade having a tapered cross-section. The ferrule is formed with a threaded portion for attaching the broadhead to an arrow shaft in a conventional manner. Through the use of powdered metallurgy, the blade may be formed of a metal having a high hardness for maintaining edge sharpness and the ferrule may be formed of a high strength material for maintaining the durability of the broadhead.

Abstract: A sinter of noble metal produced by forming in a required shape or attaching to a given object a plastic art grade clayish composition or adhesion composition comprising a noble metal powder containing at least one member selected from the group consisting of pure noble metal powders and noble metal alloy powders, 0.022-3.0 wt. % of a water-soluble cellulose type resin, 0.02-3.0 wt. % of starch, or 0-0.5 wt. % of a reticular macromolecular substance formed by condensation of a component unit having phenyl propane as a backbone as an organic type binder, and water, drying to hardness the shaped composition or adhering composition, and sintering the hardened shaped composition or adhering composition at a temperature in the range of from the melting point of the noble metal and 70° C. lower than the melting point. A method for the production of the sinter of noble metal. A sinter of noble metal and an attached sinter of noble metal.

Abstract: A method of extruding an electrode, batch material, particularly a zinc or nickel, electrode material, and an extruder assembly for extruding the material, are described. The method and extruder are designed to produce a low compaction of the material and low, back pressure, whereby working of the batch material is limited.