Abstract: The disclosure relates to a method of rapidly removing binder from a "green" body composed of metal or cermet fine particles and a carbon-containing binder wherein the debinderizing step is performed in a water saturated atmosphere to provide chemical reaction with elemental carbon, the reaction products being removed from the system.

Abstract: The invention resides in a process of preparing an inhomogeneous sintered body by adjoining metal powder with refractory ceramic powder at normal powder metallurgical pressures and sintering conditions. The invention is characterized thereby that the sintered body is manufactured in one layer or several layers having displaced mixing ratio between the ceramics and the metal and that the binding between ceramics and metal is strengthened with monoaluminium phosphate or a monoaluminium phosphate former. The sintered body can be used for example as heat shielding.

Abstract: Preselected surface areas of a prosthesis are covered by a blend of matching primary metallic particles and expendable particles. The particles are compressed and heated to assure that deformation and metallurgical bonding occurs between them and between the primary particles and the surface boundaries of the prosthesis. Porosity is achieved by removal of the expendable material. The result is a coating including discrete bonded particles separated by a network of interconnected voids presenting a homogeneous porous coating about the substrate. It has strength suitable for bone implant usage without intermediate adhesives, and adequate porosity to promote subsequent bone ingrowth.

Abstract: Uranium dioxide powder produced by a gas phase process in which uranium hexafluoride is reacted with dry steam and then with steam and/or hydrogen at a higher temperature is subjected to mechanical treatment, e.g. milling, to break down its structure and increase its packing density. Other powders may be included with the uranium dioxide. The treated powder is mixed with a limited quantity (e.g. 0.5% by weight) of binder, preferably a high strength adhesive, to produce a free flowing powder and formed into pellets by pressing. The pellets are then sintered. Optionally the free flowing powder is spheroidised by tumbling prior to pressing into pellets.

Abstract: A method is disclosed for making a fuel pellet for a nuclear reactor. A mixture is prepared of PuO.sub.2 and UO.sub.2 powders, where the mixture contains at least about 30% PuO.sub.2, and where at least about 12% of the Pu is the Pu.sup.240 isotope. To this mixture is added about 0.3 to about 5% of a binder having a melting point of at least about 250.degree. F. The mixture is pressed to form a slug and the slug is granulated. Up to about 4.7% of a lubricant having a melting point of at least about 330.degree. F. is added to the granulated slug. Both the binder and the lubricant are selected from a group consisting of polyvinyl carboxylate, polyvinyl alcohol, naturally occurring high molecular weight cellulosic polymers, chemically modified high molecular weight cellulosic polymers, and mixtures thereof. The mixture is pressed to form a pellet and the pellet is sintered.

Abstract: A method for consolidating powder utilizing slurry extrusion or rolling techniques. A metallic powder, binder and boron containing activator are mixed together to form a slurry. The slurry is introduced into an active forming apparatus whereupon it is formed into an object of predetermined shape and sintered.

Abstract: A high strength powder metal part formed from an alloy of iron, nickel, molybdenum and carbon and having an ultimate tensile strength of at least 175,000 pounds per square inch. The powder metal part is made by mixing the alloy with a lubricant, forming the mixture into the desired part shape, sintering in a dissociated ammonia atmosphere, and cryogenically cooling the sintered part.

Abstract: The specification discloses a powder process in which metal or ceramic particles are mixed with a binder such as ultra high molecular weight polyethylene powder and are compacted. The compacted shape is heated to a temperature near the melting point of the binder to consolidate the binder and produce a green shape. The green shape is formed and the binder is removed. Thereafter, the shape is sintered to form a final part.

Abstract: A method for manufacturing a metal sintered body disclosed herein is characterized by the use of steps of: mixing 70 to 90 weight % of self-fluxing alloy powder and 10 to 30 weight % of metal powder of high melting point having a higher melting point than that of the self-soluble metal powder and in which the self-fluxing alloy powder is liable to be deposited thereon to obtain a metal powder having a sintering property; using a material in which 1 to 10 weight % of plastic binder is kneaded with the metal powder having a sintering property to obtain a molded body having a predetermined shape; and sintering the molded body at a temperature in excess of a liquid phase line of the self-fluxing alloy powder.

Abstract: A composition for fixing a metal powder molding at sintering, which is used, in the case of disposing a metal powder molding formed by rolling a mixture of a metal powder and a synthetic resin-based binder on a metal base material and sintering the metal powder molding in a non-oxidizing atmosphere, by interposing between the metal powder molding and the base material, comprising a thermosetting resin composition containing a thermosetting resin as the essential component, the amount of the residual carbon of which after the completion of sintering is at least about 0.5% by weight.

Abstract: The present invention concerns the manufacture of bars, wires or profiled elements by hot transformation which may be followed by cold transformation. The invention particularly concerns a new process for the manufacture of a composite billet for hot transformation as well as a method for the manufacture of products which are difficult to transform by making use of such a composite billet.

Abstract: A copper-rich metal shape is produced by forming a coherent forerunner shape consisting essentially of cupreous powder, said powder containing a proportion of copper oxide sufficient for facilitating the obtaining of a high sinter density in sintered porous mass, and in a reducing atmosphere at temperature that will sinter copper present, converting said forerunner shape into a porous sintered mass virtually devoid of copper oxide. Said porous mass can be worked so virtually full density if desired.

Abstract: The disclosure relates to a feedstock of particulate material for use in formation of articles therefrom, the feedstock including a homogeneous combination of large particles, small particles and a binder. The large particles comprise less than about 60% by volume of the feedstock and are defined as particles having a diameter greater than their diffusion length. The fine particles and binder combined comprise more than about 40% by volume of the feedstock, the fine particles being defined as particles having a diameter less than their diffusion length.

Abstract: A magnetic powder core, suitable for use in a low frequency power device, is prepared by a method including the steps of coating an atomized iron powder from an aqueous solution of potassium dichromate, drying the powder, compressing the powder to form a compact and heat treating the compact until it becomes partially sintered. Cores having coercivities below 240.sup.A /m, saturation inductions exceeding 1.3 Tesla and resistivities exceeding 500 microhm cm are disclosed.

Abstract: In a method of producing unbaked agglomerates, green pellets or briquettes are produced by adding 5 to 30% of reduced iron powder, mill scale powder or iron sand and also adding a binder consisting of a cement or granulated blast furnace slag and then the green pellets or briquettes are dry cured thereby producing agglomerates having excellent reducing performance.

Abstract: A metal powder sheet for use for forming a sintered layer on a metal substrate. The sheet includes powders of a metal which provides a required physical property such as wear-resistance and ultra-fine powders of a metal having a powder size finer than 1 micron. These powders are kneaded with an addition of an acryl resin as a binder. The ultra-fine powders make it possible to carry out the sintering process at a lower temperature.

Abstract: A process for producing a flat product such as a coin includes the steps of forming a slurry comprising a suspension of particulate material in a film-forming cellulose derivative, depositing a quantity of this slurry onto a support surface, drying the slurry to form a self-supporting flat product, and removing the dried product from the support surface. The particulate material essentially comprises metallic particles and matter whose chemical composition and physical properties differ from those of the metallic particles such that the added matter is not or only partially taken into solution with the metallic particles on heat treatment of the product whereby the presence of the added matter can readily be detected following such heat treatment.

Abstract: The present invention discloses a method for densifying previously sintered parts constructed of powdered metals, ceramics or the like to nearly 100% theoretical density. The method of the present invention comprises heating the parts containing binder and hard phase above their liquid phase temperature and then applying a pressure in a predetermined range to the parts for a predetermined period of time and simultaneously maintaining the parts at or above their liquid phase temperature. This pressure range is set so that the pressure is below the pressure necessary to overcome the capillary force acting on the binder to keep the binder from entering the voids but above the pressure necessary to physically move or collapse the microstructure inwardly, thus filling the voids with a homogenous mixture of binder and hard phase. The method of the present invention achieves complete closure of even large voids and the elimination of substantially all porosity within the part.

Abstract: A canless method for hot working a nickel-base gas atomized alloy powder. The powder is blended with nickel powder, consolidated and sintered to a sufficient green strength. The surface of the resultant form is sealed to create an oxygen impervious layer so as to prevent oxidation therein. The sealed surface, in a sense, acts as a can. The form is then reheated and hot worked.

Abstract: Method for producing molded metallic honeycomb structures of high physical strength and porosity, the method comprising forming a honeycomb structure by extruding through a die a kneaded mixture of a metal powder and a binder capable of forming a supporting bone structure for the metal powder upon application of heat, and, after drying, sintering the honeycomb structure.

Abstract: A porous metal body, e.g. an electrode for an electric cell, is prepared using the following steps:preparing a foam by adding a surface active agent and a gelling agent to water and then foaming the mixture by stirring and/or blowing air through it;incorporating metal powder in the foam in order to obtain a suspension of the metal therein;shaping the foam with its suspension of metal, and adding a stabilizing agent thereto, said stabilizing agent being one which polymerizes on contact with water, thereby causing the shaped foam to set in shape; andheating the set foam to pyrolize the organic material therein and to sinter the metal.This method produces a more even and a more reliable pore size than has previously been possible.

Abstract: The invention relates to an improvement of the flowability and an increase in the bulk density of high-surface area valve metal powders by means of the addition of finely divided extraneous metal oxides in quantities of up to 5000 ppm, relative to the quantity of metal, before the powder-metallurgical processing of the valve metal powder.

Abstract: A powder alloy sheet including powders of wear-resistant eutectic alloy in a quantity of 85 to 97% in volume, and acrylic resin binder in a quantity of 15 to 3% in volume.There is also disclosed a method for forming a wear-resistant layer on a workpiece comprising steps of providing a powder alloy sheet comprised on 85 to 97 vol. % of powders of wear-resistant eutectic alloy and 15 to 3 vol. % of acrylic resin binder, bonding the sheet on a workpiece surface, heating the workpiece under a non-oxidizing atmosphere to a semi-liquid phase sintering temperature to sinter the alloy powder.

Abstract: The present invention relates to a method for manufacturing a high-strength sintered silicon carbide article and more particularly, to a method for a sintered silicon carbide article having high mechanical strength by mixing a finely divided silicon carbide powder with the definite amounts of a specific carbon-containing material, a boron compound and silicon powder as densification aids, shaping and then sintering said shaped article under an inert atmosphere.

Abstract: A precision molded article, such as a die cavity, is made by combining granules of a first metal or alloy and a second metal or alloy, the second metal or alloy having a homogeneous appearance at some temperature below its melting point, and a higher Rockwell Hardness than the first metal or alloy, mixing the granules with a heat fugitive organic binder, molding the granule-binder mixture into a green molded preform, thermally degrading and removing essentially all the binder to form a skeletal preform, and infiltrating the preform with a third metal or alloy which will wet the second metal or alloy and has a lower Rockwell Hardness than the second metal or alloy, thereby forming a molded article having granules of first metal or alloy the majority of which are fully enveloped within a single skeleton of the second metal or alloy, the skeleton of second metal or alloy being surrounded by layers or matrices of softer metals.

Abstract: A sintered high vanadium high speed steel with an excellent hardness and ductility of composition C 1.4-6.2%, W+2 Mo (W-equivalent) 10.0-24.0%, Cr 3.0-6.0%, V 8.5-28%, Co less than 17%, the remainder Fe and inevitable impurities, and a method of producing same.It can be produced by the steps of commingling the alloy constituents in the form of pulverulent oxides and carbon powder, heating the mixture in a stream of hydrogen, thereby reducing the mixture by the carbon and hydrogen simultaneously to yield an alloy powder, adjusting the composition and the grain size of the obtained alloy powder, pressing the alloy powder to a compact, sintered the compact in a vacuum, and finally converting the matrix of the sintered body into martensite by heat treatment.

Abstract: The present invention provides a method of preventing the segregation of powders of different specific gravities in a metal powder composition. The powder metal is admixed with the powders of lesser specific gravities, and furfuryl alcohol is added at the same time. While mixing, an acid is added to react with the furfuryl alcohol to convert the alcohol to a solid resin film on the powder metal particles. The powders of lesser specific gravities are bonded to the metal powder particles by the resin, and segregation of the metal powder and the lighter powders is eliminated.

Abstract: A metal powder containing particles of iron or steel and particles of an alloying element is apt to segregation and dusting. It has now been found that segregation and dusting can be reduced or eliminated if the powder contains a binding agent in solid or liquid state. It is preferred to add to the metal powder one of the agents polyethylene glycol, polypropylene glycol, glycerine, and polyvinyl alcohol, in a quantity of 0.005-0.2 percent by weight.

Abstract: A process for making sintered metal articles of high strength in which a flowable mass of metallic particles is initially formed into a green compact having shape stability in a forming machine of the type used in the fabrication of sand cores in the metal casting field. The green compact is then subjected to sintering and the sintered body may be pressed, forged or mechanically shaped in other ways. The core blowing or core-sand slinging machine used to produce the green metal compact is surprisingly effective in producing a dense, reproducible structure in light of the fact that sand cores for casting purposes are intentionally made frangible to enable them to be removed effectively from the casting.

Abstract: A method of manufacturing molded articles of metal alloys, especially of nickel-base alloys, chromium-base alloys, titanium-base alloys, and dispersion-hardened alloys. A powder of the alloy, or a blend of powders of alloy constituents, is mixed with one or more plastics, selected from thermoplastics, duroplastics, and internal lubricants to form an injectionable granulate compound, the plastic content amounting to about 30% to 50% by volume. The compound is prepared by dissolving the plastic in a solvent which will not attack the base material of the alloy, and by blending it with the metal powder, after which the solvent is evaporated. The injectionable granulate compound is then injection molded to form a molded article. By heat treatment at 600.degree. C. or below in inert gas the plastic is eliminated from the molded article. The article is then sintered. To improve its strength, the article may subsequently be subjected to hot isostatic pressing.

Abstract: A high current density cathode is made by first forming an active porous h purity tungsten pellet by the steps of:(A) mixing tungsten powder with about 1 to 5 percent by weight of the mixture of an activator powder and compacting the powders at a pressure of about 35 tons per square inch to form a pellet,(B) sintering the pellet in a non-oxidizing atmosphere at about 1800 degrees C. for about 11/2 to 31/2 hours to the desired porosity,(C) filling the porous pellet with a filler material,(D) machining to the desired size and shape,(E) removing the filler material, and then forming the cathode by impregnating the pellet with Ba.sub.5 Sr(WO.sub.6).sub.2 at about 1700 degrees C. in an inert atmosphere and subsequently firing for 2 minutes at 1800 degrees C. in dry hydrogen.

Abstract: A method and system whereby binder can be removed from a green body much more rapidly than in prior art systems without interfering with the integrity or aesthetics of the final part by providing a binder system having at least two components and preferably a mold release agent, the binder system having differing melting points. Each binder component can have parts with different melting temperature. When the temperature is raised to a point above the intermediate temperature at which the binder system flows, binder will proceed to exude to the surface of the green body wherefrom it can be removed.The binder is removed from the surface of the green body by blowing a non-saturated chemically inert atmosphere over the surface of the green body rapidly whereby the atmosphere at a region near the surface of the green body does not become saturated with the binder vapors.

Abstract: The invention is directed to the production of non-fragile shaped members from powders comprising spheroidal metal particles.For this purpose, the invention provides a process for the production of shaped parts from powders comprising spheroidal metal particles which are mixed with from 0.2% to 2% of lubricant, comprising the combination of the following successive steps, performed in the below-indicated order:(a) mixing the powder formed by spheroidal metal particles with an amount of water-soluble cellulose gum between 0.2% and 2%, and with an amount of water which is also between 0.2% and 2%;(b) a cold compacting operation;(c) an optional oven drying operation;(d) a two-phase sintering operation, in an atmosphere which is neutral or reducing with respect to the compacted powder, the first phase being effected at a temperature of from 300.degree. to 500.degree. C. and the second phase being effected at a temperature which is substantially higher and variable with the nature of the powder.

Abstract: Copper base spinodal alloy strip of good strength and ductility is provided, the alloy containing 5 to 35 percent nickel, 7 to 13 percent tin, balance essentially copper, and having an unaged microstructure characterized by an equiaxed grain structure of substantially all alpha, face-centered-cubic phase with a substantially uniform dispersed concentration of tin and a substantial absence of tin segregation. The strip is prepared from copper alloy powder of the indicated composition by a process comprising the steps of compaction, sintering, cooling, rolling and annealing. The strip after aging may contain up to about 50 percent alpha plus gamma phase.