Patents by Inventor Leslie John Farthing
Leslie John Farthing has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Patent number: 10926334Abstract: A powder metal composition for high wear and temperature applications is made by atomizing a melted iron based alloy including 3.0 to 7.0 wt. % carbon; 10.0 to 25.0 wt. % chromium; 1.0 to 5.0 wt. % tungsten; 3.5 to 7.0 wt. % vanadium; 1.0 to 5.0 wt. % molybdenum; not greater than 0.5 wt. % oxygen; and at least 40.0 wt. % iron. The high carbon content reduces the solubility of oxygen in the melt and thus lowers the oxygen content to a level below which would cause the carbide-forming elements to oxidize during atomization. The powder metal composition includes metal carbides in an amount of at least 15 vol. %. The microhardness of the powder metal composition increases with increasing amounts of carbon and is typically about 800 to 1,500 Hv50.Type: GrantFiled: January 27, 2020Date of Patent: February 23, 2021Assignee: Tenneco Inc.Inventors: Philippe Beaulieu, Denis B. Christopherson, Jr., Leslie John Farthing, Todd Schoenwetter, Gilles L'Espérance
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Publication number: 20200156156Abstract: A powder metal composition for high wear and temperature applications is made by atomizing a melted iron based alloy including 3.0 to 7.0 wt. % carbon; 10.0 to 25.0 wt. % chromium; 1.0 to 5.0 wt. % tungsten; 3.5 to 7.0 wt. % vanadium; 1.0 to 5.0 wt. % molybdenum; not greater than 0.5 wt. % oxygen; and at least 40.0 wt. % iron. The high carbon content reduces the solubility of oxygen in the melt and thus lowers the oxygen content to a level below which would cause the carbide-forming elements to oxidize during atomization. The powder metal composition includes metal carbides in an amount of at least 15 vol. %. The microhardness of the powder metal composition increases with increasing amounts of carbon and is typically about 800 to 1,500 Hv50.Type: ApplicationFiled: January 27, 2020Publication date: May 21, 2020Inventors: Philippe BEAULIEU, Denis B. Christopherson, JR., Leslie John Farthing, Todd Schoenwetter, Gilles L'Espérance
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Patent number: 10563695Abstract: A bushing formed of different alloys selected to accommodate different operating conditions is provided. For example, the bushing could include an iron-based alloy in a portion of the bushing exposed to lower temperatures, and a cobalt-based alloy in a portion of the bushing exposed to higher temperatures. The first and second alloys could be axially or radially aligned. The iron based alloy includes 10 to 30 wt % Cr, 0 to 21 wt % Ni, 0 to 10 wt % Mo, 0 to 5 wt % W, 0 to 3 wt % C, 0 to 4 wt % V, 0 to 20 wt % Co, and a balance of Fe; and the cobalt based alloy includes 10 to 30 wt % Cr, 5 to 21 wt % Ni, 0 to 10 wt % Mo, 0 to 10 wt % W, 0 to 3 wt % V, 0.5 to 3 wt % C, and a balance of Co.Type: GrantFiled: April 12, 2018Date of Patent: February 18, 2020Assignee: Tenneco Inc.Inventors: Leslie John Farthing, Jens Wellmann
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Patent number: 10543535Abstract: A powder metal composition for high wear and temperature applications is made by atomizing a melted iron based alloy including 3.0 to 7.0 wt. % carbon; 10.0 to 25.0 wt. % chromium; 1.0 to 5.0 wt. % tungsten; 3.5 to 7.0 wt. % vanadium; 1.0 to 5.0 wt. % molybdenum; not greater than 0.5 wt. % oxygen; and at least 40.0 wt. % iron. The high carbon content reduces the solubility of oxygen in the melt and thus lowers the oxygen content to a level below which would cause the carbide-forming elements to oxidize during atomization. The powder metal composition includes metal carbides in an amount of at least 15 vol. %. The microhardness of the powder metal composition increases with increasing amounts of carbon and is typically about 800 to 1,500 Hv50.Type: GrantFiled: September 13, 2017Date of Patent: January 28, 2020Assignees: Tenneco Inc., Corporation de L'Ecole Polytechnique De MontrealInventors: Philippe Beaulieu, Denis B. Christopherson, Jr., Leslie John Farthing, Todd Schoenwetter, Gilles L'Espérance
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Publication number: 20190210105Abstract: A powder metal material comprises pre-alloyed iron-based powder including carbon present in an amount of 0.25 to 1.50% by weight of the pre-alloyed iron-based powder. Graphite is admixed in an amount of 0.25 to 1.50% by weight of the powder metal material. The admixed graphite includes particles finer than 200 mesh in an amount greater than 90.0% by weight of the admixed graphite. Molybdenum disulfide is admixed in an amount of 0.1 to 4.0% by weight of the powder metal material, copper is admixed in an amount of 1.0 to 5.0% by weight of the powder metal material, and the material is free of phosphorous. The powder metal material is then compacted and sintered at a temperature of 1030 to 1150° C. At least 50% of the admixed graphite of the starting powder metal material remains as free graphite after sintering.Type: ApplicationFiled: March 18, 2019Publication date: July 11, 2019Inventors: Denis Boyd Christopherson, JR., LESLIE JOHN FARTHING, JEREBY RAYMOND KOTH
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Patent number: 10232438Abstract: A powder metal material comprises pre-alloyed iron-based powder including carbon present in an amount of 0.25 to 1.50% by weight of the pre-alloyed iron-based powder. Graphite is admixed in an amount of 0.25 to 1.50% by weight of the powder metal material. The admixed graphite includes particles finer than 200 mesh in an amount greater than 90.0% by weight of the admixed graphite. Molybdenum disulfide is admixed in an amount of 0.1 to 4.0% by weight of the powder metal material, copper is admixed in an amount of 1.0 to 5.0% by weight of the powder metal material, and the material is free of phosphorous. The powder metal material is then compacted and sintered at a temperature of 1030 to 1150° C. At least 50% of the admixed graphite of the starting powder metal material remains as free graphite after sintering.Type: GrantFiled: June 18, 2014Date of Patent: March 19, 2019Assignee: Tenneco IncInventors: Denis Boyd Christopherson, Jr., Leslie John Farthing, Jeremy Raymond Koth
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Patent number: 10124411Abstract: A powder metal composition for high wear and temperature applications is made by atomizing a melted iron based alloy including 3.0 to 7.0 wt. % carbon; 10.0 to 25.0 wt. % chromium; 1.0 to 5.0 wt. % tungsten; 3.5 to 7.0 wt. % vanadium; 1.0 to 5.0 wt. % molybdenum; not greater than 0.5 wt. % oxygen; and at least 40.0 wt. % iron. The high carbon content reduces the solubility of oxygen in the melt and thus lowers the oxygen content to a level below which would cause the carbide-forming elements to oxidize during atomization. The powder metal composition includes metal carbides in an amount of at least 15 vol. %. The microhardness of the powder metal composition increases with increasing amounts of carbon and is typically about 800 to 1,500 Hv50.Type: GrantFiled: September 16, 2015Date of Patent: November 13, 2018Assignees: Federal-Mogul LLC, La Corporation de l'Ecole Polytechnique de MontrealInventors: Philippe Beaulieu, Denis B. Christopherson, Jr., Leslie John Farthing, Todd Schoenwetter, Gilles L'Esperance
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Publication number: 20180298947Abstract: A bushing formed of different alloys selected to accommodate different operating conditions is provided. For example, the bushing could include an iron-based alloy in a portion of the bushing exposed to lower temperatures, and a cobalt-based alloy in a portion of the bushing exposed to higher temperatures. The first and second alloys could be axially or radially aligned. The iron based alloy includes 10 to 30 wt % Cr, 0 to 21 wt % Ni, 0 to 10 wt % Mo, 0 to 5 wt % W, 0 to 3 wt % C, 0 to 4 wt % V, 0 to 20 wt % Co, and a balance of Fe; and the cobalt based alloy includes 10 to 30 wt % Cr, 5 to 21 wt % Ni, 0 to 10 wt % Mo, 0 to 10 wt % W, 0 to 3 wt % V, 0.5 to 3 wt % C, and a balance of Co.Type: ApplicationFiled: April 12, 2018Publication date: October 18, 2018Inventors: Leslie John FARTHING, Jens WELLMANN
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Publication number: 20180169751Abstract: A thermometric powder metal material for testing to replicate an actual powder material during use of the actual powder metal material in an internal combustion engine is provided. The thermometric powder metal material includes pores and has a decrease in hardness as a function of temperature according to the following equation: D Hardness/D Temperature=>0.5 HV/° C. The properties of the actual powder metal material, when the actual powder metal is used in an internal combustion engine, can be estimated using the thermometric powder metal material by first adjusting the thermal conductivity of the thermometric powder metal material or controlling the porosity of the thermometric powder metal material to replicate the actual powder metal material, and then subjecting thermometric powder metal material to an engine test. For example, the thermal conductivity can be adjusted by infiltrating the thermometric powder metal material with copper.Type: ApplicationFiled: December 15, 2017Publication date: June 21, 2018Inventors: Philippe BEAULIEU, Denis B. CHRISTOPHERSON, JR., Leslie John FARTHING, Gilles L'ESPERANCE, Olivier SIOUI-LATULIPPE
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Publication number: 20180001387Abstract: A powder metal composition for high wear and temperature applications is made by atomizing a melted iron based alloy including 3.0 to 7.0 wt. % carbon; 10.0 to 25.0 wt. % chromium; 1.0 to 5.0 wt. % tungsten; 3.5 to 7.0 wt. % vanadium; 1.0 to 5.0 wt. % molybdenum; not greater than 0.5 wt. % oxygen; and at least 40.0 wt. % iron. The high carbon content reduces the solubility of oxygen in the melt and thus lowers the oxygen content to a level below which would cause the carbide-forming elements to oxidize during atomization. The powder metal composition includes metal carbides in an amount of at least 15 vol. %. The microhardness of the powder metal composition increases with increasing amounts of carbon and is typically about 800 to 1,500 Hv50.Type: ApplicationFiled: September 13, 2017Publication date: January 4, 2018Inventors: Philippe BEAULIEU, Denis B. CHRISTOPHERSON, JR., Leslie John FARTHING, Todd SCHOENWETTER, Gilles L'ESPERANCE
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Publication number: 20170129016Abstract: A powder metal steel alloy composition for high wear and temperature applications is made by water atomizing a molten steel alloy composition containing C in an amount of at least 3.0 wt %; at least one carbide-forming alloy element selected from the group consisting of: Cr, V, Mo or W; an O content less than about 0.5 wt %, and the balance comprising essentially Fe apart from incidental impurities. The high carbon content reduces the solubility of oxygen in the melt and thus lowers the oxygen content to a level below which would cause the carbide-forming element(s) to oxidize during water atomization. The alloy elements are thus not tied up as oxides and are available to rapidly and readily form carbides in a subsequent sintering stage. The carbon, present in excess, is also available for diffusing into one or more other admixed powders that may be added to the prealloyed powder during sintering to control microstructure and properties of the final part.Type: ApplicationFiled: January 13, 2017Publication date: May 11, 2017Inventors: DENIS B. CHRISTOPHERSON, JR., LESLIE JOHN FARTHING, TODD SCHOENWETTER, GILLES L'ESPERANCE, PHILIPPE BEAULIEU
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Patent number: 9624568Abstract: A thermal spray powder is provided for use in a thermal spray technique, such as flame spraying, plasma spraying, cold spraying, and high velocity oxygen fuel spraying (HVOF). The thermal spray powder is formed by water or gas atomization and comprises 3.0 to 7.0 wt. % carbon, 10.0 to 25.0 wt. % chromium, 1.0 to 5.0 wt. % tungsten, 3.5 to 7.0 wt. % vanadium, 1.0 to 5.0 wt. % molybdenum, not greater than 0.5 wt. % oxygen, and at least 40.0 wt. % iron, based on the total weight of the thermal spray powder. The thermal spray powder can be applied to a metal body, such as a piston or piston ring, to form a coating. The thermal spray powder can also provide a spray-formed part.Type: GrantFiled: March 8, 2013Date of Patent: April 18, 2017Assignees: Federal-Mogul CorporationInventors: Denis B. Christopherson, Jr., Gilles L'Esperance, Jeremy Koth, Philippe Beaulieu, Leslie John Farthing, Todd Schoenwetter
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Patent number: 9546412Abstract: A powder metal steel alloy composition for high wear and temperature applications is made by water atomizing a molten steel alloy composition containing C in an amount of at least 3.0 wt %; at least one carbide-forming alloy element selected from the group consisting of: Cr, V, Mo or W; an O content less than about 0.5 wt %, and the balance comprising essentially Fe apart from incidental impurities. The high carbon content reduces the solubility of oxygen in the melt and thus lowers the oxygen content to a level below which would cause the carbide-forming element(s) to oxidixe during water atomization. The alloy elements are thus not tied up as oxides and are available to rapidly and readily form carbides in a subsequent sintering stage. The carbon, present in excess, is also available for diffusing into one or more other admixed powders that may be added to the prealloyed powder during sintering to control microstructure and properties of the final part.Type: GrantFiled: April 7, 2009Date of Patent: January 17, 2017Assignee: Federal-Mogul CorporationInventors: Denis B. Christopherson, Jr., Leslie John Farthing, Todd Schoenwetter, Gilles L'Esperance, Philippe Beaulieu
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Publication number: 20160001369Abstract: A powder metal composition for high wear and temperature applications is made by atomizing a melted iron based alloy including 3.0 to 7.0 wt. % carbon; 10.0 to 25.0 wt. % chromium; 1.0 to 5.0 wt. % tungsten; 3.5 to 7.0 wt. % vanadium; 1.0 to 5.0 wt. % molybdenum; not greater than 0.5 wt. % oxygen; and at least 40.0 wt. % iron. The high carbon content reduces the solubility of oxygen in the melt and thus lowers the oxygen content to a level below which would cause the carbide-forming elements to oxidize during atomization. The powder metal composition includes metal carbides in an amount of at least 15 vol. %. The microhardness of the powder metal composition increases with increasing amounts of carbon and is typically about 800 to 1,500 Hv50.Type: ApplicationFiled: September 16, 2015Publication date: January 7, 2016Inventors: Philippe Beaulieu, Denis B. Christopherson, JR., Leslie John Farthing, Todd Schoenwetter, Gilles L'Esperance
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Patent number: 9162285Abstract: A powder metal composition for high wear and temperature applications is made by atomizing a melted iron based alloy including 3.0 to 7.0 wt. % carbon; 10.0 to 25.0 wt. % chromium; 1.0 to 5.0 wt. % tungsten; 3.5 to 7.0 wt. % vanadium; 1.0 to 5.0 wt. % molybdenum; not greater than 0.5 wt. % oxygen; and at least 40.0 wt. % iron. The high carbon content reduces the solubility of oxygen in the melt and thus lowers the oxygen content to a level below which would cause the carbide-forming elements to oxidize during atomization. The powder metal composition includes metal carbides in an amount of at least 15 vol. %. The microhardness of the powder metal composition increases with increasing amounts of carbon and is typically about 800 to 1,500 Hv50.Type: GrantFiled: March 15, 2013Date of Patent: October 20, 2015Assignees: Federal-Mogul Corporation, La Corporation De L'Ecole Polytechnique De MontrealInventors: Denis B. Christopherson, Jr., Leslie John Farthing, Todd Schoenwetter, Gilles L'Esperance, Philippe Beaulieu
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Publication number: 20140301886Abstract: A powder metal material comprises pre-alloyed iron-based powder including carbon present in an amount of 0.25 to 1.50% by weight of the pre-alloyed iron-based powder. Graphite is admixed in an amount of 0.25 to 1.50% by weight of the powder metal material. The admixed graphite includes particles finer than 200 mesh in an amount greater than 90.0% by weight of the admixed graphite. Molybdenum disulfide is admixed in an amount of 0.1 to 4.0% by weight of the powder metal material, copper is admixed in an amount of 1.0 to 5.0% by weight of the powder metal material, and the material is free of phosphorous. The powder metal material is then compacted and sintered at a temperature of 1030 to 1150° C. At least 50% of the admixed graphite of the starting powder metal material remains as free graphite after sintering.Type: ApplicationFiled: June 18, 2014Publication date: October 9, 2014Inventors: Denis Boyd Christopherson, JR., Leslie John Farthing, Jereby Raymond Koth
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Patent number: 8801828Abstract: A powder metal material comprises pre-alloyed iron-based powder including carbon present in an amount of 0.25 to 1.50% by weight of the pre-alloyed iron-based powder. Graphite is admixed in an amount of 0.25 to 1.50% by weight of the powder metal material. The admixed graphite includes particles finer than 200 mesh in an amount greater than 90.0% by weight of the admixed graphite. Molybdenum disulfide is admixed in an amount of 0.1 to 4.0% by weight of the powder metal material, copper is admixed in an amount of 1.0 to 5.0% by weight of the powder metal material, and the material is free of phosphorous. The powder metal material is then compacted and sintered at a temperature of 1030 to 1150° C. At least 50% of the admixed graphite of the starting powder metal material remains as free graphite after sintering.Type: GrantFiled: August 3, 2012Date of Patent: August 12, 2014Assignee: Federal-Mogul CorporationInventors: Denis Boyd Christopherson, Jr., Leslie John Farthing, Jeremy Raymond Koth
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Publication number: 20130028780Abstract: A powder metal material comprises pre-alloyed iron-based powder including carbon present in an amount of 0.25 to 1.50% by weight of the pre-alloyed iron-based powder. Graphite is admixed in an amount of 0.25 to 1.50% by weight of the powder metal material. The admixed graphite includes particles finer than 200 mesh in an amount greater than 90.0% by weight of the admixed graphite. Molybdenum disulfide is admixed in an amount of 0.1 to 4.0% by weight of the powder metal material, copper is admixed in an amount of 1.0 to 5.0% by weight of the powder metal material, and the material is free of phosphorous. The powder metal material is then compacted and sintered at a temperature of 1030 to 1150° C. At least 50% of the admixed graphite of the starting powder metal material remains as free graphite after sintering.Type: ApplicationFiled: August 3, 2012Publication date: January 31, 2013Inventors: Denis Boyd Christopherson, JR., Leslie John Farthing, Jeremy Raymond Koth
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Patent number: 8277533Abstract: A most preferred composition for the mixture, prior to sintering into an article (ideally a valve seat insert), is as follows: 35% hard phase, 65% matrix (excepting incidental impurities), the hard phase component being 2.2% C, 29.1% Cr, 4.9% Co, 5.3% Ni, 20.2% W with the balance being Fe and allowing less than 2% for one or more machinability aids and solid lubricants, and the matrix component being one of a high chrome steel powder (e.g. 18% Cr, 1% Ni, 2.5% Mo, balance Fe), a low alloy steel powder (3% Cu, 1% C, balance Fe; 3% Cr, 0.5% Mo, 1% C, balance Fe; 4% Ni, 1.5% Cu, 0.5% Mo, 1% C, balance Fe; 4% Ni, 2% Cu, 1.4% Mo, 1% C, balance Fe), or a tool steel powder (5% Mo, 6% W, 4% Cr, 2% V, 1% C, balance Fe), or a low-alloy steel powder as above but which issued in conjunction with a copper infiltration process during sintering.Type: GrantFiled: August 9, 2007Date of Patent: October 2, 2012Assignee: Federal-Mogul Sintered Products LimitedInventors: Leslie John Farthing, Paritosh Maulik
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Patent number: 8257462Abstract: A powder metal material comprises pre-alloyed iron-based powder including carbon present in an amount of 0.25 to 1.50% by weight of the pre-alloyed iron-based powder. Graphite is admixed in an amount of 0.25 to 1.50% by weight of the powder metal material. The admixed graphite includes particles finer than 200 mesh in an amount greater than 90.0% by weight of the admixed graphite. Molybdenum disulfide is admixed in an amount of 0.1 to 4.0% by weight of the powder metal material, copper is admixed in an amount of 1.0 to 5.0% by weight of the powder metal material, and the material is free of phosphorous. The powder metal material is then compacted and sintered at a temperature of 1030 to 1150° C. At least 50% of the admixed graphite of the starting powder metal material remains as free graphite after sintering.Type: GrantFiled: October 15, 2009Date of Patent: September 4, 2012Assignee: Federal-Mogul CorporationInventors: Denis Boyd Christopherson, Jr., Leslie John Farthing, Jeremy Raymond Koth