Forming Articles By Uniting Randomly Associated Metal Particles Patents (Class 419/61)
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Patent number: 6926969Abstract: The invention relates to a process for the production of sintered porous bodies, to porous bodies produced correspondingly using the process, and to their use. With the solution according to the invention, sintered bodies which achieve improved properties, such as an increased surface area, deformability of the structures at room temperature or modification of the initial pore volume, are to be produced. To this end, at least one sintering-active powder which forms at least one intermetallic phase or mixed crystals is applied to the surface of a porous basic body. Heat treatment is to be carried out subsequently, in which intermetallic phases or mixed crystals which increase the specific surface area can be formed.Type: GrantFiled: October 4, 2002Date of Patent: August 9, 2005Assignees: Inco Limited, Fraunhofer-Gesellschaft zur Forderung der angewandten Forschung e. V.Inventors: Alexander Bohm, Hartmut Gohler, Dirk Naumann
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Patent number: 6769159Abstract: A method for producing a ceramic electronic part includes forming a plurality of internal electrodes arranged in a ceramic sintered compact, superimposed via a ceramic layer. The free ends of the internal electrodes are formed to have a wedge-like cross-sectional shape, with the length L of the wedge and the internal thickness t of the electrode at the base of the wedge satisfying the relationship L>2t so that there is no risk of generating inter-layer peel-off or delamination in the ceramic layers.Type: GrantFiled: June 6, 2001Date of Patent: August 3, 2004Assignee: Murata Manufacturing Co., Ltd.Inventors: Tatsuo Haratani, Yasunobu Yoneda, Kyoshin Asakura
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Publication number: 20040141871Abstract: The present invention is an apparatus for filling a multi-powder including a powder box (10) including a plurality of powder chambers storing a plurality of powders whose constituent compositions differ in a divided manner, and a gas feed pipe (14) disposed on the bottom side of the powder chamber and having an introducing hole for introducing a gas, wherein it can fill a plurality of the powders into a cavity (24) at once through the bottom openings of the powder box by introducing a gas through the introducing hole to substantially equalize the respective flow resistances of a plurality of the powders. Thus, it is possible to fill the powders whose constituent compositions differ at once without disposing them in a mixed manner.Type: ApplicationFiled: October 27, 2003Publication date: July 22, 2004Inventors: Mikio Kondo, Hiroshi Okajima, Yoshitaka Takahashi
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Patent number: 6676896Abstract: The invention relates to a method of a composite material from superposed layers of solid and frothable metallic materials. The structural component consists of at least one layer of a solid metallic material and at least one layer of frothable metallic material. The structural component may be structured as a composite sheet or as a hollow body. The fabrication method of the structural component insures a good bond between the solid metallic layer and the frothable layer and that the frothable layer is securely attached to the solid metallic layer.Type: GrantFiled: November 19, 2001Date of Patent: January 13, 2004Assignee: Fraunhofer-Gesellschaft zur Foerderung der angwandten Forschung e.V.Inventor: Joachim Baumeister
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Publication number: 20030072670Abstract: A method of fabricating multi-layer bronze bearings includes laying down a first layer of copper-based powder metal material of a first composition onto a steel backing strip. At least a second layer of copper-based powder metal material of a second composition different than that of the first is laid down on the first layer, without significantly densifying the first layer.Type: ApplicationFiled: October 15, 2002Publication date: April 17, 2003Applicant: FEDERAL-MOGUL WORLD WIDE, INC.Inventor: James R. Toth
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Publication number: 20030056619Abstract: A method of making sheet bar and other precursors of formed products to be made by extensive working. The method includes providing a powder metal, preferably under 100 PPM oxygen content of non-spherical particles, compacting the powder into a coherent precursor form of at least 100 pounds, whereby a precursor is provided enabling extended fabrication to a finished product form. The finished product is resistant to breakup in fabrication due to oxide inclusion effect and produces a low oxygen end product. The method can process multiple species of metals that include at least one higher melting metal and one lower melting metal to produce an alloy or micro-composite of the metals as worked, where one metal is preferably a refractory metal (Ta, Nb, W, Wo, Zr, Hf, V and Re). The process is controlled to cause powder of the higher melting metal to be extended into a fibrous form.Type: ApplicationFiled: October 9, 2002Publication date: March 27, 2003Inventors: Prabhat Kumar, Paul Aimone, Robert W. Balliett, Anthony V. Parise, Thomas M. Ramlow, Henning Uhlenhut
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Publication number: 20020130041Abstract: A method of regenerating a phase-change sputtering target for optical storage media. First, a used powder-metallurgy sputtering target composed of a target material, an adhesion material, and a backing plate is recycled. Then, the target material is separated from the backing plate. Then, the target adhesion material is scraped from the recycled target material Thereafter, the surface of the recycled target material is processed. Finally, the backing plate, a new adhesion material, the recycled target material, and new powders are placed in a vacuum thermal-pressure furnace in sequence to perform a thermal-pressure sintering process.Type: ApplicationFiled: March 12, 2002Publication date: September 19, 2002Inventors: Jyh-Chung Wen, Ming-Shyong Lai, Bean-Jon Li
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Publication number: 20020112955Abstract: Refractory metal products, such as tantalum on non-refractory conductive metal backings, e.g. copper, can be rejuvenated after metal consumption in selected zones by powder filling the zones and high energy heating at high scan speed to sinter the added powder, without complete melting of the powder fill, thus establishing a microstructure consistent with the balance of the reclaimed product and avoiding the separation of the copper backing and tantalum sputter plate. The rejuvenation method can be applied to non-mounted refractory metal products that are subject to non-uniform erosion, etching, chipping or other metal loss. The form of such refractory metal products can be as plate, rod, cylinder, block or other forms apart from sputter targets. The process can be applied to, for example, x-ray disks or targets (molybdenum plate on carbon backing).Type: ApplicationFiled: February 14, 2002Publication date: August 22, 2002Applicant: H.C. Starck, Inc.Inventors: Paul Aimone, Prabhat Kumar, Peter R. Jepson, Henning Uhlenhut, Howard V. Goldberg
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Publication number: 20020064476Abstract: A niobium powder comprising at least one element selected from the group consisting of chromium, molybdenum, tungsten, boron, aluminum, gallium, indium, thallium, cerium, neodymium, titanium, rhenium, ruthenium, rhodium, palladium, silver, zinc, silicon, germanium, tin, phosphorus, arsenic, bismuth, rubidium, cesium, magnesium, strontium, barium, scandium, yttrium, lanthanum, praseodymium, samarium, europium, gadolinium, terbium, dysprosium, holmium, erbium, thulium, ytterbium, lutetium, hafnium, vanadium, osmium, iridium, platinum, gold, cadmium, mercury, lead, selenium and tellurium; a sintered body of the niobium powder; and a capacitor comprising a sintered body as one electrode, a dielectric material formed on the surface of the sintered body, and counter electrode provided on the dielectric material.Type: ApplicationFiled: August 10, 2001Publication date: May 30, 2002Applicant: SHOWA DENKO K.K.Inventors: Kazuhiro Omori, Kazumi Naito
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Patent number: 6395687Abstract: A method is provided for lubricating a die cavity that includes applying a lubricant composition containing a high melting point polymeric wax lubricant to the wall of a die cavity. Preferably, the lubricant is a polyamide lubricant that has a melting temperature greater than the temperature of the die wall during use. The present invention also provides a method of making a compacted metal part that includes applying the lubricant composition to an internal wall of a die cavity, introducing a metal-based powder composition into the die cavity; and compacting the powder composition at a pressure sufficient to form a compacted part from the metal powder composition.Type: GrantFiled: May 24, 2001Date of Patent: May 28, 2002Assignee: Hoeganaes CorporationInventor: Francis G. Hanejko
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Publication number: 20020054824Abstract: A sintered rare earth magnet is produced by finely pulverizing a coarse rare earth magnet alloy powder to an average particle size of 1-10 &mgr;m in a non-oxidizing atmosphere; introducing the resultant fine rare earth magnet alloy powder into a non-oxidizing liquid comprising at least one oil selected from the group consisting of mineral oils, synthetic oils and vegetable oils, and at least one lubricant selected from the group consisting of esters of aliphatic acids and monovalent alcohols, esters of polybasic acids and monovalent alcohols, esters of aliphatic acids and polyvalent alcohols and their derivatives to prepare a slurry; molding the slurry; degreasing the resultant green body; sintering the degreased green body; and then heat-treating the green body.Type: ApplicationFiled: September 14, 2001Publication date: May 9, 2002Applicant: HITACHI METALS, LTD.Inventors: Hisato Tokoro, Kimio Uchida
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Publication number: 20020051726Abstract: A powder pressing apparatus comprises a powder feeding apparatus. The powder feeding apparatus includes a container having a bottom portion provided with a powder holding portion formed with openings, and an impactor. The impactor is hit against the container to give an impulsive force, thereby feeding the powder contained in the container into the cavity formed in a die via the openings. The powder fed in the cavity is pressed, and the obtained compact is sintered into a sintered magnet. The powder feeding apparatus may include a feeder box containing the powder, and the feeder box may be provided therein with a rod member, and an opening of the feeder box may be provided with a linear member. In this case, the powder is fed into the cavity while moving the rod member in the horizontal direction in the feeder box, when the feeder box is above the cavity.Type: ApplicationFiled: September 6, 2001Publication date: May 2, 2002Inventors: Akira Nakamura, Atsuo Tanaka, Shouichi Matsugami, Tadahiro Iwasaki, Yoshiro Takano
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Publication number: 20020041819Abstract: A method of making sheet bar and other precursors of formed products to be made by extensive working. The method includes providing a powder metal, preferably under 100 PPM oxygen content of non-spherical particles, compacting the powder into a coherent precursor form of at least 100 pounds, whereby a precursor is provided enabling extended fabrication to a finished product form. The finished product is resistant to breakup in fabrication due to oxide inclusion effect and produces a low oxygen end product. The method can process multiple species of metals that include at least one higher melting metal and one lower melting metal to produce an alloy or micro-composite of the metals as worked, where one metal is preferably a refractory metal (Ta, Nb, W, Wo, Zr, Hf, V and Re). The process is controlled to cause powder of the higher melting metal to be extended into a fibrous form.Type: ApplicationFiled: July 16, 2001Publication date: April 11, 2002Applicant: H.C. Starck, Inc.Inventors: Prabhat Kumar, Paul Aimone, Robert W. Balliett, Peter R. Jepson, Anthony V. Parise, Thomas M. Ramlow, Henning Uhlenhut
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Patent number: 6329076Abstract: A hydrogen storage material (1) having excellent hydrogen storage capability and having such a low hydrogen desorption temperature as not to significantly hinder the use thereof, and also capable of being mass-produced, and a manufacturing method of the same can be obtained. The hydrogen storage material has a layered deformation structure including plastic deformation, and one layer (2) of the layered deformation structure is formed from an alloy or compound including an element of groups 2A, 3A and 4A or an element of at least one of the groups 2A, 3A and 4A, and another layer (3) being in contact with the one layer is formed from an alloy or compound including an element of groups 6A, 7A and 8A or an element of at least one of the groups 6A, 7A and 8A.Type: GrantFiled: February 14, 2001Date of Patent: December 11, 2001Assignee: Sumitomo Electric Industries, Ltd.Inventors: Nozomu Kawabe, Kouichi Sogabe, Shousaku Yamanaka, Yoshinobu Takeda, Takashi Uemura
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Patent number: 6224816Abstract: Tool having a molding surface is formed from a flowable material (e.g., powder material) wherein the shape of molding surface is formed from a molding process using a master pattern having a surface with a shape substantially the same as the shape of the molding surface to be formed. The tool has at least one thermal control element located within it and spaced from the molding surface where a component used in forming the thermal control element is located within the flowable material prior to solidifying the material. The powder material is preferably a mixture of metals. The thermal control elements include fluid flow paths, heating elements, temperature sensors, and the like.Type: GrantFiled: September 17, 1998Date of Patent: May 1, 2001Assignee: 3D Systems, Inc.Inventors: Charles W. Hull, Michael S. Lockard, Thomas A. Almquist
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Patent number: 6210625Abstract: The invention is a method of making a novel spherical form of granulated products that can be effectively used in various product forms in drug, fertilizer, foodstuff, feed, agricultural chemical, catalyst, ceramics, powder metallurgy, detergent, plastic, and bio-material fields, for instance, as catalysts, lightweight materials, sound-insulating materials, microcapsules, and lightweight aggregates. To obtain a granulated product which is a spherical solid shell having a spherical space therein, a polymer having high water absorption properties is swollen by the absorption of water therein, and then brought in contact with a powder to form a powder layer all over the surface of the swollen polymer particle. This spherical particle is then dried and fired if necessary.Type: GrantFiled: March 29, 1999Date of Patent: April 3, 2001Assignee: Mikuni CorporationInventors: Mitsuhiro Matsushita, Shinpei Inamura
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Patent number: 6086820Abstract: A method for producing an electrode of Ni/metal hydride alloy secondary cells. The electrode may be produced by mixing an active material with approximately 10-50 wt % of Cu powders, which can serve as a binder as well as a current collector, and cold-pressing the mixture at a pressure of 10 ton/cm. As the Cu-compacted electrode continues to experience the cycle of charge and discharge, the desolution-deposition of Cu is gradually produced. This desolution-deposition of Cu allows Cu to be deposited on the surface of the electrode comprising the hydrogen storage alloy, so that the electrode can be similar to a conventional Cu-electroless plated electrode in surface morphology. Consequently, the method of the invention can be an alternative for conventional electroless plating, which significantly improves the general functions of hydrogen storage alloy electrode, including low temperature dischargeability and high rate capability, without producing pollution of the environment.Type: GrantFiled: April 14, 1998Date of Patent: July 11, 2000Assignee: Korea Advanced Institute of Science & TechnologyInventors: Jai Young Lee, Kuk Jin Jang, Jae Han Jung, Dong Myung Kim, Ji Sang Yu, Sang Min Lee, Jeong Gun Park, Ho Lee
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Patent number: 5985202Abstract: A method and apparatus for forming a laminated object using a laser-discharging means a laser beam, a material capable of forming a solid layer by receiving the laser beam, and a mask for interrupting the laser beam. The method includes the steps of: forming a layer of the material on a surface, covering the material with the mask, and discharging the laser beam onto the material covered with the mask to solidify the material and form the solid layer on the surface. The above cycle is repeated to produce a laminated object. The method and the apparatus are characterized in the adjusting at least one of a distance from the laser-discharging means to the mask and a distance from the mask to the material, so that the extent of the laser beam is adjusted and the dimension of the laminated object is adjusted.Type: GrantFiled: December 2, 1997Date of Patent: November 16, 1999Assignee: Toyota Jidosha Kabushiki KaishaInventors: Motoaki Ozaki, Yukio Otsuka, Hiromoto Satoh
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Patent number: 5980813Abstract: Novel compositions and methods are provided for use in the stepwise, layer by layer fabrication of three-dimensional objects, in which a build material contains a metal having a covalent bond to a non-metal, and the layers are processed to produce the three-dimensional object at least in part through a chemical reaction which alters the covalent bond of the metal. In a first aspect of the invention the build material includes a metal that is covalently bound to a polymeric precursor. In another aspect of the invention, the build material includes a metal, Me, that is covalently bound to a first ligand, L.sub.1. Following deposition of the build material, the first ligand undergoes a redox reaction with a second ligand, L.sub.2, thereby breaking the covalent bond of the metal. In more preferred embodiments of this class, L.sub.1 and L.sub.2 react to form a gas, and the metal reacts to form an oxide such as MeSO.sub.x, MeNO.sub.x, MeCO.sub.x and so forth.Type: GrantFiled: June 26, 1998Date of Patent: November 9, 1999Assignee: SRI InternationalInventors: Subhash C. Narang, Susanna C. Ventura, Sunity Sharma, John S. Stotts
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Patent number: 5925463Abstract: The object of the invention is a method for the electrochemical preparation of metal colloids with particle sizes of less than 30 nm, characterized in that one or more metals of groups Ib, IIb, III, IV, V, VI, VIIb, VIII, lanthanoides, and/or actinoides of the periodic table are cathodically reduced in the presence of a stabilizer, optionally with a supporting electrolyte being added, in organic solvents or in solvent mixtures of organic solvents and/or water within a temperature range of between -78.degree. C. and +120.degree. C. to form metal colloidal solutions or redispersible metal colloid powders, optionally in the presence of inert substrates and/or soluble metal salts of the respective metals.The invention further relates to soluble or redispersible colloids as well as application on substrates and immobilization thereof, in particular for the preparation of catalysts.Type: GrantFiled: December 18, 1996Date of Patent: July 20, 1999Assignee: Studiengesellschaft Kohle mbHInventors: Manfred T. Reetz, Wolfgang Helbig, Stefan Andreas Quaiser
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Patent number: 5905424Abstract: Bonded magnets made from gas atomized powders of an rare earth alloy and having good hard magnetic characteristics are provided. The powders have an alloy composition comprising approximately 15 to 34 weight % of RE, 0.8 to 1.2 weight % of B, 0.5 to 4 weight % of TiC, balanced with at least one of Fe and Co, wherein RE is one or more rare earth elements selected from the group consisting of Y, La, Ce, Pr, Nd, Sm, Er, Gd, Tb, Dy, Ho, Er, Tm, Yb and Lu.Type: GrantFiled: August 4, 1997Date of Patent: May 18, 1999Assignee: Magnequench International, Inc.Inventor: Viswanathan Panchanathan
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Patent number: 5826160Abstract: A method and apparatus for fabricating high density monolithic metal and alloy billets. The process requires preheating precursor materials of metal or alloy billets by means of a combustion synthesis called Self-Propagating High-Temperature Synthesis (SHS). The reaction takes place in an insulated reaction vessel where the precursors, in a powder form, are heated to high temperatures. The precursors are then compacted to high density by means of pressure waves generated by detonation of an explosive. The method is capable of producing high purity tungsten and tungsten-based alloys of greater than 90% theoretical density.Type: GrantFiled: August 14, 1995Date of Patent: October 20, 1998Assignee: The United States of America as represented by the Secretary of the ArmyInventor: Laszlo J. Kecskes
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Patent number: 5809393Abstract: A sputtering target comprising a body of metal such as aluminum and its alloy with an ultrafine grain size and small second phase. Also described is a method for making an ultra-fine grain sputtering target comprising melting, atomizing, and depositing atomized metal to form a workpiece, and fabricating the workpiece to form a sputtering target. A method is also disclosed that includes the steps of extruding a workpiece through a die having contiguous, transverse inlet and outlet channels of substantially identical cross section, and fabricating the extruded article into a sputtering target. The extrusion may be performed several times, producing grain size of still smaller size and controlled grain texture.Type: GrantFiled: October 30, 1995Date of Patent: September 15, 1998Assignee: Johnson Matthey Electronics, Inc.Inventors: John Alden Dunlop, Jun Yuan, Janine Kiyabu Kardokus, Roger Alan Emigh
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Patent number: 5718865Abstract: A moulded alum composition is formed by mixing crushed solid alum with a polyol plasticiser followed by heating to form a slurry, and then pouring the mixture into a mould. No mechanical cutting and grinding is required and weakening cracks and fissures present in the raw alum are removed.Type: GrantFiled: December 24, 1996Date of Patent: February 17, 1998Inventor: Darren John Askew
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Patent number: 5711866Abstract: A metallic composite solid, containing alloys and/or intermetallics, is formed by compacting at moderate pressure a mixture of powder particles, foils or sheets at a temperature close to room temperature, well below the melting temperature of the constituent components and without the addition of low melting metals such as mercury, indium or gallium acting as a sintering agent. This low temperature consolidation of the powder mixture is enhanced by having the surface oxide of the powder particles removed, prior to consolidation, and/or by coating the particles with an oxide-replacing metal such as silver or gold. The coating process may be replacement reactions, autocatalytic reduction or electrolytic reduction. The composite formation is assisted by the addition of a liquid acid such as fluoroboric acid, sulfuric acid, fluoric acid, adipic acid, ascorbic acid, or nitric acid.Type: GrantFiled: May 9, 1995Date of Patent: January 27, 1998Assignee: The United States of America as represented by the Secretary of CommerceInventors: David S. Lashmore, Moshe P. Dariel, Christian E. Johnson, Menahem B. Ratzker, Anthony A. Giuseppetti, Frederick C. Eichmiller, Glenn L. Beane, David R. Kelley
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Patent number: 5597515Abstract: A process for producing a conductive, fluorine-doped titanium dioxide product which is doped throughout, said process comprising the steps of: (a) reacting the precursors in a system to form fluorine-doped TiO.sub.2, said precursors consisting essentially of a titanium alkoxide and a fluorine source; (b) reducing the fluorine-doped titanium dioxide product at a temperature sufficient to form said conductive, fluorine-doped titanium dioxide product; and (c) recovering the reduced product.Type: GrantFiled: September 27, 1995Date of Patent: January 28, 1997Assignee: Kerr-McGee CorporationInventors: James W. Kauffman, Bruce R. Palmer
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Patent number: 5594930Abstract: A brazeable aluminum material is composed of an aluminum core and a brazing agent layer consisting of a brazing agent thermally sprayed onto covering a surface of the core. A number of unmolten minute particles of the brazing agent are present in the brazing agent layer, which contains at least an aluminum-silicon alloy and/or a mixture of aluminum and silicon. Characteristic features of a method of producing the brazeable aluminum material are the steps of: preparing a powder composed of minute particles; and thermally spraying the powder onto the aluminum core in such a state that only a surface of each minute particle is molten, with a pith of the particle remaining unmolten. The powder is an Al-Si alloy and/or a mixture of Al powder and Si powder.Type: GrantFiled: October 27, 1993Date of Patent: January 14, 1997Assignee: Showa Aluminum CorporationInventors: Takashi Terada, Masahiro Kojima, Taizo Morita, Katsuyuki Arakawa, Ichiro Iwai, Masakazu Furuta
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Patent number: 5566373Abstract: A method and apparatus for manufacturing a powder metallurgy article comprising two or more individually compacted layers is described. The apparatus includes a number of powder deposition means for depositing powder into at least one die cavity, the number of powder deposition means corresponding to at least the number of different powder compositions in an article being compacted, a die assembly having a female die body which is moveable with respect to a first press ram, a mechanically driven second press ram, means for driving said second press ram, control system means for controlling the relative positions and movements of said female die body, said first press ram, said second mechanically driven press ram and said powder deposition means such that they operate in synchronism, characterised by said control system means including an angle counter having proportional drive means from the press apparatus such that one cycle of the angle counter corresponds to a required number of press compaction strokes.Type: GrantFiled: September 26, 1994Date of Patent: October 15, 1996Assignee: Komage Gellner Maschinenfabrik GmbHInventors: Hans-Georg Seimetz, Andrew R. Baker
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Patent number: 5538684Abstract: The present invention provides lubricant compositions for the powder metallurgical field. The lubricant compositions contain a solid phase lubricant such as graphite, molybdenum disulfide, and polytetrafluoroethylene in combination with a liquid phase lubricant that is a binder for the solid phase lubricant. The binder can be chosen from various classes of compounds including polyethylene glycols, polyethylene glycol esters, partial esters of C.sub.3-6 polyhydric alcohols, polyvinyl esters, and polyvinyl pyrrolidones. The binder is solubilized in an organic solvent.Type: GrantFiled: June 6, 1995Date of Patent: July 23, 1996Assignee: Hoeganaes CorporationInventors: Sydney Luk, Ann Lawrence
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Patent number: 5518684Abstract: A lead frame for use in an integrated circuit package is herein disclosed wherein the lead frame is produced by molding an electrically conductive material into a desired lead frame shape. There is also disclosed several possible arrangements for a lead frame produced using the molding method including, protrusions on the lead frame adapted to provide a mechanical connection to the integrated circuit package, a heat sink molded as an integral part of the lead frame with heat dissipating characteristics specific to the application in which the lead frame will be used, and an arrangement which provides a heat conducting portion adapted to thermally connect a component attached to the lead frame to an external heat sink.Type: GrantFiled: May 10, 1995Date of Patent: May 21, 1996Assignee: National Semiconductor CorporationInventor: David A. Pruitt
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Patent number: 5509189Abstract: An electrochemical device including a solid electrolyte and solid electrode composed of materials having different chemical compositions and characterized by different electrical properties but having the same crystalline phase is provided. A method for fabricating an electrochemical device having a solid electrode and solid electrolyte characterized by the same crystalline phase is provided.Type: GrantFiled: December 15, 1994Date of Patent: April 23, 1996Assignee: Massachusetts Institute of Technology, a MA corp.Inventors: Harry L. Tuller, Steve A. Kramer, Marlene A. Spears, Uday B. Pal
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Patent number: 5486240Abstract: A method of making a permanent magnet wherein 1) a melt is formed having a base alloy composition comprising RE, Fe and/or Co, and B (where RE is one or more rare earth elements) and 2) TR (where TR is a transition metal selected from at least one of Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, W, and Al) and at least one of C and N are provided in the base alloy composition melt in substantially stoichiometric amounts to form a thermodynamically stable compound (e.g. TR carbide, nitride or carbonitride). The melt is rapidly solidified in a manner to form particulates having a substantially amorphous (metallic glass) structure and a dispersion of primary TRC, TRN and/or TRC/N precipitates. The amorphous particulates are heated above the crystallization temperature of the base alloy composition to nucleate and grow a hard magnetic phase to an optimum grain size and to form secondary TRC, TRN and/or TRC/N precipitates dispersed at grain boundaries.Type: GrantFiled: April 25, 1994Date of Patent: January 23, 1996Assignee: Iowa State University Research Foundation, Inc.Inventors: R. William McCallum, Daniel J. Branagan
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Patent number: 5472661Abstract: Method of distributing and retaining insoluble additive particles uniformly throughout a mass of moldable metal particles. The additive particles are suspended in a solution of a polymeric binder and spray-coated onto the metal particles. When the solvent evaporates, the additives remain glued to the metal particles by the binder.Type: GrantFiled: December 16, 1994Date of Patent: December 5, 1995Assignee: General Motors CorporationInventor: David E. Gay
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Patent number: 5466415Abstract: Thick-skinned extruded metal honeycomb structures, and a method and apparatus for making them, are disclosed wherein a plasticized powder metal extrusion batch is extruded though a die assembly comprising a die and annular mask, the mask having a central outlet for extrusion of the skin and honeycomb core and an extrudate reservoir adjacent the central outlet, the die and mask cooperating to form a skinforming gap fed by the die and by the extrudate reservoir, such that batch material supplied from the reservoir and directly from the die combines to form a thickened outer skin which is integral with, and resistant to separation from, the honeycomb core.Type: GrantFiled: October 20, 1994Date of Patent: November 14, 1995Assignee: Corning IncorporatedInventors: Kevin R. Brundage, Lawrence S. Rajnik
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Patent number: 5466310Abstract: A nitride of a metal or solid metalloid is produced by ball milling a powder of a metal or metalloid in a nitrogen, or nitrogen-containing atmosphere (such as ammonia). The pressure in the ball mill is normally from 100 to 5,000 kPa, typically about 300 kPa. The ball mill temperature may be from room temperature to 500.degree. C., preferably from 200.degree. C. to 400.degree. C. The product powder is normally pressure moulded and annealed at 800.degree. C. for about 1 hour to produce a strong, hard body. Controlling the degree of nitration, or mixing the product nitride powder with a metal powder before pressure moulding, enables a composite comprising a metal matrix with a dispersed nitride phase to be produced. An alternative technique, involves ball milling the metal or metalloid powder with an organic nitrogen-containing chemical which dissociates in the ball mill. This yields a mixture of the nitride and carbide of a metal or solid metalloid.Type: GrantFiled: August 18, 1993Date of Patent: November 14, 1995Assignee: The Australian National UniversityInventors: Barry W. Ninham, Andrzej Calka, James S. Williams
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Patent number: 5458847Abstract: A electroless plating method of an Ni--Al intermetallic compound includes steps of a) providing a reducing solution containing a reducing agent and reducing nickel ions, b) adding a proper amount of aluminum powder to the reducing solution, and c) permitting the reducing agent to reduce the reducing nickel ions to be deposited on the aluminum powder. Such electroless plating method permits the Ni--Al compound to be produced inexpensively/efficiently/fastly.Type: GrantFiled: September 22, 1993Date of Patent: October 17, 1995Assignee: National Science CouncilInventor: Chen-Ti Hu
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Patent number: 5455002Abstract: A plastic working method for making a holed metal part. A holed blank with a through hole is placed at the center in a die member which has a die and a container continuing to the die. The die is pushed toward a punch, inserting into the through hole a first portion of a mandrel which has cross sections with at least two different cross-sectional areas. The blank is compressed by a counter punch fitting with the container and a punch pressing the die end face of the die member toward the counter punch to cause the blank plasticly to flow into a space formed between the die hole of the die and the first portion of the mandrel and while applying a compressive force to the blank by the punch and the counter punch, pulling out the first portion of the mandrel out of the blank through hole while inserting a further portion of the mandrel into the through hole so as plastically to flow the blank into a gap between the first portion of the mandrel and the through hole.Type: GrantFiled: March 23, 1994Date of Patent: October 3, 1995Assignee: Aida Engineering, Ltd.Inventors: Kazuto Kobayashi, Toshio Suzuki, Takashi Nakano
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Patent number: 5447682Abstract: According to the method of making a magnetic coating material, 100 parts by weight of a magnetic metal powder, 1 to 10 parts by weight of fatty acid, 1 to 5 parts by weight of a dispersing agent, and a solvent are combined in the absence of a binding agent, wherein the solvent is present in sufficient amount to yield an admixture having a solids concentration of the magnetic metal powder in the range from 65 to 70 percent. The admixture is kneaded using a pressure kneader. The kneaded admixture is then blended with a binding agent to provide the magnetic coating material.Type: GrantFiled: June 24, 1993Date of Patent: September 5, 1995Assignee: Minnesota Mining and Manufacturing CompanyInventor: Yusuki Saito
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Patent number: 5393482Abstract: A multiple beam laser sintering device includes a sintering beam 64 having a focal point at a powder bed 68 and at least one defocussed laser beam 116 incident on a region near the focal point of the focussed beam 64. The sintering beam 64 raises the temperature of the powder 84 to the sintering temperature. The defocussed beam 116 raises the temperature of the material surrounding the sintering beam 64 to a level below the sintering temperature, thereby reducing the temperature gradient between the sintering location and the surrounding material. Thermal radiation may be measured from one or both beams and used to control the power of one or both beams and the power of one or both beams may be controlled to maintain the temperature at a desired level. Alternatively, a plurality of defocussed beams may be used to provide either a plurality of thermal gradient steps, or to control the temperature of each region around the sintering point independently.Type: GrantFiled: October 20, 1993Date of Patent: February 28, 1995Assignee: United Technologies CorporationInventors: John A. Benda, Aristotle Parasco
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Patent number: 5376328Abstract: There is disclosed a precious metal article which is formed of a solid-phase sintered product of a precious metal powder. For manufacturing the precious metal article, a moldable mixture which contains a precious metal powder and a binder removable by sintering is shaped into a prescribed molded object, and the molded object is then subjected to sintering. The moldable mixture is produced by preparing a precious metal powder, preparing a jellylike cellulose binder by blending a cellulose with water and leaving for a prescribed period of time, and blending the precious metal powder and the jellylike cellulose binder together. The most preferable moldable mixture contains 50 to 90% by weight of precious metal powder, 0.8 to 8% by weight of water-soluble cellulose binder, 0.08 to 3% by weight of a surface-active agent. 0.1 to 3% by weight of oil, balance water and unavoidable impurities.Type: GrantFiled: April 22, 1994Date of Patent: December 27, 1994Assignee: Mitsubishi Materials CorporationInventors: Koji Hoshino, Masaki Morikawa, Tohru Kohno, Koshiro Ueda, Masaki Miyakawa
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Patent number: 5342574Abstract: A method for producing an anisotropic rare earth magnet is improved by extruding using a compacted material formed in a shape having difference in level between the center part to be in contact with the end face of a punch and the outer peripheral part to be faced with a molding cavity formed between the punch and a cylindrical die of a mold.Type: GrantFiled: April 6, 1993Date of Patent: August 30, 1994Assignee: Daido Tokushuko Kabushiki KaishaInventors: Yasuaki Kasai, Hiyoshi Yamada, Norio Yoshikawa
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Patent number: 5336378Abstract: A sputtering target for forming a thin film consisting of high-purity titanium, in which the content of alkali metal is 0.1 ppm or less, the content of radio active elements is 1 ppb or less, and the oxygen content is 100 ppm or less, and, further, the balance of the elements is Ti, is produced by a fused salt electrolysis, in which the members of the electrolytic cell being in contact with the fused salt consist of Ni.Type: GrantFiled: September 9, 1992Date of Patent: August 9, 1994Assignee: Japan Energy CorporationInventors: Eiji Nishimura, Masami Kuroki, Naoyuki Kikutake, Yuuichiro Shindou
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Patent number: 5314655Abstract: Continuous powder metallurgy compacts are produced from metal powder (1) placed in a tapered powder consolidation region (2) of a forming die (1). The die is made to undergo ultrasonic radial vibration about the consolidation region to effect radial compaction of the powder. The powder is progressively densified as it moves through the die, due to the tapered construction of the consolidation region, and emerges from the die at sufficient density to allow handling and further processing.Type: GrantFiled: May 31, 1991Date of Patent: May 24, 1994Assignee: Manganese Bronze LimitedInventor: Geoffrey Greetham
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Patent number: 5152959Abstract: The present invention relates to a process for forming a composite strip material without any sintering step. The process includes blending a powdered high conductivity material such as powdered copper with a powdered low thermal expansion phase material such as a nickel-iron alloy, compacting the powders to form a green composite strip, heating the green strip to a hot rolling temperature and hot rolling the heated strip to a desired gauge. The heated strip is reduced less than about 45% to minimize the deformation of the low thermal expansion phase particles.Type: GrantFiled: June 24, 1991Date of Patent: October 6, 1992Assignee: AMETEK Speciality Metal Products DivisionInventor: Clive R. Scorey
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Patent number: 5037492Abstract: Diffusion alloying techniques are used to introduce low level additives into hot-worked Nd-Fe-B magnets. The powdered metal is added to the rapidly solidifed ribbons of the magnetic alloy prior to hot working. Diffusion alloying during hot-working permits the final chemistry of the magnet and more specifically the grain boundaries to be determined during the final processing steps. Elements which diffuse into the matrix, such as zinc, copper and nickel, enhance the coercivity by as much as 100 percent in die-upset magnets. At optimum levels, approximately 0.5-0.8 weight percent, the additives did not diminish the remanence or energy product of the magnet.Type: GrantFiled: December 17, 1990Date of Patent: August 6, 1991Assignee: General Motors CorporationInventors: Earl G. Brewer, Carlton D. Fuerst
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Patent number: 5028363Abstract: A method of casting a powdered material. A slurry is formed by dispersing metal powder or ceramic powder into a dispersing medium mainly consisting of a substance extractable by a liquid or supercritical carbon dioxide and having a melting point between 0.degree. C. and 100.degree. C., and the slurry is poured into a liquid non-absorbing mold where the slurry is cooled to freeze and solidify into a molding. The main constituent of the dispersing medium in the molding is extracted and removed by the liquid or supercritical carbon dioxide.Type: GrantFiled: January 16, 1990Date of Patent: July 2, 1991Assignee: NKK CorporationInventors: Hiroaki Nishio, Takeshi Kawashima, Yoshio Takagi
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Patent number: 4799955Abstract: Disclosed is a composite metal powder made from a base iron powder milled with an alloying component such as nickel, copper, managnese, chromium, silicon, phosphorus, boron, vanadium, and molybdenum, where the composite metal powder has a compressibility comparable to the compressibility of the soft base iron powder prior to milling. Such a composite is obtained by using a short mill time followed by an annealing step.Type: GrantFiled: October 6, 1987Date of Patent: January 24, 1989Assignee: Elkem Metals CompanyInventor: Melvin L. McClellan
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Patent number: 4774749Abstract: A plain bearing comprises a metal cylinder as an external member and a resinous cylinder as an internal member, in which the outer surface of the resinous cylinder is firmly engaged and bitten with a concavo-convex portion formed on the inner surface of the metal cylinder. A process for manufacturing the plain bearing comprises producing the metal cylinder, forming the concavo-convex portion on the inner surface of the metal cylinder, combining the concavo-convex portion of the metal cylinder with the resinous cylinder, inserting a core pin into the interior of a combined cylinder of the metal cylinder and the resinous cylinder, squeezing the combined cylinder through a draw die and producing a finished plain bearing.Type: GrantFiled: November 3, 1986Date of Patent: October 4, 1988Assignee: Nippon Seiko Kabushiki KaishaInventor: Kyozaburo Furumura
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Patent number: 4762754Abstract: Shock wave formation of superconductive ceramic oxide electric and magnetic circuit elements with improved microstructures and mechanical properties.Type: GrantFiled: October 23, 1987Date of Patent: August 9, 1988Assignee: The United States of America as represented by the United States Department of EnergyInventors: William J. Nellis, M. Brian Maple, Theodore H. Geballe
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Patent number: 4717627Abstract: Shock wave formation of thin layers of materials with improved superconducting and permanent magnetic properties and improved microstructures.Type: GrantFiled: December 4, 1986Date of Patent: January 5, 1988Assignee: The United States of America as represented by the United States Department of EnergyInventors: William J. Nellis, Theodore H. Geballe, M. Brian Maple