Aluminum Base Patents (Class 148/437)
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Patent number: 6017403Abstract: An aluminum-based alloy having the general formula Al.sub.x L.sub.y M.sub.z (wherein L is Mn or Cr; M is Ni, Co, and/or Cu; and x, y, and z, representing a composition ratio in atomic percentages, satisfy the relationships x+y+z=100, 75.ltoreq.x.ltoreq.95, 2.ltoreq.y.ltoreq.15, and 0.5.ltoreq.z.ltoreq.10) having a metallographic structure comprising a quasi-crystalline phase possesses high strength and high rigidity. In order to enhance the ductility and toughness of the aluminum-based alloy, the atomic percentage of M may be further limited to 0.5.ltoreq.z.ltoreq.4, and more preferably to 0.5.ltoreq.z.ltoreq.3. The aluminum-based alloy is useful as a structural material for aircraft, vehicles and ships, and for engine parts; as material for sashes, roofing materials, and exterior materials for use in construction; or as materials for use in marine equipment, nuclear reactors, and the like.Type: GrantFiled: February 15, 1996Date of Patent: January 25, 2000Assignees: Yamaha Corporation, Isuyoshi Masumoto, Akihisa InoueInventors: Tsuyoshi Masumoto, Akihisa Inoue, Yuma Horio
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Patent number: 5993572Abstract: In a thixocasting process, the following steps are used: a step of subjecting, to a heating treatment, an Al-Si based alloy material having a hypo eutectic crystal composition and a characteristic that a first angled endothermic section appearing due to the melting of a eutectic crystal and a second angled endothermic section appearing due to the melting of a component having a melting point higher than a eutectic point exist in a differential calorimetric curve, thereby preparing a semi-molten Al-Si based alloy material having solid and liquid phases coexisting therein; a step of pouring the semi-molten Al-Si based alloy material into a cavity in a casting mold under pressure; and a step of solidifying the semi-molten Al-Si based alloy material under pressure. When the temperature of a rise-start point in the first angled endothermic section is represented by T.sub.1, and the temperature of a drop-end point the first angled endothermic sections is represented by T.sub.Type: GrantFiled: October 9, 1996Date of Patent: November 30, 1999Assignee: Honda Giken Kogyo Kabushiki KaishaInventors: Nobuhiro Saito, Haruo Shiina, Takeyoshi Nakamura, Takeshi Sugawara, Kazuo Kikawa
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Patent number: 5989365Abstract: In a metallic ingot used as a forging stock, high dimensional accuracy, small dispersion of weight, good inner quality, and small radius of meniscus are required. In the metallic ingot fulfilling these requirements, the metallic melt 7 is completely filled the mold comprising a sprue 4 closed after pouring of the melt and is forcedly solidified at its bottom by the cooling plate 1. The crystal grains grow almost parallel to the rising direction of the upper surface of the melt 7. The ingot has no cutting surface on the casting surface.Type: GrantFiled: April 22, 1998Date of Patent: November 23, 1999Assignee: Showa Denko Kabushiki KaishaInventors: Shigeru Yanagimoto, Masashi Fukuda, Yoshiaki Sutou, Takayuki Kato
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Patent number: 5980660Abstract: A metal alloy mass of a defined porosity for forming in the semi-solid state. When the porosity is measured by cooling in ambient air from a temperature corresponding to a liquid fraction ratio between 30 and 70% to the ambient temperature, the mass has a porosity ratio, measured by image analysis, between 2 and 20%, and preferably between 3 and 8%. Alternatively, when the gassing level is measured by a solidification test under 80 hPa, the mass has a volumetric porosity ratio between 3 and 50% and preferably between 4 and 25%.Type: GrantFiled: February 3, 1997Date of Patent: November 9, 1999Assignee: Aluminium PechineyInventors: Michel Garat, Christian Pluchon, Willem Loue, Michel Brimont, Marc Tavernier
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Patent number: 5976641Abstract: An Al alloy film containing one kind or two or more kinds of alloy components selected from a group of Ti, Zr, Hf, V, Nb, Ta, Cr, Mo and Mn in a total amount of 0.1 to 10 at %, and a melting Al alloy sputtering target for depositing the Al alloy film, wherein the above-mentioned film is used as a reflection film for an optical recording medium, a shading film for a liquid crystal display panel or for a solid image pickup device, and an Al alloy thin film line or electrode material for a semiconductor device.Type: GrantFiled: July 7, 1997Date of Patent: November 2, 1999Assignee: Kabushiki Kaisha Kobe Seiko ShoInventors: Takashi Onishi, Kazuo Yoshikawa, Seiji Nishi, Seigou Yamamoto
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Patent number: 5976278Abstract: An aluminum-based alloy composition having improved combinations of corrosion resistance, drawability, bendability and extrudability consists essentially of, in weight percent, not more than about 0.03% copper, between about 0.1 and up to about 1.5% manganese, between about 0.03 and about 0.35% titanium, an amount of magnesium up to about 1.0%, less than 0.01% nickel, between about 0.06 and about 1.0% zinc, an amount of zirconium up to about 0.3%, amounts of iron and silicon up to about 0.50%, up to 0.20% chromium, with the balance aluminum and inevitable impurities. A process of making an aluminum alloy article having high corrosion resistance, drawability, bendability and hot deformability is also provided.Type: GrantFiled: October 3, 1997Date of Patent: November 2, 1999Assignee: Reynolds Metals CompanyInventor: Subhasish Sircar
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Patent number: 5968292Abstract: A billet of an aluminum alloy for thermally transforming from a dendritic microstructure to a globular structure and for forming in a semi-solid condition into a shaped aluminum alloy article; the billet having a dendritic microstructure having a grain size in the range of 20 to 250 .mu.m provided by a solidification rate in the range of 5.degree. to 100.degree. C./sec between liquidus and solidus temperatures when the aluminum alloy is cast into billet; the billet having a dendritic microstructure thermally transformable to the globular structure or non-dendritic structure by heat applied to the billet at a heat-up rate greater than 30.degree. C. per minute to a superheated temperature of 3.degree. to 50.degree. C. above solidus temperature of the aluminum alloy; the billet in the globular structure or non-dendritic structure and in the semi-solid condition having the ability to be formed into the shaped aluminum article.Type: GrantFiled: September 2, 1997Date of Patent: October 19, 1999Assignee: Northwest AluminumInventor: S. Craig Bergsma
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Patent number: 5944918Abstract: An aluminum-alloy article such as a fastener is prepared by providing an aluminum-alloy article that is not in its final heat-treated state, and is preferably in its annealed state. A curable organic coating material is also provided. The method includes applying the organic coating material to the aluminum-alloy article, and heat-treating the coated aluminum article to its final heat-treated state, thereby simultaneously curing the organic coating.Type: GrantFiled: October 7, 1996Date of Patent: August 31, 1999Assignee: McDonnell Douglas CorporationInventor: Steven G. Keener
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Patent number: 5942054Abstract: An improved elastic member (24) for micromechanical devices (12). The micromechanical device (12) includes a stationary member (28) and a moving member (26) which are connected together by a elastic member (24). Because of repeated and frequent movement of the moving member (26), the elastic member (24) can become permanently flexed or deformed, resulting in poor operation of the device. Aluminum alloys are formed to include oxygen, in combination with nitrogen if desired, to obtain a film with dramatically reduced load relaxation characteristics. Oxygen is added to an Argon sputter gas during deposition, and an amorphous film is produced.Type: GrantFiled: December 20, 1996Date of Patent: August 24, 1999Assignee: Texas Instruments IncorporatedInventors: John Harold Tregilgas, Richard Lee Knipe, Thomas William Orent, Hidekazu Yoshihara, Elliott Keith Carpenter
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Patent number: 5916390Abstract: The invention relates to a cylinder liner sealed into a reciprocating piston engine comprising a supereutectic aluminum/silicon alloy which is free of mixed-in particles of hard material and which is composed in such a way that fine silicon primary crystals and intermetallic particles automatically form from the melt as hard particles. A blank is allowed to grow from finely sprayed melt droplets by spray compaction, with a fine distribution of hard particles being produced by setting the spray for small melt droplets. The blank can then be formed by cold extrusion to create a shape approximating the cylinder lining. After premachining, the surface is fine machined, honed in at least one stage and then the hard particles lying at the surface are mechanically exposed, is forming plateau areas of hard particles which project above the remaining surface of the base microstructure of the alloy.Type: GrantFiled: November 10, 1997Date of Patent: June 29, 1999Assignee: Mercedes-Benz AGInventors: Franz Ruckert, Peter Stocker, Roland Biedermann
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Patent number: 5913989Abstract: A process of manufacturing aluminum can body stock involving the following steps. A molten aluminum alloy is prepared, the alloy containing Mg in the range 1.1 to 1.5% by weight, Mn in the range 0.4 to 0.9% by weight, Cu in the range 0.2 to 0.4% by weight, Fe in the range 0.2 to 0.7% by weight, Si in the range 0.07 to 0.3% by weight, all other elements each less than 0.05% by weight to a maximum of 0.2% for all other elements. The alloy is cast in a continuous strip casting process to produce a slab having a thickness of at least 9 mm. The slab is rolled using at least 83% reduction to produce a re-roll strip. The re-roll strip is coiled to form a coil and the coil to cool is allowed to cool naturally. The re-roll strip is then annealed and cold rolled to a final gauge of between 0.26 and 0.4 mm, using a reduction of between 75 and 85%, with no interanneal. The resulting strip can be used as can body stock having a 45 degree earing of less than 3% and a yield strength after stoving of at least 38.Type: GrantFiled: July 8, 1996Date of Patent: June 22, 1999Assignee: Alcan International LimitedInventors: Paul Wycliffe, Ed Luce, David J. Lloyd, John Fitzsimon, Gene Burger
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Patent number: 5902546Abstract: There is disclosed a high heat resistant aluminum alloy impeller, which is suitably used as an impeller, especially for a centrifugal compressor, and for the rotor and the blade of a turbo molecular pump or the scroll of a scroll compressor. Also, a method for manufacturing this aluminum alloy impeller is disclosed. The impeller is composed of an Al--Fe rapid solidification aluminum alloy, which is produced by a spray forming process for spraying a molten metal with inert gas and rapidly solidifying the metal at a cooling speed of 10.sup.2 .degree. C./sec. or higher while simultaneously deposing the metal. The rapid solidification aluminum alloy is subjected to hot extrusion processing within a temperature range of 200.degree. C. to 600.degree. C. and further subjected to hot forging.Type: GrantFiled: May 9, 1997Date of Patent: May 11, 1999Assignee: Mitsubishi Heavy Industries, Ltd.Inventors: Nozomu Kawasetsu, Masatomo Shinohara, Kouichiro Imakiire, Masanori Kimura, Keiichi Shiraishi, Masayuki Hayakawa, Kazuhisa Shibue, Yoshimasa Okubo, Naoki Tokizane
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Patent number: 5900210Abstract: A high-strength and high-ductility aluminum-base alloy consisting of a composition of general formula: Al.sub.ba1 Mn.sub.a Si.sub.b or Al.sub.ba1 Mn.sub.a Si.sub.b TM.sub.c (wherein TM is one or more elements selected from the group consisting of Ti, V, Cr, Fe, Co, Ni, Cu, Y, Zr, La, Ce and Mm; and a, b and c are, in atomic percentages, 2.ltoreq.a.ltoreq.8, 0.5.ltoreq.b.ltoreq.6, 0<c.ltoreq.4, and a.gtoreq.b), wherein the alloy contains quasi-crystals. The an aluminum-base alloy have superior mechanical properties such as high hardness, high strength and high ductility.Type: GrantFiled: March 7, 1997Date of Patent: May 4, 1999Assignee: YKK CorporationInventors: Erik Buchler, Kazuhiko Kita
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Patent number: 5898020Abstract: A biaxially textured article includes a rolled and annealed, biaxially textured substrate of a metal having a face-centered cubic, body-centered cubic, or hexagonal close-packed crystalline structure; and an epitaxial superconductor or other device epitaxially deposited thereon.Type: GrantFiled: May 22, 1996Date of Patent: April 27, 1999Inventors: Amit Goyal, John D. Budai, Donald M. Kroeger, David P. Norton, Eliot D. Specht, David K. Christen
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Patent number: 5888661Abstract: A composite structure including a substrate and a heat protection element on the substrate, wherein the heat protection element includes a quasicrystalline aluminum alloy of one or a number of quasicrystalline phases which are either quasicrystalline phases in the strict sense, or approximating phases, wherein the quasicrystalline phases exhibit a thermal diffusivity, measured at ambient temperature, lower than 2.5.times.10.sup.-6 m.sup.2 /s, and a thermal diffusivity measured in the temperature range 650.degree.-750.degree. C. which does not exceed the thermal diffusivity measured at ambient temperature by more than a factor of 3, and wherein the quasicrystalline aluminum alloy comprises Al.sub.a Pd.sub.b Mn.sub.c X.sub.d Y.sub.e T.sub.f I.sub.Type: GrantFiled: April 1, 1997Date of Patent: March 30, 1999Assignee: Centre National de la Recherche ScientifiqueInventors: Jean-Marie Dubois, Pierre Archambault, Bernard Colleret
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Patent number: 5882443Abstract: Aluminum-strontium enriched master alloy granules for use primarily in modifying the eutectic phase in aluminum-silicon casting alloys. The master alloy granules are predominantly intermetallic compounds Al.sub.4 Sr, Al.sub.2 Sr or Alsr and mixtures thereof. By using such intermetallic dominant alloys in a granulated state rapid dissolution in aluminum-silicon alloy melts is achieved. The master alloy composition can be directly added to a content of the melt or injected into it. The master alloy composition can also be mixed with aluminum granules and extruded into a rod or entrained into a billet of cast aluminum.Type: GrantFiled: June 28, 1996Date of Patent: March 16, 1999Assignee: Timminco LimitedInventors: Douglas J. Zuliani, Bahadir Kulunk
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Patent number: 5879478Abstract: The invention relates to an aluminum alloy for thixoforming with the composition (by weight): Si: 5%-7.2% Cu: 1%-5% Mg<1% Zn<3% Fe<1.5% other elements<1% each and<3% in total, with % Si<7.5-% Cu/3, which, when reheated to the semisolid state to the point at which a liquid fraction ratio between 35 and 55% is obtained, has an absence of non-remelted polyhedral silicon crystals.Type: GrantFiled: February 26, 1997Date of Patent: March 9, 1999Assignee: Aluminium PechineyInventors: Willem Loue, Michel Garat
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Patent number: 5876525Abstract: In order to simplify the production of a nigh-resistance bobbin body made of an aluminum alloy, the following process steps are performed: (a) extruding or flow extruding an essentially cylindrical bobbin blank; (b) cutting the bobbin blank to a length including the desired bobbin body length plus an overlength sufficient to form end flanges on the bobbin body; (c) shaping end flanges at both ends of the bobbin body from the overlength portion; hardening the bobbin body; and age-hardening (aging) the bobbin body. Various process parameters are described.Type: GrantFiled: November 30, 1993Date of Patent: March 2, 1999Assignee: Hilebrandt-Spolen-Bobbins GmbHInventors: Michael Prechtel, Davorin Lenarcic
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Patent number: 5865914Abstract: There is claimed a lower wing structure for a commercial jet aircraft which includes a substantially unrecrystallized rolled plate member made from an aluminum alloy consisting essentially of about 3.6 to 4.0 wt. % copper, about 1.0 to 1.6 wt. % magnesium, about 0.3 to 0.7 wt. % manganese, about 0.05 to 0.25 wt. % zirconium, the balance aluminum and incidental elements and impurities. On a preferred basis, the alloy products of this invention include very low levels of both iron and silicon, typically on the order of less than 0.1 wt. % each, and more preferably about 0.05 wt. % or less iron and about 0.03 wt. % or less silicon. This alloy composition may be rolled to form lower wing skin plates and extruded or rolled to form wing box stringers therefrom.Type: GrantFiled: August 11, 1997Date of Patent: February 2, 1999Assignee: Aluminum Company of AmericaInventors: Lynette M. Karabin, John Liu, Allison S. Warren, Gary H. Bray
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Patent number: 5863359Abstract: There is claimed a lower wing structure for a commercial jet aircraft which includes a substantially unrecrystallized rolled plate member made from an aluminum alloy consisting essentially of about 3.6 to 4.0 wt. % copper, about 1.0 to 1.6 wt. % magnesium, about 0.3 to 0.7 wt. % manganese, about 0.05 to 0.25 wt. % zirconium, the balance aluminum and incidental elements and impurities. On a preferred basis, the alloy products of this invention include very low levels of both iron and silicon, typically on the order of less than 0.1 wt. % each, and more preferably about 0.05 wt. % or less iron and about 0.03 wt. % or less silicon. This alloy composition may be rolled to form lower wing skin plates and extruded or rolled to form wing box stringers therefrom.Type: GrantFiled: June 9, 1995Date of Patent: January 26, 1999Assignee: Aluminum Company of AmericaInventors: Lynette M. Karabin, John Liu, Allison S. Warren, Gary H. Bray
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Patent number: 5858131Abstract: An aluminum-based alloy having the general formula Al.sub.100 -(a+b)Q.sub.a M.sub.b (wherein Q is V, Mo, Fe, W, Nb, and/or Pd; M is Mn, Fe, Co, Ni, and/or Cu; and a and b, representing a composition ratio in atomic percentages, satisfy the relationships 1.ltoreq.a.ltoreq.8, 0<b<5, and 3.ltoreq.a+b.ltoreq.8) having a metallographic structure comprising a quasi-crystalline phase, wherein the difference in the atomic radii between Q and M exceeds 0.01 .ANG., and said alloy does not contain rare earths, possesses high strength and high rigidity. The aluminum-based alloy is useful as a structural material for aircraft, vehicles and ships, and for engine parts; as material for sashes, roofing materials, and exterior materials for use in construction; or as materials for use in marine equipment, nuclear reactors, and the like.Type: GrantFiled: May 14, 1997Date of Patent: January 12, 1999Assignees: Tsuyoshi Masumoto, Akihisa Inoue, Yamaha Corp.Inventors: Akihisa Inoue, Hisamichi Kimura, Yuma Horio
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Patent number: 5849115Abstract: A differential thermal analysis thermograph for a thixocasting aluminum alloy material is such that, a relationship, E.sub.1 >E.sub.2, is established between a peak value E.sub.1 of a first angled endothermic section generated by eutectic melting and a peak value E.sub.2 of a second angled endothermic section generated by melting of an element having a melting point higher than the eutectic point. Thus, a liquid phase produced by the eutectic melting has a large latent heat due to the fact that the peak value E.sub.1 of the first angled endothermic section is larger than the peak value E.sub.2 of the second angled endothermic section in a semi-molten eutectic aluminum alloy material derived from the thixocasting aluminum alloy material. As a result, in a solidification step of the thixocasting process, a liquid phase produced by the eutectic melting is sufficiently fed around a solid phase in response to the solidification and shrinkage of the solid phase, and then solidified.Type: GrantFiled: May 21, 1997Date of Patent: December 15, 1998Assignee: Honda Giken Kogyo Kabushiki KaishaInventors: Haruo Shiina, Nobuhiro Saito, Takeyoshi Nakamura, Takeshi Sugawara
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Patent number: 5840135Abstract: Articles of manufacture are made of aluminum-beryllium alloys having substantially randomly distributed aluminum-rich and beryllium rich phases to provide substantially isotropic mechanical properties, such as high stiffness and low co-efficients of thermal expansion, whereby the articles of manufacture provide more rapid and accurate responses.Type: GrantFiled: May 2, 1996Date of Patent: November 24, 1998Assignee: Brush Wellman Inc.Inventors: Larry A. Grant, James M. Marder, Wayne L. Wright
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Patent number: 5834129Abstract: The present invention relates to supports for lithographic printing plates and to a process for producing the same. In particular, the invention relates to aluminum plates having an electrochemically grained and anodized surface which is has a smooth, shiny surface and hence greater image contrast when a lithographic image is formed thereon. The surface has a substantially uniform surface topography comprising peaks and valleys and surface roughness parameters wherein Ra ranges from about 0.10 to about 0.50 microns, Rz ranges from about 0.00 to about 5.00 microns, Rt ranges from about 0.00 to about 6.00 microns and Rp ranges from about 0.00 to about 4.00 microns. The surface preferably has tristimulus color coordinate values wherein L ranges from about 35.00 to about 75.00, a ranges from about -4.00 to about +4.00 and b ranges from about -4.00 to about +4.00.Type: GrantFiled: November 6, 1997Date of Patent: November 10, 1998Assignee: Bayer CorporationInventors: Major S. Dhillon, Gerhard Sprintschnik, Jose G. Gonzales
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Patent number: 5803995Abstract: The calcium-aluminum system hydrogen absorbing alloy of the present invention is an alloy which is composed of a mixture P of Ca with Mg and an Al base alloy Q, has a molar ratio P:Q of 1:1.5 to 2.8 and shows a Laves phase with the C15-type structure as the fundamental structure thereof.Type: GrantFiled: February 10, 1997Date of Patent: September 8, 1998Assignee: Agency of Industrial Science and TechnologyInventors: Hideaki Tanaka, Hiroshi Miyamura, Nobuhiro Kuriyama, Tetsuo Sakai, Itsuki Uehara
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Patent number: 5795541Abstract: An aluminum alloy sheet for printing plate contains Fe: 0.2 to 0.6 Wt %, Si: 0.03 to 0.15 Wt %, Ti: 0.005 to 0.05 Wt %, Ni: 0.005 to 0.20 Wt %, and remainder of Al and inevitable impurity, wherein a ratio of Ni content and Si content satisfies 0.1.ltoreq.Ni/Si.ltoreq.3.7. The aluminum alloy sheet is manufactured by homogenizing an aluminum alloy ingot at a temperature in a range of 500.degree. to 630.degree. C., after performing hot rolling at start temperature in a range of 400.degree. to 450.degree. C., providing cold rolling and intermediate annealing, and further performing final cold rolling. By this, the aluminum alloy sheet for printing plate is prevented from pit generation upon dipping in electrolytic solution in a condition where an electric power is not applied. Uniformity of grained surface of the aluminum alloy sheet by electrolytic treatment can be improved.Type: GrantFiled: December 26, 1996Date of Patent: August 18, 1998Assignee: Kabushiki Kaisha Kobe Seiko ShoInventors: Masaki Tanigawa, Shinichiro Hosono, Kozo Hoshino, Yoshihiko Asakawa
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Patent number: 5779824Abstract: An aluminum alloy support for a planographic printing plate is disclosed, which is an aluminum alloy plate comprising 0<Fe.ltoreq.0.20 wt %, 0.ltoreq.Si.ltoreq.0.13 wt %, Al.gtoreq.99.7 wt % and the balance of inevitable impurity elements, wherein the number of intermetallic compounds present in the arbitrary thickness direction with in 10 .mu.m from the plate surface is from 100 to 3,000 per mm.sup.2 and the intermetallic compound has an average particle size of from 0.5 to 8 .mu.m, with the intermetallic compounds having a particle size of 10 .mu.m or more being in a proportion by number of 2% or less. Also disclosed is a method for producing the above-described aluminum alloy support.Type: GrantFiled: July 20, 1995Date of Patent: July 14, 1998Assignee: Fuji Photo Film Co., Ltd.Inventors: Hirokazu Sawada, Hirokazu Sakaki, Tsutomu Kakei, Akio Uesugi, Masaya Matsuki
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Patent number: 5772801Abstract: In a process for the forming of wheel rims in metal alloy, a cast blank undergoes a cold chip removal process by cutting its central area, its inner surface and its lateral surface in order to obtain a semi-finished work which is then heated and plastically deformed by flow forming along its lateral surface to obtain an inner edge, an outer edge and a middle portion with a defined machine allowance; the rim thus obtained undergoes another cold chip removal process by cutting in order to work it down to the required size; the latter process may be preceded by solution and age hardening heat treatments.Type: GrantFiled: September 23, 1996Date of Patent: June 30, 1998Assignee: Reynolds Wheels S.p.A.Inventors: Valter Baldi, David J. Edwards, deceased
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Patent number: 5772800Abstract: An aluminium alloy plate is provided with a thickness of more than 2 inches, e.g. 6, 7 or 8 inches, and having an average logarithmic fatigue life of more than 100,000 cycles determined in accordance with ASTM test method E 466. The density of micropores with a size larger than 80 .mu.m in all locations in the midplane (T/2) midwidth position at head and tail ends of the finished plate as measured by Optical Microscopy of samples in any plane perpendicular to the midplane is less than 0.025 micropores per cm.sup.2. The plate may be formed by degassing of a melt to give a specified porosity of the cast ingot, and by hot rolling with at least one specified high reduction ratio pass.Type: GrantFiled: June 6, 1995Date of Patent: June 30, 1998Assignee: Hoogovens Aluminium Walzprodukte GmbHInventors: Alfred L. Heinz, Werner A. Schelb, Alfred J. P. Haszler, Otmar M. Muller
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Patent number: 5744734Abstract: A method for fabricating articles of high-temperature aluminum alloys having a compressional strength of at least 20 kg/mm.sup.2 at temperatures of 300.degree. C. or greater, is disclosed. The method comprises the steps of: (a) forming a porous preform from particles of a first aluminum alloy via cold-pressing, the preform having the shape and dimension of the aluminum alloy article to be fabricated; (b) squeeze-casting a molten second aluminum alloy into void spaces of the porous preform to form an aluminum composite containing the first aluminum alloy, which serves as a reinforcement phase, dispersed in the second aluminum alloy, which serves as a matrix phase; (c) wherein the molten second aluminum alloy is cast at such temperatures so as to cause a surface of the first aluminum alloy particles to melt and thereby form a strong bonding with the second aluminum alloy.Type: GrantFiled: October 31, 1995Date of Patent: April 28, 1998Assignee: Industrial Technology Research InstituteInventors: Chih-Chao Yang, Edward Chang
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Patent number: 5735976Abstract: A novel method for producing a ceramic phase particle dispersoid in metal and a novel product composed thereof are disclosed, including finely sized carbide phase particles formed in situ in a molten metal by salt-based liquid state reaction with Ti, B, Si, Sc, Hf, Nb, Ta, Zr, Mo, Al (when the molten metal matrix is not aluminum), or V and a halide salt containing carbon particles to form a uniform distribution of finely sized ceramic phase particles formed and dispersed in-situ in the metal matrix. The step of reacting includes vigorously stirring to form a reaction mixture at an elevated temperature for a residence time less than one hour to form a uniform distribution of particles sized less than 2.5 microns uniformly dispersed in-situ in the metal matrix.Type: GrantFiled: January 31, 1996Date of Patent: April 7, 1998Assignee: Aluminum Company of AmericaInventors: Men Glenn Chu, Siba P. Ray
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Patent number: 5725694Abstract: A free-machining alloy is disclosed containing bismuth, tin and indium. The free-machining constituents act as low melting point compounds for machining and are specially adapted for use in aluminum alloys such as AA6000 series and AA 2000 series alloys. The bismuth, tin and indium are effective replacements for the lead and bismuth addition used previously to improve machinability.Type: GrantFiled: November 25, 1996Date of Patent: March 10, 1998Assignee: Reynolds Metals CompanyInventor: Subhasish Sircar
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Patent number: 5718777Abstract: An amorphous alloy which is resistant to hot corrosion in sulfidizing and oxidizing atmospheres at high temperatures, consisting of at least one element selected from the group of Al and Cr and at least one element selected from the refractory metals Mo, W, Nb, and Ta, a portion of the set forth refractory metals being allowed to be substituted with at least one element selected from Fe, Co, Ni and Cu. The addition of Si further improves the alloy's oxidation resistance.Type: GrantFiled: July 23, 1996Date of Patent: February 17, 1998Assignees: Koji Hashimoto, YKK CorporationInventors: Koji Hashimoto, Hiroki Habazaki, Stanislaw Mrowec, Marek Danielewski
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Patent number: 5714018Abstract: A high-strength and high-toughness aluminum-based alloy having a composition represented by the general formula: Al.sub.a Ni.sub.b X.sub.c M.sub.d Q.sub.e, wherein X is at least one element selected from the group consisting of La, Ce, Mm, Ti and Zr; M is at least one element selected from the group consisting of V, Cr, Mn, Fe, Co, Y, Nb, Mo, Hf, Ta and W; Q is at least one element selected from the group consisting of Mg, Si, Cu and Zn; and a, b, c, d and e are, in atomic percentage, 83.ltoreq.a.ltoreq.94,3, 5.ltoreq.b.ltoreq.10, 0.5.ltoreq.c.ltoreq.3, 0.1.ltoreq.d.ltoreq.2, and 0.1.ltoreq.e.ltoreq.2. The aluminum-based alloy has a high strength and an excellent toughness and can maintain the excellent characteristics provided by a quench solidification process even when subjected to thermal influence at the time of working. In addition, it can provide an alloy material having a high specific strength by virtue of minimized amounts of elements having a high specific gravity to be added to the alloy.Type: GrantFiled: October 27, 1992Date of Patent: February 3, 1998Assignee: YKK CorporationInventors: Kazuhiko Kita, Hidenobu Nagahama, Takeshi Terabayashi, Makoto Kawanishi
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Patent number: 5698049Abstract: A method for producing aluminum matrix composites containing refractory aluminide whiskers or particulates which are formed in-situ is disclosed. Aluminum and refractory metal materials are blended in powder form and then heated to a temperature above the melting point of aluminum. A solid/liquid reaction between the molten aluminum and solid refractory metal provides a desired volume fraction of refractory aluminide reinforcement phase (in situ whiskers or particulates). Upon cooling the molten, unreacted portion of aluminum solidifies around the in situ reinforcements to create the improved composite material.Type: GrantFiled: June 26, 1996Date of Patent: December 16, 1997Assignee: McDonnell Douglas CorporationInventor: David M. Bowden
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Patent number: 5693897Abstract: A high strength, heat resistant aluminum-based alloy having a composition represented by the general formula Al.sub.bal Ti.sub.a Fe.sub.b or the general formula Al.sub.bal Ti.sub.a Fe.sub.b M.sub.c, wherein M represents at least one element selected from among V, Cr, Mn, Co, Y, Zr, Nb, Mo, Ce, La, Mm (misch metal), Hf, Ta and W; and a, b and c are, in weight percentage, 7.ltoreq.a.ltoreq.20, 0.2.ltoreq.b.ltoreq.6 and 0<c.ltoreq.6. A compacted and consolidated aluminum-based alloy having high strength and heat resistance is produced by melting a material having the above-specified composition, rapidly solidifying the melt into powder or flakes, compacting the resulting powder or flakes, and compressing, forming and consolidating the compacted powder or flakes by conventional plastic working.Type: GrantFiled: February 22, 1996Date of Patent: December 2, 1997Assignee: YKK CorporationInventor: Kazuhiko Kita
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Patent number: 5667600Abstract: Disclosed is a practical aluminum-based alloy containing 1 to 99 weight percent beryllium and improved methods for the investment casting of net shape aluminum-beryllium alloy parts.Type: GrantFiled: March 31, 1994Date of Patent: September 16, 1997Assignee: Brush Wellman, Inc.Inventors: Fritz C. Grensing, James M. Marder, Jere H. Brophy
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Patent number: 5656105Abstract: The calcium-aluminum system hydrogen absorbing alloy of the present invention is an alloy which is composed of a mixture P of Ca with (optional) Mg and an Al base alloy Q, has a molar ratio P:Q of 1:1.5 to 2.8 and shows a Laves phase with the C15-type structure as the fundamental structure thereof.Type: GrantFiled: June 27, 1995Date of Patent: August 12, 1997Assignee: Agency of Industrial Science & TechnologyInventors: Hideaki Tanaka, Hiroshi Miyamura, Nobuhiro Kuriyama, Tetsuo Sakai, Itsuki Uehara
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Patent number: 5654107Abstract: A wear resisting aluminum alloy composite material consisting of 10 to 40% by volume of a hybrid compact and the balance substantially an aluminum alloy matrix, wherein the hybrid compact contains 85 to 95% by weight of an inorganic whisker which is 0.2 to 1.2 .mu.m in diameter and 10 to 30 .mu.m in length, and 5 to 15% by weight of an alumina fiber which is 100 to 300 .mu.m in length, and the aluminum alloy matrix contains 4 to 12% by weight of a silicon having an average grain size of not more than 5 .mu.m. The composite material offers good properties such as anti-seizure property and wear resistance. The composite material is suitable for sliding members. Aluminum borate whisker and potassium titanate whisker may be preferably used as the inorganic whisker.Type: GrantFiled: October 5, 1995Date of Patent: August 5, 1997Assignee: Daido Metal Company Ltd.Inventors: Tadashi Tanaka, Masaaki Sakamoto, Koichi Yamamoto, Yoshiaki Sato, Eiji Kato
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Patent number: 5647919Abstract: A high strength, rapidly solidified alloy consisting of aluminum and, added thereto, additive elements. The mean crystal grain size of the aluminum is 40 to 1000 nm, the mean size of particles of a stable phase or a metastable phase of various intermetallic compounds formed from the aluminum and the additive element and/or various intermetallic compounds formed from the additive elements themselves is 10 to 800 nm, and the intermetallic compound particles are distributed in a volume fraction of 20 to 50% in a matrix consisting of aluminum. The rapidly solidified alloy has an improved strength at room temperature and a high toughness and can maintain the properties inherent in a material produced by the rapid solidification process even when it undergoes a thermal influence during working.Type: GrantFiled: October 5, 1994Date of Patent: July 15, 1997Assignee: YKK CorporationInventors: Kazuhiko Kita, Hidenobu Nagahama
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Patent number: 5643372Abstract: An improvement to a process for treating an aluminum alloy for the series AA 2000 or AA 6000 comprising solution heat treating, quenching and natural or artificial aging, in which conventional heat solution heat treating is defined as solution heat treating the alloy at a temperature which is 5.degree. to 10.degree. C. below a known eutectics melting temperature for the alloy. The improvement comprises solution heat treating at a temperature which is 10.degree. to 100.degree. C. below the conventional solution heat treating temperature in order to desensitize the alloy to intercrystalline corrosion.Type: GrantFiled: August 15, 1994Date of Patent: July 1, 1997Assignee: Pechiney RhenaluInventors: Pierre Sainfort, Jean Domeyne, Timothy Warner
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Patent number: 5643371Abstract: A method and apparatus for continuously cladding cast material includes simultaneously roll bonding a cladding liner stock to a material exiting a continuous casting apparatus. At the same time the liner stock is roll bonded to the cast material, the clad cast material is hot worked to form a clad product. A spray shield is positioned near the interface where the liner stock contacts the as cast material to prevent any impurities such as rolling lubricants from contaminating the bonding interface between the liner stock and the surface of the as cast material.Type: GrantFiled: June 7, 1995Date of Patent: July 1, 1997Assignee: Reynolds Metals CompanyInventors: Rodney E. Hanneman, Arthur L. Girard
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Patent number: 5632827Abstract: A aluminum alloy in the form of bulk includes an aluminum matrix and carbon particles having an average particle size of 100 nm or less and dispersed in the aluminum matrix in an amount of 1 to 40 atomic % with respect to the total atoms constituting the aluminum alloy. The aluminum alloy is produced by preparing a raw material comprising aluminum and carbon as components and forming an aluminum alloy by inserting the raw material into a cavity formed by a set of dies and applying repeatedly plastic deformation to the raw material while maintaining the temperature of the raw material in the range of from 100 to 400.degree. C.Type: GrantFiled: May 24, 1995Date of Patent: May 27, 1997Assignee: Kabushiki Kaisha Toyota Chuo KenkyushoInventors: Hironori Fujita, Fumio Nonoyama, Atsushi Danno
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Patent number: 5626692Abstract: The invention provides an aluminum-base composite material. The aluminum-base material contains a uniform distribution of carbide particles and lubricating phase particles such as carbon or graphite. The carbide particles increase hardness for improved wear resistance. The lubricating phase particles provide improved wear resistance and especially improve unlubricated wear resistance under increased loads. Finally, a dispersoid of nickel aluminide intermetallic phase may also be used to provide additional hardness and wear resistance. The composite is formed by introducing carbide particles and lubricating phase such as graphite into a molten aluminum alloy to neutraliize buoyancy and to form an aluminum-base mixture. Mixing the aluminum-base mixture to uniformly distribute carbide and carbon particles throughout the molten aluminum. Carbide and carbon particles counteract each other to remain uniformly distributed throughout the aluminum-base alloy despite prolonged holding or cooling times.Type: GrantFiled: March 1, 1994Date of Patent: May 6, 1997Assignee: INCO LimitedInventors: Pradeep K. Rohatgi, James A. E. Bell, Thomas F. Stephenson
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Patent number: 5614150Abstract: A method for producing aluminum matrix composites containing refractory aluminide whiskers or particulates which are formed in-situ is disclosed. Aluminum and refractory metal materials are blended in powder form and then heated to a temperature above the melting point of aluminum. A solid/liquid reaction between the molten aluminum and solid refractory metal provides a desired volume fraction of refractory aluminide reinforcement phase (in situ whiskers or particulates). Upon cooling the molten, unreacted portion of aluminum solidifies around the in situ reinforcements to create the improved composite material.Type: GrantFiled: September 28, 1994Date of Patent: March 25, 1997Assignee: McDonnell Douglas Corp.Inventor: David M. Bowden
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Patent number: 5614036Abstract: A high heat resisting and high abrasion resisting aluminum alloy and aluminum alloy powder have superior toughness, abrasion resistance, high temperature strength, and creep resistance and are useful to form engine parts for automobiles, airplanes, etc. The high heat resisting and high abrasion resisting aluminum alloy comprises 2 to 15 wt % of Ni, 0.2 to 15 wt % of Si, 0.6 to 8.0 wt % of Fe, one or two of 0.6 to 5.0 wt % of Cu and 0.5 to 3 wt % of Mg, the total amount of Cu and Mg being equal to or less than 6 wt %, one or two of 0.3 to 3 wt % of Zr and 0.3 to 3 wt % of Mo, the total amount of Zr and Mo being equal to or less than 4 wt %, 0.05 to 10 wt % of B, and the balance of Al and unavoidable impurities, and is produced by powder metallurgy.Type: GrantFiled: January 30, 1996Date of Patent: March 25, 1997Assignees: Toyota Jidosha Kabushiki Kaisha, Toyo Aluminium Kabushiki KaishaInventors: Kunihiko Imahashi, Hirohisa Miura, Yasuhiro Yamada, Hirofumi Michioka, Jun Kusui, Akiei Tanaka
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Patent number: 5607523Abstract: A high-strength aluminum-based alloy consisting of a composition represented by the general formula: Al.sub.bal Q.sub.a M.sub.b X.sub.c, wherein Q is at least one element selected from the group consisting of Mn and Cr; M is at least one element selected from the group consisting of Co, Ni, and Cu; X is at least one of rare earth elements including Y, or Misch metal (Mm); and a, b and c are, in atomic percentages, 1.ltoreq.a.ltoreq.7, 0.5.ltoreq.b.ltoreq.5, and 0<c.ltoreq.5, the aluminum-based alloy containing quasicrystals in the structure thereof. The quasicrystals may be of an icosahedral phase (I phase), a decagonal phase (D phase), or a crystalline phase akin thereto and the structure may comprise the quasicrystalline phase and a phase formed of any one of an amorphous phase, aluminum, and a supersaturated aluminum solid solution or a composite (mixed phase) thereof.Type: GrantFiled: January 9, 1995Date of Patent: March 4, 1997Assignees: Tsuyoshi Masumoto, Akihisa Inoue, YKK CorporationInventors: Tsuyoshi Masumoto, Akihisa Inoue, Junichi Nagahora, Toshisuke Shibata, Kazuhiko Kita
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Patent number: 5603783Abstract: A one-piece steering wheel is formed as a unitary casting from an alloy that includes 11.5% to 14% by weight silicon, and 350 to 450 parts per million strontium. Preferably the steering wheel mold is rotated during casting at relatively high rotational speeds exerting 100 g to 250 g force on the wheel. An optimum rotational speed is disclosed. A one-piece steering wheel formed according to the invention exhibits minimal length ferro-silicon hair-like strands, and thus exhibits reduced brittleness.Type: GrantFiled: June 21, 1994Date of Patent: February 18, 1997Assignee: M. J. Grootes Investments CCInventor: Cornelius J. T. Ferreira
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Patent number: 5593515Abstract: A high strength aluminum-based alloy, which having a composition of the general formula: Al.sub.bal Q.sub.a M.sub.b X.sub.c T.sub.d, wherein Q represents at least one element selected from the group consisting of Mn, Cr, V, Mo and W; M represents at least one element selected from the group consisting of Co, Ni, Cu and Fe; X represents at least one element selected from rare earth elements including Y or Mm; T represents at least one element selected from the group consisting of Ti, Zr and Hf; and a, b, c and d represent the following atomic percentages: 1.ltoreq.a.ltoreq.7, 0>5, 0>c.ltoreq.5 and 0>d.ltoreq.2, and contains quasi-crystals in the structure thereof. The alloy of the present invention is excellent in the hardness and strength at both room temperature and a high temperature, and also in thermal resistance and ductility.Type: GrantFiled: March 27, 1995Date of Patent: January 14, 1997Assignees: Tsuyoshi Masumoto, Akihisa Inoue, Teikoku Piston Ring Co., Ltd., Yamaha Corporation, YKK CorporationInventors: Tsuyoshi Masumoto, Akihisa Inoue, Hisamichi Kimura, Yoshiyuki Shinohara, Yuma Horio, Kazuhiko Kita
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Patent number: 5585067Abstract: An aluminum alloy containing at least one alloying metal selected from the group consisting of bismuth, cadmium, indium and lead in a quantity greater than the maximum solubility of the metal in solid aluminum. More than 80% by weight of the alloying metals are finely dispersed in a solid aluminum matrix in the form of globules or crystals with a size of less than 5 micrometers. The alloy can be obtained by means of mechanical or electromagnetic agitation of the alloy in the course of solidifying, and in the case of continuously casting a liquid alloy, the agitation can be accomplished by means of an alternating magnetic field which is coaxial to the continuous casting axis.Type: GrantFiled: April 6, 1995Date of Patent: December 17, 1996Assignee: Aluminium PechineyInventors: Michel Leroy, Marc Marticou