Patents Represented by Attorney, Agent or Law Firm John J. Prizzi
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Patent number: 7485278Abstract: A ceramic composite made by compacting a starting powder blend. The composite includes between about 50 volume percent and about 99 volume percent of a ceramic matrix; and between about 1 volume percent and about 50 volume percent as-processed silicon carbide whiskers. The ceramic composite having a fracture toughness (KIC) of greater than about 4.0 MPam1/2. The ceramic has a silicon carbide whisker density as measured in whiskers per square millimeter equal to or less than about 1500 times the volume percent of silicon carbide whiskers, but in a density sufficient for the ceramic composite to have the fracture toughness.Type: GrantFiled: February 22, 2005Date of Patent: February 3, 2009Assignee: Kennametal Inc.Inventors: Pankaj K. Mehrotra, Shanghua Wu
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Patent number: 7455918Abstract: A coated body that includes a substrate and a coating scheme on the substrate. The coating scheme on the substrate wherein the coating scheme includes an alpha-alumina coating layer that exhibits a platelet grain morphology at the surface of the alpha-alumina coating layer or a kappa-alumina coating layer that exhibits either a lenticular grain morphology or a polyhedra-lenticular grain morphology at the surface thereof or an alpha-kappa-alumina coating layer that exhibits either a large multifaceted grain morphology or a polyhedra-multifaceted grain morphology at the surface thereof.Type: GrantFiled: March 12, 2004Date of Patent: November 25, 2008Assignee: Kennametal Inc.Inventors: Alfred S. Gates, Jr., Pankaj K. Mehrotra, Charles G. McNerny, Peter R. Leicht
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Patent number: 7431747Abstract: The invention relates to a cutting tool made of ceramics, cermet or cemented carbide and including a rake face, a flank face and a cutting edge at the intersection of rake face and flank face, as well as a multi-layered wear resisting coating including a layer which is made of aluminum oxide and deposited on a hard material layer, in which for avoiding an increase in the width of wear mark, with simultaneous retention of the resistance to cratering of the rake face, the aluminum oxide layer of the coating is removed on the flank face and the underlying hard material layer is exposed at least in portions. The aluminum oxide layer of the coating is removed on the flank face preferably by means of laser beam treatment.Type: GrantFiled: January 12, 2006Date of Patent: October 7, 2008Assignee: Kennametal Inc.Inventors: Hans-Wilm Heinrich, Günter Roder, Günther Häupl
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Patent number: 7429152Abstract: An uncoated cutting tool that comprises a body containing a pocket. A polycrystalline cubic boron nitride blank has a cutting tip. The blank is brazed into the pocket using a braze alloy whereby there is a braze joint between the body and the polycrystalline cubic boron nitride blank. The braze alloy has a liquidus temperature of at least about 900 degrees Centigrade wherein the braze alloy is selected from the group comprising a nickel-gold braze alloy containing nickel and gold, a copper-gold braze alloy containing copper and gold, a silver-titanium braze alloy containing silver and titanium, and a silver-palladium braze alloy containing silver and palladium.Type: GrantFiled: June 17, 2003Date of Patent: September 30, 2008Assignee: Kennametal Inc.Inventors: Edward J. Oles, Alfred S. Gates, Jr., Kent L. Reiner, William M. Alexander, IV, Jean-Pierre Genain
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Patent number: 7402540Abstract: A ceramic body that includes between about 15 volume percent and about 35 volume percent of a boron carbide irregular-shaped phase, and at least about 50 volume percent alumina, and the ceramic body has a fracture toughness (KIC, 18.5 Kg Load E&C) greater than or equal to about 4.5 MPa·m0.5.Type: GrantFiled: January 3, 2007Date of Patent: July 22, 2008Assignee: Kennametal Inc.Inventors: Russell L. Yeckley, Shanghua Wu
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Patent number: 7381016Abstract: An uncoated cutting tool that comprises a body containing a pocket. A polycrystalline cubic boron nitride blank has a cutting tip. The blank is brazed into the pocket using a blaze alloy whereby there is a braze joint between the body and the polycrystalline cubic boron nitride blank. The braze alloy has a liquidus temperature of at least about 900 degrees Centigrade wherein the braze alloy is selected from the group comprising a nickel-gold braze alloy containing nickel and gold, a copper-gold braze alloy containing copper and gold, a silver-titanium braze alloy containing silver and titanium, and a silver-palladium braze alloy containing silver and palladium.Type: GrantFiled: October 25, 2005Date of Patent: June 3, 2008Assignee: Kennametal Inc.Inventors: Edward J. Oles, Alfred S. Gates, Jr., Kent L. Reiner, William M. Alexander, IV, Jean-Pierre Genain
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Patent number: 7375044Abstract: A process for making a ceramic body that includes the following steps: providing a starting powder mixture, the starting powder mixture comprises between about 15 volume percent and about 35 volume percent boron carbide powder and at least about 50 volume percent alumina powder and no more than about 5 volume percent of a sintering aid; and consolidating the powder mixture at a temperature equal to between about 1400 degrees Centigrade and 1850 degrees Centigrade to achieve a ceramic with a density equal to greater than 99 percent of theoretical density.Type: GrantFiled: January 3, 2007Date of Patent: May 20, 2008Assignee: Kennametal Inc.Inventors: Russell L. Yeckley, Shanghua Wu
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Patent number: 7368406Abstract: A ceramic body, as well as a method for making the same, wherein the ceramic body contains aluminum oxynitride and whiskers, (and optionally) one or more of titanium carbonitride, and/or alumina, and/or zirconia, and/or other component(s).Type: GrantFiled: September 23, 2005Date of Patent: May 6, 2008Assignee: Kennametal Inc.Inventors: Russell L. Yeckley, Shanghua Wu
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Patent number: 7357697Abstract: The invention relates to abrasive water jet systems comprising an abrasive water jet mixing tube having a longitudinal bore lined with a superhard material, including such systems which use cubic boron carbide (CBN), diamond, or other materials with a hardness greater than that of alumina as the abrasive material. The invention also comprises methods of using an AWJ system having a mixing tube having a longitudinal bore lined with a superhard material. Some embodiments include AWJ mixing tubes comprised of a plurality of connected components. Such connections may be disconnectable.Type: GrantFiled: May 24, 2002Date of Patent: April 15, 2008Assignee: Kennametal Inc.Inventors: Ted R. Massa, John J. Prizzi, David R. Siddle
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Patent number: 7335615Abstract: A method of machining a workpiece including the steps of providing a workpiece; providing a ceramic cutting insert having a rake surface and a flank surface wherein the rake surface and the flank surface intersect to form a cutting edge and the ceramic cutting insert having a substrate that comprises between about 15 volume percent and about 35 volume percent of a boron carbide phase and at least about 50 volume percent alumina and has a fracture toughness (KIC, 18.5 Kg Load E&C) greater than or equal to about 4.5 MPa·m0.5; causing relative rotational movement between the workpiece and the ceramic cutting insert wherein the surface speed of the relative rotational movement is equal to or greater than about 457 surface meters per minute; and bringing the ceramic cutting insert and the workpiece into contact with each other so as to remove material from the workpiece.Type: GrantFiled: January 3, 2007Date of Patent: February 26, 2008Assignee: Kennametal Inc.Inventors: Russell L. Yeckley, Shanghua Wu
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Patent number: 7309673Abstract: A SiAlON ceramic body made from a starting powder mixture that includes silicon nitride powder and one or more powders that provide aluminum, oxygen, nitrogen, and two selected rare earth elements to the SiAlON ceramic body wherein the selected rare earth elements are selected from at least two groups of the following three groups of rare earth elements wherein Group I comprises La, Ce, Pr, Nd, Pm, Sm and Eu, and Group II comprises Gd, Tb, Dy and Ho, and Group III comprises Er, Tm, Yb and Lu. The SiAlON ceramic body includes a two phase composite that includes an alpha prime SiAlON phase and a beta prime SiAlON phase wherein the alpha prime SiAlON phase contains one or more of the selected rare earth elements excluding La and Ce. The silicon nitride powder makes up at least about 70 weight percent of the starting powder mixture wherein the beta-silicon nitride content of the silicon nitride powder has a lower limit equal to zero weight percent and an upper limit equal to about 1.Type: GrantFiled: February 9, 2005Date of Patent: December 18, 2007Assignee: Kennametal Inc.Inventor: Russell L. Yeckley
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Patent number: 7309475Abstract: A process of making aluminum oxynitride powder including the steps of: forming a powder mixture by mixing alumina powder and aluminum nitride powder according to the following formula: ((4?x)/3) alumina and x aluminum nitride wherein x is in mole percent and ranges between about 0.31 and about 0.61; adding between about 0.1 mole percent and about 1.0 mole percent of pure aluminum powder to the powder mixture; and reacting the powder mixture containing aluminum at a temperature between about 1600° C. and about 1900° C. for a duration between about 2 hours and about 24 hours in a flowing nitrogen atmosphere so as to form aluminum oxynitride.Type: GrantFiled: April 26, 2006Date of Patent: December 18, 2007Assignee: Kennametal Inc.Inventors: Russeli L. Yeckley, Shanghua Wu
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Patent number: 7262145Abstract: A ceramic body, as well as a method for making the same, wherein the ceramic body contains aluminum oxynitride and whiskers, (and optionally) one or more of titanium carbonitride, and/or alumina, and/or zirconia, and/or other component(s).Type: GrantFiled: April 7, 2005Date of Patent: August 28, 2007Assignee: Kennametal Inc.Inventors: Russell L. Yeckley, Shanghua Wu
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Patent number: 7223709Abstract: A method of making a SiAlON ceramic body that includes a two phase composite comprising an alpha prime SiAlON phase and a beta prime SiAlON phase, the method includes the steps of: providing a starting powder that comprises at least about 70 weight percent silicon nitride powder and one or more other powders that provide aluminum, oxygen, nitrogen, and at least two selected rare earth elements to the SiAlON ceramic body wherein the rare earth elements are selected from at least two groups of the following three groups of rare earth elements wherein Group I comprises La, Ce, Pr, Nd, Pm, Sm and Eu, and Group II comprises Gd, Tb, Dy and Ho, and Group III comprises Er, Tm, Yb and Lu; and consolidating the starting powder mixture to form a ceramic body comprising a two phase composite comprising an alpha prime SiAlON phase and a beta prime SiAlON phase, and the alpha prime SiAlON phase containing one or more of the selected rare earth elements excluding La and Ce, and the ceramic body having a composition fallingType: GrantFiled: June 22, 2006Date of Patent: May 29, 2007Assignee: Kennametal Inc.Inventor: Russell L. Yeckley
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Patent number: 7217674Abstract: A ceramic body, as well as a method of making the ceramic body, wherein in one aspect a hot-pressing method is used to produce the ceramic body. In another aspect, a sintering to full density method is used to produce the ceramic body. The hot-pressed ceramic body contains between about 15 volume percent and about 35 volume percent of a boron carbide phase and at least about 50 volume percent of alumina, and the substrate has a fracture toughness (KIC, 18.5 Kg Load E&C) greater than or equal to about 4.5 MPa·m0.5. The sintered to full density ceramic body contains between about 15 volume percent and about 50 volume percent of a boron carbide irregular-shaped phase and at least about 50 volume percent alumina.Type: GrantFiled: December 19, 2005Date of Patent: May 15, 2007Assignee: Kennametal Inc.Inventors: Russell L. Yeckley, Shanghua Wu
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Patent number: 7189031Abstract: A toolholder has an insert clamp in the form of a lever that urges the top of a cutting insert into the pocket of the toolholder. The lever may be spring biased against the insert and may also be dynamically activated by rotation of the toolholder. Additionally, the lever may be on the form of a cam. A method is described of securing a cutting insert within the pocket using the lever.Type: GrantFiled: December 11, 2003Date of Patent: March 13, 2007Assignee: Kennametal Inc.Inventors: John J. Bellinger, Nathan L. Goldblatt, Rachel Suling Lin, James David Rene Raskob
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Patent number: 7163657Abstract: A sintered cemented carbide body (e.g., a cutting tool) and a method of making the same. The sintered cemented carbide body includes tungsten carbide, a binder phase of at least one metal of the iron group or an alloy thereof, and one or more solid solution phases. Each one of the solid solution phases has at least one of the carbides and carbonitrides of a combination of zirconium, niobium, and tungsten. The method includes the steps of providing a powder mixture that contains tungsten carbide, a binder metal powder comprising at least one metal of the iron group or an alloy thereof, and at least one of the carbides and carbonitrides of both zirconium and niobium including a powder of the carbides or carbonitrides of zirconium and niobium, forming a green compact of said powder mixture, and vacuum sintering or sinter-HIP said green compact at a temperature of from 1400 to 1560° C.Type: GrantFiled: December 3, 2003Date of Patent: January 16, 2007Assignee: Kennametal Inc.Inventors: Hans-Wilm Heinrich, Manfred Wolf, Dieter Schmidt
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Patent number: 7156006Abstract: A cutting insert rotated about its axis may be utilized during a metalworking operation and applied against the rotating workpiece to enhance tool performance. A method, including an assembly with a rotatable insert mounted to a toolholder may be utilized to achieve this result.Type: GrantFiled: September 2, 2003Date of Patent: January 2, 2007Assignee: Kennametal Inc.Inventors: Gregory A. Hyatt, Linn R. Andras, Ted R. Massa
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Patent number: 7094717Abstract: A method for making a crystallized ceramic body containing a two phase composite comprising an alpha prime SiAlON phase that contains ytterbium and a beta prime SiAlON phase, the process includes the steps of: blending together a starting powder mixture that upon densification forms the SiAlON ceramic, the starting powder includes at least about 70 weight percent silicon nitride powder wherein the silicon nitride powder contains beta silicon nitride in an amount less than or equal to about 1.Type: GrantFiled: April 18, 2005Date of Patent: August 22, 2006Assignee: Kennametal Inc.Inventor: Russell L. Yeckley
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Patent number: 7049256Abstract: A SiAlON ceramic body made from a starting powder mixture that includes silicon nitride powder, and one or more powders that provide aluminum, oxygen, nitrogen and ytterbium to the SiAlON ceramic. The SiAlON ceramic body includes a two phase composite comprising alpha prime SiAlON phase, which is present in an amount greater than or equal to about 20 weight percent of the two phase composite, and a beta prime SiAlON phase wherein the alpha prime SiAlON phase containing ytterbium therein. The starting silicon nitride powder contains less than or equal to about 1.6 weight percent beta-silicon nitride. The ceramic body further includes an intergranular phase that includes an intergranular crystalline phase comprising at least one of YbAG and J-phase. The overall composition of the ceramic body is YbaSibAlcOdNe, wherein when a is less than 0.05, the relative intensity of the peak associated with either one or both intergranular crystalline phases of YbAG and J-phase is greater than about 2.Type: GrantFiled: June 5, 2003Date of Patent: May 23, 2006Assignee: Kennametal Inc.Inventor: Russell L. Yeckley