Abstract: A method for producing a fully dense permanent magnet article by placing a particle charge of the desired permanent magnet alloy in a container, sealing the container, heating the container and charge and extruding to achieve a magnet having mechanical anisotropic crystal alignment and full density.

Abstract: A powder metallurgy produced high speed tool steel article comprising a mixture of prealloyed high speed tool steel particles coated with a hard, wear resistant material, such as a carbide or nitride, mixed with prealloyed high speed tool steel uncoated particles; the particles are compacted to essentially full density and the hard, wear resistant material is at the boundaries of the coated particles and contained in a continuous matrix of the high speed tool steel. The article is produced by hot compacting a particle charge to essentially full density of a mixture of the coated and uncoated particles.

Abstract: A permanent magnet alloy having at least one light rare earth element, iron and carbon. The alloy has a cellular microstructure of at least two solid phases with a Fe.sub.14 R.sub.2 C.sub.1 magnetically hard, tetragonal major phase surrounded by at least one minor phase. The light rare earth element may be Pr or Nd. At least one heavy rare earth element, such as Dy, may be used. Boron may be included in the alloy. The alloy is produced by casting and heating to form the Fe.sub.14 R.sub.2 (C,B).sub.1 magnetically hard, tetragonal major phase.

Abstract: A powder metallurgy produced high speed tool steel article comprising a mixture of prealloyed high speed tool steel particles coated with a hard, wear resistant material, such as a carbide or nitride, mixed with prealloyed high speed tool steel uncoated particles; the particles are compacted to essentially full density and the hard, wear resistant material is at the boundaries of the coated particles and contained in a continuous matrix of the high speed tool steel. The article is produced by hot compacting a particle charge to essentially full density of a mixture of the coated and uncoated particles.

Abstract: A method for producing a dysprosium-iron alloy for use in the manufacture of rare-earth element containing, iron-boron permanent magnets. A particle mixture of dysprosium oxide, iron, boron and calcium is compacted, the compact is heated to form a metallic compound comprising dysprosium, boron and iron and to form calcium oxide. There is no need for additives such as calcium chloride that aid in particle disintegration during washing.A particle mass of -35 mesh is produced from the compact. The particle mass is washed with cold water, and the water is reacted with the calcium oxide and calcium to form calcium hydroxide, while preventing oxidation of the particle mass. The calcium hydroxide is removed from the particle mass as by repeated water washing.

Abstract: A free-machining, austenitic stainless steel having low carbon plus nitrogen contents in combination with manganese and sulfur additions. The steel may have silicon of 0.045 to 1.00 percent.

Abstract: A rare-earth element permanent magnet alloy characterized by good magnetic alignment and high energy product, said magnet consisting essentially of, in atomic percent, at least one rare earth element didymium, mischmetal, neodymium and thorium 12 to 20, boron 4 to 14 and balance iron.

Abstract: A resulfurized, chromium-nickel austenitic stainless steel having improved machinability resulting from low carbon and low nitrogen contents in combination with manganese and sulfur additions. The composition of the steel consists essentially of, in weight percent, carbon plus nitrogen total up to 0.065, preferably up to 0.040 or 0.056, chromium 16 to 30, preferably 17 to 19, nickel 5 to 26, preferably 6 to 14, sulfur 0.10 to 0.45, preferably 0.10 to 0.25, more preferably 0.25 to 0.45, manganese 0.75 to 2.0, silicon up to 1, phosphorus up to about 0.20, molybdenum up to 1.0 and copper up to 1.00, and balance iron and incidental impurities.

Abstract: A chromium-nickel-copper, age-hardenable martensitic stainless steel having improved machinability in the solution-treated and also in the age-hardened condition. The steel has carbon plus nitrogen up to 0.08%, preferably 0.05 or 0.035% for purposes of improved machinability.

Abstract: A powder-metallurgy alloy article having a good combination of wear resistance and corrosion resistance. The article is further characterized by an attainable minimum hardness after heat treatment of 60R.sub.c and a martensitic structure. The article is made from prealloyed particles of the composition, in percent by weight, carbon 2.5-5, manganese 0.2-1, phosphorus 0.10 maximum, sulfur 0.10 maximum, silicon 1 maximum, nickel 0.5 maximum, chromium 15-30, molybdenum, 2-10 vanadium 6-11, nitrogen 0.15 maximum and balance, iron. The article has a fine, uniform distribution of a MC and other carbide phases.

Abstract: A powder-metallurgy method and assembly for producing tubular product having at least one surface and preferably an interior surface thereof clad with an alloy different from and preferably more resistant to destructive media than the material from which the remainder of the tubing is constructed. An assembly is constructed of a metal tubing having an internal surface to be clad and a tubular insert mounted generally axially within the tubing in spaced-apart relation to the internal surface thereof, which provides a generally annular cavity between the internal surface of the tubing and the tubular insert. This cavity is filled with metal particles of a composition to be clad on the tubing internal surface. The cavity is sealed and the assembly is heated to an elevated temperature at which it is extruded to compact metal particles introduced to the cavity to substantially full density and metallurgically bond the particles to the internal surface to provide a desired destructive-media resistant cladding.

Abstract: An age-hardenable, corrosion-resistant, nickel-base fully dense article of compacted prealloyed particles. The article has a fine, uniformly distributed gamma-prime phase for strength and hardness. The alloy consists essentially of, in weight percent, carbon 0.05 max, chromium 15 to 25, molybdenum 6.5 to 10, columbuium 4 to 6.5, iron 9 max, aluminum 0.2 to 0.8, nitrogen 0.05 max, titanium, 0.6 max, and balance nickel. The alloy article has an absence of interstitial phases at prior particle boundaries and may be age-hardened to a minimum room-temperature 0.2% offset yield strength of 120,000 psi.

Abstract: A rare-earth element permanent magnet alloy characterized by good magnetic alignment and high energy product, said magnet consisting essentially of, in atomic percent, at least one rare earth element didymium, mischmetal, neodymium and thorium 12 to 20, boron 4 to 14 and balance iron.

Abstract: A powder-metallurgy method and assembly for producing tubular product having at least one surface and preferably an interior surface thereof clad with an alloy different from and preferably more resistant to destructive media than the material from which the remainder of the tubing is constructed. An assembly is constructed of a metal tubing having an internal surface to be clad and a tubular insert mounted generally axially within the tubing in spaced-apart relation to the internal surface thereof, which provides a generally annular cavity between the internal surface of the tubing and the tubular insert. This cavity is filled with metal particles of a composition to be clad on the tubing internal surface. The cavity is sealed and the assembly is heated to an elevated temperature at which it is extruded to compact metal particles introduced to the cavity to substantially full density and metallurgically bonded the particles to the internal surface to provide a desired destructive-media resistant cladding.

Abstract: A powder-metallurgy method for producing tubular product having at least one surface and preferably an internal surface thereof clad with an alloy different from and preferably more resistant to destructive media than the material from which the remainder of the tubing is constructed. An assembly is constructed of a metal tubing having an internal surface to be clad and a tubular insert mounted generally axially within the tubing in spaced-apart relation to the internal surface thereof, which provides a generally annular cavity between the internal surface of the tubing and the tubular insert. This cavity is filled with metal particles of a composition to be clad on the tubing internal surface. The cavity is sealed and the assembly is heated to an elevated temperature at which it is forged to compact the metal particles introduced to the cavity to substantially full density and metallurgically bond the particles to the internal surface of the tubing to provide a desired destructive-media resistant cladding.

Abstract: A chromium-nickel austenitic stainless steel having improved machinability resulting from low carbon and nitrogen contents, along with a high manganese to sulfur ratio. The composition of the steel consists essentially of, in weight percent, carbon plus nitrogen up to 0.060, preferably up to 0.049, and most preferred up to 0.032, chromium 16 to 30, preferred 17 to 19, nickel 5 to 26, preferred 6 to 14, sulfur 0.25 to 0.45, manganese over 2 to about 7 and at least about eight times the sulfur content, balance iron and incidental impurities.

Abstract: A method for producing high speed, tool and die steel articles from prealloyed powders. The method comprises placing particles of a prealloyed steel composition from which the article is to be made in a deformable container, heating the container and particles and then passing the heated container through a forging box having a plurality of hammers evenly spaced around the container and adapted to extend and retract radially to impart a radial forging action to the container. The forging action is of a magnitude and duration to compact the particles to an essentially fully dense article. Preferably, there are four hammers arranged in two pairs with the hammer of each pair being opposed and adapted to extend and retract in unison.

Abstract: A permanent magnet alloy that when used in the production of a permanent magnet results in a magnet that is highly resistant to disintegration when exposed to a combination of humidity and heat. Consequently, the alloy consists essentially of, in weight percent, 30 to 36 of at least one rare earth element, 60 to 66 iron, 6,000 to 35,000 ppm oxygen and balance boron.

Abstract: A method for making rare earth-permanent magnets wherein a molten mass of a rare earth magnet alloy is produced such as by induction melting and while in a protective atmosphere is introduced in the form of a stream into a chamber having a protective atmosphere and a bottom portion containing a cooling medium, such as a cryogenic liquid which may be liquid argon. After cooling and solidification, the alloy is collected from the chamber and comminuted to produce particles. The particles are formed into a magnet body. Alternately, the stream may be atomized, as by striking the same with a jet of inert gas, to produce discrete droplets, which droplets are directed to the cooling medium at the chamber bottom for cooling, solidification and collection.

Abstract: Fully dense consolidated powder alloys of iron, cobalt and/or nickel characterized by having an ultrafine microstructure exhibiting a substantially uniformly dispersed harding phase of particle size essentially less than 3 microns, are produced from prealloyed powders by rapidly quenching an atomized molten alloy charge and subjecting the solidified alloy powder particles to the step of hot consolidation to produce substantially fully dense metal stock directly from prealloyed powder.