One Or More Components Not Compacted Patents (Class 419/7)
  • Patent number: 6391251
    Abstract: A method and apparatus for embedding features and controlling material composition in a three-dimensional structure (130) is disclosed. The invention enables the control of material characteristics, within a structure (130) made from a plurality of materials, directly from computer renderings of solid models of the components. The method uses stereolithography and solid model computer file formats to control a multi-axis head (480) in a directed material deposition process (123). Material feedstock (126, 127) is deposited onto a pre-heated substrate (19). Depositions (15) in a layer-by-layer pattern, defined by solid models (141, 146), create a three-dimensional article having complex geometric details. Thermal management of finished solid articles (250-302), not available through conventional processing techniques, is enabled by embedded voids (152) and/or composite materials (126, 127), which include dissimilar metals (210, 216).
    Type: Grant
    Filed: May 9, 2000
    Date of Patent: May 21, 2002
    Assignee: Optomec Design Company
    Inventors: David M. Keicher, James L. Bullen, Pierrette H. Gorman, James W. Love, Kevin J. Dullea, Mark E. Smith
  • Publication number: 20020041818
    Abstract: To make a three-dimensional object, an optical beam is first irradiated on a predetermined portion of a powder layer to form a sintered layer, which is then covered with a new powder layer. The optical beam is again irradiated on a predetermined portion of the new powder layer to form another sintered layer that has been united with the underlying sintered layer. These processes are repeatedly carried out to form a plurality of sintered layers united together, which have a size greater than that of a target shape of the three-dimensional object. A surface region of a shaped object formed by then is removed during the formation of the plurality of sintered layers.
    Type: Application
    Filed: September 28, 2001
    Publication date: April 11, 2002
    Applicant: MATSUSHITA ELECTRIC WORKS, LTD.
    Inventors: Satoshi Abe, Norio Yoshida, Yoshikazu Higashi, Hirohiko Togeyama, Isao Fuwa, Shushi Uenaga, Seizo Machida
  • Patent number: 6355211
    Abstract: A method for producing high performance components by the consolidation of powdered materials under conditions of hot isostatic pressure. The method uses the inclusion of reactive materials mixed into pressure-transmitting mold materials and into the powder to be consolidated to contribute to in-situ materials modification including purification, chemical transformation, and reinforcement. The method also uses encapsulation of the mold in a sealed container to retain the mold material in position, and to exclude air and contaminants.
    Type: Grant
    Filed: February 7, 2000
    Date of Patent: March 12, 2002
    Inventor: Xiaodi Huang
  • Patent number: 6274082
    Abstract: A process for producing a shaped article, comprising: preparing a first powder having high strength and rigidity after completion of forming, and a second powder having abrasion resistance and surface hardness after completion of forming; compacting those powders to provide a forming material comprising a base part comprising the first powder and a supplemental part comprising the second powder; and forming the forming material into a shaped article by plastic processing, thereby producing a shaped article in which the base part and the supplemental part have different characteristics. The first powder preferably comprises a rapidly-solidified alloy powder and the second powder preferably comprises at least one member selected from among Al2O3, Si3N4, BN, SiC, Al4C3, Al8B2O15 and B2O or a mixture of the member and the first powder which may be the same one actually used as the first powder or another one having a different compositions from that of the actually used first powder.
    Type: Grant
    Filed: September 2, 1999
    Date of Patent: August 14, 2001
    Assignee: YKK Corporation
    Inventors: Junichi Nagahora, Koju Tachi, Koji Saito, Teruaki Onogi
  • Patent number: 6114048
    Abstract: The invention provides for a functionally-graded metal substrate that is made of at least two metal compositions, a functional insert and a surrounding body that surrounds the functional insert. In a preferred embodiment of the invention a functional insert powder composition of loose powder metal is placed in a compact of a surrounding body powder composition and both metal compositions are sintered in a sintering furnace to form a sintered part. The sintered part is infiltrated in part or in whole with a molten metal compound to produce a functionally graded metal substrate having a density of at least 90% of theoretical. A heat-generating component such as a chip can be attached to the metal substrate for use in microelectronic packaging. When the functionally-graded metal substrate has two discrete compositions of copper/tungsten the surrounding body which has a CTE that ranges from about 5.6ppm/.degree. C. to about 7 ppm/.degree. C.
    Type: Grant
    Filed: September 4, 1998
    Date of Patent: September 5, 2000
    Assignee: Brush Wellman, Inc.
    Inventors: David E. Jech, Jordan P. Frazier, Richard H. Sworden, Juan L. Sepulveda
  • Patent number: 6104015
    Abstract: This disclosure sets forth a microwave sintering process for green oxide particles introduced from a source such as a hopper or a container, a downwardly directed funnel and a discharge outlet from the funnel. Particles are introduced into an elongate rotatable tube. The tube is inclined at a controlled angle. Particles traverse the tube, passing through a central heating zone between inlet and outlet. The time interval of the particles in the heating zone is controlled by adjustment of the angle of inclination, particle size, and rotation rate to assure that all particles are processed and converted from green to sintered oxide particles.
    Type: Grant
    Filed: January 8, 1999
    Date of Patent: August 15, 2000
    Inventors: Ponnarassery Sukumaran Jayan, Narayanan Ananthaseshan, Balachandran Subramaniam, Murugappan Vellayan Murugappan
  • Patent number: 6063333
    Abstract: This disclosure features a process of making a two part drill bit insert, namely, a body portion of hard particles such as tungsten carbide particles mixed in an alloy binding the particles. The alloy preferably comprises 6% cobalt with amounts up to about 10% permitted. The body is sintered into a solid member, and also joined to a PDC crown covering the end. The crown is essentially free of cobalt. The process sinters the crown and body while preserving the body and crown cobalt differences.
    Type: Grant
    Filed: May 1, 1998
    Date of Patent: May 16, 2000
    Assignees: Penn State Research Foundation, Dennis Tool Company
    Inventor: Mahlon Denton Dennis
  • Patent number: 6015627
    Abstract: A head drum for supporting a magnetic head for magnetically recording information on and reproducing information from a magnetic tape includes an inner body of an aluminum alloy, and a wear-resistant layer of a sintered powdery alloy disposed around an outer circumference of the inner body in at least a region for sliding contact with an elongate magnetic recording medium. The wear-resistant layer has a thickness of at least 0.2 um, and the sintered powdery alloy comprises a powdery alloy of 17 to 38% of Si, 0.5 to 5% of Cu, 0.3 to 5% of Mg, and the remainder of aluminum.
    Type: Grant
    Filed: September 3, 1997
    Date of Patent: January 18, 2000
    Assignees: Sony Corporation, Sumitomo Light Metal Industries, Ltd.
    Inventors: Yasuhiro Hirafune, Akio Kikuchi
  • Patent number: 6007764
    Abstract: The present invention is a method which customizes the penetration depth of a heat-fusible powder used in solid freeform fabrication process such as laser sintering. The penetration depth of the heat-fusible powder is customized by combining opaque and transparent powders at a ratio which ensures that the beam contacts a portion of powder beneath its surface, thereby promoting complete layer sintering as well as adherence to previously sintered layers.
    Type: Grant
    Filed: March 27, 1998
    Date of Patent: December 28, 1999
    Assignee: United Technologies Corporation
    Inventors: John A. Benda, Aristotle Parasco
  • Patent number: 6004505
    Abstract: The present disclosure is directed to a method of converting green particles to form finished particles. The apparatus used for sintering incorporates an elongate hollow tube, an insulative sleeve there about to define an elevated temperature zone, and a microwave generator coupled through a wave guide into a microwave cavity incorporated the tube. The particles are moved through the tube at a controlled rate to assure adequate exposure to the microwave radiation. Another form sintered a solid part in a cavity or mold.
    Type: Grant
    Filed: July 26, 1996
    Date of Patent: December 21, 1999
    Assignees: Dennis Tool Corporation, The Penn State Research Foundation
    Inventors: Rustum Roy, Dinesh Agrawal, Jiping Cheng, Mahlon Dennis, Paul D. Gigil
  • Patent number: 5940674
    Abstract: A process for making a component includes the steps of: depositing a layer of a porous material; positioning a mask near to the deposited layer; applying a bonding material that will cause any contacted portions of the porous material to become bonded together, over and through the mask, such that the bonding material is applied to one or more selected regions of the recently deposited layer of porous material; and repeating the foregoing three steps a selected number of times to produce a selected number of successive layers, said bonding material causing each of said successive layers to become bonded to an adjacent layer. Any unbonded porous material that is not at the selected regions is easily removed. The mask may be an open stencil mask, or a screen mask. If open stencil masks are used, there may be more than one mask for a single layer of porous material. Successive masks may be positioned by a continuous sheet, a rotating disk, or individually, such as by a robot.
    Type: Grant
    Filed: April 9, 1997
    Date of Patent: August 17, 1999
    Assignee: Massachusetts Institute of Technology
    Inventors: Emanuel M. Sachs, Michael J. Cima
  • Patent number: 5903815
    Abstract: A product and method are disclosed for constructing a powdered metal component from two or more discreet powdered metals in which one or more of the powdered metals is weldable following compaction while the other powdered metal is not A die having two die parts which together define a die cavity therebetween corresponding in shape to the desired metal component is first partially filled with one of the powdered metals and the remainder of the die cavity is then filled with the other powdered metal. The die parts are then compressed together to form the pressed component which, after removal from the die, is sintered. The weldable powdered metal is either powdered iron or powdered steel having a carbon content less than about 0.6% by weight carbon. Conversely, the other powdered metal is powdered steel or iron or alloyed, or mixtures thereof, having a carbon content typically greater than 0.6% by weight for enhanced hardness of the part.
    Type: Grant
    Filed: February 12, 1992
    Date of Patent: May 11, 1999
    Assignee: ICM/Krebsoge
    Inventor: Norman William Scott
  • Patent number: 5901336
    Abstract: A process for bonding a first metal such as beryllium to a second metal such as a copper alloy using a powder metallurgy compositional gradient. According to one aspect of the present invention, a sequence of powder layers is located between beryllium and copper alloy pieces, the layers containing mixtures of a beryllium powder and a copper powder, e.g., of a copper alloy, high purity copper and/or the like. The composition of the layers is adjusted such that the layer adjacent the beryllium piece is beryllium rich, and so that the layers become progressively richer in copper as they get closer to the copper piece. The variation in composition between the pieces produces the compositional gradient. Bonding of the beryllium and copper alloy pieces is then accomplished by a hot consolidation technique such as hot isostatic pressing, vacuum hot pressing, solid state bonding or diffusion bonding at a temperature generally within a range of 500.degree. and 800.degree. C.
    Type: Grant
    Filed: August 30, 1996
    Date of Patent: May 4, 1999
    Assignee: Brush Wellman Inc.
    Inventor: David E. Dombrowski
  • Patent number: 5805971
    Abstract: A method of producing a three-dimensional form includes the steps of spraying from at least one nozzle a gas including particles of materials having different properties onto a base surface to deposit a layer of particles, repeatedly spray-depositing layers of particles each on the upper surface of a deposition layer, thereby building up a three-dimensional object consisting of the accumulated deposition layers each having different properties in a two-dimensional plane, and utilizing the different properties in the accumulated deposition layers to remove part of the three-dimensional object, thereby producing a desired three-dimensional form.
    Type: Grant
    Filed: September 12, 1995
    Date of Patent: September 8, 1998
    Assignee: Agency of Industrial Science & Technology, Ministry of International Trade & Industry
    Inventor: Jun Akedo
  • Patent number: 5799238
    Abstract: A method making a titanium ceramic composite involves forming a hot pressed powder body having a microstructure comprising at least one titanium metal or alloy layer and at least one ceramic particulate reinforced titanium metal or alloy layer and hot forging the hot pressed body follwed by hot rolling to substantially reduce a thickness dimension and substantially increase a lateral dimension thereof to form a composite plate or sheet that retains in the microstructure at least one titanium based layer and at least one ceramic reinforced titanium based layer in the thickness direction of the composite plate or sheet.
    Type: Grant
    Filed: June 14, 1995
    Date of Patent: August 25, 1998
    Assignee: The United States of America as represented by the United States Department of Energy
    Inventors: George T. Fisher, II, Jeffrey S. Hansen, Laurance L. Oden, Paul C. Turner, Thomas L. Ochs
  • Patent number: 5732323
    Abstract: The invention relates to a method for the fabrication of dimensionally accurate metal pieces by sintering a material which, before the sintering, consists of a blend of three pulverous ingredients, of which the first ingredient is in the main an iron-group metal, the second ingredient is in the main copper and phosphorus, and the third ingredient is an alloy of copper and some other metal. The shape of the piece is produced by layer-by-layer freeform selected area laser sintering, wherein a layer of the said powder blend is spread on a base, those regions of the layer which correspond to this cross-sectional surface of the piece are heated by a laser beam to the sintering temperature. Thereafter further successive powder layers are spread one on top of another, and in each layer in turn those areas which correspond to the cross-sectional surface of the piece in that layer are laser sintered.
    Type: Grant
    Filed: March 21, 1997
    Date of Patent: March 24, 1998
    Assignee: Aktiebolaget Electrolux
    Inventor: Olli Juhani Nyrhila
  • Patent number: 5655209
    Abstract: Process for producing multilayer ceramic substrates using greensheet technology and thin dielectric ceramic greensheets for miniaturization purposes. The process avoids the screening of the thin greensheets by forming self-supporting fusible particulate metal electrode layers, interposing them with the thin greensheets and sintering the assembly to form the multilayer substrates such as integrated capacitors.
    Type: Grant
    Filed: March 28, 1995
    Date of Patent: August 5, 1997
    Assignee: International Business Machines Corporation
    Inventors: Jon Alfred Casey, John Paul Gauci, Dinesh Gupta, Robert Anthony Rita, Robert J. Sullivan
  • Patent number: 5649277
    Abstract: An apparatus and process for the free-forming manufacture of three-dimensal components. A powder-binder mixture, or a material with a high melting point, is plasticized or made molten, by raising the temperature inside a process chamber. The resulting molten material is discharged under pressure through a nozzle which is arranged at the end of the process chamber. The material inside the process chamber is deposited in layers. The processing direction and processing speed of the nozzle are programmed. An embodiment of the invention is disclosed in which a non-molten powder is deposited and supported by the deposition of a second powder alongside the non-molten powder.
    Type: Grant
    Filed: June 13, 1994
    Date of Patent: July 15, 1997
    Assignee: Fraunhofer-Gesellschaft Zur Foerderung Der Angewandten Forschung E.V.
    Inventors: Mathias Greul, Ewald Staskewitsch, Wilhelm Steger, Theo Pintat, Martin Geiger, Klaus Melchior
  • Patent number: 5628850
    Abstract: A method for producing input/output connections in a ceramic device is disclosed. The ceramic device can provide wraparound input/output connections. The method can include first providing first and second green ceramic layers, forming at least one via in each ceramic layer, the at least one via in the second layer being offset from and connecting to the via in the first ceramic layer, filling the vias with metallization, laminating the ceramic layers to form a laminate, scoring the laminate along at least one line extending through the first via and into a portion of the second ceramic layer such that the line does not intersect the at least one second via the ceramic laminate and metalization, and cleaving the laminate along the scored line. A ceramic device using this method can provide a wraparound connection extending partially up the side thereof, which can be advantageous in many multi-layer applications.
    Type: Grant
    Filed: July 20, 1995
    Date of Patent: May 13, 1997
    Assignee: Motorola, Inc.
    Inventors: Carlos A. Sanchez, Rong-Fong Huang, Michael W. Murphy
  • Patent number: 5564063
    Abstract: A method for manufacture of at least one micronozzle in an aerostatic bearing, wherein at least one hole is placed into a compacted bearing surface from porous sintered material by means of a laser beam and disposed so as to be distributed across the surface. The holes distributed across the compacted bearing surface constitute micronozzles of an aerostatic bearing.
    Type: Grant
    Filed: February 2, 1995
    Date of Patent: October 8, 1996
    Assignee: Joachim Heinzl
    Inventors: Joachim Heinzl, Michael Muth, Bernd Schulz
  • Patent number: 5487952
    Abstract: There are sintered Bi.sub.2 Te.sub.3 -based thermoelectric materials containing Ag.sub.2 S, which prevent p- to n-type transition of Bi.sub.2 Te.sub.3 -based thermoelectric materials during polycrystalline sintering and have improved thermoelectric properties.
    Type: Grant
    Filed: November 18, 1994
    Date of Patent: January 30, 1996
    Inventors: Han-Ill Yoo, Tae Ho Park, Dae Suk Kang, Beoung Doo Yoo
  • Patent number: 5466415
    Abstract: 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: Grant
    Filed: October 20, 1994
    Date of Patent: November 14, 1995
    Assignee: Corning Incorporated
    Inventors: Kevin R. Brundage, Lawrence S. Rajnik
  • Patent number: 5427733
    Abstract: A temperature-controlled laser sintering system includes a laser beam 12 which is focussed onto a sintering bed 38 by a focussing mirror 26 and a set of scanning mirrors 32,34. Thermal radiation 114 emitted from the sintering bed 38 are imaged to the scanning mirrors and to a dichroic beamsplitter 110 which reflects such radiation but passes the wavelength of the laser beam 12. The radiation 118 is focussed onto an optical detector 126 which provides a signal on a line 128 to a power control circuit 104. The power control circuit 104 controls a modulator 100 which modulates the power of the laser beam 112 so as to maintain the thermal radiation emission 114 (and thus the temperature at the sintering location) at a substantially constant level.
    Type: Grant
    Filed: October 20, 1993
    Date of Patent: June 27, 1995
    Assignee: United Technologies Corporation
    Inventors: John A. Benda, Aristotle Parasco
  • Patent number: 5413753
    Abstract: Methods of forming composite articles of superconducting materials and metal at ambient temperature by applying a mixture of metal and binder to a ceramic oxide preform to yield a coated preform which is then heat treated to provide composite articles of superconducting ceramic and metal.
    Type: Grant
    Filed: September 17, 1993
    Date of Patent: May 9, 1995
    Assignee: E. I. Du Pont de Nemours and Company
    Inventor: George E. Zahr
  • Patent number: 5376462
    Abstract: A thixoformable material and a method for forming it are provided in which the material comprises a series of sequentially deposited layers of substantially metallic material, at least some of the layers having different properties. The layers may be of different materials or the layers may differ in that some are provided with reinforcing material whereas other are not. The reinforcing material may consist of particles of spherical, fiberous or other shapes and may be made of various carbides or other suitable reinforcing materials.The thixoformable material may be formed in sheets, cylindrical forms or any other shape and subsequently cut to the volume and/or shape required for the forming stage.A layered material of this sort offers the advantages of thixoformable materials but with enhanced toughness and damage resistance due to the layered 3-dimensional structure.
    Type: Grant
    Filed: May 18, 1993
    Date of Patent: December 27, 1994
    Assignee: Lucas Industries public limited company
    Inventor: Peter R. G. Anderson
  • Patent number: 5167913
    Abstract: A method of forming an adherent layer of metallurgy on a ceramic substrate which includes the steps of obtaining a ceramic material containing a polymeric binder and copper metallurgy patterns within the ceramic body. In one embodiment of the invention, the ceramic body also contains MgO.Thereafter, a surface layer of metallurgy is formed on the surface of the ceramic body. In one embodiment, the surface layer is nickel and in another embodiment, the surface layer is copper or gold.Then, the ceramic body undergoes a sintering cycle which includes the steps of pyrolysis, binder burnoff and, lastly, densification and, in some cases, crystallization. During densification and crystallization, there is a predetermined steam atmosphere which meets the following requirements: a partial pressure of oxygen less than that necessary to satisfy the equilibrium equation 4Cu+O.sub.2 =2Cu.sub.2 O; and a partial pressure of oxygen less than or equal to that necessary to satisfy the equilibrium equation 2Ni+O.sub.
    Type: Grant
    Filed: December 23, 1991
    Date of Patent: December 1, 1992
    Assignee: International Business Machines Corporation
    Inventors: John Acocella, Philip L. Flaitz, Raj N. Master, Chandrasekhar Narayan, Sarah H. Knickerbocker, Paul H. Palmateer, Sampath Purushothaman, Srinivasa S. N. Reddy
  • Patent number: 5132080
    Abstract: A process for producing porous articles from metal powders. A slurry including metal powders is deposited on a horizontally moving surface. The slurry/moving surface combination is passed through an evaporating zone, a calender zone and a sintering zone to form the desired article. The article is then separated from the moving surface.
    Type: Grant
    Filed: November 28, 1944
    Date of Patent: July 21, 1992
    Assignee: Inco Limited
    Inventor: Leonard B. Pfeil
  • Patent number: 5122335
    Abstract: A suction controlled gear ring pump effects a continuous decrease of the vacuum occurring in the feed cells of the pump at higher rotational speeds due to the long movement path of the feed cells from the end of the suction region to the beginning of the discharge opening and the thereby occurring diminution of the feed cells. In order to prevent squeeze oil when working at a lower rotating speed, the feed cells positioned successively in the feed direction are connected between the teeth respectively with the neighboring feed cells by overflow channels extending through the gear teeth, check valves in said overflow channels preventing a flow against the feed direction.
    Type: Grant
    Filed: August 27, 1991
    Date of Patent: June 16, 1992
    Inventor: Siegfried Eisenmann
  • Patent number: 5118663
    Abstract: A method and apparatus for manufacturing a superconductor wire has a wire take-up spool and a feed speed control spool. A wire substrate is taken from the feed speed control spool and onto the take-up spool as the wire take-up spool is rotated. The wire passes through a container which holds a diffusion barrier material, where the diffusion barrier material is electrophoretically deposited onto the wire substrate and subsequently sintered. The wire is also passed through a container which holds a superconductor material suspended in solution, and a layer of the superconductor material is electrophoretically deposited onto the diffusion barrier. The grains of the superconductor layer are then magnetically aligned and sintered. Also, a silver coating is electrophoretically deposited onto the superconductor layer and sintered. A diffusion bonding inhibitor material is then applied to the silver coating. Then, the silver-coated superconductor wire is spooled and heated to four hundred degrees centigrade (400.
    Type: Grant
    Filed: September 21, 1990
    Date of Patent: June 2, 1992
    Assignee: General Atomics
    Inventors: Lawrence D. Woolf, Michael V. Fisher, William A. Raggio, Frederick H. Elsner
  • Patent number: 5038014
    Abstract: A component is fabricated by depositing a succession of overlying beads of a material, the pattern and position of the beads being assigned the proper characteristics of the corresponding section of the desired component. Shape definition is accomplished by characterizing the component as a series of sections or slices having the thickness of the bead, and programming a computer-controlled deposition head to deposit a succession of beads with the respective patterns and positions. Deposition is preferably by precision laser welding. Complex shapes having properties comparable to properties of forged or cast material are readily prepared. The material used in successive beads may be varied, producing a component of graded composition to achieve particular properties in various regions.
    Type: Grant
    Filed: December 1, 1989
    Date of Patent: August 6, 1991
    Assignee: General Electric Company
    Inventors: Vanon D. Pratt, Wilbur D. Scheidt, Eric J. Whitney
  • Patent number: 4959273
    Abstract: A corrosion-resistant R-Fe-B type sintered permanent magnet exhibiting deterioration of not more than 5 % from the initial magnetic properties after being tested for 500 hours under the conditions of a temperature of 80.degree. C. and a relative humidity of 90 % is produced by:causing at least one colloidal noble metal selected from the group consisting of Pd, Ag, Pt and Au to be adsorbed in a colloidal state or forming a thin layer thereof through vapor deposition on the surface of the sintered body; applying at least one base metal selected from the group consisting of Ni, Cu, Sn and Co containing P and/or B by electroless plating; and further applying at least one base metal selected from the same group.The noble metal layer is 1-10 nm thick. The electroless plating layer is no more than 10 .mu.m and the electrolytic plating layer 5-60 .mu.m thick.
    Type: Grant
    Filed: September 18, 1989
    Date of Patent: September 25, 1990
    Assignees: Sumitomo Special Metals Co., Ltd., Toda Kogyo Corp.
    Inventors: Atsushi Hamamura, Takaki Hamada, Kouki Tokuhara, Yukimitsu Miyao, Tomoyuki Imai, Nanao Horiishi
  • Patent number: 4923761
    Abstract: The invention is related to a bearing material having multiple layers therein and a method for manufacturing the same. The invention features that a bearing layer consisting mainly of an integrated resin powder is formed on a porous layer covering a back metal, such as a steel plate of like, that the integrated resin powder consists of P T F E resin precipitate and F E P resin precipitate and/or P F A resin precipitate and that each particle of the integrated resin powder is covered with Pb-Sn alloy powders.Accordingly, the integrated resin powder independently provides a predetermined lubricating property. In addition, since these resin precipitates are in unity, it is possible to maintain excellent cavitation resistance property and load resistance property, even under severe boundary conditions.Furthermore, since each of the integrated resin powder is covered with the Pb-Sn alloy powder, an uniform and deep penetration of the alloy powder into pores of the porous layer can be easily obtained.
    Type: Grant
    Filed: September 6, 1989
    Date of Patent: May 8, 1990
    Assignee: NDC Company, Ltd.
    Inventor: Takeshi Shindo
  • Patent number: 4913737
    Abstract: Metallic sintered parts with hollow structure and high density and toughness can be produced easily be kneading a raw metallic powder with an aqueous solution of an organic binder, extruding the resulting kneaded mixture, removing the organic binder from the extruded product and sintering the binder removed extruded product.
    Type: Grant
    Filed: June 3, 1988
    Date of Patent: April 3, 1990
    Assignee: Hitachi Metals, Ltd.
    Inventors: Hideki Nakamura, Takayuki Fukaya
  • Patent number: 4793968
    Abstract: A sintered metal part which has a pressed and sintered core; the part is coated with a sintered metal surface layer; the layer has a property different from that of the metal part; the interior regions of the core are free of the metal constituting the coating; and process for making the parts.
    Type: Grant
    Filed: June 27, 1984
    Date of Patent: December 27, 1988
    Assignee: Sermatech International, Inc.
    Inventors: Mark F. Mosser, Bruce G. McMordie
  • Patent number: 4780274
    Abstract: A method of manufacturing by a powder metallurgy process a rotary drill bit including a bit body having a plurality of cutting elements mounted on the outer surface thereof comprises the steps of forming a hollow mould for moulding at least a portion of the bit body, packing the mould with powdered matrix material, and infiltrating the material with a metal alloy in a furnace to form a matrix. Before packing the mould with powdered matrix material, there are postioned in spaced locations on the interior surface of the mould a plurality of cutting element, each of which is formed of a material, such as a polycrystalline diamond material, which is thermally stable at the temperature necessary to form the matrix. Also positioned in the mould, adjacent the rearward side of each cutting element, is a support material such that, at least after formation of the matrix, the support material has a higher modulus of elasticity than the matrix.
    Type: Grant
    Filed: October 24, 1986
    Date of Patent: October 25, 1988
    Assignee: Reed Tool Company, Ltd.
    Inventor: John D. Barr
  • Patent number: 4775598
    Abstract: A process is described in which hollow spheres or hollow-sphere composites (moldings) having high-strength walls are produced. Additional layers are applied to metallized spherical lightweight particles having a core of foamed polymer. In order to increase the strength of the wall of the spherical particle and the strength of the molding, metallized lightweight spherical particles having a metal wall thickness of 5 to 20 microns are treated (coated) with a dispersion of particulate metal or metal oxide or particulate ceramic or refractory material, the lightweight spherical particles coated in a thickness from 15 to 500 microns are dried, the dried particles are heated to a temperature of about 400.degree. C. to effect a pyrolysis of the polymer core, and the particles are subsequently sintered at a temperature from 900.degree. to 1400.degree. C.
    Type: Grant
    Filed: November 25, 1987
    Date of Patent: October 4, 1988
    Assignee: Norddeutsche Affinerie Akitiengesellschaft
    Inventor: Manfred Jaeckel
  • Patent number: 4732818
    Abstract: The present invention relates to a composite bearing material comprising three layers: (1) a metal backing, (2) a porous metal interlayer bonded to the metal backing which includes bronze or other copper alloy particles from two distinct particle size ranges and (3) a PTFE based composition intermixed with and overlying the porous metal interlayer. In accordance with the method of the present invention, the porous metal interlayer substantially comprises a relatively non-homogeneous mixture of particles from the two distinct particle size ranges, wherein a substantial portion of the relatively fine powder is segregated adjacent the metal backing. The present invention includes a significant thickness of the PTFE based composition applied to and remaining above the surface of the porous metal backing.
    Type: Grant
    Filed: September 29, 1986
    Date of Patent: March 22, 1988
    Assignee: Federal-Mogul Corporation
    Inventors: George C. Pratt, Michael C. Montpetit, Michael D. Lytwynec
  • Patent number: 4683118
    Abstract: A process and apparatus for producing a pressed powder body from at least two different kinds of ultrafine particles. Ultrafine particles of at least two different materials are uniformly mixed together and the mixture is sprayed onto an objective surface whereby the spray pressure causes the particles to adhere and form the pressed powder body. The apparatus includes mixing means, means for conveying the mixture of ultrafine particles, and a pressed powder body forming chamber including nozzle means for spraying the mixture of ultrafine particles, an objective surface and means for evacuating the chamber and introducing an inert gas therein.
    Type: Grant
    Filed: October 9, 1985
    Date of Patent: July 28, 1987
    Assignee: Research Development Corporation of Japan
    Inventors: Chikara Hayashi, Seiichiro Kashu
  • Patent number: 4665828
    Abstract: The invention relates to a penetrator (1, 11) made of heavy metal, such as, for instance, tungsten heavy metal or depleted uranium, for driving-cage projectiles which have the penetrator led by the driving cage in the gun barrel. The driving cage (6, 12) detaches itself from the penetrator after the launch. The penetrator (1, 11) shows lower strength and higher ductility in the middle portion (d) of its length than in its head portion (c) and, in its tail portion, it shows higher strength and lower ductility than in its middle portion (d) and lower strength and higher ductility than in its head portion (c). This shall decrease the risk of fracture when striking an armour.
    Type: Grant
    Filed: November 23, 1984
    Date of Patent: May 19, 1987
    Assignee: Voest-Alpine Aktiengesellschaft
    Inventor: Ekkehard Auer
  • Patent number: 4624830
    Abstract: A method of manufacturing by a powder metallurgy process a rotary drill bit including a bit body having a plurality of cutting elements mounted on the outer surface thereof comprises the steps of forming a hollow mould for moulding at least a portion of the bit body, packing the mould with powdered matrix material, and infiltrating the material with a metal alloy in a furnace to form a matrix. Before packing the mould with powdered matrix material, there are positioned in spaced locations on the interior surface of the mould a plurality of cutting elements, each of which is formed of a material, such as a polycrystalline diamond material, which is thermally stable at the temperature necessary to form the matrix. Also positioned in the mould, adjacent the rearward side of each cutting element, is a support material such that, at least after formation of the matrix, the support material has a higher modulus of elasticity than the matrix.
    Type: Grant
    Filed: November 30, 1984
    Date of Patent: November 25, 1986
    Assignee: NL Petroleum Products, Limited
    Inventor: John D. Barr
  • Patent number: 4608225
    Abstract: A composition for fixing a metal powder molding at sintering, which is used, in the case of disposing a metal powder molding formed by rolling a mixture of a metal powder and a synthetic resin-based binder on a metal base material and sintering the metal powder molding in a non-oxidizing atmosphere, by interposing between the metal powder molding and the base material, comprising a thermosetting resin composition containing a thermosetting resin as the essential component, the amount of the residual carbon of which after the completion of sintering is at least about 0.5% by weight.
    Type: Grant
    Filed: April 26, 1985
    Date of Patent: August 26, 1986
    Assignees: Nitto Electric Industrial Co. Ltd., Mazda Motor Corporation
    Inventors: Takahumi Sakuramoto, Eishi Asoshina, Takashi Tominaga, Yukio Shimizu, Tsuyoshi Morishita, Sigemi Osaki, Noriyuki Sakai
  • Patent number: 4602953
    Abstract: The disclosure relates to a feedstock of particulate material for use in formation of articles therefrom, the feedstock including a homogeneous combination of large particles, small particles and a binder. The large particles comprise less than about 60% by volume of the feedstock and are defined as particles having a diameter greater than their diffusion length. The fine particles and binder combined comprise more than about 40% by volume of the feedstock, the fine particles being defined as particles having a diameter less than their diffusion length.
    Type: Grant
    Filed: March 13, 1985
    Date of Patent: July 29, 1986
    Assignee: Fine Particle Technology Corp.
    Inventor: Raymond E. Wiech, Jr.
  • Patent number: 4596692
    Abstract: A process for forming a wear-resistant, sintered layer on an iron based substrate which comprises steps of providing a first alloy sheet containing 94 to 99 weight % of Fe-Cr type alloy particles and 6 to 1 weight % of acryl binder and a second alloy sheet containing 94 to 99 weight % of eutectic alloy particles and 6 to 1 weight % of acryl binder, placing the first and second alloy sheets in a superposed condition on the substrate, and heating in a non-oxidating atmosphere to a temperature which is higher than a solidus temperature of the eutectic alloy but lower than a solidus temperature of the Fe-Cr type alloy.
    Type: Grant
    Filed: February 19, 1985
    Date of Patent: June 24, 1986
    Inventors: Tsuyoshi Morishita, Sigemi Osaki, Yasuhumi Kawado, Yukio Shimizu, Toshiharu Konishi, Takahumi Sakuramoto
  • Patent number: 4507262
    Abstract: Utilizing an organometallic precursor, a metal oxide is formed within the pores of a porous sintered blank substantially uniformly throughout the porosity of the blank producing a porous bubble pressure barrier of predetermined pore size. The barrier is integrally sintered to a face of an electrode, the median pore size of the barrier being significantly smaller than that of the electrode, producing a composite useful as an electrode in a molten carbonate fuel cell. The blank and the electrode are composed of metal.
    Type: Grant
    Filed: April 5, 1984
    Date of Patent: March 26, 1985
    Assignee: General Electric Company
    Inventors: Bradley R. Karas, Charles E. Baumgartner
  • Patent number: 4472350
    Abstract: A valve seat or similar article produced by sintering a compound body is improved in economy and producibility by employing a method wherein the amount of a second powder for forming the compound body is controlled so as to be minimized. A first powder is initially charged into a compression space and lightly compressed to form a preparatory compact of a desired shape. Subsequently, the second powder is charged in over the preparatory compact to a degree controlled by the displacement of the compact, and the preparatory compact and the second powder are forcefully compressively integrally molded to form a final compact which is then sintered to form the finished product.
    Type: Grant
    Filed: June 9, 1983
    Date of Patent: September 18, 1984
    Assignee: Nippon Piston Ring Co., Ltd.
    Inventor: Shigeru Urano
  • Patent number: 4456577
    Abstract: A method of producing a rotary dresser include forming a core piece of an iron-base powder and filling in tungsten or like metal powder between the core and an outer mold member containing diamond grit or the like. The construction is then heated to melt and infiltrate a metal alloy, such that a network structure is formed about the powdered metal particles. In a further embodiment, the metal materials may be arranged in concentric form about a metal bushing such that the bushing is included in the final structure.
    Type: Grant
    Filed: May 11, 1982
    Date of Patent: June 26, 1984
    Assignee: Osaka Diamond Industrial Company, Ltd.
    Inventors: Takao Kawakita, Kazuo Yamaguchi, Sadao Date
  • Patent number: 4419413
    Abstract: A powder compression molding method for producing a multilayer powder compression molded article having a plurality of different material layers disposed in a compression direction utilizes relative movements between an upper punch, a lower punch, a die having a step formed therein, and two feed shoes. The powder compression molded article thus formed requires a reduced amount of a special layer. The powder compression molding method includes forming a first space by moving the die relative to the lower punch, introducing a first powder into the first space through a first feed shoe, lowering the lower punch relative to the die to form a second space so that an upper surface of the first powder on the step of the die and on the lower punch has a nonuniform height, introducing a second powder into the second space, and moving the upper punch towards the lower punch to compress the first and second powders.
    Type: Grant
    Filed: February 23, 1982
    Date of Patent: December 6, 1983
    Assignee: Nippon Piston Ring Co., Ltd.
    Inventor: Tadashi Ebihara
  • Patent number: 4414284
    Abstract: A piston ring produced by a powder metallurgical method has a nearly triangular zone in cross section made of a low density sintered alloy metal powder. One edge of an outer peripheral surface or bottom surface of the piston ring forms a vertex of the triangular zone. The remainder of the piston ring is composed of a high density sintered alloy metal powder. This piston ring has a high abrasion resistance at the area thereof which slides on the cylinder wall and can be produced at low cost.
    Type: Grant
    Filed: February 23, 1982
    Date of Patent: November 8, 1983
    Assignee: Nippon Piston Ring Co., Ltd.
    Inventor: Tadashi Ebihara
  • Patent number: 4406857
    Abstract: The properties of copper-tin-lead alloys are improved with respect to mechanical resistance and resistance to corrosion by the incorporation therein, in specific proportions of nickel. Antifriction layers on steel supporting strips are obtained by sintering and rolling onto steel strips metal powder particles obtained by powdering a metal alloy of 2-10% nickel, 8-27% lead, 0.5-10% tin and the balance copper.
    Type: Grant
    Filed: September 22, 1981
    Date of Patent: September 27, 1983
    Assignee: Metal Leve S.A. Industria e Comercio
    Inventors: Duraid Mahrus, Antonio C. Paulos
  • Patent number: H546
    Abstract: The formation of thin-film resistors by the ion implantation of a metallic conductive layer in the surface of a layer of phosphosilicate glass or borophosphosilicate glass which is deposited on a silicon substrate. The metallic conductive layer materials comprise one of the group consisting of tantalum, ruthenium, rhodium, platinum and chromium silicide. The resistor is formed and annealed prior to deposition of metal, e.g. aluminum, on the substrate.
    Type: Grant
    Filed: February 26, 1988
    Date of Patent: November 1, 1988
    Assignee: The United States of America as represented by the Secretary of the Air Force
    Inventors: George L. Schnable, Chung P. Wu