Patents Examined by Daniel Jenkins
  • Patent number: 7060222
    Abstract: An infiltrant is used to fill a metal powder skeleton. The infiltrant is similar in composition to the base powder, but contains a melting point depressant. The infiltrant will quickly fill the powder skeleton, then as the melting point depressant diffuses into the base powder, the liquid will undergo solidification and the material will eventually homogenize. This process allows more accurate control of dimensions in large parts with uniform or homogeneous microstructure or bulk properties.
    Type: Grant
    Filed: May 21, 2001
    Date of Patent: June 13, 2006
    Assignee: Massachusetts Institute of Technology
    Inventors: Emanuel M. Sachs, Adam M. Lorenz, Samuel Allen
  • Patent number: 7056397
    Abstract: The invention concerns a method of improving the properties of a hydrogen storage alloy powder for a negative electrode of a rechargeable nickel hydride battery. The method comprises the steps of hydriding a powdered alloy starting material, oxidizing the obtained hydride alloy powder and washing the oxidized powder. The invention also concerns the obtained powder.
    Type: Grant
    Filed: May 16, 2001
    Date of Patent: June 6, 2006
    Assignee: Höganäa Ab
    Inventors: Dag Noréus, Ye Zhou
  • Patent number: 7052648
    Abstract: To manufacture a flange for a compressor with a relief groove by using powder metallurgy in order to prevent deformation of the compressor in operation, powder material for the flange is charged into a mold; an ablative member having a melting point lower than that of the powder material is positioned at a place where a relief groove is to be formed; the flange is formed by compressing the powder material and the ablative member; and the formed flange is sintered at a temperature between the melting points of the power material and the ablative member so as to melt and remove the ablative member.
    Type: Grant
    Filed: April 4, 2001
    Date of Patent: May 30, 2006
    Assignee: Korea Sintered Metal Co., Ltd.
    Inventor: Jong-Kwan Park
  • Patent number: 7052559
    Abstract: A welding flux for use in welding stainless steel parts to increase welding penetration, consisting essentially a base material obtained from manganese peroxide (MnO2), and an activator selected from a material group that includes zinc oxide (ZnO), silicon dioxide (SiO2), chromium oxide (CrO2), titanium dioxide (TiO2), molybdenum dioxide (MoO2), and iron oxide (Fe2O2).
    Type: Grant
    Filed: March 26, 2004
    Date of Patent: May 30, 2006
    Assignee: National Chiao Tung University
    Inventors: Chang-Pin Chou, Her-Yueh Huang, Sheang-Wen Shyu, Kueng-Hueng Tseng, Tsung-Chieh Yang
  • Patent number: 7052558
    Abstract: A soldering paste flux for use in soldering copper and copper alloy piping and the like is formed of 40–70% nonylphenol ethoxylate (preferably Tergitol NO-10® made by Dow Chemical), 10–30% glyceryl monostearate, 3–10% acid activator, 3–10% water, and 4–15% mineral salt. The acid activator is preferably a mineral acid and, most preferably, hydrobromic acid. The mineral salt is preferably zinc bromide.
    Type: Grant
    Filed: April 8, 2005
    Date of Patent: May 30, 2006
    Assignee: Chemicals and Metals Technologies, Inc.
    Inventors: Daniel M. Sabarese, Mark A. Sabarese, Harold A. Stuhler
  • Patent number: 7045092
    Abstract: A perpendicular pressing/compacting method for a rare-earth alloy powder is provided to produce a sintered magnet with excellent magnetic properties. A method for pressing a rare-earth alloy powder by using a die is provided. The die is made of a non-magnetic material and has a die hole to define a cavity and a pair of yoke members provided on both sides of the cavity. The method includes the steps of: providing the rare-earth alloy powder; filling the cavity of the die with the rare-earth alloy powder; and compressing the rare-earth alloy powder, loaded in the cavity, between a pair of opposed press surfaces. A pulse magnetic field substantially perpendicular to a compressing direction is not applied until the apparent density of the rare-earth alloy powder in the cavity reaches a predetermined value, at least equal to 47% of the true density thereof, while the compressing step is being carried out.
    Type: Grant
    Filed: April 4, 2003
    Date of Patent: May 16, 2006
    Assignee: Neomax Co., Ltd.
    Inventors: Atsushi Ogawa, Shuhei Okumura
  • Patent number: 7037466
    Abstract: After recycled titanium alloy chips are crushed and cleaned, they are pressed into cylindrically briquettes with a relative density of 0.6, and placed into capsules. The capsules are heated and placed into a preheated pressing rig. The pressing rig repetitively applies axial force to the capsule, resulting in a relative density of at least 0.95. The product billets are used for consumable electrodes, secondary casting alloys, forgings, extruded semi-finished products and the like.
    Type: Grant
    Filed: September 29, 2003
    Date of Patent: May 2, 2006
    Inventors: Vladimir Leonidovich Girshov, Arnold Nikolayevich Treschevskiy, Victor Georgievich Kochkin, Alexey Alexandrovich Abramov, Natalja Semenovna Sidenko
  • Patent number: 7037463
    Abstract: A metallic article is prepared by first furnishing at least one nonmetallic precursor compound, wherein all of the nonmetallic precursor compounds collectively containing the constituent elements of the metallic article in their respective constituent-element proportions. The constituent elements together form a titanium-base alloy having a stable-oxide-forming additive element therein, such as magnesium, calcium, scandium, yttrium, lanthanum, cerium, praseodymium, neodymium, promethium, samarium, europium, gadolinium, terbium, dysprosium, holmium, erbium, thulium, ytterbium, and lutetium, and mixtures thereof. The stable-oxide-forming additive element forms a stable oxide in a titanium-based alloy. At least one additive element is present at a level greater than its room-temperature solid solubility limit in the titanium-base alloy. The precursor compounds are chemically reduced to produce an alloy material, without melting the alloy material. The alloy material may be consolidated.
    Type: Grant
    Filed: December 23, 2002
    Date of Patent: May 2, 2006
    Assignee: General Electric Company
    Inventors: Andrew Philip Woodfield, Clifford Earl Shamblen, Eric Allen Ott, Michael Francis Xavier Gigliotti
  • Patent number: 7025928
    Abstract: A method of flow forming sintered metal parts. The first step is forming a round disk by conventional powder metal process. The disk can be a donut shape part with or without a flange on one side of its outer diameter. The disk can then be copper impregnated or used as is, depending on the requirements. The disk is placed in a spinner held in proper tooling and grooves are spun in its outer diameter. The spinning can be done with a finishing roller or by a pre-finishing roller, followed by a finishing roller. This process not only creates a part with great accuracy, it also densifies and eliminates the powder metal porosities on the surface layer by the pressures inserted in spinning.
    Type: Grant
    Filed: July 24, 2003
    Date of Patent: April 11, 2006
    Assignee: The Gates Corporation
    Inventor: Yahya Hodjat
  • Patent number: 7025930
    Abstract: In a process for handling green compacts made from a rare earth metal-based magnetic alloy powder by a press machine to slide, on a sintering support plate, the green compacts, the support plate used has a surface roughness degree Ra in a range of 0.6 to 47 ?m. At a first step, the green compacts are disposed in a first position near a final transport position, and at a second step, the said green compacts disposed in the first position are slid on the sintering support plate and disposed in the final transport position. Thus, by using the support plate having a surface roughness degree in a particular range, the green compacts made from the rare earth metal-based magnetic alloy powder can be sintered without occurrence of the deposition of the green compacts to the support plate, the chipping of the green compacts and the like. In addition, the efficiency of operation of the press machine can be increased.
    Type: Grant
    Filed: February 4, 2003
    Date of Patent: April 11, 2006
    Assignee: Neomax Co. Ltd.
    Inventors: Shuhei Okumura, Hiroshi Hashikawa
  • Patent number: 7025929
    Abstract: The invention provides a method and apparatus for densifying the teeth of a powder metal preform gear. The die includes an aperture for receiving a body of the gear and a plurality of grooves for receiving the teeth of the gear. The grooves have a length and a variable width along the length. The grooves narrow tangentially relative to the aperture. The powder metal preform gear is urged through the die and the teeth are plastically and elastically deformed at a relatively narrow portion of the groove. After passing through the narrow portion of the groove and being compressed, the teeth can at least partially recover. The grooves defined by the die can be helical for forming a helical groove.
    Type: Grant
    Filed: April 8, 2004
    Date of Patent: April 11, 2006
    Assignee: PMG Ohio Corp.
    Inventors: Juan R. L. Trasorras, Eric T. Riley
  • Patent number: 7008491
    Abstract: A method for fabricating an article of a titanium-base alloy, such as an alpha-beta titanium gas turbine fan or compressor disk, uses a starting ingot having a thickness of at least about 20 inches, and which is made of a titanium-base alloy having a temperature-composition phase diagram with a beta-phase field and an alpha-beta phase field. The method includes first forging the starting ingot in the beta-phase field to form an in-process billet, thereafter second forging the in-process billet in the alpha-beta phase field, thereafter heating the in-process billet into the beta-phase field to recrystallize the in-process billet, and thereafter third forging the in-process billet. The step of third forging includes forging the in-process billet from a first forging thickness of not less than about 15 inches to a second forging thickness of not more than about 13 inches, at a third-forging temperature of from about 1550° F. to about 1725° F.
    Type: Grant
    Filed: November 12, 2002
    Date of Patent: March 7, 2006
    Assignee: General Electric Company
    Inventor: Andrew Philip Woodfield
  • Patent number: 7001570
    Abstract: A metal-made seamless pipe is provided, containing at least one metal selected from the group consisting of metals each having a melting point of 1,600° C. or more, and has a porosity of 0.3 to 25%. The porosity is defined as a ratio of the open pores present at the outer surface of the pipe to the total surface area of the outer surface of the pipe. The open pores do not include through-pores perforating to the inner surface of the pipe. A process for producing such a metal-made seamless pipe is also provided. The metal-made seamless pipe is low in processability but can be produced having a small thickness and a small inner diameter, having superior mechanical strength and gastightness, and can be suitably used as a sealing member of a translucent vessel of a high-pressure discharge lamp.
    Type: Grant
    Filed: April 25, 2003
    Date of Patent: February 21, 2006
    Assignee: NGK Insulators, Ltd.
    Inventor: Norikazu Niimi
  • Patent number: 6991687
    Abstract: Vacuum carburizing of ferrous workpieces is performed at low pressure in a vacuum furnace using a napthene hydrocarbon as the carburizing medium. The furnace is constructed to be generally transparent to the napthene so that cracking tends to occur at the workpiece which functions as a catalyst to minimize carbon deposits. The napthene is supplied in liquid form to fuel injectors which inject the liquid napthene as a vapor at duty cycles and firing orders to produce a uniform dispersion of the hydrocarbon gas about the work resulting in uniform carburizing of the workpieces. An in-situ methane infrared sensor controls the process. Hydrogen is added to the napthene to either assure full carbon potential and produce methane or to perform variable carburizing.
    Type: Grant
    Filed: July 26, 2002
    Date of Patent: January 31, 2006
    Assignee: Surface Combustion, Inc.
    Inventors: Ralph Paul Poor, Garry W. Barbee, Stephen Harry Verhoff, James Edward Brug
  • Patent number: 6986866
    Abstract: A method and apparatus for the cross-hole pressing of cutting inserts is disclosed whereby a green part is fabricated using metallurgical powder and an opening is imparted within the green part by placing the metallurgical powder about an oval-shaped core rod. Using a press with a uni-axial press motion, a core rod is placed within the cavity of a mold and metallurgical powder placed around the core rod and thereafter compressed to form a green part. The subject invention is also directed to an article formed utilizing such a process and the uni-axial press used to produce such an insert.
    Type: Grant
    Filed: November 4, 2002
    Date of Patent: January 17, 2006
    Assignee: Kennametal Inc.
    Inventors: Richard J. Gubanich, Edward M. Dinco
  • Patent number: 6977060
    Abstract: A method for making a material system includes the steps of: providing a chamber, placing hollow geometric shapes in the chamber, closing the chamber, evacuating air from the chamber, feeding a binder for the shapes into the evacuated chamber to impregnate the geometric shapes, drying the binder permeated geometric shapes, and heating the hollow shapes and binder to provide a unitary, sintered material system.
    Type: Grant
    Filed: March 28, 2000
    Date of Patent: December 20, 2005
    Assignee: Siemens Westinghouse Power Corporation
    Inventors: Gary Brian Merrill, Jay Edgar Lane
  • Patent number: 6974558
    Abstract: To provide a substrate material made of an aluminum/silicon carbide composite alloy which has a thermal conductivity of 100 W/m×K or higher and a thermal expansion coefficient of 20×10?6/° C. or lower and is lightweight and compositionally homogeneous. A substrate material made of an aluminum/silicon carbide composite ally which comprises Al—SiC alloy composition parts and non alloy composition part and dispersed therein from 10 to 70% by weight silicon carbide particles, and in which the fluctuations of silicon carbide concentration in the Al—SiC alloy composition parts therein are within 1% by weight. The substrate material is produced by sintering a compact of an aluminum/silicon carbide starting powder at a temperature not lower than 600° C. in a non-oxidizing atmosphere.
    Type: Grant
    Filed: August 10, 2001
    Date of Patent: December 13, 2005
    Assignee: Sumotomo Electric Industries, Ltd.
    Inventors: Shinichi Yamagata, Yugaku Abe, Makoto Imamura, Akira Fukui, Yoshishige Takano, Takatoshi Takikawa, Yoshiyuki Hirose
  • Patent number: 6972109
    Abstract: Metal-matrix composites with combinations of physical and mechanical properties desirable for specific applications can be obtained by varying and controlling selected parameters in the material formation processes, particularly by increasing the microstructural homogeneity of the composite, while maintaining a constant mixture ratio or volume fraction. In one embodiment of the invention, a CuSiC composite having increased thermal conductivity is obtained by closely controlling the size of the SiC particles. In another embodiment of the invention, AlSiC composites which exhibit increased ultimate tensile and yield strengths are made by closely controlling the size of SiC and Al particles.
    Type: Grant
    Filed: November 13, 2002
    Date of Patent: December 6, 2005
    Assignee: The United States of America as represented by the Secretary of the Air Force
    Inventors: Jonathan E. Spowart, Benji Maruyama, Daniel B. Miracle
  • Patent number: 6969430
    Abstract: This invention is directed to a process and apparatus for producing high productivity carburizing. A process is introduced that uses a gas mixture made up of CO, H2, CO2, H2O, CH4 and N2, such that the product of the % CO and % H2 is greater than about 1600; the ratio of CO/CO2 is greater than 10; and the ratio of H2/H2O is greater than about 10. The gas mixture is controlled for a short time. A reactor for generating a gas mixture for carburizing steel is also introduced. This reactor is composed of a cylindrically symmetric body; a first central tube containing electrical heating elements for gas flow; a second central tube concentrically disposed around the first central tube; and a plurality of catalyst beds disposed in an annular space in a segmented fashion around the second central tube.
    Type: Grant
    Filed: June 5, 2002
    Date of Patent: November 29, 2005
    Assignee: Praxair Technology, Inc.
    Inventors: Jaak Stefaan Van den Sype, Alan Russell Barlow, Edison Viotto
  • Patent number: 6967001
    Abstract: The invention refers to a new method for preparing sintered structural parts of carbon or tool steels or high speed steel having a carbon content of up to 2% by weight, wherein an agglomerated spherical powder comprising at least 0.5% of a thermo-reversible hydrocolloid is pressed to a green body of high density which is then heated at 450–650° C. to remove the non-carbon content of the hydrocolloid and subsequently sintered at about 1100–1400° C. to structural parts having high strength properties.
    Type: Grant
    Filed: April 26, 2001
    Date of Patent: November 22, 2005
    Assignee: Metals Process Systems
    Inventor: Christer Aslund