Abstract: The invention relates to a method of forming honeycomb structures having cross-directional flow channels, such as cross-flow cellular bodies using a novel movable die which is adapted to move while extrudate is passing through the die, thus causing the cells or channels to alternate between straight-through flow, Z-flow, L-flow, U-flow or other similar cross-directional flow patterns. This novel die arrangement may be comprised of either a single movable die body, or a plurality of die parts or sections all of which are independently movable relative to the other.

Abstract: A heat sink composed of thermally conductive particles dispersed in a monolithic structure having a continuous microstructure; and the method of forming a heat sink by molding the heat sink from a thermoplastic or epoxy material which has been filled with thermally conductive particles, debinding the molded heat sink and densifying the debound heat sink into a monolithic structure.

Abstract: An article with a high temperature superalloy body having a directionally oriented microsuucture and a structural discontinuity, such as a crack, or surface erosion or wear portion, is repaired, to provide a repaired article, using a mixture of Ni base ahoy powders. One powder includes a careful balance of the temperature depressants Si and B. In the one powder, Si is included in the range of about 0.05-2.2 wt. % to provide about 0.02-1.3 wt. % Si in a repaired portion as bonded with the article. In that same powder, B is include in the range of about 0.2-1.2 wt. % to provide about 0.08-0.7 wt. % in that repaired portion. In the repair method, the repaired portion can be provided, when shorter brazing times are used, with improved mechanical properties by diffusing the brazed alloy and aging the repaired structure in the range of about 1600.degree.-1700.degree. F. for a time in the range of about 1-16 hours.

Abstract: An unsintered aluminum nitride body including:(a) 1 to 5 weight percent of a vitreous solid of boria, alumina, and calcia in the proportions of (1) boria between 3 and 25 weight percent, (2) alumina between 10 and 50 weight percent, and (3) calcia between 40 and 80 weight percent; and(b) aluminum nitride powder as the balance of the aluminum nitride body.The invention further relates to a method of forming the unsintered aluminum nitride body and then sintering it at a temperature between 1550 and 1650 degrees Centrigrade so as to form a dense, thermally conductive aluminum nitride body.

Abstract: A metal matrix composite component e.g. a brake disc, is provided with a protective coating to prevent displacement of the reinforcing filler in the matrix when the component is placed under load. Preferably the protective coating is metal, alloy, composite, refractory or ceramic applied e.g. by electro-plating.

Abstract: Subject boron carbide to a passivation treatment at a temperature within a range of 1350.degree. C. to less than 1800.degree. C. prior to infiltration with a molten metal such as aluminum. This method allows control of kinetics of metal infiltration and chemical reactions, size of reaction products and connectivity of B.sub.4 C grains and results in cermets having desired mechanical properties.

Abstract: This invention relates to a method for producing a self-supporting body comprising the steps of:(a) forming a permeable mass comprising at least one solid-phase oxidant selected from the group consisting of the halogens, sulphur and its compounds, metals, metal oxides other than the silicates, and metal nitrides other than those of boron and silicon;(b) orienting said permeable mass and a source of said parent metal relative to each other so that formation of said oxidation reaction product will occur into said permeable mass;(c) heating said source of parent metal to a temperature above the melting point of said parent metal but below the melting point of said oxidation reaction product to form a body of molten parent metal;(d) reacting said body of molten parent metal with said at least one solid-phase oxidant at said temperature to permit said oxidant at said temperature to permit said oxidation reaction product to form; and(e) maintaining at least a portion of said at least one oxidation reaction product

Abstract: To manufacture a reflector formed by a reflective metallic layer on a metallic matrix composite support, a metallic layer having a reflective surface whose shape is at least approximately identical to the required geometrical shape is disposed on a mold surface having a geometrical shape complementary to the required geometrical shape of the reflector. Fibers to constitute the composite support are draped on the metallic layer. They are metallized by the metallic or intermetallic material to form the metallic matrix. This layer and the metallized fibers are subjected to temperature and pressure conditions adapted to press the reflective surface strongly against the mold surface and to cause diffusion welding of the layer with the metallized fibers and of the metallized fibers with themselves so as to integrate the layer to the composite support during consolidation of the latter.

Abstract: A TiCN-based cermet cutting insert superior in toughness with improved wear resistance includes a binding phase and at least two hard dispersion phases. One of the hard dispersion phases includes one of a duplex and triplex structure having a core structure containing at least one of titanium carbonitride and a carbonitride solid solution of Ti and one of a V, Cr, Ti, Nb, Zr, W and Mo (hereinafter referred to as a (Ti,M)CN. The other hard dispersion phase includes a single structure wherein the core structure is composed of at least one of (Ti,M)CN or (Ti,M)CN and TiCN.

Abstract: A metal alloy article is proved with an improved fretting wear resistant coating combination for use in the temperature range of about 650.degree.-1100.degree. F. on an article contact surface shaped to cooperate with an abutting member. An example is a gas turbine engine blade base carried by an abutting support slot. The coating combination includes an inner portion of a Ni base alloy having a room temperature annealed yield strength of greater than about 30 ksi to less than about 57 ksi and densely deposited from a powder, for example by the high velocity oxygen--fuel thermal spray process rather than by other processes such as air plasma spray. Cured on the inner portion is an outer portion of graphite particles mixed in an inorganic binder capable of stable use in the range of about 650.degree.-1100.degree. F., for example silicates or phosphates, such as of aluminum.

Abstract: This invention discloses processes and articles for the manufacturing of composite plated articles comprising finely divided particulate matter dispersed within metallic matrices and having light emitting properties, such articles being useful in the metallization of articles and their reuse through subsequent rejuvenation, without damaging the base metal of said articles.

Abstract: A process of forming a sintered article for powder metal comprising blending carbon and ferro alloys and lubricant with compressible elemental iron powder, pressing said blended mixture to form sintering said article, and then high temperature sintering said article in a reducing atmosphere to produce a sintered article having a high density from a single compression.

Abstract: In order to form internal conductors of a multilayer ceramic electronic component such as a multilayer ceramic capacitor, copper paste containing copper powder having a mean particle size of 0.3 to 2 .mu.m in a particle size range of 0.1 to 4 .mu.m and ceramic powder having a main component which is common to that of a ceramic material contained in the multilayer ceramic electronic component and being in a particle size range of 0.5 to 8 .mu.m, as well as an organic vehicle and a solvent with the contents of the copper powder and the ceramic powder and the total content of the organic vehicle and the solvent in ranges of 40 to 70 percent by weight, 1 to 15 percent by weight and 25 to 60 percent by weight respectively is applied onto ceramic green sheets. The ceramic green sheets provided with such copper paste films are stacked and fired so that occurrence of voids in the laminate and deformation of the laminate are suppressed in the as-obtained multilayer ceramic electronic component.

Abstract: Apparatus for use in cooling an integrated circuit structure. The apparatus includes a heat sink having a first portion configured for thermal engagement with an integrated circuit device and a second portion configured for the dissipation of heat into an ambient fluid, such as air. The heat sink is made from a powdered metal which, in one preferred embodiment, includes copper. The heat sink may be formed from the plurality of discrete layers, each layer having a button projecting from one surface, and a depression formed in an opposing surface. The depression is configured to receive a projecting button portion from another layer. In an alternative embodiment the heat sink includes a plurality of plugs projecting from the generally flat surface.

Abstract: A coated palladium fine powder comprising palladium particles of a mean particle size in the range of 0.1 to 1.0 .mu.m which are coated with nickel or alloy of nickel with other metal are employable, optionally in combination with palladium particles or palladium-coated ceramic particles of a mean particle size in the range of 0.1 to 1.0 .mu.m, for preparing an electroconductive paste.

Abstract: A process of coining sintered articles of powder metal comprising: blending carbon, ferro manganese, and lubricant with compressible elemental iron powder, pressing the blended mixture to form the articles, high temperature sintering of the articles in a reducing atmosphere and then coining the sintered articles to final shape so as to narrow the tolerance variability of coined articles and substantially eliminate secondary operations.

Abstract: A method of manufacturing a lead-provided porous metal sheet comprises the steps of: forming a porous metal material having a metal layer on a surface of a framework of a porous base material comprising a foamed sheet and the like, by plating the porous base material and/or applying fine metal powders thereto; passing the porous metal material through a pair of rolls having a plurality of projections formed thereon to compress the porous metal material against the projections and reduce or eliminate pores so as to form one or more recesses extending; and forming solid metal portions by applying fine metal powders to the entire recesses.

Abstract: A titanium alloy matrix fiber reinforced composite made from titanium alloy sheet processed to have ductility up to about 35%. Of particular usefulness is the composite having a Ti.sub.3 Al titanium aluminide having this level of ductility. The composites have good resistance to thermal cyclic fatigue.

Abstract: Method for continuously extruding powdered, comminuted, or particulated feed material with a Conform extrusion machine or the like in cooperation with a forming wheel rotatably disposed within a portion of the Conform wheel to compress the feed material into a compacted feedstock. Compressing of the feed material into a compacted feedstock enables uniform and reliable conveyance of the feed material into the extrusion machine without unnecessarily subjecting the compressed feedstock to air or oxygen. An auxiliary shoe member conforming to the outer periphery of the forming wheel and to the Conform shoe enables separation of the compacted feedstock from the forming wheel. The auxiliary shoe directs the compacted feedstock into a passageway formed by the Conform machine extrusion wheel and extrusion shoe.

Abstract: Metal alloy foils are made directly from metal alloy powders by hot pressing. These metal alloy foils are characterized by having a thickness of 0.017 in. or less, and by the fact that they are fine-grained and substantially free of oxygen, nitrogen and deformation-induced defects. In particular, Ti-base alloy foils having an average thickness of about 0.011 in. have been formed directly from Ti-base alloy powders. These as-pressed Ti-base alloy foils are also ductile and adapted for subsequent forming operations, including cold rolling. The deformation which may be imparted in a single pass through cold-rolling to these Ti-base alloy foils is at least about 5%, with up to about 45% deformation imparted to one of these alloys in multiple passes without stress relief annealing. Total reductions in thickness of up to 90% are achieved by a combination of cold-rolling and stress relief annealing.