Patents Examined by John N. Greaves
  • Patent number: 5552109
    Abstract: This invention relates to a process of forming a sintered article of powder metal comprising blending graphite and lubricant with a pre-alloyed iron based powder, pressing said blended mixture to shape in a single compaction stage sintering said article, and then high temperature sintering said article in a reducing atmosphere to produce a sintered article having a density greater than 7.4 g/cc.
    Type: Grant
    Filed: June 29, 1995
    Date of Patent: September 3, 1996
    Inventors: Rohith Shivanath, Peter Jones, Danny T. D. Thieu
  • Patent number: 5549975
    Abstract: A coated tool consisting of a cermet body and a refining layer thereon. The refining layer is a wear resistant layer of (Ti, Me) N, wherein Me is at least one metal which forms a stable oxide at a temperature above 700.degree. C.
    Type: Grant
    Filed: July 20, 1994
    Date of Patent: August 27, 1996
    Assignee: Balzers Aktiengesellschaft
    Inventors: Hans Schulz, Josef Maushart
  • Patent number: 5549951
    Abstract: Ultrafine whiskery or columnar ceramic particles, a method for producing the ultrafine particles, and a sintered article obtained by sintering the ultrafine ceramic particles are disclosed. The ultrafine ceramic particles are produced by thermally melting a matrix alloy of a composition of Al--M.sup.1, wherein M.sup.1 stands for at least one metallic element selected from the group consisting of Cr, Co, and Fe, or Al--M.sup.1 --M.sup.2, wherein M.sup.2 stands for at least one metallic element selected from the group consisting of Au, Cu, Dy, Er, Ga, Ge, Gd, Hf, Ho, Lu, Mn, Mo, Nb, Nd, Ni, Pr, Re, Sb, Sc, Si, Sn, Ta, Tb, Ti, Tm, V, W, Y, Zn, or Zr, in a nitriding atmosphere containing nitrogen and causing the vaporized raw material to react with the nitrogen in the atmosphere.
    Type: Grant
    Filed: September 7, 1994
    Date of Patent: August 27, 1996
    Assignees: YKK Corporation, Tsuyoshi Masumoto, Akihisa Inoue, Honda Giken Kogyo Kabushiki Kaisha
    Inventors: Tadashi Yamaguchi, Katsutoshi Nosaki, Inoue Akihisa, Tsuyoshi Masumoto
  • Patent number: 5545487
    Abstract: The Al-Si sintered alloy having good mechanical strength and elongation and is especially excellent in wear resistance, and a method for producing the same. The sintered alloy consists of 2.4-23.5% Si, 2-5% Cu, 0.2-1.5% Mg, 0.01-1% of transition metals and the balance of aluminum and unavoidable impurities, and has a dapple grain structure of an Al-solid solution phase and an Al-Si alloy phase containing dispersed pro-eutectic Si crystals having a maximum diameter of 5-60 .mu.m either in the whole body or in the surface contact portion, and the area ratio of the Al-solid solution phase in the grain structure is in the range of 20-80%.
    Type: Grant
    Filed: February 9, 1995
    Date of Patent: August 13, 1996
    Assignees: Hitachi Powdered Metals Co., Ltd., Honda Giken Kogyo Kabushiki Kaisha
    Inventors: Zenzo Ishijima, Jun-ichi Ichikawa, Shuji Sasaki, Hideo Shikata, Hideo Urata, Shoji Kawase, Jun-ichi Ueda
  • Patent number: 5538684
    Abstract: The present invention provides lubricant compositions for the powder metallurgical field. The lubricant compositions contain a solid phase lubricant such as graphite, molybdenum disulfide, and polytetrafluoroethylene in combination with a liquid phase lubricant that is a binder for the solid phase lubricant. The binder can be chosen from various classes of compounds including polyethylene glycols, polyethylene glycol esters, partial esters of C.sub.3-6 polyhydric alcohols, polyvinyl esters, and polyvinyl pyrrolidones. The binder is solubilized in an organic solvent.
    Type: Grant
    Filed: June 6, 1995
    Date of Patent: July 23, 1996
    Assignee: Hoeganaes Corporation
    Inventors: Sydney Luk, Ann Lawrence
  • Patent number: 5538683
    Abstract: A powder-metallurgy-produced, essentially titanium-free, nickel-containing maraging steel article such as for use in the manufacture of die casting die components and other hot work tooling components. The article preferably contains an intentional addition of niobium. The article may be produced as a hot-isostatically-compacted, solution annealed, fully dense mass of prealloyed particles, or alternately, as a hot-isostatically-compacted, plastically deformed and solution annealed, fully dense mass of prealloyed particles.
    Type: Grant
    Filed: December 7, 1993
    Date of Patent: July 23, 1996
    Assignee: Crucible Materials Corporation
    Inventors: Kenneth E. Pinnow, Carl J. Dorsch
  • Patent number: 5534220
    Abstract: A method is described for the manufacture of a sintered ferrous-based material having improved machinability, the method comprises the steps of making a mixture of a ferrous-based powder, the mixture including a compound containing at least one metal from the group comprising manganese and the alkaline-earth series of metals; at least one sulphur donating material; pressing the powder mixture and sintering the pressed mixture so as to cause the formation by reaction during sintering of at least one stable metal sulphide within the sintered material. Materials and articles made by the method are also described.
    Type: Grant
    Filed: September 30, 1994
    Date of Patent: July 9, 1996
    Assignee: Brico Engineering Limited
    Inventors: Charles G. Purnell, Mohammad S. Mahmoud, Helen A. Brownlie
  • Patent number: 5534353
    Abstract: A composite sintered material of a mixed-phase structure comprising fine particles of hard compound compactly and uniformly dispersed in grains of matrix of titanium or titanium alloy. The material is outstanding in abrasion resistance, strength, toughness, etc., and also has high resistance to corrosion by molten nonferrous metals and is therefore reduced in the likelihood of dissolving out into the melt.The sintered material is produced by uniformly mixing together a metal powder for forming the matrix of the desired sintered material and a powder for forming particles of hard compound to be dispersed, molding the powder mixture into a block under pressure, atomizing the block while melting the block and sintering the resulting powder.
    Type: Grant
    Filed: February 1, 1994
    Date of Patent: July 9, 1996
    Assignee: Kubota Corporation
    Inventors: Takahiro Kaba, Takashi Nishi, Tsuyoshi Mitsuhashi
  • Patent number: 5534219
    Abstract: A method for producing a multifilamentary superconductor containing niobium-tin (Nb.sub.3 Sn). A fully bonded niobium/copper composite billet is formed having a plurality of longitudinally extending channels which are symmetrically distributed with reference to transverse cross-sections of the billet, each channel being filled with an inert removable filler material. The inert filler material is removed to open the longitudinally extending channels in the billet. Tin or a tin alloy is inserted into the channels, and the niobium/copper composite billet with the inserted tin or tin alloy is cold drawn to the desired final dimensions. The drawn composite is then heated to effect in situ formation of the niobium-tin.
    Type: Grant
    Filed: May 27, 1994
    Date of Patent: July 9, 1996
    Assignee: Oxford Instruments Inc.
    Inventors: William G. Marancik, Seungok Hong, Rouyi Zhou
  • Patent number: 5532069
    Abstract: A dispersion-strengthened aluminum alloy having a composite structure containing a matrix of .alpha.-aluminum and a precipitation deposited phase of an intermetallic compound with the intermetallic compound in a volume ratio of not more than 35 vol. %, has both high strength and high toughness. The precipitation phase of the intermetallic compound has an aspect ratio of not more than 3.0, the .alpha.-aluminum has a crystal grain size which is at least twice the grain size of the precipitation phase of the intermetallic compound, and the crystal grain size of the .alpha.-aluminum is not more than 200 nm. It is possible to obtain an aluminum alloy having the aforementioned limited structure by carrying out first and second heat treatments on gas-atomized powder containing at least 10 vol. % of an amorphous phase or a green compact thereof and thereafter carrying out hot plastic working.
    Type: Grant
    Filed: December 22, 1994
    Date of Patent: July 2, 1996
    Assignees: Tsuyoshi Masumoto, Akihisa Inoue
    Inventors: Tsuyoshi Masumoto, Akihisa Inoue, Toshihiko Kaji, Junji Iihara, Yoshishige Takano
  • Patent number: 5531956
    Abstract: A method for producing a ribbed electrode for a fuel cell including the steps of depositing a suspension of a powdered electrode metal onto the face of a substantially flat porous electrode metal substrate, forming a plurality of raised structures on the face of the electrode, and sintering the electrode.
    Type: Grant
    Filed: April 27, 1995
    Date of Patent: July 2, 1996
    Assignee: Institute of Gas Technology
    Inventors: Estela T. Ong, Nellie Burton-Gorman
  • Patent number: 5531958
    Abstract: The present invention provides a method of increasing debinding rates in Powder Injection Molding of metal and ceramic parts by use of a catalytic binding system.
    Type: Grant
    Filed: October 17, 1995
    Date of Patent: July 2, 1996
    Assignee: BASF Corporation
    Inventor: David C. Krueger
  • Patent number: 5529602
    Abstract: Disclosed is a sintered iron alloy and a method of manufacturing the same. The sintered alloy comprises: an alloy matrix and a lead phase for imparting lubricability to the sintered alloy. The alloy matrix comprises a first alloy phase being composed of 0.5 to 3% nickel by weight, 0.5 to 3% molybdenum by weight, 5.5 to 7.5% cobalt by weight, 0.6 to 1.2% carbon by weight, and the balance iron, and a second alloy phase being composed of 26 to 30% molybdenum by weight, 7 to 9% chromium by weight, 1.5 to 2.5% silicon by weight, and the balance cobalt. The content of the lead phase in the sintered alloy is not more than 3.5% by weight. The lead phase is dispersed in the alloy matrix and a pore which is formed in the alloy matrix. The ratio of the lead dispersed in the alloy matrix to the total lead phase is 60% by weight or more, and the lead phase dispersed in the alloy matrix is particles in which the maximum particle size is 10 .mu.m or less.
    Type: Grant
    Filed: February 22, 1995
    Date of Patent: June 25, 1996
    Assignees: Hitachi Powdered Metals Co., Ltd., Nissan Motor Co., Ltd.
    Inventors: Kei Ishii, Yoshimasa Aoki, Hideaki Kawata, Akira Fujiki, Katsuyuki Nakamura, Kazuhiko Takahashi
  • Patent number: 5529745
    Abstract: By compacting in a magnetic field a mixture containing powder raw material A having a composition represented by (Tb.sub.x Dy.sub.1-x)T.sub.y wherein T is at least one metal of Fe, Co, and Ni and 0.30<x.ltoreq.x 0.50 and 1.70.ltoreq.y.ltoreq.2.00, powder raw material B having a composition represented by (Dy.sub.1-t Tb.sub.t).sub.z T.sub.1-z wherein 0.ltoreq.t.ltoreq.0.30 and 0.40.ltoreq.z.ltoreq.0.80 and optionally, powder raw material C consisting essentially of element T, and sintering the compact, there is prepared a magnetostrictive material having a composition represented by (Tb.sub.v Dy.sub.1-v)T.sub.w wherein 0.27.ltoreq.v<0.50 and 1.70.ltoreq.w.ltoreq.2.00, with grains oriented along [111] axis. The material having minimal crystalline magnetic anisotropy at room temperature and large magnetostrains is obtained at low cost by powder metallurgy.
    Type: Grant
    Filed: April 18, 1995
    Date of Patent: June 25, 1996
    Assignee: TDK Corporation
    Inventors: Teruo Mori, Tomoko Nakamura
  • Patent number: 5529600
    Abstract: A material for friction components made by a process including the steps of providing a first powder consisting of grains of a comparatively harder material with a comparatively higher coefficient of friction and an average grain size of from 60 to 100 microns, and a second powder consisting of grains of comparatively softer material with a comparatively lower coefficient of friction and an average grain size of from 60 to 100 microns; mixing the first powder and the second powder to form a powder mixture having a total volume; and subjecting the powder mixture to a pressure and temperature sufficient for the grains of the first powder to be intermixed with the comparatively softer material of the second powder so that the comparatively harder material substantially fills an intergranular space between the grains of the first powder to form the material for the friction components, the comparatively harder material occupying from 1/3 to 4/5 of the total volume of the powder mixture.
    Type: Grant
    Filed: July 22, 1994
    Date of Patent: June 25, 1996
    Assignee: Sintermetal S.A.
    Inventors: Antonio R. Fernandez, Pascal Belair, Jean R. Gras
  • Patent number: 5529603
    Abstract: It is an object of the present invention to provide a fire resistance bond magnet having superior temperature properties and most suitable for convergence use in picture tubes for display and high precision television, and alloy powders for bond magnet, without containing Co which is restricted in resources. The flame retardancy bond magnet having superior temperature properties and most suitable for convergence use in picture tubes for display and high precision television can be provided at low cost without containing Co, by using the alloy powders for bond magnet consisting of Al-Ni-Cu-(Ti, Nb)-Fe without Co, and having an isotropy and mean particle sizes of 10 .mu.m to 200 .mu.m, and kneading, molding and curing the 20 wt % to 80 wt % alloy powders together with a chlorine flame retardant, a flame retardant assistant such as antimony trioxide and zinc boric acid and a binder.
    Type: Grant
    Filed: June 17, 1994
    Date of Patent: June 25, 1996
    Assignee: Sumitomo Special Metals Company Limited
    Inventors: Michio Yamashita, Hirokazu Kitayama, Yoshihiko Nishino, Toshihiro Hurukawa
  • Patent number: 5529746
    Abstract: The invention relates to a process for pressing electrically conductive powders to high-density compacts in dimensionally stable pressing molds, whereby the achievable compression density is greater than 96% and, in many cases, amounts to almost 100% of the theoretical density of suitable materials. For said purpose, static pressing of the powders according to conventional methods is superimposed by a second process step, in which from 1 to 3 electric current pulses of from 5.times.10.sup.-5 to 5.times.10.sup.-2 s duration and high electric power are applied to the punches of the press. As opposed to known methods, no notable sintering of powder of particles occurs in such process. The process is especially suitable for the manufacture of high-density and high-strength, sintered mass-produced components, where compacts are produced on automatic presses with high cycle frequencies.
    Type: Grant
    Filed: March 8, 1995
    Date of Patent: June 25, 1996
    Inventors: Walter Knoss, Manfred Schlemmer
  • Patent number: 5529747
    Abstract: A formable composite magnetic flux concentrator material is composed of about 65% to 90% ferromagnetic material, such as iron powder, and about 35% to 10% binder, the binder being a mixture of an epoxy and one or more catalysts. The concentrator material is provided in a formable state as a putty-like body which can be worked into any desired shape dictated by the configuration of the induction heating coil used in a particular application. In one form, the density of the concentrator material is increased by application of vibration, compression and vacuum to de-air the material and to reduce voids therein. In another form, the iron powder comprises spherical-shaped particles and non-spherical shaped powders chosen in a ratio to maximize the density of material available.
    Type: Grant
    Filed: December 7, 1994
    Date of Patent: June 25, 1996
    Assignee: Learflux, Inc.
    Inventor: Thomas J. Learman
  • Patent number: 5527504
    Abstract: To a fine R-Fe-B alloy powder comprised predominantly of 10-30 atomic % of R (wherein R stands for at least one elements selected from rare earth elements including yttrium), 2-28 atomic % of B, and 65-82 atomic % of Fe in which up to 50 atomic % of Fe may be replaced by Co, at least one boric acid ester compound such as tributyl borate is added as a lubricant in a proportion of 0.01%-2% by weight and mixed uniformly before, during, or after fine grinding of the alloy powder. The resulting powder mixture is compacted by compression molding in a magnetic field and the green compacts are sintered and aged. Compression molding can be performed continuously without need of mold lubrication, and the resulting magnets have improved magnet properties with respect to residual flux density, maximum energy product, and intrinsic coercive force.
    Type: Grant
    Filed: May 9, 1995
    Date of Patent: June 18, 1996
    Assignees: Sumitomo Metal Industries, Ltd., Sumitomo Special Metals Co. Ltd.
    Inventors: Yoshihisa Kishimoto, Nobushige Hiraishi, Wataru Takahashi, Masakazu Ohkita, Naoyuki Ishigaki, Yutaka Matsuura
  • Patent number: 5527480
    Abstract: This invention relates to new ceramic piezoelectric compositions having superior electrical properties, processes for the preparation of the new piezoelectric composition and applications for the new compositions. Specifically, a solid solution composition of 85.5-87.5 molar percent lead zinc niobate, 9.5-9.7 molar percent lead titanate and 3-5 molar percent of a barium titanate dopant or strontium titanate dopant has exhibited desirable electrical properties. This specific composition is well suited for use in a 3-1 connectivity composite, which can be used as a hydrophone. These compositions may be prepared by oxide sintering techniques utilizing extremely high purity materials, or alternatively, by a sol gel process.
    Type: Grant
    Filed: June 11, 1987
    Date of Patent: June 18, 1996
    Assignee: Martin Marietta Corporation
    Inventors: Alex E. Bailey, Inam Jawed, Andrew P. Ritter, Audrey E. Sutherland, Stephen R. Winzer