Incorporating Particulate Material Patents (Class 164/97)
  • Patent number: 6247221
    Abstract: A process for sealing a ceramic filter by infiltrating a metal into an end of the filter. The process includes the steps of contacting the end of a porous ceramic filter with a molten metal, whereby the metal enters into the ceramic matrix to substantially fill the void space. The ceramic filter is cooled to form a filter having a ceramic-metal composite portion. The present invention also provides a filter having an infiltrated metal seal. Methods for joining infiltrated ends are also provided.
    Type: Grant
    Filed: December 23, 1997
    Date of Patent: June 19, 2001
    Assignee: Coors Tek, Inc.
    Inventors: Marcus A. Ritland, Dennis W. Readey, Richard N. Kleiner, Jack D. Sibold, Kyle Knudson, Steven Landin, Paul Thoen
  • Patent number: 6223805
    Abstract: The present invention relates to a novel method for forming cast metal matrix composite bodies. In particular, the present invention relates to a novel method for forming or recycling metal matrix composite bodies so as to render such bodies in a condition for casting or recasting as a cast metal matrix composite body. Specifically, a scrap metal matrix composite body and preferably a scrap cast metal matrix composite body is placed into a crucible, optionally along with unreinforced matrix metal and/or virgin metal matrix composite material. Whether the scrap and/or virgin materials are placed into the crucible in solid or molten form, the contents of the crucible are ultimately rendered molten to form a composite melt.
    Type: Grant
    Filed: April 22, 1994
    Date of Patent: May 1, 2001
    Assignee: Lanxide Technology Company, LP
    Inventors: Charles Robert Banning, John Thomas Burke, Alan Scott Nagelberg, Vilupanur Alwar Ravi, Michael Allan Richmond, Chwen Chih Yang
  • Patent number: 6209621
    Abstract: An implantable prosthesis having porous textured surface regions and methods for making the same provide improved prostheses and prosthesis manufacturing methods. The implantable prostheses contain one more bead preforms that are secured to the metallic prosthesis components during the casting process to form porous textured surface regions in desired areas of the prostheses.
    Type: Grant
    Filed: July 7, 1995
    Date of Patent: April 3, 2001
    Assignee: Depuy Orthopaedics, Inc.
    Inventor: Debra J. Treacy
  • Patent number: 6183876
    Abstract: For forming a preform of composite material, such as aluminum-based composite material (MMC) by using friction during the forming thereof, ceramic reinforcement, such as Al2O3 and binder are prepared, and the prepared reinforcement and the silanor group binder are put into a die for press forming. During the forming, polycondensation occurs due to frictional heat generated between the fibrous or grain-like particles of the reinforcement and the silanor group binder to harden it, thereby obtaining a preform in which the particles of the reinforcement are fixedly connected to one another.
    Type: Grant
    Filed: July 7, 1998
    Date of Patent: February 6, 2001
    Assignee: Honda Giken Kogyo Kabushiki Kaisha
    Inventors: Yasuhiro Nakao, Kunitoshi Sugaya, Hiroto Shoji
  • Patent number: 6170556
    Abstract: Equipment for the preparation of electric conducting composite samples by infiltration in a mold characterized in that it essentially comprises: a pressurization/infiltration chamber having at least one opening to connect it by means of appropriate tubes with a vacuum line and a pressure line and devices for sealing both under vacuum and under pressure; a sample-holder, inside said chamber, made of a material with a high thermal conductivity with one or more seats in each of which a mold is housed consisting of: a chemically inert and thermally stable tube made of a non-porous material; a plug, situated at one end of the tube, of a material which is different from the tube; a chemically inert and thermally stable spacer of non-porous material, situated inside the tube in contact with the plug; a device for creating a vacuum in the chamber; a device for pressurizing the chamber; a device for the thermal treatment of the sample-holder.
    Type: Grant
    Filed: July 22, 1998
    Date of Patent: January 9, 2001
    Assignee: ENIRISORSE S.p.A.
    Inventors: Marino Battagliarin, Emilio Sentimenti, Letizia Meregalli
  • Patent number: 6171713
    Abstract: An impeller shoe (110) having a front side (112) with a series of half column members (114) and raised upper and lower rims (116, 118) that form the impact surface of the impeller shoe. Half columns (114) and raised rims (116, 118) are formed with carbide material (120) formed therein in order to improve wear resistance at these critical surfaces.
    Type: Grant
    Filed: July 17, 1998
    Date of Patent: January 9, 2001
    Assignee: Smith & Stout Research and Development
    Inventors: Jerry I. Smith, Anthony E. Stout
  • Patent number: 6148899
    Abstract: A mold cavity in a mold vessel is evacuated. A charge of molten infiltrant is transported into the mold vessel while the vacuum is maintained in the mold cavity. Pressure is applied to the molten infiltrant to move the molten infiltrant from the mold vessel into the mold cavity. The molten infiltrant is cooled in the mold cavity to solidify the infiltrant. A fill tube can be used to transport the infiltrant to the mold vessel.
    Type: Grant
    Filed: January 29, 1998
    Date of Patent: November 21, 2000
    Assignee: Metal Matrix Cast Composites, Inc.
    Inventors: James A. Cornie, Stephen S. Cornie, Ralph P. Mason, Mark A. Ryals
  • Patent number: 6136452
    Abstract: A method through which we can synthesize Functionally Graded Materials (FGM). Such materials are made so that their composition changes gradually from one point to another, such as in the example of gradient index (GRIN) optical components. A novel aspect of our method is the imposition of a centrifugal force during the combustion synthesis of composite materials for structural, optical, or electronic applications, with the result that the composition and the particle size of the metallic (or ceramic) component changes continuously and across the thickness of the product. We have prepared such FGM as ZrO.sub.2 +Ni, ZrO.sub.2 +Cu and Al.sub.2 O.sub.3 +Cu.
    Type: Grant
    Filed: February 27, 1998
    Date of Patent: October 24, 2000
    Assignee: The Regents of the University of California
    Inventors: Zuhair A. Munir, Wei Nong Lai, Subhash H. Risbud, Benjamin J. McCoy
  • Patent number: 6129135
    Abstract: A predetermined quantity of a metal-matrix composite material is injected to a heating crucible along an angular infeed direction toward a location therein at which a vortex is formed by the blade of an agitator through which the material is stirred while being superheated above the melting temperature to a pouring temperature under which the melted material is transferred to a casting mold after surface skimming thereof to form a product having improved wear resistance properties.
    Type: Grant
    Filed: June 29, 1999
    Date of Patent: October 10, 2000
    Assignee: The United States of America as represented by the Secretary of the Navy
    Inventors: Amarnath P. Divecha, Subhash D. Karmarkar, William A. May, James M. Kerr, William A. Ferrando, Scott M. Hoover
  • Patent number: 6129134
    Abstract: Reinforcing particles within a flux are dispersed through a metal matrix osited into a crucible purged of air by infeed of argon gas during heating of the matrix to a melted state for completing particle dispersion by agitation before remelting thereof after solidification. The remelted matrix with the particles fully dispersed therein is then allowed to undergo sedimentation increasing particle concentration along a flat surface portion of the final product having increased wear resistance thereat.
    Type: Grant
    Filed: March 11, 1999
    Date of Patent: October 10, 2000
    Assignee: The United States of America as represented by the Secretary of the Navy
    Inventor: Amarnath P. Divecha
  • Patent number: 6125914
    Abstract: A mold having a supply tube in a lower portion and in which has been placed a fibrous preform, is placed in a container. A crucible filled with magnesium blocks is placed under the mold. The magnesium is heated and the mold is preheated under vacuum until the fusion of the magnesium starts. The tube is then introduced into the magnesium and a neutral gas circulation is set up in the container, under a vacuum insufficient to trigger the evaporation of magnesium. After its complete fusion, the magnesium is transferred into the mold by a rapid pressurization of the container. The mold is then cooled and the part removed from the mold.
    Type: Grant
    Filed: November 23, 1998
    Date of Patent: October 3, 2000
    Assignee: Aerospatiale Societe Nationale Industrielle
    Inventors: Laetitia Billaud, Philippe Le Vacon
  • Patent number: 6099664
    Abstract: The invention provides a method of making a titanium boride metal matrix alloy, by firing a particulate reaction mixture comprising titanium, matrix material and a source of boron (e.g. boron carbide), under conditions such that the titanium and boron react exothermically to form a dispersion of fine particles (preferably greater than 1 micron and less than 10 microns in size) comprising titanium boride (plus titanium carbide where the source of boron is boron carbide) in a predominantly metal matrix. The titanium and matrix are preferably added as a titanium alloy such as ferrotitanium (e.g. eutectic ferrotitanium) or titanium-aluminium. The reaction conditions are preferably selected so that during the reaction a molten zone moves through the body of the reaction mixture, and the average size of the resulting hard particles is uniform throughout the resulting dispersion.
    Type: Grant
    Filed: November 28, 1997
    Date of Patent: August 8, 2000
    Assignee: London & Scandinavian Metallurgical Co., Ltd.
    Inventors: Peter Davies, James Leslie Frederick Kellie, Richard Nigel Mc Kay, John Vivian Wood
  • Patent number: 6044894
    Abstract: A method for preparing a light metal or light metal alloy composite product, wherein (a) an aqueous slurry containing water, a reinforcement powder, a metal powder and an alumina sol binder is prepared; (b) a preform is prepared from the slurry; (c) the preform is sintered; and (d) the sintered preform is impregnated with a melt of a light metal or a light metal alloy to produce a light metal or a light metal alloy based composite product.
    Type: Grant
    Filed: February 22, 1996
    Date of Patent: April 4, 2000
    Assignee: Mazda Motor Corporation
    Inventors: Makoto Fujita, Kazuo Sakamoto, Yukihiro Sugimoto, Yukio Yamamoto
  • Patent number: 6035923
    Abstract: A porous composite forming material is held in a cavity of a casting mold, and molten light alloy is poured into the cavity of the casting mold through a gate. Then a gas pressure is applied to the cavity in the casting mold with the cavity closed, thereby impregnating the pores of the porous composite forming material with the molten light alloy and forming a composite portion formed of a composite material of the light alloy and the composite forming material.
    Type: Grant
    Filed: August 28, 1996
    Date of Patent: March 14, 2000
    Assignee: Mazda Motor Corporation
    Inventors: Nobuyuki Oda, Yukihiro Sugimoto, Kazuo Sakamoto
  • Patent number: 6033791
    Abstract: A wear resistant, high-impact iron alloy member (20,22) suitable for use in an impact rock crusher and a method of making the same. The invention provides a white iron alloy member (20,22) having at least one wear surface (24) with carbide granules encapsulated in a matrix (28) of white iron and contained in a selected region adjacent the wear surface (24) of the member (20,22). The iron alloy member is made by a method of casting comprising the steps of: placing a molding insert (35,40) in a mold (60) at a selected location adjacent the wear surface (24); positioning a quantity of carbide granules (29), most preferably tungsten carbide granules 29, in the molding insert (35,40) before pouring; and pouring molten white iron alloy into the mold (60) to form the casting.
    Type: Grant
    Filed: April 4, 1997
    Date of Patent: March 7, 2000
    Assignee: Smith and Stout Research and Development, Inc.
    Inventors: Jerry I. Smith, Anthony E. Stout
  • Patent number: 6032720
    Abstract: A process of making a vane for a rotary expansible chamber device, comprising the steps of: providing an open vane die having a die cavity, wherein said die cavity comprises a body cavity section corresponding to a body of the vane, a first tip cavity section corresponding to a first tip of the vane, and a second tip cavity section corresponding to a second tip of the vane; providing a preheated, porous carbon preform in the first tip cavity section of the vane die, the preform having a shape corresponding to at least a portion of the first tip cavity section; closing the vane die; injecting a castable admixture comprising a metal alloy and a plurality of inorganic particles into the die cavity and filling the vane die cavity with the injected admixture; impregnating the preform with the metal alloy of the injected admixture, substantially all of the inorganic particles from the injected admixture being filtered out by the preform as the admixture flows into the preform; allowing the castable admixture to sol
    Type: Grant
    Filed: July 22, 1998
    Date of Patent: March 7, 2000
    Assignee: Tecumseh Products Company
    Inventors: Otto K. Riegger, Robert B. Weatherwax, III
  • Patent number: 6015528
    Abstract: A composite material mixture of free flowing reinforcement particles in a molten metal is solidified at a cooling rate greater than about 15.degree. C. per second between the liquidus and solidus temperatures of the matrix alloy. This high cooling rate imparts a homogeneous structure to the solid composite material. Care is taken to avoid the introduction of gas bubbles into the molten composite material while the mixture is stirred to prevent segregation of the particles. For viscous melts, an artificial surface layer such as a fiberglass blanket may be used to prevent entrapment of bubbles during pre-casting stirring. Additionally, gas bubbles are removed from the molten mixture by filtering and skimming.
    Type: Grant
    Filed: March 4, 1996
    Date of Patent: January 18, 2000
    Assignee: Alcan International Limited
    Inventors: Richard S. Bruski, Larry G. Hudson, Iljoon Jin, David J. Lloyd, Michael D. Skibo
  • Patent number: 5983973
    Abstract: A mold vessel having a mold cavity is heated and evacuated. A charge of molten infiltrant is provided into the mold vessel from a source not in vacuum communication with the mold vessel while a reduced pressure is maintained in the mold cavity. Pressure is applied to the molten infiltrant to move it into the mold cavity. The molten infiltrant in the mold cavity is cooled to solidify the molten infiltrant. The mold cavity may contain a preform to produce a metal matrix composite.
    Type: Grant
    Filed: June 27, 1997
    Date of Patent: November 16, 1999
    Assignee: Massachusetts Institute of Technology
    Inventor: James A. Cornie
  • Patent number: 5983974
    Abstract: A lid for a chip/package system includes a body sized to fit over an integrated circuit chip and being connectable to a package. The body has at least two regions exhibiting different coefficients of thermal expansion, with one CTE matching that of the chip and the other matching that of the package.
    Type: Grant
    Filed: April 9, 1998
    Date of Patent: November 16, 1999
    Assignee: W. L. Gore & Associates, Inc.
    Inventor: Mark F. Sylvester
  • Patent number: 5976277
    Abstract: A high speed tool steel and a manufacturing method therefor are disclosed, in which carbides are formed in the matrix in a uniform manner, thereby obtaining a high toughness and a high abrasion resistance. The high speed tool steel according to the present invention includes a basic composition of W.sub.a Mo.sub.b Cr.sub.c Co.sub.d V.sub.x C.sub.y Fe.sub.z where the subscripts meet in weight %: 5.0%.ltoreq.a.ltoreq.7.0%, 4.0%.ltoreq.b.ltoreq.6.0%, 3.0%.ltoreq.c.ltoreq.5.0%, 6.5%.ltoreq.d.ltoreq.9.5%, 2.2%.ltoreq.x.ltoreq.8.3%, 1.1%.ltoreq.y.ltoreq.2.18%, and 66.52%.ltoreq.z.ltoreq.73.7%. The final structure has carbides uniformly distributed within a martensite matrix, which are mainly MC and M.sub.6 C carbides. The method includes the steps of melting the above-defined alloy composition, gas spraying the melted alloy to form a bulk material, heat treating the bulk material to decompose the M.sub.2 C carbides to stabilize M.sub.6 C carbides and hot working the heat treated bulk material to a desired shape.
    Type: Grant
    Filed: May 8, 1997
    Date of Patent: November 2, 1999
    Assignees: Pohang Iron & Steel Co., Ltd., Research Institute of Industrial Science & Technology
    Inventors: Woo Jin Park, Eon Sik Lee, Sang Ho Ahn
  • Patent number: 5944097
    Abstract: A substrate carrier for a ceramic substrate which supports one or more high power semiconductor devices which is fabricated from a metal base composite and which includes strategically located high conductivity copper based inserts to provide an effective heat transfer path to a heat sink for high power electronic devices. The coefficient of thermal expansion of both the metal based composite and the copper based inserts substantially match that of the substrate. The substrate carrier is formed by a pressure casting process where a porous preform of SiC, for example, is infiltrated with molten aluminum.
    Type: Grant
    Filed: May 6, 1997
    Date of Patent: August 31, 1999
    Assignee: Northrop Grumman Corporation
    Inventors: Mehmet N. Gungor, J. Donald Gardner, Jr., William R. Larimer
  • Patent number: 5941297
    Abstract: Metal matrix composite is made by assembling pre-forms of porous reinforcing material with an array of separator plates in a die in a pressure vessel, and infiltrating molten metal matrix material. Pre-evacuation followed by pressurisation when the molten metal matrix material is introduced into the die aids the infiltration. Re-introduction of gas during initial heating prior to melting speeds the heat-up process.
    Type: Grant
    Filed: September 23, 1996
    Date of Patent: August 24, 1999
    Assignee: AEA Technology PLC
    Inventor: Robin Michael Kurt Young
  • Patent number: 5934355
    Abstract: A formed porous body of oxide ceramic and an aluminum alloy block are placed in a crucible in an atmospheric furnace, and a magnesium source is placed in another crucible in the atmospheric furnace. An argon gas is then introduced into the atmospheric furnace, which is then heated to produce a magnesium vapor from the magnesium source and melt the aluminum alloy block. Then, the argon gas is replaced with a nitrogen gas to generate magnesium nitride. The magnesium nitride reduces an oxide on surfaces of the formed porous body, exposing metal atoms on the surfaces of the formed porous body. The molten aluminum alloy permeates the formed porous body under a pressure lower or higher than the atmospheric pressure or alternate pressures lower and higher than the atmospheric pressure.
    Type: Grant
    Filed: December 2, 1997
    Date of Patent: August 10, 1999
    Assignee: Honda Giken Kogyo Kabushiki Kaisha
    Inventors: Yasuhiro Nakao, Kunitoshi Sugaya, Hiroto Shoji
  • Patent number: 5900277
    Abstract: A process for preparing complex-shaped, ceramic-metal composite articles, comprising:a) contacting a non-wettable powder that is non-wetting to a metal to be used for infiltration with a shaped ceramic body to form a layer(s) of the non-wettable powder on one or more surface(s) of the shaped ceramic body wherein the shaped ceramic body has a region(s) where there is no layer of the non-wettable powder;b) infiltrating the shaped ceramic body with the metal through the region(s) where there is no layer of the non-wettable powder such that a complex-shaped ceramic-metal composite comprising one or more metal phases and one or more ceramic phases is formed, wherein the article has substantially the net shape of the shaped ceramic body and the undesirable regions of excess metal on the surface and undesirable phases within the complex-shaped ceramic-metal composite article near the surface are located only in the region(s) where there is no layer of the non-wettable powder.
    Type: Grant
    Filed: December 9, 1996
    Date of Patent: May 4, 1999
    Assignee: The Dow Chemical Company
    Inventors: Richard T. Fox, Chan Han, Aleksander J. Pyzik, Robert T. Nilsson
  • Patent number: 5899256
    Abstract: Metal matrix composites are made by infiltrating packed loose fly ash with molten metal or metal alloy under low pressure. In some embodiments the infiltration is driven by pressurized gas. Coating the fly ash prior to infiltration can lower the threshold of pressure required for satisfactory infiltration by the molten metal. In some embodiments nickel coated cenosphere fly ash is employed. Resulting metal-fly ash composites have high volume fractions of fly ash, and the fly ash is uniformely distributed in the metal matrix. The densities of the composites are relatively low, particularly in composites made using cenosphere fly ash.
    Type: Grant
    Filed: October 3, 1997
    Date of Patent: May 4, 1999
    Assignee: Electric Power Research Institute, Inc.
    Inventor: Pradeep K. Rohatgi
  • Patent number: 5897943
    Abstract: Metal matrix composites comprising of a solid preform comprising of a filler phase containing fly ash and a binding material having a binder to water ratio of 1:1 to 1:9, wherein the preform contains a metal homogeneously distributed within the preform.
    Type: Grant
    Filed: January 23, 1997
    Date of Patent: April 27, 1999
    Assignee: Electric Power Research Institute, Inc.
    Inventor: Pradeep K. Rohatgi
  • Patent number: 5896911
    Abstract: A metal ground engaging tool (GET) component is selected. One or more critical wear surfaces on the GET component are identified. The GET component is selectively reinforced by depositing one or more metal matrix composite components at the one or more identified critical wear surfaces on the GET component. The metal matrix composite components consist of a reinforcement preform and a metal. The preform is formed from a material selected from one of ceramic, cermet, or mixtures thereof. The metal is selected from one of iron, alloy steel, or mixtures thereof. The reinforcement preform is present in the metal matrix composite in the range of about 30% to about 60% by volume.
    Type: Grant
    Filed: March 29, 1996
    Date of Patent: April 27, 1999
    Assignee: Caterpillar Inc.
    Inventor: Gerald A. Gegel
  • Patent number: 5890530
    Abstract: Method of making MMC components by an infiltration process, with a preform (3) which is disposed inside a crucible (6) and, optionally, held by a preform holder (2), being placed inside a pressure container (1), wherein the atmosphere inside the pressure container (1) is changeable during the production process, and after the infiltration metal (4) has melted on, the preform (3) is contained inside a sealed atmosphere in the presence of an oxygen-binding material.
    Type: Grant
    Filed: June 19, 1996
    Date of Patent: April 6, 1999
    Assignee: Electrovac, Fabrikation elektrotechnischer Spezialartikel Gesellschaft m.b.H.
    Inventor: Theodore N. Schmitt
  • Patent number: 5876659
    Abstract: Fiber bundle reinforced composite material useful for various high temperature structural members having excellent strength, toughness and resistance to oxidation and a process for producing the same. The fiber bundle reinforced composite material is reinforced with fiber bundles each having a plurality of continuous inorganic fibers bundled with medium such as carbon, being oriented in one, two or three directions, or randomly in the matrix which is reinforced with nano-sized particles precipitated. The fiber bundle reinforced composite material has a desired orientation of fibers and enables production of fiber bundle reinforced composite members having excellent strength and toughness.
    Type: Grant
    Filed: July 24, 1997
    Date of Patent: March 2, 1999
    Assignee: Hitachi, Ltd.
    Inventors: Yoshiyuki Yasutomi, Shigeru Kikuchi, Yukio Saito, Kunihiro Maeda
  • Patent number: 5875877
    Abstract: A structural fiber reinforced ceramic matrix composite (FRCMC) material adapted for clutch use. The entirety of the frictional components of a clutch mechanism or only particular components thereof can be made of the FRCMC material. One embodiment has integrally molded fiber reinforced ceramic matrix composite clutch friction pads forming the friction surfaces of metal clutch parts. Clutch components exhibiting a higher temperature and wear-resistance than currently available clutch parts are described. These clutch components and pads exhibit improved performance at high temperatures and are highly wear-resistant in comparison to current clutch components.
    Type: Grant
    Filed: February 4, 1998
    Date of Patent: March 2, 1999
    Assignee: Northrop Grumman Corporation
    Inventors: Steven Donald Atmur, Thomas Edward Strasser, William Scott Richardson
  • Patent number: 5873402
    Abstract: A process of making a casing having at least one open end and formed with electric conducting passages and connections for electronic components or switching circuits, includes the following steps: preparing a formed body, made of ceramics, glass, glass-ceramics, metal or silicon carbide, with passageways in form of bores and/or indentations, placing the formed body in a mold and pouring liquid metal in the mold to surround the formed body, thereby filling the first passageways, and removing metal from the formed body to leave metal only in the first passageways.
    Type: Grant
    Filed: April 17, 1996
    Date of Patent: February 23, 1999
    Assignee: Electrovac, Fabrikation Elektrotechnischer Spezialartikel Gesellschaft M.B.H.
    Inventors: Helmut Nechansky, Theodor Schmitt
  • Patent number: 5865912
    Abstract: Described herein is an SiC-reinforced aluminum alloy composite material of the type having silicon carbide uniformly dispersed in an aluminum alloy matrix containing magnesium as a strengthening element, characterized in that the composite material contains Al4C3 in an amount smaller than 0.5 wt % and residual oxygen in an amount smaller than 0.4 wt %, and has a modulus of elasticity higher than 9000 kgf/mm.sup.2.
    Type: Grant
    Filed: August 16, 1993
    Date of Patent: February 2, 1999
    Assignee: Kabushiki Kaisha Kobe Seiko Sho
    Inventors: Hiroyuki Morimoto, Kenichiro Ouchi, Hiroshi Iwamura
  • Patent number: 5865238
    Abstract: A Billet formed of an aluminum alloy matrix and ceramic particles is heated in an oxygen-containing atmosphere, forming an aluminum oxide surface and softening the matrix alloy. The semi-solid billet then is compressed in a die casting sleeve and the softened matrix material is displaced into a die to form the shape.
    Type: Grant
    Filed: April 1, 1997
    Date of Patent: February 2, 1999
    Assignee: Alyn Corporation
    Inventors: Robin A. Carden, Thomas Flessner
  • Patent number: 5845698
    Abstract: The present invention relates to a manufacturing method of aluminum alloy having high wear resistance, in particular, to manufacturing method of aluminum alloy by dispersing silicon particle on only required part of wear resistance, and infiltrating the molten metal into the preform of silicon particle.
    Type: Grant
    Filed: November 13, 1995
    Date of Patent: December 8, 1998
    Assignee: Hyundai Motor Company
    Inventor: Jun-Su Kim
  • Patent number: 5839496
    Abstract: Disclosed are a composite material having an anti-wear property and a process for producing the same. The composite material includes a matrix of a low melting point Sn alloy having a melting point of from 80.degree. to 280.degree. C., and metallic dispersing particles dispersed in the matrix in an amount of from 10 to 50% by volume. When the composite material is utilized to make a rough mold for preparing a prototype, it sharply improves the anti-wear property of the rough mold, and it can be refused for a plurality of times without adversely affecting the sharply improved anti-wear property. The composite material provides the advantageous effect best when the metallic dispersing particles are Fe-C alloy dispersing particles and/or Fe-W-C alloy dispersing particles which were subjected to a surface treatment including an Sn or Ni electroplating followed by a ZnCl.sub.2 .multidot.NH.sub.4 Cl flux depositing.
    Type: Grant
    Filed: November 8, 1996
    Date of Patent: November 24, 1998
    Assignees: Toyota Jidosha Kabushiki Kaisha, Nisshin Steel Co., Ltd.
    Inventors: Satoru Kito, Masahito Ito, Fuminori Matuda, Eiki Takeshima, Yasuji Tanaka, Takahiro Fujii, Kenjiro Izutani
  • Patent number: 5817164
    Abstract: Improvements in metallurgical conversion in accordance with the present intion consist in the preparation of a semifinished item (a charge stock) in the form of a pig by forming thereof in a molding box of a casting machine from a solid filler, for the most part an oxidizing agent, and a liquid pig iron followed by cooling, provided said solid filler and said liquid pig iron undergo, in the process of forming, an action which prevents the floating up of the solid filler in the liquid pig iron. Such an action is effected both by applying a mechanical force, in particular by providing a casting machine with a cantilever (8) having a hollow roller (9) which rests on a molding box (2) and a weighting material (10), and by choosing relative dimensions of the solid filler pieces and selecting a rate of pig casting. Optimal conditions for using such semifinished item for metallurgical conversion which in accordance with the present invention is carried out in oxygen converters and arc furnaces are described.
    Type: Grant
    Filed: March 12, 1996
    Date of Patent: October 6, 1998
    Assignee: Aktsionernoe Obschestvo Zakrytogo TIPA "Intermet-Service & Co."
    Inventors: Genrikh Alexeevich Dorofeev, Serafim Zakharovich Afonin, Alexei Grigorievich Zubarev, Evgeniy Nektarievich Ivashina, Alexandr Vladimirovich Makurov, Alexandr Nikolaevich Panfilov, Vyacheslav Vasilievich Ryabov, Anatoly Georgievich Sitnov, Jury Viktorovich Utkin, Evgeniy Khristoforovich Shakhpazov, Mark Aronovich Tseitlin
  • Patent number: 5803153
    Abstract: Inserts of powder compacts or metal matrix composite inserts in the form of rods, bars, plates, wires, wire mesh, ribbons, chaplets, mold coatings or machining chips are placed in the sprue, sprue basin, runner, or a mold in gate of a static sand mold. The molten metal stream partly or completely melts the inserts releasing the reinforcements which get mixed with the molten alloy streams to form the shaped casting of the composite.
    Type: Grant
    Filed: August 26, 1996
    Date of Patent: September 8, 1998
    Inventor: Pradeep K. Rohatgi
  • Patent number: 5803152
    Abstract: The present invention relates to eutectic alloy systems, such as white irons, in which a primary phase grows out of the melt when the melt is cooled below the liquidus temperature and comprises pouring the molten metal alloy at a temperature at or above the liquidus in a stream into a casting mould to form a casting and introducing a particulate material into the stream of molten metal to extract heat from the molten metal alloy to undercool the molten metal alloy from the pour temperature into the primary phase solidification range between the liquidus and the solidus temperatures of the alloy and thereby initiate primary phase nucleation and restrict primary phase growth. The primary function of the particulate material is to act as a heat sink but the particulate material may at least partially dissolve in the melt and may act as a seeding agent for the primary phase. The invention is described with particular reference to high chromium hypereutectic white irons.
    Type: Grant
    Filed: June 18, 1996
    Date of Patent: September 8, 1998
    Assignee: Warman International Limited
    Inventors: Kevin Francis Dolman, Craig Ian Walker, Charles Philip Harris, Andrew William Thomson
  • Patent number: 5791397
    Abstract: The present invention relates to a process for producing a Mg-based composite material by using Mg or a Mg alloy as the matrix and utilizing a spontaneous infiltration phenomenon. This process comprises the step of bringing a powder mixture composed of a reinforcing agent and a infiltration agent into contact with a molten matrix metal comprising Mg or a Mg alloy, so as to cause the molten matrix metal to infiltrate into the powder mixture. The present invention also relates to a process for producing a Mg-based composite material which comprises the steps of forming a preform composed of a reinforcing agent and a infiltration agent and causing a molten matrix metal comprising Mg or a Mg alloy to infiltrate into the preform.
    Type: Grant
    Filed: March 12, 1996
    Date of Patent: August 11, 1998
    Assignee: Suzuki Motor Corporation
    Inventors: Masayoshi Suzuoki, Hiromitsu Kaneda, Yoshinobu Sano, Takao Cho
  • Patent number: 5787960
    Abstract: A preform of reinforcement material is infiltrated with fusible metal without preceding vacuum treatment of the preform through gas pressure application solely. The infiltrated preform is allowed to solidify under pressure.
    Type: Grant
    Filed: March 13, 1997
    Date of Patent: August 4, 1998
    Assignee: Electrovac, Fabrikation Elektrotechnischer Spezialartikel Gesellschaft m.b.H.
    Inventor: Theodore Schmitt
  • Patent number: 5785109
    Abstract: A method for casting wear resistant parts which is capable of forming a hardened portion at a desired position with ease, whereby a wear resistant part can be obtained which has both wear resistance and toughness. To this end, the method includes the steps of filling the cacity of a holding member (16), which can be melted into molten steel, with a hardened portion forming material (19) comprising superhard particles (17), placing the holding member (16) which has been so filled with the hardened portion forming material (19) in a casting mold (10), pouring molten steel into the casting mold (10), thereby causing not only the holding member (16) to be melted into molten steel but also the superhard particles (17) to be dispersed, and solidifying the molten steel. In addition, the hardened portion forming material (19) can be constituted by superhard particles (17) and graphite powder (18) and/or metallic powder.
    Type: Grant
    Filed: February 4, 1997
    Date of Patent: July 28, 1998
    Assignee: Komatsu Ltd.
    Inventor: Hiroyuki Hongawa
  • Patent number: 5780166
    Abstract: A rotating gate feeder (1) for feeding substantially particulate material comprises a housing (2) and a rotor (3) and also an end cap (8) at each end of the housing. The invention is characterized in that a wear-resistant coating (6) is cast directly on to the inner wall (14) of the housing which faces towards the rotor (3). The inner wall (14) of the housing functions as an outer mold and a purpose-adapted core (15) is used as an inner mold. The housing (2) may be provided at certain points with release zones on the inner walls (14) which face towards the cast wear-resistant coating (6). One or more wear members (12) having greater wear resistance than the molding compound may be embedded therein.
    Type: Grant
    Filed: June 3, 1996
    Date of Patent: July 14, 1998
    Assignee: AMECO International AS
    Inventor: Ivar Lund
  • Patent number: 5775402
    Abstract: Processes for providing enhanced thermal properties of tooling, particularly metal and metal/ceramic molds, made by solid free form fabrication techniques, such as the three dimensional printing process, and the tooling made by these processes are disclosed. The methods of enhancing thermal properties include incorporating integral contour coolant channels into the mold, adding surface textures to the coolant channels, creating high thermal conductivity paths between the surfaces and the coolant channels, and creating low thermal inertia regions in the mold.
    Type: Grant
    Filed: October 31, 1995
    Date of Patent: July 7, 1998
    Assignee: Massachusetts Institute of Technology
    Inventors: Emanuel Sachs, Steven P. Michaels, Samuel M. Allen
  • Patent number: 5775403
    Abstract: A method of fabricating MMCs having high thermal conductivity coupled with coefficient of thermal expansion (CTE) values which approximates the CTE of ceramics and semi-conductor materials typically used in electronic packaging. The method comprises preparing a formed agglomeration of powder particles (preform); partially sintering the preform; placing the partially sintered preform into a forming chamber; infiltrating the preform with liquid-phase metal; and allowing the liquid-phase metal to solidify and form an MMC around and through the preform. In a preferred embodiment, the preform is constructed from silicon carbide, and the metal matrix is an aluminum-silicon alloy.
    Type: Grant
    Filed: June 7, 1995
    Date of Patent: July 7, 1998
    Assignee: Aluminum Company of America
    Inventors: M. K. Premkumar, Ralph R. Sawtell, Frankie E. Phelps, James A. DerKacy, David I. Yun
  • Patent number: 5765623
    Abstract: The invention provides a new method for casting alloys containing a finely divided phase. A bath of the molten metal having a melting point is provided. A finely divided solid metal having a melting point greater than the melting point of molten metal is introduced into the molten metal. The finely divided metal is reacted with the molten metal to form a solid phase within the molten metal. The molten bath is then mixed to distribute the solid phase within the molten metal. The molten alloy is then cast into a solid object containing the solid phase. The solid phase is insoluble in the matrix and has a size related to the initial size of the finely divided solid. The alloy of the invention advantageously consists essentially of, by weight percent, about 3 to 40 aluminum, about 0.8 to 25 nickel, about 0 to 12 copper and balance zinc and incidental impurities. The alloy has a zinc-containing matrix with nickel-containing aluminides distributed throughout the matrix.
    Type: Grant
    Filed: October 2, 1995
    Date of Patent: June 16, 1998
    Assignee: Inco Limited
    Inventors: Malcolm Charles Evert Bell, James Alexander Evert Bell, Carlos Manuel Diaz, Thijs Eerkes, Thomas Francis Stephenson, Scott Thomas Campbell, John Francis Brennan, Anthony Edward Moline Warner
  • Patent number: 5765624
    Abstract: A iron-based material such as cast iron is made by a process wherein filler particles are added to an iron base metal, as the base metal is poured into the mold. Pieces containing ceramic filler particles held together by a binder can be disposed in the mold prior to pouring molten iron base metal therein. Molten iron base metal is then poured into the mold so that the molten base metal contacts the pieces, gradually dissolving the filler. The filler becomes distributed throughout the molten base metal within the mold. Upon cooling, the base metal has the filler distributed therein, resulting in a iron-based material. The resulting material is particularly useful for making vehicle parts normally made of cast iron or steel.
    Type: Grant
    Filed: October 23, 1995
    Date of Patent: June 16, 1998
    Assignee: Oshkosh Truck Corporation
    Inventors: Robert M. Hathaway, Pradeep K. Rohatgi
  • Patent number: 5755272
    Abstract: Method for producing metal matrix composites. The method includes the steps of placing a substantially liquid metal in the vicinity of a reinforcement material and in the vicinity of the source of a transient magnetic field sufficient to produce an electromagnetic body force within the metal. The magnetic field is activated thereby propelling the substantially liquid metal into the reinforcement material thereby producing metal matrix composites.
    Type: Grant
    Filed: March 27, 1996
    Date of Patent: May 26, 1998
    Assignee: Massachusetts Institute of Technology
    Inventors: Andreas Mortensen, Richard M. Andrews, Merton C. Flemings
  • Patent number: 5752561
    Abstract: In the production of a metal charge for steelmaking in arc furnaces, a method for producing a low density intermediate charging stock by prefilling the ingot molds of a casting machine with a substance that releases gas at a temperature below the temperature of the charged pig iron, such as limestone, dolomite or caprolactam.
    Type: Grant
    Filed: December 5, 1995
    Date of Patent: May 19, 1998
    Assignee: Intermet-Service & Co.
    Inventors: Genrikh Alekseevich Dorofeev, Aleksandr Vladimirovich Makurov, Anatolii Georgievich Sitnov, Aleksandr Nikolaevich Panfilov, Eduard Emmanuilovich Minikes, Nikolai Ivanovich Yurin, Arkadii Nikolaevich Ponomarev, Yevgenii Nektar'Veich Ivashina, Gennadii Pavlovich Zuev
  • Patent number: 5735332
    Abstract: The present invention is directed to a process for fabricating ceramic-metal composites having continuous ceramic and metal phases. The process includes the steps of contacting a porous ceramic matrix material with a molten metal whereby capillary action pulls the metal into the ceramic matrix to substantially fill the void space. The present invention also provides a ceramic-metal composite having continuous metal and ceramic phases.
    Type: Grant
    Filed: February 3, 1997
    Date of Patent: April 7, 1998
    Assignee: Coors Ceramics Company
    Inventors: Marcus A. Ritland, Dennis W. Readey
  • Patent number: 5715887
    Abstract: The present invention relates to a metal wood golf club head comprising a metal outer husk with a hollow inside portion and foaming metal or foaming carbon material compounded with carbon fibers arranged in the hollow inside portion and a metal wood golf club with this club head, and a method for producing the club head and the golf club by casting with said foaming metal or said foaming carbon material compounded with carbon fibers as a core which is rough-cut by machine to leave the portion to be kept in cutting and then is formed by a mold and covered with metal sheet.
    Type: Grant
    Filed: October 26, 1995
    Date of Patent: February 10, 1998
    Inventor: Toshihiro Hosokawa