Abstract: The present invention provides a hydrogen absorbing alloy compact for use as the negative electrode of an alkaline rechargeable battery which is made without the aid of a current-collecting support, contains a binder dispersed in the interstices formed by mutual contact of hydrogen absorbing alloy particles and on the alloy surfaces, and has a bulk density of 3.5 to 6.0 g/cm3. The present invention also provides a compact electrode which is made by forming a porous hydrogen absorbing alloy compact containing neither current-collecting support nor binder, impregnating the compact with an aqueous solution (or solvent solution) of a binder, and then drying the compact to remove the water (or solvent) alone, so that the strength of the compact is increased and good electrical contact between alloy particles is established.

Abstract: A highly functional film-coated powder which is produced without using the method based on the hydrolysis of a metal alkoxide and without using a metal alkoxide, which is an expensive compound, or a highly flammable organic solvent and which therefore can be obtained at a low overall product cost without necessitating explosion-proof facilities in the production equipment and while attaining easy temperature and humidity regulation; and a process for producing the same. The film-coated powder comprises a base particle having films on the surface thereof, wherein at least one of the films is formed by reaction of a metal salt in an aqueous solvent having a constant pH. By the technique, the surface of base particle can be evenly coated with a solid phase film while inhibiting particle aggregation without precipitating an independent solid phase in the liquid phase.

Abstract: A wedding ring is manufactured by a process comprising the production of a metal powder by the atomizing of a stream of molten precious metal, for example a gold alloy, the compaction of the metal powder into a hollow cylindrical body, the sintering of the compacted body, optionally the compression of the sintered body into a more toroidal shape, optionally the sintering of the toroidal body and the subjecting of the body to ring-rolling and annealing. The powder that is compacted any also comprise a minor proportion of precious-metal powder obtained by means other than atomization. The process may also be applied to the manufacture of artifacts other than rings by compacting the powder into an appropriate shape and modifying the compressing step, if employed, as appropriate to the intended product; in such embodiments, the ring-rolling step may be replaced by an appropriate step of further modifying the shape and/or dimension of the body. or may be omitted entirely.

Abstract: Insertion of light elements such as H,C, or N in the R2Fe17 (R=rare earth metal) series has been found to modify the magnetic properties of these compounds, which thus become prospective candidates for high performance permanent magnets. The most spectacular changes are increases of the Curie temperature, Tc, of the magnetization, Ms, and of coercivity, Hc, upon interstitial insertion. A preliminary product having a component R—Fe—C,N phase is produced by a chemical route. Rare earth metal and iron amides are synthesized followed by pyrolysis and sintering in an inert or reduced atmosphere, as a result of which, the R—Fe—C,N phases are formed. Fabrication of sintered rare earth iron nitride and carbonitride bulk magnet is impossible via conventional process due to the limitation of nitridation method.

Abstract: A W—Cu—Ni alloy having thermophysical properties suitable for use in electrical contacts and electrodes is described. The alloy is formed by direct sintering of a powder blend comprising a tungsten-copper composite powder and a nickel powder. The tungsten-copper composite powder component of the blend comprises individual dual phase particles having a copper phase and a tungsten phase wherein the tungsten phase substantially encapsulates the copper phase. The method for direct sintering the W—Cu—Ni alloy substantially eliminates the formation of brittle intermetallics and slumping during sintering.

Abstract: This invention concerns a lubricant for warm compaction of iron-based metallurgical powder compositions. 50 to 100% by weight of the lubricant is a polyester, aromatic or partly aromatic, which has a number-average molecular weight Mn of 5,000-50,000. This invention further concerns a metal powder composition containing the lubricant, a method for making sintered products by using the lubricant, and use of the same in warm compaction of metallurgical powders.

Abstract: A superhard filler hardmetal having a superhard material filler, binder metal or matrix and in some instances at least a first hard component is disclosed. The superhard filler hardmetal has a porosity rating of substantially A06, B00, C00 or better and may be essentially pore free, i.e., A00, B00, C00. The superhard filler hardmetal is formed by mechanically mixing a superhard material, in some instances at least a first hard component and a binder metal or matrix precursor, shaping the mixture into a green body and consolidating the green body at a preselected temperature, superatmospheric pressure and time at temperature and time at superatmospheric pressure sufficient to form the superhard filler hardmetal. The consolidation preferably occurs without the formation of a liquid in the body and at least a portion of the time at superatmospheric pressure is at the preselected temperature. Diamond filler and boron nitride filler are examples of superhard materials usable as filler.

Abstract: A method for forming a composite vapor-deposited film one side of which suitable for vapor-deposition on a phosphor surface of a CRT, such as a color television picture tube, has high light reflectivity, and the other side of which has a property to absorb radiant heat, and a composite vapor-deposition material suitable for vacuum deposition are disclosed. The composite vapor-deposition material has a high vapor-pressure metal envelope and a low vapor-pressure metal in the core region of the envelope. Low vapor-pressure metal powder should preferably be dispersed and held by high vapor-pressure metal powder in the core region. Vacuum deposition using this composite vapor-deposition material yields a composite deposited film having a composition comprising almost 100% of the high vapor-pressure metal formed in the initial stage of evaporation, and a composition comprising 100% of the low vapor-pressure metal formed in the final stage of evaporation.

Abstract: A hard member for use as a wear part or a hard insert for a point attack style of tool or a rotary style of tool. The hard member having a composition of between about 5 volume percent and about 40 volume percent binder alloy, and between about 60 volume percent and about 95 volume percent tungsten carbide. The tungsten carbide has an average grain size between about 1 micrometer and about 30 micrometers. The binder alloy comprises an alloy of nickel and chromium wherein the nickel ranges between about 70 weight percent and less than 93 weight percent and the chromium ranges between greater than 7 weight percent and about 30 weight percent.

Abstract: The method for preparation of sintered permanent magnets according to the present invention comprises the steps of: mixing fully fine powder of a crystalline mother alloy for permanent magnet containing a rare-earth element, Fe and B as the essential components with fine powder of zinc oxide, compaction molding the resulted mixture in the presence of a magnetic field, sintering the compacted mixture in vacuum to cause generation of oxygen and metallic zinc by thermal decomposition of the zinc oxide; segregation of a part of metallic component in the mother alloy at the boundary and inside of the mother alloy crystal; formation of amorphous metallic oxide by forced oxidation of the segregated metal with the generated oxygen; crystallization of the amorphous metallic oxide; formation of an epitaxial junction between the crystallized metallic oxide and the mother alloy crystal; and evaporation of the metallic zinc into the vacuum, and quenching the sintered compact.

Abstract: A paste to be fired at a temperature lower than melting point of silver for forming a circuit board comprising surface-modified silver powder consisting essentially of metal silver particles having an average particle size of not more than 10 &mgr;m and at least one member selected from the group consisting of oxides and double oxides containing at least one metal element selected from the group consisting of those belonging to Groups 2 to 14 of Periodic Table whose atomic number falls within the range of from 12 to 82, which is adhered to the surface of the individual metal silver particles. The surface-modified silver powder has an elevated sintering-initiation temperature and a reduced rate of heat shrinkage due to sintering. Therefore, the surface-modified silver powder is particularly suitable for use in making a circuit board, in particular an LTCC circuit board.

Abstract: The present invention concerns a process of preparing high density, warm compacted bodies of a stainless steel powder comprising the steps of providing a mixture of a low carbon, low oxygen stainless steel powder including 10-30% by weight of Cr, optional alloying elements and graphite and inevitable impurities, mixing the powder with a high temperature lubricant and compacting the mixture at an elevated temperature. The invention also concerns a composition of the stainless steel powder, optional additional alloying elements and a high temperature lubricant.

Abstract: The present invention relates to a process for manufacturing atomized metal powder in an atomization plant comprising a casting box, a reactor vessel, a powder container and sedimentation equipment. The production process takes place with controlled thermal balance. The invention also relates to an atomization plant, atomized metal powder and the use of the metal powder as coolant in the manufacture of steel.

Abstract: The present invention is a new method for forming a high density hard facing rod. The rod is particularly suitable for hardfacing downhole tools including both fixed cutter and rolling cutter drill bits, bias pads for downhole rotary steerable systems, and stabilizers, and for other types of tools requiring strong and wear resistant hardfacings. The method includes the steps of: preparing a powder mix comprising carbide and metal powders, a fugitive binder, and other additives to render a moldable rheology; forming the powder mix into a powder core encased with a metal sheath to form a core-sheath assembly; and isostatically compacting the core-sheath assembly to densify the core to at least 65% of theoretical density and mechanically attach the sheath. The core fugitive binder along with residual volatile constituents may be thermally removed with or without vacuum, reducing, or inert environment prior to weld application of the composite rod.

Abstract: The method of producing an R—Fe—B magnet of the present invention is characterized in that R—Fe—B alloy fine powder is molded in a magnetic field and sintered using a lubricant for molding magnets containing specific components, individually or as a mixture, of specific amounts of methyl caproate and/or methyl caprylate, which provide high crystal orientation, and lubricant comprising depolymerized polymer for improving molded article strength, or a lubricant for molding magnets wherein Ti coupling agent that improves crystal orientation is added to this lubricant for molding magnets. Each particle of the fine powder has a high degree of crystal orientation in the direction of the magnetic field, and molded article strength is markedly improved, leading to improved mass-productivity and yield. Moreover, the above-mentioned lubricants do not react with this magnet powder during sintering and are emitted as a gas.

Abstract: The present invention provides a diamond sintered compact tool. Which is excellent in economy as well as cutting edge strength. A diamond sintered compact cutting tool comprising a diamond sintered compact sintered at an ultra-high pressure and high temperature and a WC—Co cemented carbide substrate directly bonded to the diamond sintered compact during a step of sintering and brazed to a tool base through the WC—Co cemented carbide substrate, in which a ratio of the thickness of the WC—Co cemented carbide substrate to the thickness of the diamond sintered compact layer satisfies the relation of: 0.8≦WC—Co cemented carbide substrate/diamond sintered compact layer≦3.0 and the diamond sintered compact layer has a thickness of 0.05 mm to 0.5 mm, preferably 0.05 mm to 0.45 mm, more preferably 0.12 mm to 0.36 mm.

Abstract: An iron-graphite composite powder having a microstructure comprising carbon clusters embedded in a ferrous matrix is disclosed. Also disclosed is a process for preparing the iron-graphite composite powder, a process for preparing sintered articles from this composite powder and the sintered articles prepared thereby.

Abstract: A process for producing a high-density iron-based green compact is provided that can form a green compact with a high density. Also provided is a process for producing a sintered compact from the green compact. A specified combination lubricant is applied to the surface of a die for compacting by electrical charging, wherein the combination lubricant includes a first lubricant having a melting point that is higher than a preset compacting temperature, and a second lubricant having a melting point that is lower than a compacting temperature. A heated iron-based powder mixture is filled into the die, followed by compacting, whereby a green compact is formed. The green compact can be sintered to provide a sintered compact.

Abstract: The present invention relates to a method an apparatus for fabricating a component by a direct laser process. One form of the present invention contemplates a gas turbine engine blade having an abrasive tip formed directly thereon.

Abstract: A method of consolidating metal powder to form an object that includes pressing the powder into a preform, and preheating the preform to elevated temperature; providing flowable pressure transmitting particles and transmitting microwaves into the particles to heat same, and providing a bed of the flowable and heated pressure transmitting particles; positioning the preform in such relation to the bed that the particles substantially encompass the perform; and pressurizing the bed to compress the particles and cause pressure transmission to the preform, thereby to consolidate the preform into a desired object shape, the powder of step a) consisting essentially of at least two of the following: W, Ni, Fe, Co, manganese and titanium, and preferably at least three of same.