Heat And Pressure Simultaneously To Effect Sintering Patents (Class 419/48)
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Patent number: 6652616Abstract: In accordance with the method according to the present invention, particles consisting of ferrotitanium, ferroniobium or ferrovanadium are dispersed and hot compacted in a metal matrix powder consisting of hardening steel or heat-resistant alloys. In so doing, titanium, niobium or vanadium carbide is obtained in situ by a solid-state reaction, i.e. without melting, from the carbon admixed or contained in the matrix powder and the ferroalloy particles. Carbon can also be absorbed from the gaseous phase and it may be substituted by nitrogen. This method permits a reasonably-priced introduction of hard particles into the composite material, the hard particles having a size that is necessary as a protection against scoring wear.Type: GrantFiled: May 28, 2002Date of Patent: November 25, 2003Assignee: Maschienfabrik Koppern GmbH & Co. KGInventors: Hans Berns, Birgit Wewers
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Patent number: 6653548Abstract: A cuboid p-type and an n-type thermoelectric conversion material having a composite of an alloy powder for a rare earth magnet and a bismuth-based thermoelectric conversion material that has been rendered a p-type semiconductor or an n-type semiconductor by the addition of the required dopant, are arranged alternately with a material with low thermal conductivity and high electrical resistivity interposed between them. The low- and the high-temperature sides of these thermoelectric conversion materials are connected with wires, a magnetic field is applied in the x axis direction, a temperature gradient ∇T is imparted in the z axis direction a p-n junction is created, and thermoelectromotive force is extracted from the connection end in a plane in the y axis direction. There is a marked increase in the Seebeck coefficient even though no magnetic field is applied externally.Type: GrantFiled: October 10, 2001Date of Patent: November 25, 2003Assignee: Sumitomo Special Metals Co., Ltd.Inventor: Osamu Yamashita
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Patent number: 6635098Abstract: A low cost titanium, titanium alloy material, or Ti matrix composite comprising clean and divided titanium turnings that are blended with titanium, titanium alloy powder, and/or ceramic powder and consolidated is provided. A method of making the material is also provided. The low cost material is formed into preshapes, such as a billet, which is subsequently used as feedstock for extrusion, forging, casting, or rolling.Type: GrantFiled: February 12, 2002Date of Patent: October 21, 2003Assignee: Dynamet Technology, Inc.Inventors: Stanley Abkowitz, Susan M. Abkowitz, Harold L. Heussi, Kevin M. McCarthy
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Patent number: 6632263Abstract: An iron-based sintered powder metal mixture for valve guides, valve seat inserts and other high temperature, high wear applications requiring excellent net-shape stability during sintering comprises a powder metal mixture consisting essentially of 0.5-2.0 wt. % of fine, soluble graphite which goes into solution in the elemental iron matrix, 0.5-2.5 wt. % stable graphite which remains as free graphite in the sintered structure, 0.5-3.0 MoS2, which reacts with 1.0-5.0 wt. % copper to drive a sintering reaction at relatively low sintering temperatures of between 1030—1150° C. The resulting sintered particles have good mechanical strength and wear resistance and possess excellent machineability and dimensional stability.Type: GrantFiled: May 1, 2002Date of Patent: October 14, 2003Assignee: Federal - Mogul World Wide, Inc.Inventors: Salvator Nigarura, Mark Birler, Juan Trasorras
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Publication number: 20030168094Abstract: A thermoelectric material is prepare by mixing and melting at least two members selected from bismuth, tellurium, selenium, antimony, and sulfur to obtain an alloy ingot; grinding the alloy ingot to obtain powder of the alloy ingot; and hot pressing the powder of the alloy ingot. The hot pressing is performed under the conditions of a temperature of 500° C. or higher and 600° C. or lower and a pressure of 20 MPa or higher and 45 MPa or lower.Type: ApplicationFiled: February 13, 2003Publication date: September 11, 2003Applicant: MITSUI MINING & SMELTING CO., LTD.Inventors: Norihiko Miyasita, Tomoyasu Yano, Ryoma Tsukuda, Isamu Yashima
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Thermoelectric element, method of fabricating the same, and thermoelectric module employing the same
Patent number: 6617504Abstract: A method of fabricating a thermoelectric element of enhanced thermoelectric performance is provided by improving the preparation of thermoelectric material and employing hot plastic working in combination. The method comprises the step (a) of mixing and heat-melting a raw material of a predetermined composition; the step (b) of turning the heat-melted material 106 into microglobules by either of scattering and spraying, and then quenching the microglobules, thereby providing a globular powdery thermoelectric material; and the step (c) of plastically deforming the thermoelectric material in a hot condition, thereby to bring crystal grains of the thermoelectric material into a crystal orientation affording an excellent figure of merit.Type: GrantFiled: May 9, 2001Date of Patent: September 9, 2003Assignee: Komatsu Ltd.Inventors: Takeshi Kajihara, Akio Konishi, Yong Hoon Lee, Kiyoharu Sasaki, Kenichi Tomita, Takeji Kajiura -
Patent number: 6610246Abstract: A powder material is put into a cylindrical mold and electrodes are brought into contact with the side surface of the mold and a current is applied to sinter the material in the mold while a pressure is applied to the material. In this process, local temperature difference is kept as small as possible. A pair of electrodes are brought into contact with the side circumferential surface of a cylindrical mold (25) filled with a powder material (28) to which a pressure is applied and a current is applied to the mold (25) to heat the powder material (28) in the mold (25) and a sintered body is obtained. In order to sinter the material by the current application through the pair of electrodes, two pairs of electrodes (19a, 19b, 19c, 19d) which face each other are all brought into contact with the side surface of the mold (25) and the current is supplied through the electrodes (19) alternately.Type: GrantFiled: June 28, 2002Date of Patent: August 26, 2003Assignee: Akane Co., Ltd.Inventor: Kenichi Sunamoto
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Patent number: 6602314Abstract: The present invention provides an aluminum composite material having neutron absorbing power that improves the ability to absorb neutrons by increasing the content of B, while also being superior to materials of the prior art in terms of mechanical properties and workability. The aluminum composite material having neutron absorbing power contains in Al or an Al alloy matrix phase B or a B compound having neutron absorbing power in an amount such that the proportion of B is 1.5% by weight or more to 9% by weight or less, and the aluminum composite material has been pressure sintered.Type: GrantFiled: March 30, 2001Date of Patent: August 5, 2003Assignee: Mitsubishi Heavy Industries, Ltd.Inventors: Yasuhiro Sakaguchi, Tomikane Saida, Kazuo Murakami, Kazuhisa Shibue, Naoki Tokizane, Tatsumi Takahashi
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Patent number: 6562207Abstract: Sputter target, method of manufacture of same and sputter coating process using the target as a sputtering source are disclosed. The sputter target comprises an Me/Si multi-phase, consolidated blend wherein the Si component is present in a very small amount of about trace—0.99 mole Si:1 mole Me. Preferably, Me comprises one or more of Ta, Ti, Mo, or W. The targets are made from the requisite powders via HIP consolidation to provide densities of greater than 98 % of the theoretical density. The targets are especially useful in reactive cathodic sputtering systems employing N2 as the reactive gas to form amorphous Me/Si/N layers.Type: GrantFiled: January 14, 2000Date of Patent: May 13, 2003Assignee: Tosoh SMD, Inc.Inventor: Eugene Y. Ivanov
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Patent number: 6562290Abstract: 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.Type: GrantFiled: August 20, 2001Date of Patent: May 13, 2003Assignee: H.C. Starck Inc.Inventors: Helmut Meinhardt, Bernd Meyer, Matthias Knüwer, Dietmar Fister, Wolfgang Wiezoreck
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Patent number: 6551372Abstract: A nickel base powder metallurgy superalloy gas turbine engine disk for a compressor or turbine. The wrought powder metallurgy gas turbine engine disk has desirable fatigue crack growth resistance and a superior balance of tensile, creep rupture and low cycle fatigue strength characteristics. In one embodiment the disk defines a segregation free homogenous structure.Type: GrantFiled: September 15, 2000Date of Patent: April 22, 2003Assignee: Rolls-Royce CorporationInventors: Bruce A. Ewing, Sushil K. Jain, Kenneth A. Green, Randolph C. Helmink, Allister James
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Patent number: 6551374Abstract: The present invention relates to a method of controlling the microstructures of Cu—Cr-based contact materials for vacuum interrupters, in which a heat-resistant element is added to the Cu—Cr-based contact materials to obtain an excellent current interrupting characteristic and voltage withstanding capability, and contact materials manufactured thereby. The method of controlling the microstructures of Cu—Cr-based contact materials includes the steps of mixing a copper powder used as a matrix material, a chromium powder improving an electrical characteristic of the contact material and a heat-resistant element powder making the chromium particles in the matrix material fine to thereby obtain mixed powder, and subjecting the mixed powder to one treatment selected from sintering, infiltration and hot pressing to thereby obtain a sintered product.Type: GrantFiled: April 10, 2001Date of Patent: April 22, 2003Assignee: Korea Institute of Science and TechnologyInventors: Jung Mann Doh, Jong Ku Park, Mi Jin Kim
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Patent number: 6525260Abstract: A silicon-based polycrystal powder, which contains no more than 30 at % Ge, C, Sn, or another such element that does not generate carriers as well as an added element that does generate carriers, and which has a crystal structure including crystal grains made up of at least 80 at % silicon, and a grain boundary phase where at least one type of said added element is precipitated at the boundary of said crystal grains, is mixed with a clathrate compound powder with low thermal conductivity and electrical resistivity, and this mixture is subjected to hot compression molding, the product of which has a composite structure in which the particles of the clathrate compound polycrystals are disposed around the particles of the silicon-based polycrystals.Type: GrantFiled: August 17, 2001Date of Patent: February 25, 2003Assignee: Sumitomo Special Metals Co., Ltd.Inventors: Osamu Yamashita, Nobuhiro Sadatomi, Tsunekazu Saigo
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Patent number: 6503444Abstract: 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.Type: GrantFiled: September 27, 2001Date of Patent: January 7, 2003Assignee: Höganäs ABInventor: Ola Andersson
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Publication number: 20020170821Abstract: A cobalt-chromium-boron-platinum sputtering target alloy having multiple phases. The alloy can include Cr, B, Ta, Nb, C, Mo, Ti, V, W, Zr, Zn, Cu, Hf, O, Si or N. The alloy is prepared by mixing Pt powder with a cobalt-chromium-boron master alloy, ball milling the powders and HIP'ing to densify the powder into the alloy.Type: ApplicationFiled: April 11, 2001Publication date: November 21, 2002Inventors: Michael Sandlin, Bernd Kunkel, Willy Zhang, Phillip Corno
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Patent number: 6464747Abstract: Sintered cermet materials far tools such as cutting tools, which are excellent in heat resistance, wear resistance and fracture resistance, are inexpensive, and have long life time, and a method for producing such sintered cermet materials. The sintered cermet materials for tools are composed of sintered bodies which are obtained by preparing a mixed powder containing powders of TiCN, Si3N4, Al2O3, CrxN (x=1-2.7 and ZrN, at least one powder of W and WC, and at least one kind of metal powder selected from the group consisting of Co, Ni, Ta and Mo, and sintering the mixed powder .Type: GrantFiled: November 26, 2001Date of Patent: October 15, 2002Assignees: Aisin Seiki Kabushiki Kaisha, Tomei Diamond Co., Ltd.Inventors: Yasuhiro Enya, Kenji Gotoh, Satoru Hosomi
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Patent number: 6458317Abstract: A plating material mainly consisting of nickel-titanium is hot pressed onto a surface.Type: GrantFiled: February 12, 2001Date of Patent: October 1, 2002Assignee: Valtion Teknillinen TutkimuskeskusInventors: Jari Koskinen, Eero Haimi
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Method for preparing Ag-ZnO electric contact material and electric contact material produced thereby
Patent number: 6432157Abstract: An object of the present invention is to provide a method of producing an Ag—ZnO electric contact material which can uniformly disperse ZnO micrograms in Ag; which maintains low contact resistance; which exhibits enhanced welding resistance and wear resistance; and which is suitable in view of production costs. The method of producing an Ag—ZnO electrical contact material comprises casting Ag and Zn at predetermined proportions and subjecting the resultant Ag—ZnO alloy to internal oxidation so as to disperse ZnO in Ag, the method being characterized in that an Ag—Zn alloy comprising 5-10 wt. % (as reduced to weight of metal) Zn, the balance being Ag, is formed into chips; the chips are subjected to internal oxidation; the internally oxidized chips are compacted to thereby form billets; the billets are pressed and sintered; and subsequently, the sintered billets are extruded, to thereby yield uniform dispersion, in Ag, of ZnO micrograms.Type: GrantFiled: November 30, 2000Date of Patent: August 13, 2002Assignee: Tanaka Kikinzoku Kogyo K.K.Inventors: Tetsuya Nakamura, Osamu Sakaguchi, Hiroyuki Kusamori, Osamu Matsuzawa, Masahiro Takahashi, Toshiya Yamamoto -
Publication number: 20020102398Abstract: The invention describes composite coatings, in particular comprising carbon and another metallic element such as silicon or aluminum. These coatings have improved properties compared with pure tetrahedral amorphous carbon coatings, in that they have reduced stress levels and can be deposited at higher thicknesses, while retaining acceptable hardness and other useful mechanical properties. Also described are methods of making composite coatings, materials for making the coatings and substrates coated therewith. Specifically, a method of applying a coating to a substrate using a cathode arc source, comprises generating an arc between a cathode target and an anode of the source and depositing positive target ions on the substrate to form the coating, wherein the coating is a composite of at least first and second elements and the target comprises said at least first and second elements.Type: ApplicationFiled: March 25, 2002Publication date: August 1, 2002Inventors: Xu Shi, Hong Siang Tan, Beng Kang Tay
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Patent number: 6402802Abstract: Embodiments include a method for fabricating a nanograined component from a nanograined powder composition. A compact is formed from the nanograined powder composition and sufficient heat is applied to the compact to generate at least one exothermic reaction while the compact is at a temperature lower than its eutectic temperature. Pressure is applied to the powder compact during the heating operation to consolidate the powder compact. The application of heat and pressure are controlled to inhibit grain growth and form a component having a nanograined microstructure that is at least 98 percent dense at a temperature lower than the eutectic temperature.Type: GrantFiled: October 28, 1999Date of Patent: June 11, 2002Assignee: The Penn State Research FoundationInventor: Ram B. Bhagat
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Patent number: 6403875Abstract: 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).Type: GrantFiled: February 23, 2001Date of Patent: June 11, 2002Assignee: Mitsui Mining & Smelting Company, Ltd.Inventors: Shinji Karino, Ryouma Tsukuda, Yuichi Anno, Isamu Yashima, Hitoshi Kajino
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Patent number: 6365095Abstract: The present invention concerns a process of preparing high density, warm compacted bodies of a stainless steel powder comprising the steps of providing a mixture of a low carbon, low oxygen stainless steel powder including 10-30% by weight of Cr, optional alloying elements and graphite and inevitable impurities, mixing the powder with a high temperature lubricant and compacting the mixture at an elevated temperature. The invention also concerns a composition of the stainless steel powder, optional additional alloying elements and a high temperature lubricant.Type: GrantFiled: January 24, 2001Date of Patent: April 2, 2002Assignee: Höganäs ABInventor: Anders Bergkvist
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Patent number: 6336950Abstract: An aspect of this invention is an electrode rod for spark alloying, comprising a compact of a first powder of a first component which comprises a metal selected from a group of Fe, Co, Ni, metals of 4a, 5a and 6a of the periodic table and Si, and a second powder of a second component which is capable of self-propagating high temperature synthesis to form with said first component carbide, nitride, boride, silicide or intermetallic compound, said first and second powders being mixed intimately with each other and formed into an axial rod.Type: GrantFiled: May 5, 2000Date of Patent: January 8, 2002Assignees: The Ishizuka Research Institute Ltd., Moscow Steel and Alloys Institute, SHS-CenterInventors: Mitsue Koizumi, Manshi Ohyanagi, Satoru Hosomi, Evgeny Alexandrovich Levashov, Alexander Gennadievich Nikolaev, Alexander Evgenievich Kudryashov
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Patent number: 6332905Abstract: The invention according to the present application provides a high strength solidification body by solidifying a starting metallic powder of iron and the like by means of plastic working using hydrostatic pressing, which is, for instance, a high strength high toughness steel material and the like having a superfine texture comprising a crystalline texture consisting of grains 5 &mgr;m or less in average diameter, or preferably, 3 &mgr;m or less in average diameter. Furthermore, the present invention provides a steel material included in the high strength solidification body, which contains oxide grain 0.2 &mgr;m or less in diameter at a volume ratio of from 0.5 to 60%.Type: GrantFiled: December 4, 2000Date of Patent: December 25, 2001Assignees: Japan as represented by Director General of National Research Institute for Metals, Kawasaki Steel CorporationInventors: Minoru Ootaguchi, Shuji Wanikawa, Yuji Muramatsu, Kaneaki Tsuzaki, Kotobu Nagai, Toru Hayashi
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Patent number: 6319460Abstract: A metal-matrix diamond or cubic boron nitride composite and method of making the same are disclosed. The metal-matrix/diamond composite includes grains of diamond uniformly distributed in a metal matrix. Alternatively, grains of cubic boron nitride may be used. Suitable metals for the metal matrix material may include nickel, cobalt, iron, and mixtures or alloys thereof. Other transition metals also may be used. The metal-matrix/diamond or metal-matrix/cubic boron nitride composite has high fracture toughness due to its fine microstructure. Such a metal-matrix/diamond or metal-matrix/cubic boron nitride composite is suitable for use in blanks or cutting elements for cutting tools, drill bits, dressing tools, and wear parts. It also may be used to make wire drawing dies.Type: GrantFiled: August 10, 2000Date of Patent: November 20, 2001Assignee: Smith International, Inc.Inventor: Zhigang Fang
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Publication number: 20010037938Abstract: A refractory metal silicide target is characterized by comprising a fine mixed structure composed of MSi2 (where M: refractory metal) grains and Si grains, wherein the number of MSi2 grains independently existing in a cross section of 0.01 mm2 of the mixed structure is not greater than 15, the MSi2 grains have an average grain size not greater than 10 &mgr;m, whereas free Si grains existing in gaps of the MSi2 grains have a maximum grain size not greater than 20 &mgr;m. The target has a high density, high purity fine mixed structure with a uniform composition and contains a small amount of impurities such as oxygen etc. The employment of the target can reduce particles produced in sputtering, the change of a film resistance in a wafer and the impurities in a film and improve yield and reliability when semiconductors are manufactured.Type: ApplicationFiled: May 2, 2001Publication date: November 8, 2001Applicant: KABUSHIKI KAISHA TOSHIBAInventors: Michio Sato, Takashi Yamanobe, Tohru Komatsu, Yoshiharu Fukasawa, Noriaki Yagi, Toshihiro Maki, Hiromi Shizu
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Patent number: 6306339Abstract: 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.Type: GrantFiled: October 10, 2000Date of Patent: October 23, 2001Assignee: Kiyokawa Plating Industries, Co., Ltd.Inventors: Tadashi Kiyokawa, Hajime Kiyokawa, Masayuki Takashima
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Patent number: 6299831Abstract: A method is provided for fabricating Cu/Cr sputter targets having a density of at least about 90% of theoretical density and an oxygen content of less than about 1000 ppm. According to the principles of the present invention, Cu and Cr powders, each having particles in the size range of about 20 &mgr;m to about 150 &mgr;m and having oxygen contents preferably less than about 1200 ppm and 600 ppm, respectively, are blended and pressed by hot pressing. A low-oxygen content, high-density Cu/Cr target is thereby achieved for the sputtering of thin films having a defect generation of about 0%.Type: GrantFiled: July 14, 1999Date of Patent: October 9, 2001Assignee: Praxair S.T. Technology, Inc.Inventor: Chi-Fung Lo
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Patent number: 6290903Abstract: 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.Type: GrantFiled: April 10, 2000Date of Patent: September 18, 2001Inventors: Louis Grace, Jr., Nathaniel G. Grace, Matthew L. Grace
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Patent number: 6291806Abstract: The process of bonding a first workpiece to a second workpiece is disclosed comprising the steps of fabricating a sintered bonding pad formed from a matrix of randomly oriented metallic fibers. The bonding pad is interposed between the first and the second workpiece and the first and second workpieces are biased into engagement with the bonding pad. Heat is applied to the first workpiece to the second workpiece for transforming substantially all of the metallic fibers into a liquid for bonding the first workpiece to the second workpiece.Type: GrantFiled: September 30, 1999Date of Patent: September 18, 2001Assignee: USF Filtration and Separations Group, Inc.Inventors: Nathaniel R. Quick, Tao Li, Robert Malanga
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Patent number: 6287513Abstract: Disclosed is a method of shaping powdered metal parts comprising: (a) providing powdered metal from a source; (b) applying a heated fugitive coating to the powdered metal; (c) passing the powdered metal through a heated tube from a supply thereof to the die for the molding of the part; (d) monitoring the temperature of the heated tube during the passage of the powdered metal there through; (e) heating the die and monitoring the temperature thereof; (f) heating a punch die and monitoring the temperature thereof; (g) after filling the die with coated powdered metal, compacting the powdered metal by applying pressure from the punch die to the filled die thereby compacting the metal to a desired shape.Type: GrantFiled: August 24, 1999Date of Patent: September 11, 2001Assignee: Delphi Technologies, Inc.Inventors: Thomas G. Grady, Tom L. Stuart, Scott M. Clase, Bradley D. Beard
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Patent number: 6284013Abstract: There is provided a high-purity ruthenium sputtering target with a low impurity content, in particular producing extremely few particles, which is suitable for applications such as the formation of semiconductor thin films. The high-purity ruthenium sputtering target is manufactured by feeding crude ruthenium powder into a sodium hydroxide solution; blowing an ozone-containing gas while or after blowing chlorine gas into the solution to form ruthenium tetroxide; absorbing the ruthenium tetroxide in a hydrochloric acid solution or a mixed solution of hydrochloric acid and ammonium chloride, and evaporating the solution to dryness; sintering the resultant ruthenium salt in a hydrogen atmosphere to form high-purity ruthenium powder; and hot-pressing the ruthenium powder into a sputtering target.Type: GrantFiled: March 8, 2000Date of Patent: September 4, 2001Assignee: Japan Energy CorporationInventors: Yuichiro Shindo, Tsuneo Suzuki
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Patent number: 6280496Abstract: A silicon carbide based composite material includes as a first component, a metal mainly consisting of aluminum or copper, and as a second component, particles mainly consisting of silicon carbide having high purity and few defects. The material is obtained by heating a compact of the raw material powder containing the first and second components at a temperature not lower than the melting point of the metal mainly consisting of aluminum or copper, and by forging and solidifying under pressure. Preferably, the silicon carbide raw material powder is prepared to have high purity by carrying out a preliminary treatment, or the material after forging or a material obtained through a conventional infiltration process is further heated at a temperature lower than the melting point of the first component. In this manner, an improved superior thermal conductivity can be obtained.Type: GrantFiled: September 8, 1999Date of Patent: August 28, 2001Assignee: Sumitomo Electric Industries, Ltd.Inventors: Chihiro Kawai, Shin-ichi Yamagata, Akira Fukui, Yoshinobu Takeda
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Patent number: 6254660Abstract: The invention relates to a Cr2O3-forming alloy that is resistant to oxidization and/or corrosion at high temperature, especially by glass, characterized in that it contains, in dispersion within its matrix, chromium oxide Cr2O3, or a precursor of this oxide. This alloy can be prepared by powder metallurgy using a process of hot consolidation of metallic powders, in particular by sintering. The alloy is especially suitable for articles which are to be used in a high-temperature oxidizing or corrosive environment.Type: GrantFiled: November 25, 1998Date of Patent: July 3, 2001Assignee: Saint-Gobain RechercheInventors: Jean-Luc Bernard, Michel Bousquet, Olivier Kessler, Pierre Steinmetz
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Patent number: 6214177Abstract: A method of producing a silicon aluminum sputtering target is provided. The target is formed from a powder base of between about 80% to about 95% by weight silicon and about 5% to about 20% by weight aluminum which is placed in a containment unit, heated under vacuum and then sealed. The base is then subjected to a pressure greater than about 3000 psi and heated to a temperature between about 1076° F. and about 1652° F. such that some, but not more than 30%, of the resulting target is formed from liquid phase silicon-aluminum.Type: GrantFiled: December 22, 1999Date of Patent: April 10, 2001Assignee: Ultraclad CorporationInventor: Joseph C. Runkle
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Patent number: 6200523Abstract: An apparatus and a method is disclosed for sintering a matrix of elements such as fibers or particles by infrared heating. A multiplicity of the elements are arranged into a matrix of substantially randomly oriented elements to form a web. The web is irradiated with infrared energy for a period of time sufficient to sinter bond each of the elements to adjacent elements of the matrix randomly oriented elements.Type: GrantFiled: September 30, 1999Date of Patent: March 13, 2001Assignee: USF Filtration and Separations Group, Inc.Inventors: Nathaniel R. Quick, Tao Li, Robert Malanga, Michael Liberman, Alexander Sobolevsky, James A. McGrath
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Patent number: 6200515Abstract: Solid reaction products with a dense nanocrystalline structure are formed from reactant particles with diameters in the nano-scale range by compacting the particles into a green body, then passing an electric current through the body causing Joule heating sufficient to initiate the reaction to form the reaction product while simultaneously applying pressure to the reacting body to density it to a density approaching the theoretical density of the pure product. Surprisingly, this process results in a reaction product that retains the nanocrystalline structure of the starting materials, despite the fact that a reaction has occurred and the materials have been subjected to highly stringent conditions of electric current, heat and pressure.Type: GrantFiled: August 13, 1999Date of Patent: March 13, 2001Assignees: Centre National de la Recherche Scientifique, The Regents of the University of CaliforniaInventors: Zuhair A. Munir, Frederic Charlot, Frederic Bernard, Eric Gaffet
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Patent number: 6168072Abstract: The present invention provides a method of diffusion bonding a first article containing a thermally activated expansion agent to a second article. The first article and the second article are placed adjacent to each other at a bonding area. The first article and the second article are constrained such that contact is maintained between the first article and the second article at the bonding area. The constrained articles are then heated at a temperature that causes the first article to expand, creating pressure between the articles at the bonding area.Type: GrantFiled: October 21, 1998Date of Patent: January 2, 2001Assignee: The Boeing CompanyInventors: Daniel S. Schwartz, Donald A. Deuser
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Patent number: 6147293Abstract: A process for producing a sintered thermoelectric semiconductor includes a first step of forming bulk crystals of a thermoelectric semiconductor and a second step of hot extrusion. The second step includes substeps of placing the bulk crystals in the cavity of a heated extrusion die, pushing the ram into the cavity, thereby compressing and crushing the bulk crystals and turning them into a molten or semi-molten state, and finally extruding the molten or semi-molten crystals, thereby sintering them and forming a sintered thermoelectric semiconductor.Type: GrantFiled: October 23, 1998Date of Patent: November 14, 2000Assignee: Aisin Seiki Kabushiki KaishaInventors: Hitoshi Tauchi, Satoru Hori, Joji Hachisuka, Makoto Yamazaki, Masayoshi Ando
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Patent number: 6110420Abstract: A composite structure and method for manufacturing same, the composite structure being comprised of metal particles and an inorganic bonding media. The method comprises the steps of coating particles of a metal powder with a thin layer of an inorganic bonding media selected from the group of powders consisting of a ceramic, glass, and glass-ceramic. The particles are assembled in a cavity and heat, with or without the addition of pressure, is thereafter applied to the particles until the layer of inorganic bonding media forms a strong bond with the particles and with the layer of inorganic bonding media on adjacent particles. The resulting composite structure is strong and remains cohesive at high temperatures.Type: GrantFiled: August 3, 1999Date of Patent: August 29, 2000Assignee: UT-Battelle, LLCInventors: Arthur J. Moorhead, Hyoun-Ee Kim
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Patent number: 6090343Abstract: A method for fabricating a triphasic composite such as a WC/Co/diamond composite with a high volume fraction of diamond in a WC/Co matrix. The method involves sintering of a WC/Co powder compact to develop a porous preform, which displays some rigidity and strength, infiltrating the porous preform with a controlled distribution of carbon, and high pressure/high temperature treatment of the carbon-containing WC/Co preform to transform the carbon to diamond. The distribution of diamond in the composite can be functionally graded to provide a WC/Co core and a diamond-enriched surface, wherein all three phases form an interconnected structure in three dimensions. Such a tricontinuous structure combines high strength and toughness with superior wear resistance, making it attractive for applications in machine tools and drill bits.Type: GrantFiled: March 25, 1998Date of Patent: July 18, 2000Assignee: Rutgers UniversityInventors: Bernard H. Kear, Rajendra K. Sadangi, Larry E. McCandlish, Oleg Voronov
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Patent number: 6086819Abstract: A process is disclosed for manufacturing thin-walled pipes made of a heat- and wear-resistant aluminium-based material. A billet or tube blank made of a hypereutectic AlSi material is produced, optionally overaged by an annealing process, then extruded into a thick-walled pipe or round bar. The thus obtained preform is severed and extruded into a thin-walled pipe. This process is particularly suitable to manufacture light metal cylinder liners for internal combustion engines, since the thus manufactured cylinder liners have the required properties regarding wear-resistance, heat-resistance and lowered pollutant emissions.Type: GrantFiled: February 27, 1998Date of Patent: July 11, 2000Assignee: Erbsloh AktiengesellschaftInventors: Bernhard Commandeur, Rolf Schattevoy, Klaus Hummert, Dirk Ringhand
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Patent number: 6077476Abstract: A method for operating a gas pressure vessel for use in hot isostatic pressing operations. This method includes heating and gas pressurizing an interior chamber of the vessel and thereafter simultaneously removing hot gas from this interior chamber and introducing cold gas to this interior chamber.Type: GrantFiled: October 23, 1998Date of Patent: June 20, 2000Assignee: Crucible Materials CorporationInventors: Michael D. Quinlan, Joseph F. Perez
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Patent number: 6071323Abstract: An alloy target comprises at least one rare earth metal element Tb, Dy, Gd, Sm, Nd, Ho, Tm, and Er with a substantial balance of a transition metal element such as Fe, Co and Ni, and has a substantially homogeneous sintered structure and a permeability of 3 or lower. The alloy target is fabricated by a process comprising steps of melting in a high-frequency furnace or crucible furnace, quenching, pulverization, and firing under pressure. After the alloy target has been used up, it is regenerated by mixing alloy powders (to be regenerated) obtained by the mechanical pulverization of the used-up target with the alloy powders obtained at the pulverization step of the aforesaid process to obtain a mixture, and firing the mixture under pressure.Type: GrantFiled: March 2, 1998Date of Patent: June 6, 2000Assignee: TDKCorporationInventor: Yukio Kawaguchi
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Patent number: 6071389Abstract: A sputter target assembly includes a cobalt target diffusion bonded to an aluminum or copper backing plate by means of a titanium interlayer. The sputter target assembly may be made by hot vacuum pressing or, preferably, by hot isostatically pressing the target, interlayer and backing plate together. Preferably, the titanium interlayer is provided as a foil, but may also be formed on a mating surface of either the target or the backing plate by electroplating, sputtering, electroless plating, or plasma spraying. The target may be advantageously machined with grooves defining salient points prior to providing the interlayer.Type: GrantFiled: August 17, 1999Date of Patent: June 6, 2000Assignee: Tosoh SMD, Inc.Inventor: Hao Zhang
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Patent number: 6065552Abstract: An earth-boring bit has cutting elements inserted within holes in the cutter support. The cutting element has a body of a fracture-tough material, preferably tungsten carbide which contains a binder of a soft metal. A layer of a composite carbide which is substantially free of a binder is attached to the cutting end of the body. One cutting element has a chisel-shaped cutting end with two flanks that converge. One of the flanks has the layer of binderless carbide. This insert is located at a junction between the gage surface and heel surface for engaging the sidewall of the bore. Also, gage inserts located in the gage surface have outer ends containing a layer of binderless carbide.Type: GrantFiled: July 20, 1998Date of Patent: May 23, 2000Assignee: Baker Hughes IncorporatedInventors: Danny E. Scott, James L. Overstreet
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Patent number: 6042780Abstract: 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.Type: GrantFiled: December 15, 1998Date of Patent: March 28, 2000Inventor: Xiaodi Huang
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Patent number: 6042777Abstract: There is provided a method for fabricating intermetallic sputter targets of two or more elements in which a mixture of two or more elemental powders are blended and synthesized within a pressing apparatus at a temperature below the melting point of the lowest melting point element in the mixture, followed by heating the synthesized intermetallic powder in the pressing apparatus to a temperature below the melting point of the intermetallic structure while simultaneously applying pressure to the powder to achieve a final density greater than 90% of theoretical density. The powder metallurgy technique of the present invention provides a better microstructure than cast structures, and avoids contamination of the sputter target by eliminating the crushing step of synthesized intermetallic chunks necessitated by separate steps of synthesizing and pressing.Type: GrantFiled: August 3, 1999Date of Patent: March 28, 2000Assignees: Sony Corporation, Materials Research CorporationInventors: Chi-Fung Lo, Darryl Draper, Hung-Lee Hoo, Paul S. Gilman
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Patent number: 6038461Abstract: There are disclosed a high temperature superconductive material which can be plastically deformed, processed optionally into predetermined configurations and industrially mass produced and a method of manufacturing a formed body of the high temperature superconductive material. Mixed is a powder raw material which is mainly composed of: 10 to 50 mol % of at least one amide or nitride of alkali metal of Li, Na or K; 10 to 60 mol % of cyanide containing at least one metal selected from aluminum, copper, silver or gold; 5 to 50 mol % of at least one pure metal selected from aluminum, copper, silver or gold; and 10 mol % or less of at least one alkaline earth metal selected from Be, Mg, Ca, Sr or Ba. The powder raw material is pressed, and heated and sintered at the temperature of 673 K to 1553 K. In this manner, obtained is the plastically deformable high temperature superconductive material which can be optionally processed through forging, rolling and the like.Type: GrantFiled: April 24, 1998Date of Patent: March 14, 2000Inventors: Yoshifumi Sakai, Itsuko Sakai
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Patent number: 6033624Abstract: Methods for the manufacture of nanostructured metals, metal carbides, and metal alloys are presented, such metals including nanostructured aluminum, chromium, iron, molybdenum, vanadium, and steel. Preferably, the nanostructured steel is of the M50 type, and comprises iron, molybdenum, chromium, vanadium and carbon. Synthesis of M50 steel further comprising nanostructured aluminum, aluminum oxide, or aluminum nitride is also described. In accordance with an important feature of this invention, the grain size of the metals and metal alloys is in the nanometer range. In accordance with the method of the present invention, the nanostructured metals, metal carbides, and metal alloys are prepared via chemical synthesis from aluminum, iron, molybdenum, chromium and vanadium starting materials. Decomposition of metal precursors or co-precipitation or precipitation of metal precursors is followed by consolidation of the resulting nanostructured powders.Type: GrantFiled: September 25, 1996Date of Patent: March 7, 2000Assignee: The University of ConneticutInventors: Kenneth E. Gonsalves, Sri Prakash Rangarajan