Abstract: A semiconductor device includes an electric conductor, a semiconductor element, and a bonding layer. The electric conductor has a main surface and a rear surface opposite to the main surface in a thickness direction. The semiconductor element includes a main body and electrodes. The main body has a side facing the main surface of the conductor, and the electrodes each protrude toward the main surface from the side of the main body to be electrically connected to the main surface. The bonding layer is held in contact with the main surface and the electrodes. Each electrode includes a base portion in contact with the main body, and a columnar portion protruding toward the main surface from the base portion to be held in contact with the bonding layer, which is a sintered body of a metal powder.

Abstract: At least a part of a burner for a catalytic reactor is coated with a silicate based nickel aluminide slurry diffusion coating.

Abstract: The present application provides a method for manufacturing a metal foam. The present application can provide a method for manufacturing a metal foam, which is capable of forming a metal foam comprising uniformly formed pores and having excellent mechanical properties as well as the desired porosity, and a metal foam having the above characteristics. In addition, the present application can provide a method capable of forming a metal foam in which the above-mentioned physical properties are ensured, while being in the form of a thin film or sheet, within a fast process time, and such a metal foam.

Abstract: A metal porous body having a three-dimensional network structure, includes: a framework forming the three-dimensional network structure; and a coating layer having fine pores and coating the framework, the three-dimensional network structure including a rib and a node connecting a plurality of ribs, the framework including an alkali-resistant first metal, the fine pores having an average fine pore diameter of 10 nm or more and 1 ?m or less, the coating layer including an alkali-resistant second metal and optionally including an alkali-soluble metal, the alkali-soluble metal being contained at a proportion of 0% by mass or more and 30% by mass or less with reference to a total mass of the framework and the coating layer.

Abstract: Provided herein are methods of preparing a metal foam that include the steps of forming a metal foam precursor with a slurry comprising a metal component, a dispersant, a binder and an antisolvent, and sintering the metal foam precursor. Such methods may provide metal foams having various pore sizes. Methods further include forming a thin metal foam on a base material.

Abstract: Described is a femoral component of a prosthetic hip implant. The femoral component can include: a neck portion; and a stem portion including a proximal end and a distal end. The neck portion extends from the proximal end, and the stem portion comprises a first solid portion and at least one additional portion including at least one of a hollow portion, a porous portion, and a second solid portion comprised of a different solid material from a solid material of the first solid portion. The first solid portion and the at least one additional portion are in a predetermined configuration. The femoral component comprises a unitary component that is formed by additive manufacturing of the femoral component from a 3D model of the femoral component.

Abstract: A semiconductor device includes an electric conductor, a semiconductor element, and a bonding layer. The electric conductor has a main surface and a rear surface opposite to the main surface in a thickness direction. The semiconductor element includes a main body and electrodes. The main body has a side facing the main surface of the conductor, and the electrodes each protrude toward the main surface from the side of the main body to be electrically connected to the main surface. The bonding layer is held in contact with the main surface and the electrodes. Each electrode includes a base portion in contact with the main body, and a columnar portion protruding toward the main surface from the base portion to be held in contact with the bonding layer, which is a sintered body of a metal powder.

Abstract: A method of forming an article including: contacting a fugitive tool with a powdered parent material; densifying the powdered material; and destructively removing the fugitive tool. A coating of a different material may be formed against the parent material using a similar approach.

Abstract: Described herein are methods and systems for using pyrophoric liquids to ignite combustible gas.

Abstract: A steel piston with a bushing applied to pin bore surfaces by laser cladding or laser additive manufacturing is provided. The bushing is formed of metal, such as bronze, and metallurgically bonded to the steel of the piston. Thus, the bushing cannot fail by rotating relative to pin bore surfaces. The bushing has a porosity ranging from 0.05% to 5%, based on the total volume of the bushing, and a thickness ranging from 0.07 mm to 6 mm. Since the metal is applied directly to the steel by laser cladding or laser additive manufacturing, the overall size of the piston is reduced, compared to typical pistons with a separate steel backed bushing, and the possibility of bushing rotation is avoided. The bushing also provides scuffing resistance and increased unit load capacity of the pin bore.

Abstract: A coating layer, for example PEEK or titanium foil, shields a bone implant surface from wearing interactions with surfaces of bone and/or other implants. The coating prevents shedding particles which are difficult to distinguish from evidence of potentially dangerous conditions, for example, microorganism contamination and/or degenerating tissue. Methods and structures for securing a coating layer are described. Other uses and implementations of coating layers are described.

Abstract: A rack-and-pinion type steering apparatus 1 comprises a gear case 3 made of aluminum or an aluminum alloy and having a hollow portion 2; a steering shaft 6 rotatably supported by the gear case 3 through rolling bearings 4 and 5; a pinion 7 which is provided integrally on a shaft end portion of the steering shaft 6 and is rotatably supported in the hollow portion 2 by the gear case 3 through the steering shaft 6; a rack bar 9 on which rack teeth 8 meshing with the pinion 7 are formed; a rack guide 10 which is disposed in the hollow portion 2 of the gear case 3 and supports the rack bar 9 slidably; and a spring 11 constituted by a coil spring for pressing the rack guide 10 toward the rack bar 9.

Abstract: Methods are provided for manufacturing an orthopedic prosthesis by resistance welding a porous metal layer of the orthopedic prosthesis onto an underlying metal substrate of the orthopedic prosthesis. The resistance welding process involves directing an electrical current through the porous layer and the substrate, which dissipates as heat to cause softening and/or melting of the materials, especially along the interface between the porous layer and the substrate. The softened and/or melted materials undergo metallurgical bonding at points of contact between the porous layer and the substrate to fixedly secure the porous layer onto the substrate.

Abstract: A method for improving resistance of a fusion reactor inner wall to plasma irradiation by using lamination structure comprises: making a material for facing plasma into multiple metal sheets, laminating the multiple metal sheets together according to a direction perpendicular to a wall surface, and combining the laminated multiple metal sheets with a copper substrate. The method relates to the field of nuclear applications, and is applicable to a plasma-facing surface on an inner wall of an apparatus for conducting a fusion reaction by using hydrogen isotopes. Not only does the method reduce aggregation of hydrogen, helium, and isotopes thereof, and the like, under a surface layer of a tungsten-based material, greatly reducing a blistering phenomenon on a surface thereof, but also reduces thermal fatigue cracking damages.

Abstract: A coating layer, for example PEEK or titanium foil, shields a bone implant surface from wearing interactions with surfaces of bone and/or other implants. The coating prevents shedding particles which are difficult to distinguish from evidence of potentially dangerous conditions, for example, microorganism contamination and/or degenerating tissue. Methods and structures for securing a coating layer are described. Other uses and implementations of coating layers are described.

Abstract: Some embodiments of the invention are directed to electrochemical fabrication methods for forming structures or devices (e.g. microprobes for use in die level testing of semiconductor devices) from a core material and a shell or coating material that (1) partially coats the surface of the structure, (2) completely coats the surface of the structure, and/or (3) completely coats the surface of structural material of each layer from which the structure is formed including interlayer regions. These embodiments incorporate both the core material and the shell material into the structure as each layer is formed along with a sacrificial material that is removed after formation of all layers of the structure. In some embodiments the core material may be a material that would be removed with sacrificial material if it were accessible by an etchant during removal of the sacrificial material.

Abstract: There is provided a Cu-based oil-impregnated sintered bearing which can be used for high-load applications such as an ABS system and a wiper motor system in automobile, can be manufactured at low cost, and is excellent in abrasion resistance and seizure resistance. The bearing contains 5 to 40% by mass of Ni, 3 to 15% by mass of Sn, 0.5 to 4.0% by mass of P, or further 0.3 to 5.0% by mass of a solid lubricant, and a remainder comprising Cu and inevitable impurities, and has a metallic structure in which a phase mainly composed of Ni and P is dispersed in a matrix, and has a 5 to 25% porosity.

Abstract: To provide a sliding member that improves seizure resistance by restraining any exposure of the porous layer and improves abrasion resistance and load resistance. The sliding member 1 constitutes a bearing having a cylindrical shape, an inner circumferential surface of which is a sliding layer 5 with an axis. In the sliding member 1, a porous layer 3 made of alloy material is formed on a surface of a metal base 2 and this porous layer 3 is covered by resin material 4 so that the sliding layer 5 is formed. In the sliding member 1, a particle size of metal powder 30 forming the porous layer 3 is within a range of 15 through 60 ?m, preferably, about 25 through 45 ?m. Further, in the sliding member 1, a thickness of the porous layer 3 is within a range of 0.06 through 0.1 mm and a thickness of the sliding layer 5 is within a range of 0.08 through 0.16 mm The thickness of the sliding layer 5 is set to be thicker on average than the thickness of the porous layer 3 so that the porous layer 3 is not exposed.

Abstract: An article comprising: a substrate; and over at least part of a surface of said substrate an outer coating of hydroxyapatite and an intermediate bonding layer bonded to said substrate and to said outer coating, wherein a mechanical interlock is present between said substrate and said outer coating.

Abstract: The porous metal foil of the present invention include a two-dimensional network structure composed of a metal fiber. This porous metal foil has a first side having a higher glossiness, and a second side having a lower glossiness located on the opposite side of the first side. The ratio of glossiness GS of the first side to glossiness GM of the second side, GS/GM, as measured at incident and reflection angles of 60 degrees in accordance with JIS Z 8741 (1997) is from 1 to 15. The present invention provides a highly useful porous metal foil which has a reduced difference in properties between both sides, in addition to the superior properties attributable to a porous metal foil, in a highly productive and cost effective manner that is suited for continuous production.

Abstract: Methods and devices are disclosed for creating a multiple alloy composite structure by forming a three-dimensional arrangement of a first alloy composition in which the three-dimensional arrangement has a substantially open and continuous porosity. The three-dimensional arrangement of the first alloy composition is infused with at least a second alloy composition, where the second alloy composition comprises a shape memory alloy. The three-dimensional arrangement is consolidated into a fully dense solid structure, and the original shape of the second alloy composition is set for reversible transformation. Strain is applied to the fully dense solid structure, which is treated with heat so that the shape memory alloy composition becomes memory activated to recover the original shape. An interwoven composite of the first alloy composition and the memory-activated second alloy composition is thereby formed in the multiple alloy composite structure.

Abstract: A method for preparing an implant having a porous metal component. A loose powder mixture including a biocompatible metal powder and a spacing agent is prepared and compressed onto a metal base. After being compressed, the spacing agent is removed, thereby forming a compact including a porous metal structure pressed on the metal base. The compact is sintered, forming a subassembly, which is aligned with a metal substrate portion of an implant. A metallurgical bonding process, such as diffusion bonding, is performed at the interface of the subassembly and the metal substrate to form an implant having a porous metal component.

Abstract: A hardmetal composite used as wear-resistant surfaces and inlays in earth-engaging equipment includes more than one hardphase. At least one hardphase has a high average particle size, for example, from 100 ?m to 2000 ?m. The hardphases vary in terms of particle size, hardness, and binder content, and at least one hardphase includes a particulate constituent capable of plastic deformation that comprises at least 1% residual porosity.

Abstract: In one aspect, composite articles are described comprising multifunctional coatings. A composite article described herein, in some embodiments, comprises a substrate and a coating adhered to the substrate, the coating comprising an inner layer and an outer layer, the inner layer comprising a presintered metal or alloy and the outer layer comprising particles disposed in a metal or alloy matrix.

Abstract: Compositions and methods for making a three dimensional structure comprising: designing a three-dimensional structure; melting the three-dimensional structure from two or more layers of a metal powder with a high energy electron or laser beam is described herein. The position where the metal is melted into the structure is formed along a layer of metal powder, wherein the location and intensity of the beam that strikes the metal layer is based on the three-dimensional structure and is controlled and directed by a processor. The instant invention comprises a novel dry state sonication step for removing metal powder that is not melted from the three dimensional structure.

Abstract: In one aspect, composite articles are described comprising multifunctional coatings. A composite article described herein, in some embodiments, comprises a substrate and a coating adhered to the substrate, the coating comprising an inner layer and an outer layer, the inner layer comprising a presintered metal or alloy and the outer layer comprising particles disposed in a metal or alloy matrix.

Abstract: During engine operation, valve retainers and valve springs are constantly rubbing and impacting each other resulting in heat and wear. The purpose of this invention is to provide a surface coating onto the valve retainer to reduce the friction with the valve spring and thus improve durability. Specifically, this invention teaches a method to thermally apply coatings to the surface of the valve retainer. Although typically fabricated from steel, the usage of lighter weight titanium valve retainers is increasing for high performance, or racing engines. The reduced mass allows valves to move more readily and requires less spring pressure to operate, producing more power and a faster revving engine, however titanium is typically not as wear resistant as the steel it replaces. In one embodiment, a porous molybdenum or other oleophilic metal is applied to the surface of the valve retainer. In another embodiment, hard coatings of cermets, carbides, and super alloys are applied as coatings to valve retainers.

Abstract: A sliding member for which adhesiveness between the surface of a base member and metal coating is enhanced. An undercoat layer having a resin material at the surface thereof is provided, and a solid lubricating portion is formed on the undercoat layer so as to provide a sliding face from at least one kind of material of silver, silver alloy, copper and copper alloy. An intermixture layer in which both the undercoat layer and the solid lubricating portion are intermixed with each other is interposed between the undercoat layer and the solid lubricating portion.

Abstract: This invention relates to thermally spray coated work rolls for use in metal or metal alloy, e.g., aluminum alloy, sheet manufacture comprising a cylindrical-like structure having an outer peripheral surface and a thermally sprayed coating on the outer peripheral surface of said cylindrical-like structure, said thermally sprayed coating comprising from about 65 to about 95 weight percent of one or more Group VI metal carbides, and from about 5 to about 35 weight percent of one or more transition metals selected from chromium, manganese, iron, cobalt and nickel. This invention also relates to a process for preparing the work rolls for use in metal or metal alloy, e.g., aluminum alloy, sheet manufacture, a method for manufacturing metal or metal alloy, e.g., aluminum alloy, sheet using the thermally spray coated work rolls, and a thermal spray powder for coating the outer peripheral surface of the work rolls for use in metal or metal alloy, e.g., aluminum alloy, sheet manufacture.

Abstract: A method of pressure forming a brown part from metal and/or ceramic particle feedstocks includes: introducing into a mold cavity or extruder a first feedstock and one or more additional feedstocks or a green or brown state insert made from a feedstock, wherein the different feedstocks correspond to the different portions of the part; pressurizing the mold cavity or extruder to produce a preform having a plurality of portions corresponding to the first and one or more additional feedstocks, and debinding the preform. Micro voids and interstitial paths from the interior of the preform part to the exterior allow the escape of decomposing or subliming backbone component substantially without creating macro voids due to internal pressure. The large brown preform may then be sintered and subsequently thermomechanically processed to produce a net wrought microstructure and properties that are substantially free the interstitial spaces.

Abstract: This invention relates to rolls for use in or in contact with molten metal comprising a roll drum having an outer peripheral surface and a thermally sprayed coating on the outer peripheral surface of said roll drum, said thermally sprayed coating comprising from about 66 to about 88 weight percent of tungsten, from about 2.5 to about 6 weight percent of carbon, from about 6 to about 20 weight percent of cobalt, and from about 2 to about 9 weight percent of chromium; a process for preparing the rolls; a method for forming a metal layer on a metal sheet utilizing the rolls, e.g., galvanization; and a thermal spray powder for coating the outer peripheral surface of the rolls.

Abstract: A system and method of forming a wear resistant composite material includes placing a porous wear resistant filler material in a mold cavity and infiltrating the filler material with a matrix material by heating to a temperature sufficient to melt the matrix material, then cooling the assembly to form a wear resistant composite material. The system and method can be used to form the wear resistant composite material on the surface of a substrate, such as a part for excavating equipment or other mechanical part. One suitable matrix material may be any of a variety of ductile iron alloys.

Abstract: A porous metal foil of the present invention comprises a two-dimensional network structure composed of metal fibers. This porous metal foil has superior properties and can be obtained in a highly productive and cost effective manner.

Abstract: In one aspect, composite articles are described comprising multifunctional coatings. A composite article described herein, in some embodiments, comprises a substrate and a coating adhered to the substrate, the coating comprising an inner layer and an outer layer, the inner layer comprising a presintered metal or alloy and the outer layer comprising particles disposed in a metal or alloy matrix.

Abstract: Polycrystalline diamond compacts for use in artificial joints achieve reduced corrosion and improved biocompatibility through the use of solvent metal formulations containing tin and through the control of solvent metal pore size, particularly in inner layers of the compact. Solvent metal formulations containing tin have been discovered which provide sintering ability, part strength, and grind resistance comparable to levels achieved by using CoCrMo solvent metals. It has been discovered that limiting the solvent metal pore size in the diamond layers minimizes or eliminates the occurrence of micro cracks in the solvent metal and significantly reduces the corrosion of the compact as manifested by the release of heavy metal ions from the compact. Polycrystalline diamond compacts which utilize both the solvent metal formulations containing tin and the control of pore sizes achieve significantly reduced corrosion and improved biocompatibility compared to prior art polycrystalline diamond compacts.

Abstract: Articles coated with wetting resistant materials are presented. One embodiment is an article comprising a substrate and a coating having low surface connected porosity disposed on the substrate. The coating comprises an oxide, which comprises aluminum, yttrium, and at least one rare earth element according to the following atomic proportions: (RxY1-x)3Al5O12 where x is in the range from about 0.001 to about 0.999, and where R is at least one of the rare earth elements, Y is yttrium, O is oxygen, and Al is aluminum.

Abstract: The method for the production of an element subject to wear, comprising a metal matrix and at least a core of hard material. The method provides a first step in which a temporary aggregation structure is prepared with at least partly open pores, which volatilize or in any case eliminate at least partly when subjected to heating. A second step in which, on the whole internal and external surface of said temporary aggregation structure, a liquid mixture of a binder with metal powders which contain hard elements or their precursors is uniformly distributed. A third step in which the temporary aggregation structure is deteriorated by means of a thermal action of controlled heating, so as to take at least part of the temporary aggregation structure to evaporation, rendering free a volume inside the core, and to consolidate the mixture according to the conformation of the temporary aggregation structure. A fourth step in which the core is disposed in a mold so as to only partly occupy the free volume of the mold.

Abstract: A kind of electrically conductive foam for preventing an electronic component from electro-magnetic interference includes the following compositions: electrically conductive material accounting for about 5% to about 10% by weight; plastic material accounting for about 10% to about 16% by weight; propellant accounting for about 65% to about 75% by weight; surfactant accounting for about 0.5% to about 4% by weight; and auxiliary material accounting for about 4% to about 5% by weight.

Abstract: A composite structure includes a substrate with pores of a first mean pore size and a coating on at least one surface of that substrate. This coating has pores of a second mean pore size where the first mean pore size is equal to or greater than said second mean pore size. When the pore size of the coating is effective to capture particulate greater than 0.2 micron, the composite may be formed into a filter effective to remove microbes from a fluid medium. One method to form the porous coating on the substrate includes: (1) forming a suspension of sinterable particles in a carrier fluid and containing the suspension in a reservoir; (2) maintaining the suspension by agitation; (3) transferring the suspension to an ultrasonic spray nozzle; (4) applying a first coating of the suspension to the substrate; and (5) sintering the sinterable particles to the substrate.

Abstract: A powder metal composite is disclosed. The powder metal composite includes a substantially-continuous, cellular nanomatrix comprising a nanomatrix material. The compact also includes a plurality of dispersed particles comprising a particle core material that comprises Mg, Al, Zn or Mn, or a combination thereof, dispersed in the nanomatrix, the core material of the dispersed particles comprising a plurality a plurality of distributed carbon nanoparticles, and a bond layer extending throughout the nanomatrix between the dispersed particles. The nanomatrix powder metal composites are uniquely lightweight, high-strength materials that also provide uniquely selectable and controllable corrosion properties, including very rapid corrosion rates, useful for making a wide variety of degradable or disposable articles, including various downhole tools and components.

Abstract: A low density abradable coating for use as a seal material is formed by depositing a metal bond coat followed by depositing a low density, porous, abradable metal seal layer on the bond coat. The seal layer is formed by co-depositing metallic sponge particles and metal precursor particles. The metal precursor particles decompose during heat treatment leaving fine pores distributed throughout the microstructure.

Abstract: A direct metal laser sintered material including a substrate formed from a laser sintering process, the substrate having at least one surface, and a cladding material brazed onto at least a portion of the surface.

Abstract: A powder-metallurgical body and a method for producing such a body. The powder-metallurgical body is formed with a seating base for seating a sealing element to produce a seal with respect to fluids, such as liquids and/or gases. The body is redensified in a low region of the seating base.

Abstract: A multilayered sliding member has a resin composition filled in pores of, and coated on the surface of, a porous sintered metal layer 2 formed on the surface of a metallic backing plate 1. The resin composition is formed by compounding a phosphate, a carbon black, a melt moldable fluororesin, and a PTFE serving as a principal component, and is preferably formed by further containing graphite and/or a low molecular weight PTFE.

Abstract: There is provided an electrode material for electrolytic capacitor that attains an unprecedentedly high capacitance. The electrode material for electrolytic capacitor comprises a layer of valve metal particles furnished on the surface thereof with an oxide film, the layer having a porosity of 20 to 60% and a specific surface area of 30×103 to 400×103 cm2/cm3, wherein the valve metal particles are mixed together, with the particle diameters exhibiting a given distribution at least within the range of 0.005 to 0.1 ?m, and form a base material surface, and wherein the valve metal consists of aluminum, and wherein the composition ratio of Al/O of the layer of valve metal particles furnished on the surface thereof with the oxide film is within the range of 2.0 to 5.5. The electrode material thus realizes high capacitance.

Abstract: A method for the manufacture of a multilevel metal part, the method including the steps of: a) compacting agglomerated spherical metal powder to a green multilevel preform such that an open porosity exists, wherein the green multilevel preform fulfils the relation zg=zHVC·a, b) debinding the green preform, c) sintering the green preform in an atmosphere including hydrogen, d) compacting the green preform with high velocity compaction to a density of at least 95% TD, e) subjecting the part to densification to a density of at least 99% TD. There is further provided a multilevel metal part. Advantages of the method include that it is possible to manufacture a multilevel part which is essentially uniform throughout the entire part and which has excellent tolerance, which at the same time has virtually full density and thereby having excellent mechanical properties as well as excellent corrosion properties.

Abstract: A system for forming a surface coating on an outer surface of a foam for use with cooling system of turbine engines. The system may include removing filler from the outer surface of the foam to expose a porous structure of the foam, whereby portions of the porous structure extend outwardly from a newly formed outer surface of the filler. A surface layer may be applied to the outer surface of the filler and exposed portions of the porous structure, whereby the surface layer is attached to the porous structure at least in part due to mechanical interaction with the portions of the porous structure extending outwardly from the newly formed outer surface of the filler. The filler material may then be removed from the porous structure.

Abstract: Methods of laser assisted plasma coating at atmospheric pressure including providing a plasma, at least one target, at least one laser, and a superalloy substrate, operably directing the laser toward the target to liberate atomic particles from the target and feed the atomic particles into the plasma, and depositing the atomic particles onto the superalloy substrate using the plasma to produce a thermal barrier coating having a column width of from about 0.5 microns to about 60 microns, and an intra column porosity of from about 0% to about 9%.

Abstract: This invention is directed to a composite laminate comprising in order (a) a flame retardant polymeric moisture barrier (b) an inorganic platelet layer and (c) a flame retardant thermoplastic film layer The invention is also directed to a thermal insulation and acoustic blanket comprising a core of fibrous material or foam surrounded by the above composite laminate wherein the thermoplastic film layer of the composite laminate contacts and encapsulates the core.

Abstract: This invention is directed to a composite laminate comprising in order (a) a flame retardant polymeric moisture barrier (b) an inorganic platelet layer and (c) a flame retardant thermoplastic film layer The invention is also directed to a thermal insulation and acoustic blanket comprising a core of fibrous material or foam surrounded by the above composite laminate wherein the thermoplastic film layer of the composite laminate contacts and encapsulates the core.