Consolidation Of Powder Prior To Sintering Patents (Class 419/38)
  • Patent number: 11945033
    Abstract: A method is provided for the heat treatment of an object comprising at least one rare-earth element with a high vapor pressure. One or more objects comprising at least one rare-earth element with a high vapor pressure are arranged in an interior of a package. An external source of the at least one rare-earth element is arranged so as to compensate for the evaporation of this same rare-earth element from the object and/or to increase the vapor pressure of the rare-earth element in the interior of the package, and the package is heat treated.
    Type: Grant
    Filed: March 31, 2022
    Date of Patent: April 2, 2024
    Assignee: VACUUMSCHMELZE GMBH & CO. KG
    Inventors: Kaan Üstüner, Matthias Katter, Christoph Brombacher, Daniela Benedikt
  • Patent number: 11837390
    Abstract: The present invention relates to an R-T-B based permanent magnet material, having a composition of RxTyTmqBz (at. %), wherein 13?x?15.5, 0.5?q?3, 0.85?z?1, y=100?x?q?z; wherein R is LRaHR1-a, LR is one selected from the group consisting of Pr, Nd, PrNd, or a combination thereof, HR is one selected from the group consisting of Dy and Tb, or a combination thereof, and 0.95?a?1; wherein T is one selected from the group consisting of Fe and Co, or a combination thereof; and Tm is a transition metal. The advantage of the method is that: plating a heavy rare earth film on alloy flakes using a magnetron sputtering device, and the coercivity of the magnet is significantly increased simply by having a “core-shell” structure without long time diffusion heat treatment.
    Type: Grant
    Filed: July 26, 2019
    Date of Patent: December 5, 2023
    Assignee: NINGBO KETIAN MAGNET CO., LTD.
    Inventors: Changjiang Yan, Nijian Qian, Wancheng Fu
  • Patent number: 11830645
    Abstract: A manufacturing method of a sintered magnet is described. The method includes forming a pre-sintering body from a first magnetic powder and a second magnetic powder (containing a heavy rare earth element, HRE) so that at least part of the second magnetic powder is provided at at least one inner portion of the pre-sintering body and surrounded format least two opposite sides by the first magnetic powder; sintering the pre-sintering body; and annealing the sintered pre-sintering body at an annealing temperature lower than the sintering temperature, thereby causing inter-grain diffusion of HRE from the HRE reservoir zone to the grain boundary phase. After the annealing, the grain boundary phase contains the HRE in a higher concentration than the main phase.
    Type: Grant
    Filed: January 2, 2020
    Date of Patent: November 28, 2023
    Assignee: ABB Schweiz AG
    Inventors: Reinhard A. Simon, Jacim Jacimovic, Lorenz Herrmann, Tomaz Tomse
  • Patent number: 11565313
    Abstract: An isostatic pressing canister for use in manufacturing a component by isostatic pressing is described. The canister comprises: a canister wall enclosing an internal cavity, the canister wall having an internal surface facing the internal cavity; a filling point for filling the internal cavity with powdered material, the filling point comprising a hole in the canister; and a structure supported within the internal cavity and located between the hole and the portion of the internal surface opposite the hole. A portion of the internal surface of the canister wall opposite the hole is shaped so that, during the filling of the internal cavity, powdered material falling from the hole and towards the portion of the internal surface is deflected away from the portion of the internal surface. A method of manufacturing a component using the canister is also described.
    Type: Grant
    Filed: February 19, 2021
    Date of Patent: January 31, 2023
    Assignee: ROLLS-ROYCE plc
    Inventors: Alasdair P C Morrison, Ryan D Pitchford, John L Sulley
  • Patent number: 11515066
    Abstract: Improved manufacturing processes and resulting anisotropic permanent magnets, such as for example alnico permanent magnets, having highly controlled and aligned microstructure in the solid state are provided. A certain process embodiment involves applying a particular orientation and strength of magnetic field to loose, binder-coated magnet alloy powder particles in a compact-forming device as they are being formed into a compact in order to preferentially align the magnet alloy powder particles in the compact. The preferential alignment of the magnet alloy powder particle is locked in place in the compact by the binder after compact forming is complete. After removal from the device, the compact can be subjected to a subsequent sintering or other heat treating operation.
    Type: Grant
    Filed: November 7, 2018
    Date of Patent: November 29, 2022
    Assignee: Iowa State University Research Foundation, Inc.
    Inventors: Aaron G. Kassen, Iver E. Anderson, Emma Marie Hamilton White, Matthew J. Kramer, David J. Byrd, Liangfa Hu
  • Patent number: 11446737
    Abstract: The molding die of the invention includes: a first die having a through-hole; a second die inserted into the through-hole and capable of moving relative to the first die; and a first punch and a second punch each insertable into the through-hole. A cavity surrounded by the second die, the first punch, and the second punch to compression-mold a molding object is formed in the through-hole. An undercut molding part is formed in the surface of the second die facing the cavity. The second die is formed so as to be splittable into two or more split bodies.
    Type: Grant
    Filed: August 15, 2017
    Date of Patent: September 20, 2022
    Assignee: Diamet Corporation
    Inventors: Tsuneo Maruyama, Yoshiki Tamura, Hideo Sakai
  • Patent number: 11389859
    Abstract: A metallic material manufactured by a method including steps of (1) subjecting a semifinished metallic billet having at least one of a nanocrystalline microstructure and an ultrafine-grained microstructure to a rotary incremental forming process to form an intermediate wrought metallic billet and (2) subjecting the intermediate wrought metallic billet to a high rate forming process, wherein the high rate forming process includes a high rate forming process average equivalent strain rate, the high rate forming process average equivalent strain rate being at least about 0.1 s?1.
    Type: Grant
    Filed: February 27, 2019
    Date of Patent: July 19, 2022
    Assignee: The Boeing Company
    Inventor: Ali Yousefiani
  • Patent number: 11351608
    Abstract: Provided is a sintered bearing (1), including 3 to 12% by mass of aluminum, 0.05 to 0.5% by mass of phosphorus, and the balance including copper as a main component, and inevitable impurities, the sintered bearing (1) having a structure in which an aluminum-copper alloy is sintered with a sintering aid added to raw material powder, a pore (db, do) in a surface layer portion of the sintered bearing (1) being formed smaller than an internal pore (di).
    Type: Grant
    Filed: April 3, 2018
    Date of Patent: June 7, 2022
    Assignee: NTN CORPORATION
    Inventors: Makoto Jinnou, Natsuhiko Mori, Yoshinori Ito
  • Patent number: 11253915
    Abstract: Disclosed are an apparatus and method for densifying or compacting powder material in the supply bin of an additive manufacture machine to improve the quality of the object being made. For example, a removable or portable apparatus can be applied to the surface of the supply bin once the bin has been filled. The apparatus can include a vibrational component that agitates the underlying powder to compact the material. The apparatus can then be removed during the remainder of the additive manufacturing process, which then follows in its normal course. A vacuum can also be used the remove of air or other gases that are emitted during the compaction process, for example, as voids are filled during densification.
    Type: Grant
    Filed: August 22, 2017
    Date of Patent: February 22, 2022
    Assignee: EOS GmbH Electro Optical Systems
    Inventors: Ankit Saharan, III, Erling Richard LaSalle
  • Patent number: 11232890
    Abstract: The present invention relates to an RFeB sintered magnet containing: 28% to 33% by mass of a rare-earth element R, 0% to 2.5% by mass of Co (cobalt) (i.e., Co may not be contained), 0.3% to 0.7% by mass of Al (aluminum), 0.9% to 1.2% by mass of B (Boron), and less than 1,500 ppm of O (oxygen), with the balance being Fe, containing an RFeAl phase having an R6Fe14-xAlx structure in a crystal grain boundary, and having a coercivity of 16 kOe or more.
    Type: Grant
    Filed: November 4, 2019
    Date of Patent: January 25, 2022
    Assignee: DAIDO STEEL CO., LTD.
    Inventor: Michihide Nakamura
  • Patent number: 11133943
    Abstract: A method for issuing a virtual document by a first computer system of an issuer, includes creating the virtual document; calculating a hash value of the virtual document; sending a signed entry request including the hash value to a blockchain server; receiving the signed entry request by the blockchain server; and executing, by the blockchain server, program instructions of a program module identified by the signed entry request, wherein the execution of the program instructions includes checking the signature of the entry request, using a public cryptographic key of the issuer registered in the blockchain, and, if the signature is valid, generating an additional block of the blockchain for the issue of the virtual document, wherein the generated block includes an entry associated with the program module and including the first hash value.
    Type: Grant
    Filed: March 16, 2018
    Date of Patent: September 28, 2021
    Assignee: BUNDESDRUCKEREI GMBH KOMMANDANTENSTRASSE 18
    Inventors: Jorg Ruckriemen, Jens Ehreke
  • Patent number: 11090721
    Abstract: A method for modifying a dimension of a cast iron pump part features placing a cast iron pump part on a base plate of a directed energy deposition (DED) machine; selecting a metal deposition procedure for depositing a metal having a combination of one or more Nickel Alloys or Nickel powders on the cast iron pump part; and depositing the metal on the cast iron pump part to modify the dimension of the cast iron pump part, based upon the metal deposition procedure selected. The selecting of the metal deposition procedure includes forming the metal by mixing metal powders that include a Nickel Alloy “A” in a specified mixed ratio with a pure Nickel powder “B” for depositing on the cast iron pump part.
    Type: Grant
    Filed: June 27, 2018
    Date of Patent: August 17, 2021
    Assignee: FLUID HANDLING LLC
    Inventor: Everaldo Ferreyra Tello
  • Patent number: 10710156
    Abstract: A method of fabricating parts out of metallic, intermetallic, ceramic, ceramic matrix composite, or metal matrix composite material with discontinuous reinforcement, includes melting or sintering powder particles by means of a high-energy beam. The powder used is a single powder of particles that present sphericity lying in the range 0.8 to 1.0 and of form factor lying in the range 1 to ?2, each powder particle presenting substantially identical mean composition, and the grain size distribution of the particles of the powder is narrowed around the mean diameter value d50% in such a manner that: (d90%?d50%)/d50%?0.66; and (d50%?d10%)/d50%?0.33; with a “span”: (d90%?d10%)/d50%?1.00.
    Type: Grant
    Filed: June 30, 2014
    Date of Patent: July 14, 2020
    Assignees: SAFRAN AIRCRAFT ENGINES, EUROPEAN AERONAUTIC DEFENCE AND SPACE COMPANY EADS FRANCE, AIRBUS HELICOPTERS
    Inventors: Christophe Colin, Laetitia Kirschner
  • Patent number: 10675685
    Abstract: A method for preventing powder depletion/contamination during a consolidation process provides a can for holding a powdered material; the can having an interior wall; a protective layer is positioned intermediate the powdered material and the interior wall utilizing a sol-gel process utilizing monodisperse nanopowders; and the protective layer being formed from a material selected from the group consisting of nickel alloys, chrome alloys, and combinations thereof.
    Type: Grant
    Filed: January 14, 2015
    Date of Patent: June 9, 2020
    Assignee: Raytheon Technologies Corporation
    Inventors: Agnieszka M Wusatowska-Sarnek, Larry G Housefield, Ruston M Moore, Enrique E Montero, Promila Bhaatia
  • Patent number: 10640851
    Abstract: Aluminium-silicon powder mixtures comprising a hypereutectic Al—Si powder, a near eutectic Al—Si powder, and a third powder which is aluminium or a hypoeutectic aluminium alloy containing alloying constituents other than silicon and less than 9 wt % silicon, with a sintering aid comprising a fourth, zinc-containing powder, are pressed and sintered to provide powder metallurgy products suitable for automotive component use in particular. The third powder in the composition permits such Al—Si powder mixtures to be compressed to a density approaching that obtained by use of an annealed powder mixture, but without the annealing step.
    Type: Grant
    Filed: May 7, 2014
    Date of Patent: May 5, 2020
    Inventors: Charles Grant Purnell, Henry Dickinson
  • Patent number: 10576542
    Abstract: The invention relates to a manufacturing system and method for manufacturing a part. A negative powder forms a holder suitable to hold particles of a positive powder in proximity to one another. A connection scheme such as heating, the use of pressure and/or a binder, when employed, connects the particles to one another to form the part.
    Type: Grant
    Filed: February 3, 2017
    Date of Patent: March 3, 2020
    Assignee: Grid Logic Incorporated
    Inventors: Matthew J. Holcomb, Ira J. Holcomb, Jr.
  • Patent number: 10546688
    Abstract: Provided is a method for producing a rare-earth magnet that can resolve a problem of deterioration of the residual magnetization and coercive force of the rare-earth magnet due to spring-back in producing the rare-earth magnet through performing hot deformation processing of upsetting on a sintered body. The method includes a first step of producing the sintered body through press-forming of magnetic powder for a rare-earth magnet, and a second step of producing a rare-earth magnet precursor through hot deformation processing of upsetting in which the sintered body is placed within a plastic processing mold and is pressurized in a predetermined direction so as to impart magnetic anisotropy to the sintered body, and performing cooling of the rare-earth magnet precursor while a predetermined pressure is kept being applied thereto in the predetermined direction, so that the rare-earth magnet is produced.
    Type: Grant
    Filed: December 14, 2017
    Date of Patent: January 28, 2020
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Daisuke Ichigozaki, Takeshi Yamamoto
  • Patent number: 10532404
    Abstract: In molding a compact having portions of an equal thickness on opposite sides of a through-hole, an advancing speed of a holder holding a powder material is adjusted before the holder is advanced and retracted over a die cavity of a die. Specifically, a first preparation of determining in advance a relation between the advancing speed of the holder and a packing density of the powder material packed in the die cavity at each of the portions to be of an equal thickness of the compact on opposite sides of the through-hole is made; and, based on the relation determined in the first preparation, the advancing speed of the holder is adjusted to a speed at which the packing density becomes uniform. Thus, the packing density of the powder material packed in the die cavity can be uniformized, so that the dimensional accuracy of the molded compact can be improved.
    Type: Grant
    Filed: March 8, 2017
    Date of Patent: January 14, 2020
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Yoshiyuki Sanada, Kazumichi Nakatani
  • Patent number: 10442737
    Abstract: A green body for a cross-hole, compacted cutting insert, as well as a cutting insert, equipment for making a green body, and method for making a green body, wherein the green body includes a first side, a second side, and a side surface extending between the first side and the second side entirely around the first side and the second side. The green body includes a quadrilateral-shaped cross-hole extending through the green body from a first location on the side surface to a second location on the side surface on an opposite side of the green body from the first location. The quadrilateral-shape of the cross-hole can assist in achieving a more uniform density of compactable material in the green body.
    Type: Grant
    Filed: December 8, 2014
    Date of Patent: October 15, 2019
    Assignee: SECO TOOLS AB
    Inventor: Dirk Sterkenburg
  • Patent number: 10395823
    Abstract: This disclosure is directed to methods for creating recycled Nd—Fe—B type permanent magnets, the methods comprising homogenizing a first population of particles of a rare earth transitional elemental additive with a second population of particles of a magnetic material, wherein the nature of the rare earth transitional elemental additive and the magnetic material are described herein. Additional steps may include compressing the population of homogenized particles together to form a green body, and heating the green body at a temperature and for a time sufficient to sinter the green body into a sintered body. Compositions resulting from these methods are also within the scope of the disclosure.
    Type: Grant
    Filed: April 8, 2016
    Date of Patent: August 27, 2019
    Assignee: Urban Mining Company
    Inventors: Miha Zakotnik, Walter Del Pozzo
  • Patent number: 10265767
    Abstract: It is an object of the present invention to provide an alloy powder that has high hardness and high corrosion resistance and can be produced from inexpensive raw materials, as well as to provide a shot material for shot peening, a powder metallurgical composition, and an iron-based sintered alloy using the alloy powder, and, in order to achieve such an object, there are provided an alloy powder including, in mass %, C: 0.6% or more and 2.4% or less, Cr: 36% or more and 60% or less, Mn: 0.1% or more and 10% or less, Mo: 0% or more and 10% or less, Si: 0% or more and less than 2%, Ni: 0% or more and 15% or less, Co: 0% or more and 5% or less, W: 0% or more and 5% or less, V: 0% or more and 5% or less, Nb: 0% or more and 5% or less, and the balance of Fe and unavoidable impurities, as well as the shot material for shot peening, the powder metallurgical composition, and the iron-based sintered alloy using the alloy powder.
    Type: Grant
    Filed: May 25, 2016
    Date of Patent: April 23, 2019
    Assignee: Sanyo Special Steel Co., Ltd.
    Inventor: Toshiyuki Sawada
  • Patent number: 10207439
    Abstract: An apparatus or assembly for forming injection molded magnets in permanent magnet rotors or laminations for such rotors. The assembly includes a plurality of platens defining an axial boundary of a die cavity and a plurality of support shoes that are radially moveable between a closed position defining a radial boundary of the die cavity, and an open position creating a gap between the rotor core and the plurality of support shoes. The assembly has an injection system for filling at least one of the plurality of voids of the rotor core with a magnetic slurry, and a plurality of alignment magnets configured to magnetically align the magnetic slurry.
    Type: Grant
    Filed: February 6, 2017
    Date of Patent: February 19, 2019
    Assignee: GM Global Technology Operations LLC
    Inventors: Edward L. Kaiser, Amanda Luedtke, Peter J. Savagian, Sinisa Jurkovic
  • Patent number: 10121589
    Abstract: A mold comprising a die, an upper punch, and a lower punch, the pressure surface of one or both of the upper and lower punches being shaped non-planar, a cavity being defined between the die and the lower punch, is combined with a feeder including a shooter provided with a main sieve at its lower end port, the main sieve having a sifting surface of substantially the same non-planar shape as the pressure surface. A rare earth sintered magnet is prepared by feeding an alloy powder into the cavity through the shooter and sieve while applying weak vibration and vertical reciprocation to the shooter, applying a uniaxial pressure to the alloy powder fill in the cavity under a magnetic field to form a precursor, and heat treating the precursor.
    Type: Grant
    Filed: December 22, 2014
    Date of Patent: November 6, 2018
    Assignee: Shin-Etsu Chemical Co., Ltd.
    Inventors: Mitsuo Kitagawa, Kazuaki Sakaki
  • Patent number: 10121588
    Abstract: A mold comprising a die, an upper punch, and a lower punch, the pressure surface of one or both of the upper and lower punches being shaped non-planar, a cavity being defined between the die and the lower punch, is combined with a feeder including a shooter provided with a main sieve at its lower end port, the main sieve having a sifting surface of substantially the same non-planar shape as the pressure surface. A rare earth sintered magnet is prepared by feeding an alloy powder into the cavity through the shooter and sieve while applying weak vibration to the shooter, applying a uniaxial pressure to the alloy powder fill in the cavity under a magnetic field to form a precursor, and heat treating the precursor.
    Type: Grant
    Filed: December 22, 2014
    Date of Patent: November 6, 2018
    Assignee: SHIN-ETSU CHEMICAL CO., LTD.
    Inventors: Mitsuo Kitagawa, Kazuaki Sakaki
  • Patent number: 10100386
    Abstract: A method for preparing an article of a base metal alloyed with an alloying element includes the steps of preparing a compound mixture by the steps of providing a chemically reducible nonmetallic base-metal precursor compound of a base metal, providing a chemically reducible nonmetallic alloying-element precursor compound of an alloying element, and thereafter mixing the base-metal precursor compound and the alloying-element precursor compound to form a compound mixture. The compound mixture is thereafter reduced to a metallic alloy, without melting the metallic alloy. The step of preparing or the step of chemically reducing includes the step of adding an other additive constituent. The metallic alloy is thereafter consolidated to produce a consolidated metallic article, without melting the metallic alloy and without melting the consolidated metallic article.
    Type: Grant
    Filed: June 15, 2012
    Date of Patent: October 16, 2018
    Assignee: General Electric Company
    Inventors: Andrew Philip Woodfield, Eric Allen Ott, Clifford Earl Shamblen, Michael Francis Xavier Gigliotti
  • Patent number: 10090104
    Abstract: A mold comprising a die, an upper punch, and a lower punch, the pressure surface of one or both of the upper and lower punches being shaped non-planar, a cavity being defined between the die and the lower punch, is combined with a feeder including a shooter provided with a main sieve at its lower end port, the main sieve having a sifting surface of substantially the same non-planar shape as the pressure surface. A rare earth sintered magnet is prepared by feeding an alloy powder into the cavity through the shooter and sieve while applying weak vibration and vertical reciprocation to the shooter, applying a uniaxial pressure to the alloy powder fill in the cavity under a magnetic field to form a precursor, and heat treating the precursor.
    Type: Grant
    Filed: December 22, 2014
    Date of Patent: October 2, 2018
    Assignee: Shin-Etsu Chemical Co., Ltd.
    Inventors: Mitsuo Kitagawa, Kazuaki Sakaki
  • Patent number: 10081149
    Abstract: Provided is a stepped die which includes: an inner ring having a cylindrical shape, and an outer ring having a cylindrical shape which is fitted on an outer periphery of the inner ring by shrinkage fitting, in which a recessed portion for molding which has a stepped portion is formed on an inner side of the inner ring. A shrinkage fitting ratio of the outer ring to the inner ring is set to a value which falls within a range of from 0.12% to 0.25%.
    Type: Grant
    Filed: October 17, 2014
    Date of Patent: September 25, 2018
    Assignee: Sumitomo Electric Sintered Alloy, Ltd.
    Inventors: Masato Uozumi, Shinichi Hirono
  • Patent number: 9868154
    Abstract: A method for creating a dynamic mold from a ferrofluid substrate in or adjacent to curable molding material is disclosed. A combination of magnetic elements is used to create a magnetic field that is capable of concentrating a ferrofluid substrate in a 3-D space. The ferrofluid substrate shapes a molding material to effect its shape. The ferrofluid, under the influence of a magnetic field, is capable of creating surface features and internal features in the molding material. Once cured or partially cured, the ferrofluid may be removed, resulting in features that are difficult to form by conventional methods.
    Type: Grant
    Filed: August 15, 2014
    Date of Patent: January 16, 2018
    Assignee: Hummingbird Nano, Inc.
    Inventor: Eleanor Augusta Hawes
  • Patent number: 9831034
    Abstract: A mold which is inexpensive and easy to process and does not embrittle. Also provided is a process by which a sintered NdFeB magnet can be produced using the mold without suffering bending or deformation. At least part (e.g., a bottom plate) of the mold is made of a carbon material. Carbon materials have lower friction with a sinter during sintering than metals. The mold hence enables a sintered NdFeB magnet to be produced without suffering the bending or deformation caused by friction due to sintering shrinkage. Carbon materials are inexpensive and easy to process. The mold does not embrittle even when repeatedly used. Such effects can be significantly produced when a carbon material is used as the bottom plate, on which the load of the sinter is imposed during sintering.
    Type: Grant
    Filed: August 20, 2008
    Date of Patent: November 28, 2017
    Assignee: INTERMETALLICS CO., LTD.
    Inventor: Masato Sagawa
  • Patent number: 9713845
    Abstract: A method for manufacturing a cutting insert having a through-hole that extends in a direction that is non-parallel to the main pressing direction. The method includes the steps of moving first and second punches within a die cavity toward each other along a first pressing axis and compacting a powder around a core rod into a cutting insert green body, wherein, during at least a portion of the compaction step, the core rod is turned a predetermined angle in alternating direction around its longitudinal axis.
    Type: Grant
    Filed: May 29, 2014
    Date of Patent: July 25, 2017
    Assignee: SANDVIK INTELLECTUAL PROPERTY AB
    Inventor: Hjalmar Staf
  • Patent number: 9546071
    Abstract: A sheet transport device includes a transport unit that transports a sheet to a reading position by a first transport roller, a driving unit that switches a rotating direction, a rotating unit that rotates the first transport roller in one direction, the rotating unit including a one-direction gear that directly meshes with a first planet gear when the driving unit rotates in a first direction and meshes with a second planet gear when the driving unit rotates in a second direction, a switch unit that switches between states in which rotation of the one-direction gear is or is not transmitted to the first transport roller, and a displacement-force applying part that applies a force for displacing the first planet gear to mesh with the one-direction gear when the first planet gear touches the switch unit.
    Type: Grant
    Filed: February 24, 2016
    Date of Patent: January 17, 2017
    Assignee: FUJI XEROX CO., LTD.
    Inventors: Masato Serikawa, Takakiyo Toba, Kazuyuki Koda, Takato Kato
  • Patent number: 9533351
    Abstract: A zirconium-doped aluminum powder metal and a method of making this powder metal are disclosed. The method of making includes forming an aluminum—zirconium melt in which a zirconium content of the aluminum—zirconium melt is less than 2.0 percent by weight. The aluminum—zirconium melt then powderized to form a zirconium-doped aluminum powder metal. The powderization may occur by, for example, air atomization.
    Type: Grant
    Filed: October 4, 2011
    Date of Patent: January 3, 2017
    Assignee: GKN Sinter Metals, LLC
    Inventors: Donald Paul Bishop, Richard L. Hexemer, Jr., Ian W. Donaldson, Randy William Cooke
  • Patent number: 9267189
    Abstract: In accordance with an exemplary embodiment, a method of forming a dispersion-strengthened aluminum alloy metal includes the steps of providing a dispersion-strengthened aluminum alloy composition in a powdered form, directing a low energy density laser beam at a portion of the powdered alloy composition, and withdrawing the laser beam from the portion of the powdered alloy composition. Subsequent to withdrawal of the laser beam, the portion of the powdered alloy composition cools at a rate greater than or equal to about 106° C. per second, thereby forming the dispersion-strengthened aluminum alloy metal.
    Type: Grant
    Filed: March 13, 2013
    Date of Patent: February 23, 2016
    Assignee: HONEYWELL INTERNATIONAL INC.
    Inventors: Donald G. Godfrey, Richard Bye, Mark C. Morris, Harry Kington
  • Patent number: 9102015
    Abstract: A thermal barrier tile (34) with a braze layer (46) co-sintered to a ceramic layer (48) is brazed to a substrate (26) of a component for fabrication or repair of a thermal barrier coating (28) for example on a gas turbine ring segment (22, 24). The tile may be fabricated by disposing a first layer of a metal brazing material in a die case (40); disposing a second layer of a ceramic powder on the metal brazing material; and co-sintering the two layers with spark plasma sintering to form the co-sintered ceramic/metal tile. A material property of an existing thermal barrier coating to be repaired may be determined (90), and the co-sintering may be controlled (93) responsive to the property to produce tiles compatible with the existing thermal barrier coating in a material property such as thermal conductivity.
    Type: Grant
    Filed: March 14, 2013
    Date of Patent: August 11, 2015
    Assignee: Siemens Energy, Inc
    Inventors: Anand A. Kulkarni, Ahmed Kamel, Stefan Lampenscherf, Jonathan E. Shipper, Jr., Cora Schillig, Gary B. Merrill
  • Patent number: 9096474
    Abstract: This invention relates to a mold for synthesizing powder, and particularly to a mold for synthesizing ceramic powder suitable for use as a mold system which is subjected to spark plasma sintering, which includes a cylindrical mold body into which a powder material used to synthesize ceramic powder is charged, and a pair of mold covers respectively disposed in contact with the top and the bottom of the mold body, thus basically suppressing the production of aggregates in synthesized powder due to pressing and also enabling the mold system to operate even when using a small amount of power, so that the system is prevented from malfunctioning and the power consumption thereof is reduced upon operating.
    Type: Grant
    Filed: April 1, 2010
    Date of Patent: August 4, 2015
    Assignee: KOREA INSTITUTE OF MACHINERY & MATERIALS
    Inventors: Sea Hoon Lee, Hai Doo Kim, Jae Woong Ko
  • Patent number: 9096034
    Abstract: A syntactic metal foam composite that is substantially fully dense except for syntactic porosity is formed from a mixture of ceramic microballoons and matrix forming metal. The ceramic microballoons have a uniaxial crush strength and a much higher omniaxial crush strength. The mixture is continuously constrained while it is consolidated. The constraining force is less than the omniaxial crush strength. The substantially fully dense syntactic metal foam composite is then constrained and deformation worked at a substantially constant volume. The deformation working is typically performed at a yield strength that is adjusted by way of selecting a working temperature at which the yield strength is approximately less than the omniaxial crush strength of the included ceramic microballoons. This deformation causes at least work hardening and grain refinement in the matrix metal.
    Type: Grant
    Filed: April 12, 2012
    Date of Patent: August 4, 2015
    Assignee: Powdermet, Inc.
    Inventors: Andrew J. Sherman, Brian Doud
  • Publication number: 20150147590
    Abstract: A new Enhanced High Pressure Sintering (EHPS) method for making three-dimensional fully dense nanostructures and nano-heterostructures formed from nanoparticle powders, and three-dimensional fully dense nanostructures and nano-heterostructures formed using that method. A nanoparticle powder is placed into a reaction chamber and is treated at an elevated temperature under a gas flow to produce a cleaned powder. The cleaned powder is formed into a low density green compact which is then sintered at a temperature below conventional sintering temperatures to produce a fully dense bulk material having a retained nanostructure or nano-heterostructure corresponding to the nanostructure of the constituent nanoparticles. All steps are performed without exposing the nanoparticle powder to the ambient.
    Type: Application
    Filed: November 14, 2014
    Publication date: May 28, 2015
    Applicant: The Government of the United States of America, as represented by the Secretary of the Navy
    Inventors: Boris N. Feigelson, James A. Wollmershauser
  • Publication number: 20150132176
    Abstract: A method for the production of a metal bearing layer (L) on a cylinder barrel (3) of a hydrostatic displacement machine (1), in particular of an axial piston machine, in which the metal bearing layer (L) is produced from a sintering powder in a sintering process. In a first production step, a dimensionally stable green compact (31) is produced from a sintering powder by a cold pressing process. In a second subsequent production step, the green compact (31) produced by the cold pressing process is sintered onto the cylinder barrel (3) in a sintering process.
    Type: Application
    Filed: September 23, 2014
    Publication date: May 14, 2015
    Inventors: Klaus Volker, Jens Gabelmann, Klaus Syndikus, Sebastian Weber
  • Publication number: 20150132175
    Abstract: A mixed powder placed in a container cavity is transferred to the cavity of a first die. A first pressure is applied to the mixed powder in the first die to form an intermediate green compact. The first die and the intermediate green compact are heated to heat the intermediate green compact to the melting point of a lubricant. The heated intermediate green compact is transferred to the cavity of a second die, and a second pressure is applied to the intermediate green compact to form a high-density final green compact.
    Type: Application
    Filed: April 22, 2013
    Publication date: May 14, 2015
    Inventors: Kazuhiro Hasegawa, Yoshiki Hirai
  • Publication number: 20150118096
    Abstract: A first die is filled with a mixed powder that is a mixture of a basic metal powder and a low-melting-point lubricant powder. A first pressure is applied to the mixed powder to form a mixed powder intermediate compressed body having a protrusion that protrudes in the pressing direction as compared with the configuration of a mixed powder final compressed body. The mixed powder intermediate compressed body is heated to the melting point of the lubricant powder. The heated mixed powder intermediate compressed body is placed in a second die. A second pressure is applied to the mixed powder intermediate compressed body to press-mold the mixed powder intermediate compressed body while crushing the protrusion in the pressing direction to form the high-density mixed powder final compressed body having high density and the desired configuration.
    Type: Application
    Filed: April 22, 2013
    Publication date: April 30, 2015
    Inventors: Kazuhiro Hasegawa, Yoshiki Hirai
  • Patent number: 9017599
    Abstract: There is provided a sliding part in which a surface coverage ratio of copper in the sliding part increases. A bearing which is the sliding part is formed by filling the raw powder into the filling portion of the forming mold, compacting the raw powder to form a powder compact, which is sintered. A copper-based raw powder is composed of a copper-based flat raw powder whose diameter is smaller than that of an iron-based raw powder and an aspect ratio larger than that of the iron-based raw powder, and a copper-based small-sized raw powder whose diameter is smaller than that of the copper-based flat raw powder. The copper is allowed to segregate at the surface of the sliding part. The surface of the bearing is covered with the copper-based small-sized raw powder and the copper-based flat raw powder, thereby the surface coverage ratio of copper can be increased.
    Type: Grant
    Filed: June 1, 2012
    Date of Patent: April 28, 2015
    Assignee: Diamet Corporation
    Inventors: Teruo Shimizu, Tsuneo Maruyama
  • Patent number: 8999230
    Abstract: New net shape strength retaining high temperature alloy parts are formed from fine metallurgical powders by mechanically blending the powders and placing them in die, placing a piston in the die, extending the piston into a driving chamber, filling the chamber with CH4 and air and compressing the powders with the filling pressure. Igniting gas in the chamber drives the piston into the cavity, producing pressures of about 85 to 150 tsi, compacting the powders into a near net shape alloy part, ready for sintering at 2300° C. without shrinking. The alloy parts are Re, Mo—Re, W—Re, Re—Hf—HfC, Re—Ta—Hf—HfC, Re—Mo—Hf—HfC, Mo—Re—Ta, Mo—Re-f-HfC, W—Re—Hf—HfC, W—Re—Ta—Hf—HfC or W—Re—Mo—Hf alloys.
    Type: Grant
    Filed: March 30, 2009
    Date of Patent: April 7, 2015
    Assignee: Utron Kinetics, LLC
    Inventors: Karthik Nagarathnam, Donald Trostle, Dennis Massey
  • Publication number: 20150093282
    Abstract: A brazing rod for forming a wear resistant coating on a substrate by a brazing process. The brazing rod includes a composite material having a plurality of round particles bound together by a binding material. Each of the plurality of round particles includes a round outer layer encapsulating a wear resistant element.
    Type: Application
    Filed: October 1, 2014
    Publication date: April 2, 2015
    Inventor: Andrew BELL
  • Publication number: 20150093274
    Abstract: Scroll members for scroll compressors made from one or more near-net shaped powder metal processes, either wholly or partially fabricated together from sections. In certain variations, the involute scroll portion of the scroll member has a modified terminal end region. The terminal end region may include an as-sintered coupling feature comprising a tip component that forms a contact surface for contacting an opposing scroll member during compressor operation. The tip component can be a tip seal or a tip cap received by the as-sintered coupling feature. The tip cap may be sinter-bonded or otherwise coupled to the terminal end region. In other variations, a terminal end region may comprise a second material including a tribological material that forms a contact surface. Methods of making such scroll members for scroll compressors are also provided.
    Type: Application
    Filed: September 26, 2014
    Publication date: April 2, 2015
    Inventors: Robert C. Stover, Marc J. Scancarello, Jean-Luc M. Caillat
  • Publication number: 20150093281
    Abstract: A method of creating a texture on at least one surface of a part is disclosed. The part is molded from a feedstock including a powder remaining solid during molding and a binder, and solidified. Then, a physical state of the binder is changed in only a predetermined portion of each surface of the part to be textured. The texture is then created from the predetermined portion by debinding and sintering the part.
    Type: Application
    Filed: September 27, 2013
    Publication date: April 2, 2015
    Applicant: Pratt & Whitney Canada Corp.
    Inventors: Marc CAMPOMANES, Orlando SCALZO, Guillaume POITRAS
  • Patent number: 8992828
    Abstract: A method for manufacturing a high ductility Ti-, Ti-alloy or NiTi-foam, meaning a compression strain higher than 10%, includes: preparing a powder suspension of a Ti-, NiTi- or Ti-alloy powder, bringing the said powder suspension into a desired form by gelcasting to form a green artifact. The method also includes a calcination step wherein the green artifact is calcined, and sintering the artifact. The calcination step includes a slow heating step wherein said green artifact is heated at a rate lower or equal to 20° C./hour to a temperature between 400° C. and 600° C. and the Ti-, NiTi- or Ti-alloy powder has a particle size less than 100 ?m. A high ductility Ti-, Ti-alloy or NiTi foam, with a compression higher than 10%, with a theoretical density less than 30%, pore size (cell size) between 50 to 1000 ?m can be obtained with such a method.
    Type: Grant
    Filed: June 7, 2006
    Date of Patent: March 31, 2015
    Assignee: Vlaamse Instelling Voor Technologisch Onderzoek (VITO)
    Inventors: Steven Mullens, Ivo Thijs, Jozef Cooymans, Jan Luyten
  • Patent number: 8980166
    Abstract: The invention relates to a method for producing a strand-like, particularly band-like semi-finished part for electrical contacts, wherein the semi-finished part has a top side intended for making the electrical contact, said top side made from a silver-based composite material in which one or multiple metal oxides or carbon are embedded, and has a carrier layer supporting the composite material made of silver or a silver-based alloy, said method having the following steps: Powder-metallurgic production of a block made from the silver-based composite material, encasing of the block made of the composite material with a powder made primarily of silver, compressing the block, encased by the metal powder, to condense the metal powder, sintering the compressed block, reshaping the sintered block by extrusion pressing, creating a partial strand with a top side made from composite material and a bottom side made from silver or a silver-based alloy.
    Type: Grant
    Filed: October 27, 2009
    Date of Patent: March 17, 2015
    Assignee: Doduco GmbH
    Inventors: Helmut Heinzel, Andreas Kraus, Evelyn Mahle-Moessner, Johann Wenz
  • Patent number: 8961719
    Abstract: A method for making a treated super-hard structure, the method including providing a super-hard structure comprising super-hard material selected from polycrystalline cubic boron nitride (PCBN) material or thermally stable polycrystalline diamond (PCD) material; subjecting the super-hard structure to heat treatment at a treatment temperature of greater than 700 degrees centigrade at a treatment pressure at which the super-hard material is not thermodynamically stable, for a treatment period of at least about 5 minutes to produce the treated super-hard structure.
    Type: Grant
    Filed: May 25, 2012
    Date of Patent: February 24, 2015
    Assignee: Element Six Limited
    Inventors: Stig Åke Andersin, Bernd Heinrich Ries, Frank Friedrich Lachmann, Lars-Ivar Nilsson
  • Publication number: 20150050179
    Abstract: The present invention provides a method to cure material (polymer, metals) into a mold against the shape of a fluid (aka the substrate). The substrate is a ferrofluid, and its shape can be dictated by surrounding magnetic fields. By manipulating the applied magnetic fields, the ferrofluid can be formed into a specific shape; then, the curing material (in fluid or powder form) can be molded against that specific shape. The ferrofluid shape can further be changed during the curing step to impact the final shape. The methods of the present invention permit fast three-dimensional molding in a programmable fashion.
    Type: Application
    Filed: August 15, 2014
    Publication date: February 19, 2015
    Inventor: Eleanor Augusta Hawes
  • Publication number: 20150037163
    Abstract: An axial flow compressor blade unit including a platform section and an airfoil section, which are used as arranged on a circumference about an axis of the compressor. The platform section includes an inner diametric surface segment inwardly of the circumference, an outer diametric surface segment outwardly of the circumference, two annular side surface segments extending in a circumferential direction, two axially side surface segments extending in the axial direction, and a coupling portion formed in each of the annular side surface segments so as to extend in the circumferential direction and being of a shape projecting or recessed in the axial direction. The airfoil section is formed to erect from the platform section so as to extend in a radial direction. The platform section and the airfoil section are formed integrally with each other while having a powdered metal sintered structure.
    Type: Application
    Filed: January 21, 2013
    Publication date: February 5, 2015
    Applicant: KAWASAKI JUKOGYO KABUSHIKI KAISHA
    Inventors: Tomoaki Ikegaya, Daisuke Hayashi, Makoto Gouda, Yuji Matsuzaki, Kei Shimada, Katsumi Ikeda