Abstract: A high strength and creep resistant soft magnetic Fe—Co alloy includes, in weight %, Fe and Co such that the difference between the Fe and Co is at least 2%, at least 35% Co, and 2.5%≦(V+Mo+Nb), wherein 0.4%≦Mo and/or 0.4%≦Nb. This alloy can further include B, C, W, Ni, Ti, Cr, Mn and/or Al. A vanadium-free high strength soft magnetic Fe—Co alloy includes, in weight %, Fe and Co such that the difference between the Fe and Co is at least 2%, and at least 15% Co, the alloy further satisfying (0.1%≦Nb and 0.1%≦W) or 0.25%≦Mn. This alloy can further include B, C, Ni, Ti, Cr and/or Al.

Abstract: A high strength soft magnetic Fe−Co−V alloy, comprising, in weight %, (Fe+Co)≧88%, (Fe−Co)≧2% or (Co−Fe)≧2%, at least 30% Co, and satisfying one of the following three conditions: (1) 0.05 to 4% Mo and 1.5 to 10% V, or (2) (Fe−Co) or (C0−Fe)≦13 and at least 4% V, or (3) at least 7% V. Additional alloying constituents, including B, C, Nb, Ti, W and Ni can be present.

Abstract: A powder metallurgical process of preparing a sheet from a powder having an intermetallic alloy composition such as an iron, nickel or titanium aluminide. The sheet can be manufactured into electrical resistance heating elements having improved room temperature ductility, electrical resistivity, cyclic fatigue resistance, high temperature oxidation resistance, low and high temperature strength, and/or resistance to high temperature sagging. The iron aluminide has an entirely ferritic microstructure which is free of austenite and can include, in weight %, 4 to 32% Al, and optional additions such as ≦1% Cr, ≧0.05% Zr ≦2% Ti, ≦2% Mo, ≦1% Ni, ≦0.75% C, ≦0.1% B, ≦1% submicron oxide particles and/or electrically insulating or electrically conductive covalent ceramic particles, ≦1% rare earth metal, and/or ≦3% Cu.

Abstract: The invention relates generally to aluminum containing iron-base alloys useful as electrical resistance heating elements. The aluminum containing iron-base alloys have improved room temperature ductility, electrical resistivity, cyclic fatigue resistance, high temperature oxidation resistance, low and high temperature strength, and/or resistance to high temperature sagging. The alloy has an entirely ferritic microstructure which is free of austenite and includes, in weight %, over 4% Al, ≦1% Cr and either ≧0.05% Zr or Zro2 stringers extending perpendicular to an exposed surface of the heating element or ≧0.1% oxide dispersoid particles. The alloy can contain 14-32% Al, ≦2% Ti, ≦2% Mo, ≦1% Zr, ≦1% C, ≦0.1% B. ≦30% oxide dispersoid and/or electrically insulating or electrically conductive covalent ceramic particles, ≦1% rare earth metal, ≦1% oxygen, ≦3% Cu, balance Fe.

Abstract: A method of making Cu, Zn, and/or Cu/Zn alloy nanoparticles subjects one or more targets to laser energy to form a vapor and condenses the vapor to form nanoparticles having an average particle size of less than 20 nm. The optional application of an electric field results in nanoparticles with aspect ratios greater than 1.0. The target(s) can be a single target or separate targets comprising a mixture of copper, zinc, and/or copper/zinc. When separate targets are used, the laser beam can be split to form two separate beams each of which is made incident upon one of the targets. The nanoparticles can be formed in a chamber having an inert atmosphere or a reactive atmosphere and a convection current is created in the chamber by maintaining the top plate at a lower temperature than the bottom plate.

Abstract: A powder metallurgical process of preparing a sheet from a powder having an intermetallic alloy composition such as an iron, nickel or titanium aluminide. The sheet can be manufactured into electrical resistance heating elements having improved room temperature ductility, electrical resistivity, cyclic fatigue resistance, high temperature oxidation resistance, low and high temperature strength, and/or resistance to high temperature sagging. The iron aluminide has an entirely ferritic microstructure which is free of austenite and can include, in weight %, 4 to 32% Al, and optional additions such as ≦1% Cr, ≧0.05% Zr ≦2% Ti, ≦2% Mo, ≦1% Ni, ≦0.75% C, ≦0.1% B, ≦1% submicron oxide particles and/or electrically insulating or electrically conductive covalent ceramic particles, ≦1% rare earth metal, and/or ≦3% Cu.

Abstract: A pressureless sintering process for producing FeAl wherein the heating rate is controlled in a manner which minimizes expansion of a mixture of elemental powders of iron and aluminum. During the process, the heating rate is maintained below 1° C./min to minimize the volume expansion during the formation of the intermediate phase Fe2Al5. As a result of the process, the final density can be increased up to 95% of the theoretical density. The sequence of phases formed during the heating of Fe+Al mixture were identified by X-ray diffraction, optical microscopy, SEM and along with DSC data were correlated to the expansion and shrinkage behavior of the samples.

Abstract: A cracking tube includes a lining of a fouling resistant and corrosion resistant iron aluminide alloy. The iron aluminide alloy can include 14-32 wt. % Al, at least 2 vol. % transition metal oxides, 0.003 to 0.020 wt. % B, 0.2 to 2.0 wt. % Mo, 0.05 to 1.0 wt. % Zr, 0.2 to 2.0 wt. %Ti, 0.10 to 1.0 wt. % La, 0.05 to 0.2 wt. % C., balance Fe, and optionally≦1 wt. % Cr, and the coefficient of thermal expansion of the iron aluminide alloy is substantially the same as the coefficient of thermal expansion over the temperature range of ambient to about 1200° C. of an outer metal layer. A cracking tube utilizing the iron aluminide alloy can be formed from powders of the iron aluminide alloy by consolidation methods including cold isostatic pressing (CIP), hot isostatic pressing (HIP), reaction synthesis, spraying techniques, or co-extrusion with a second material of the cracking tube.

Abstract: An iron aluminide fuel injector component such as a nozzle, plunger or other part is manufactured from iron aluminide or includes an iron aluminide coating on at least a portion of a surface in contact with the fuel which passes through the fuel injector. The iron aluminide alloy can include 8 to 32 wt. % Al, up to 5 wt. % refractory metal, B and/or C in amounts sufficient to form borides and/or carbides. The fuel injector component can be formed from powders of the iron aluminide alloy by powder metallurgy techniques and the coating can be formed by a diffusional reaction process, cathodic plasma process, chemical vapor deposition or physical vapor deposition. The fuel injector component is corrosion, carburization, sulfidation and/or coking resistant.

Abstract: Aluminum containing iron based alloys with enhanced ferromagnetic properties are provided. The aluminum containing iron based alloys contain additions of palladium and/or rhodium. The alloy can be an ordered, bulk iron-based alloy of the Fe3Al or FeAl type. In the case of FeAl based alloys, the alloy can contain an amount of palladium and/or rhodium effective to render the alloy ferromagnetic.

Abstract: A high strength soft magnetic Fe−Co−V alloy is provided in which the weight percent of constituents are such that (Fe+Co)≧90, (Fe−Co)≧10, and 1.5 to 10% V. Additional alloying constituents, including B, C, Nb, Ti, W, Ni and Mo, can be present.

Abstract: A creep resistant titanium aluminide alloy having fine particles such as boride particles at colony boundaries and/or grain boundary equiaxed structures. The alloy can include alloying additions such as ≦10 at % W, Nb and/or Mo. The alloy can be free of Cr, V, Mn, Cu and/or Ni and can include, in atomic %, 45 to 55% Ti, 40 to 50% Al, 1 to 10% Nb, 0.1 to 2% W, up to 1% Mo and 0.1 to 0.8% B or the alloy can include, in weight %, 50 to 65% Ti, 25 to 35% Al, 2 to 20% Nb, up to 5% Mo, 0.5 to 10% W and 0.01 to 0.5% B.

Abstract: A sintering process for producing an aluminide by reacting a first powder with a second powder, the first powder comprising MxAly wherein M is Fe, Ni or Ti, x≧1, y≧1 and x>y or y>x and the second powder comprises pure M or M alloy powder. Iron aluminides such as Fe3Al, FeAl or alloys thereof can be made by reacting powders of one or more of Fe3Al, FeAl3, FeAl2, Fe2Al5 or alloys thereof with pure iron or an iron alloy. Nickel aluminides such as Ni3Al or NiAl or alloys thereof can be made by reacting powders of one or more of NiAl3, Ni2Al3, Ni3Al2, Ni5Al3 or alloys thereof with pure Ni or a Ni alloy powder. Titanium aluminides such as Ti3Al, TiAl or alloys thereof can be made by reacting one or more of TiAl3, TiAl2 or alloys thereof with pure Ti or Ti alloy powder. The process provides a more dense product by solid state reaction of an intermediate intermetallic compound with a component of the final aluminide compact.

Abstract: A method of making intermetallic nanoparticles comprising subjecting a starting material to laser energy so as to form a vapor and condensing the vapor so as to form intermetallic nanoparticles. The starting material can be a mixture of pure elements or an alloy of two or more elements. The nanoparticles can be provided with a narrow size distribution with an average particle size of 2 to 100 nm, preferably 2 to 50 nm and more preferably 2 to 9 nm. The nanoparticles can be formed in a vacuum chamber wherein a temperature gradient is provided. The atmosphere in the chamber can be an inert atmosphere such as argon or a reactive atmosphere such as isobutene or oxygen. An electric field can be used to form filaments of the nanoparticles.

Abstract: A powder metallurgical process of preparing a sheet from a powder having an intermetallic alloy composition such as an iron, nickel or titanium aluminide. The sheet can be manufactured into electrical resistance heating elements having improved room temperature ductility, electrical resistivity, cyclic fatigue resistance, high temperature oxidation resistance, low and high temperature strength, and/or resistance to high temperature sagging. The iron aluminide has an entirely ferritic microstructure which is free of austenite and can include, in weight %, 4 to 32% Al, and optional additions such as ≦1% Cr, ≧0.05% Zr ≦2% Ti, ≦2% Mo, ≦1% Ni, ≦0.75% C, ≦0.1% B, ≦1% submicron oxide particles and/or electrically insulating or electrically conductive covalent ceramic particles, ≦1% rare earth metal, and/or ≦3% Cu.

Abstract: A powder metallurgical process of preparing iron aluminide useful as electrical resistance heating elements having improved room temperature ductility, electrical resistivity, cyclic fatigue resistance, high temperature oxidation resistance, low and high temperature strength, and/or resistance to high temperature sagging. The iron aluminide has an entirely ferritic microstructure which is free of austenite and can include, in weight %, 20 to 32% Al, and optional additions such as ≦1% Cr, ≧0.05% Zr or ZrO2 stringers extending perpendicular to an exposed surface of the heating element, ≦2% Ti, ≦2% Mo, ≦1% Zr, ≦1% C, ≦0.1% B, ≦30% oxide dispersoid and/or electrically insulating or electrically conductive covalent ceramic particles, ≦1% rare earth metal, ≦1% oxygen, and/or ≦3% Cu.

Abstract: The invention relates generally to aluminum containing iron-base alloys useful as electrical resistance heating elements. The aluminum containing iron-base alloys have improved room temperature ductility, electrical resistivity, cyclic fatigue resistance, high temperature oxidation resistance, low and high temperature strength, and/or resistance to high temperature sagging. The alloy has an entirely ferritic microstructure which is free of austenite and includes, in weight %, over 4% Al, ≦1% Cr and either ≧0.05% Zr or ZrO2 stringers extending perpendicular to an exposed surface of the heating element or ≧0.1% oxide dispersoid particles. The alloy can contain 14-32% Al, ≦2% Ti, ≦2% Mo, ≦1% Zr, ≦1% C, ≦0.1% B, ≦30% oxide dispersoid and/or electrically insulating or electrically conductive covalent ceramic particles, ≦1% rare earth metal, ≦1% oxygen, ≦3% Cu, balance Fe.

Abstract: A two-phase titanic aluminide alloy having a lamellar microstructure with little intercolony structures. The alloy can include fine particles such as boride particles at colony boundaries and/or grain boundary equiaxed structures. The alloy can include alloying additions such as ≦10 at % W, Nb and/or Mo. The alloy can be free of Cr, V, Mn, Cu and/or Ni and can include, in atomic %, 45 to 55% Ti, 40 to 50% Al, 1 to 5% Nb, 0.3 to 2% W, up to 1% Mo and 0.1 to 0.3% B. In weight %, the alloy can include 57 to 60% Ti, 30 to 32% Al, 4 to 9% Nb, up to 2% Mo, 2 to 8% W and 0.02 to 0.08% B.

Abstract: A method for making electronic circuit component having improved mechanical properties and thermal conductivity comprises steps of providing NiAl and/or Ni3Al, and forming an alumina layer thereupon prior to applying the conductive elements. Additional layers of copper-aluminum alloy or copper further improve mechanical strength and thermal conductivity.

Abstract: A powder metallurgical process of preparing iron aluminide useful as electrical resistance heating elements having improved room temperature ductility, electrical resistivity, cyclic fatigue resistance, high temperature oxidation resistance, low and high temperature strength, and/or resistance to high temperature sagging. The iron aluminide has an entirely ferritic microstructure which is free of austenite and can include, in weight %, 20 to 32% Al, and optional additions such as .ltoreq.1% Cr, .gtoreq.05% Zr or ZrO.sub.2 stringers extending perpendicular to an exposed surface of the heating element, .ltoreq.2% Ti, .ltoreq.2% Mo, .ltoreq.1% Zr, .ltoreq.1% C, .ltoreq.0.1% B, .ltoreq.30% oxide dispersoid and/or electrically insulating or electrically conductive covalent ceramic particles, .ltoreq.1 % rare earth metal, .ltoreq.1% oxygen, and/or .ltoreq.3% Cu.