Abstract: A system and method for producing material characteristics are described. A magnetic treatment chamber (14) with a high magnetic field treats workpieces; and a conveyor or transporter (26) continuously moves the workpieces (22) through the high magnetic field in the magnetic chamber. A frictional or mechanical engagement system (40a, 40b) extracts the workpieces through and out of the high magnetic field.

Abstract: A system and method for producing material characteristics are described. A magnetic treatment chamber with a high magnetic field treats workpieces; and a conveyor or transporter continuously moves the workpieces through the high magnetic field in the magnetic chamber. A frictional or mechanical engagement system extracts the workpieces through and out of the high magnetic field.

Abstract: A method for forming a transmission synchronizer friction surface includes the steps of forming a woven substrate fabric, oxidizing the substrate fabric, carbonizing the substrate fabric, densifying the carbonized substrate fabric, burnishing the densified carbonized substrate fabric, applying a thermoset adhesive to the burnished substrate fabric, and heating and pressing the piece of fabric against a conical surface of a synchronizer element. To form the fabric, yarn is formed of chopped substrate fibers, and the yarn is woven to form the woven substrate fabric. Densification is increased by extending a period of time of chemical vapor deposition to achieve a weight in an unburnished condition of at least 16 ounces per square yard for a thickness range of approximately 40 to 50 mils. Both sides of the substrate fabric are burnished. The material is pressed against the conical surface under a high pressure of at least 2000 psi to achieve the desired bonding of the substrate fabric to the conical surface.

Abstract: Grooved friction materials (12 or 14) each include a single-layer pyrolytic-carbon fabric material formed of woven or nonwoven yarn strands (20 and 22). The pyrolytic-carbon fabric material (12 or 14) has a top surface (16) and a bottom surface (18), the top surface (16) having molded grooves (28) therein. The yarn strands (20 and 22) at the grooves (28) exhibit superior integrity because they are generally whole, undamaged yarn strands. Wet friction members for friction engaging mechanisms include a support member (54, 56, or 58) and at least one piece (48, 50, or 52) of grooved friction material (14) adhered to a surface of the support member. The bulk grooved friction material (14), from which the individual pieces (48, 50, or 52) are cut, is a single-layer pyrolytic-carbon fabric material formed of yarn strands (20 and 22) and has a top surface (16) with grooves (28) therein. The yarn strands (20 and 22) at the grooves (28) are generally whole and undamaged.

Abstract: A silicon-nitride beta-phase material including a non-densified structure of beta silicon nitride crystals having appreciable strength without any significant amount of liquid forming agents is made by comminuting a slurry including a mixture of silicon powder and water to form non-oxidized surfaces on the silicon powder and to allow chemical reaction between the silicon and the water, reducing the water content of the reacted slurry to a degree sufficient to form a resultant dry mass, nitriding the dry mass by exposure to a nitriding gas including at least nitrogen to form a mass of alpha-phase silicon nitride, and converting the resultant silicon nitride mass at a conversion temperature of from about 1450.degree. C. to about 2100.degree. C. to convert the silicon nitride from an alpha-phase material to a non-densified beta phase silicon nitride material.

Abstract: Method of manufacturing a helical gear allowing strategic placement of a hardenable wear-resistant and high strength layer at predetermined locations on the gear. The method includes the steps of forming a gear core preform having the general shape of the helical gear and positioning the gear core preform within an elastomeric mold having the specific shape of the helical gear. The method also includes the steps of filling the mold at the predetermined locations with the hardenable metallurgical material and densifying the gear core preform and the metallurgical material. Lastly, the method also includes the step of heat treating the densified gear core preform and metallurgical material, to obtain the helical gear having a wear-resistant layer at the predetermined locations. A helical gear formed according to method is also provided.

Abstract: A vehicle suspension member such as leaf spring (50) is provided having at least one plate (3) having an irradiation exposed region (R) therein that is generally parallel to a longitudinal axis ("L/A") extending between opposite ends of plate (3) and operative to provide a metallurgical discontinuity extending therealong between opposite ends thereof that is effective to divert crack propagation in a direction generally parallel to axis ("L/A").

Abstract: A vehicle suspension member such as leaf spring (50) is provided having at least one plate (3) having an irradiation exposed region (R) therein that is generally parallel to a longitudinal axis ("L/A") extending between opposite ends of plate (3) and operative to provide a metallurgical discontinuity extending therealong between opposite ends thereof that is effective to divert crack propagation in a direction generally parallel to axis ("L/A").

Abstract: A process for preparing an alpha-phase silicon nitride material and thereafter sintering to a densified beta-phase silicon nitride material is disclosed which includes comminuting a slurry including a mixture of silicon powder, water, and at least one densification aid to aid in later densifying of the silicon nitride material, the comminuting being performed to form fresh, non-oxidized surfaces on the silicon powder and to allow substantial chemical reaction between the silicon and the water, reducing the water content of the reacted slurry to a degree sufficient to form a resultant dry mass, nitriding the dry mass by exposure to a sufficient amount of a nitriding gas including at least nitrogen at a sufficient temperature for a sufficient length of time to form a mass of substantially alpha-phase silicon nitride, and sintering the resultant silicon nitride mass at a sintering temperature of from about 1450.degree. C. to about 2100.degree. C.

Abstract: A process for making silicon powder or articles of manufacture such as an internal combustion engine valve by comminuting a homogeneous water-base slurry of silicon powder and at least one nitriding agent and permitting the slurry to chemically react for a time sufficient to enable the chemical reaction to substantially reach completion, then reducing the water content sufficiently to form a powder or an article and thence nitriding the article or powder by continuously varying the temperature over the range of 1000.degree. C. to 1450.degree. C. using a nitriding gas comprising nitrogen, hydrogen and helium and maintaining a constant nitriding gas composition throughout the nitriding cycle.

Abstract: A process for preparing a nitridable silicon-containing material, which process includes (a) comminuting a slurry of silicon powder, water, at least one densification aid, including Al.sub.2 O.sub.3, and another densification aid, the comminuting performed to cause substantial chemical reaction between the silicon and the water; and (b) reducing the water content of the reacted slurry to form a dry mass. In another embodiment, at least one nitriding agent may be added to aid any nitridation which may be performed.

Abstract: A process for preparing an alpha-phase silicon nitride material and thereafter converting to non-densified beta-phase silicon nitride material includes comminuting a slurry including a mixture of silicon powder and water to form non-oxidized surfaces on the silicon powder and to allow chemical reaction between the silicon and water, reducing the water content of the reacted slurry to a degree sufficient to form a resultant dry mass, nitriding the dry mass by exposure to a nitriding gas including at least nitrogen to form a mass of alpha-phase silicon nitride, and converting the resultant silicon nitride mass at a conversion temperature of from about 1450.degree. C. to about 2100.degree. C. to convert the silicon nitride from an alpha-phase material to a non-densified beta phase silicon nitride material.

Abstract: A body of sintered silicon nitride contains new non-glassy phases which produce significant X-ray diffraction peaks at 2-theta diffraction angles corresponding to d-spacings of about 2.86 Angstroms and 3.59 Angstroms and process for making same, which process includes (a) comminuting a slurry of a silicon-containing powder, water, about 0.1 to 5 volume percent of Fe.sub.2 O.sub.3, about 0.1 to 5 volume percent Al.sub.2 O.sub.3, and about 0.5 to 10 volume percent CeO.sub.2, wherein all volume percents are based on the volume of the resultant silicon nitride, the composition of the slurry being such that about a 4 to 12 volume percent liquid phase is achieved during sintering; (b) reducing the water content of the reacted slurry to form a dry mass; (c) nitriding the dry mass by exposure to a nitriding gas at an elevated temperature to form silicon nitride; and (d) sintering the silicon nitride at about 1450.degree.-2100.degree. C.

Abstract: A process for preparing a nitridable silicon-containing material, which process includes (a) comminuting a slurry of silicon powder, water, at least one densification aid, including Al.sub.2 O.sub.3, and another densification aid, the comminuting performed to cause substantial chemical reaction between the silicon and the water; and (b) reducing the water content of the reacted slurry to form a dry mass. In another embodiment, at least one nitriding agent may be added to aid any nitridation which may be performed.

Abstract: A bearing isolator having an outer metal mounting ring adapted for attachment to a mounting structure, an inner metal mounting ring, adapted for registration on the outer race of a bearing for journalling a shaft, and an energy-absorbing ring of composite material radially intermediate the metal rings. A first plurality of relatively short spokes extends between the composite ring and the outer metal ring; and, a second plurality of relatively short spokes extends between the composite ring and the inner metal ring and is circumferentially staggered from the first plurality of spokes. Resilient wave-like radial deflection of the composite ring occurs between the spokes to absorb vibration and acoustic energy.

Abstract: A process for making silicon nitride articles of manufacture such as an internal combustion engine valve (2) by providing a homogeneous water-base slurry of silicon nitride powder and at least one nitriding agent and permitting the slurry to age for a time effective to enable a chemical reaction to occur and then reducing the water content sufficiently to form the article and thence forming and nitriding the article using a compound nitriding cycle.