Nonmetal Is Elemental Carbon Patents (Class 419/11)
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Patent number: 7678325Abstract: A combination of a metal and Sn may be used as a solvent material for bulk crystallization and sintering of single crystal diamond to form a biocompatible and corrosion-resistant biomedical device.Type: GrantFiled: April 5, 2006Date of Patent: March 16, 2010Assignee: Diamicron, Inc.Inventor: Clayton F. Gardinier
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Publication number: 20100051881Abstract: The present invention relates to a composite sintering materials using a carbon nanotube (including carbide nano particles, hereinafter the same) and a manufacturing method thereof, the method comprises the steps of: combining or generating carbon 5 nanotubes in metal powers, a compacted product, or a sintered product; growing and alloying the carbon nanotubes by compacting or sintering the metal powers, the compacted product, or the sintered product; and strengthening the mechanical characteristics by repeatedly performing the sintering process and the combining process or the generating process of the carbon nanotubes.Type: ApplicationFiled: September 7, 2007Publication date: March 4, 2010Applicant: C & TECH CO., LTD.Inventors: Sang-chul Ahn, Sun-hwa Yang, Hyeung-eun Ahn
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Publication number: 20100043662Abstract: A diffusion alloyed iron powder is provided wherein tungsten W is bonded to the surfaces of the particles of an iron or iron-based powder, and wherein the diffusion alloyed iron powder comprises by weight-%: 30-60 W, with the balance being essentially only iron and unavoidable impurities.Type: ApplicationFiled: January 21, 2008Publication date: February 25, 2010Applicant: HOGANAS AB (publ)Inventors: Johan Arvidsson, Hans Söderhjelm
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Patent number: 7662424Abstract: The method of making a composite particle for an electrode in accordance with the present invention comprises a granulating step of integrating a conductive auxiliary agent and a binder adapted to bind the conductive auxiliary agent and an electrode active material together with a particle made of the electrode active material while in close contact with each other in an inert gas atmosphere so as to form a composite particle for an electrode containing the electrode active material, conductive auxiliary agent, and binder. When the composite particle obtained by this method is used as a constituent of an electrode, an electrode having an excellent electrode characteristic and an electrochemical device having excellent electrochemical characteristics can be formed easily and reliably.Type: GrantFiled: August 25, 2004Date of Patent: February 16, 2010Assignee: TDK CorporationInventors: Masato Kurihara, Satoshi Maruyama, Tadashi Suzuki
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Publication number: 20100034686Abstract: A composition having high density and low toxicity suitable for use as a shotgun pellet, a bullet or armor piercing projectile and a method for manufacturing such composition is described. This material and product are developed to economically address the toxicity problems inherent in lead shot and bullets. This composition, in its present embodiment, is also suitable for use in any product requiring high-density and low toxicity. One present embodiment maintains the magnetic properties of the projectile if desired.Type: ApplicationFiled: January 28, 2005Publication date: February 11, 2010Applicant: Caldera Engineering, LLCInventor: John Roger Peterson
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Publication number: 20100015002Abstract: In some embodiments, the present invention is directed to a new composition of matter. Such a composition generally comprises a functionalized single-wall carbon nanotube (SWNT) which is coated with a metal that would not react with carbon at elevated temperatures. The metal-coated tube is incorporated into a metal matrix that could potentially form carbides. In some or other embodiments, the present invention is directed to methods of making such compositions.Type: ApplicationFiled: April 2, 2007Publication date: January 21, 2010Inventors: Enrique V. Barrera, Yildiz Bayazitoglu, Kenneth Wilson
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Publication number: 20100008812Abstract: A hard phase forming alloy powder, for forming a hard phase dispersed in a sintered alloy, consists of, by mass %, 15 to 35% of Mo, 1 to 10% of Si, 10 to 40% of Cr, and the balance of Co and inevitable impurities. A production method, for a wear resistant sintered alloy, includes preparing a matrix forming powder, the hard phase forming alloy powder, and a graphite powder. The production method further includes mixing 15 to 45% of the hard phase forming alloy powder and 0.5 to 1.5% of the graphite powder with the matrix forming powder into a raw powder. The production method further includes compacting the raw powder into a green compact having a predetermined shape and includes sintering the green compact. A wear resistant sintered alloy exhibits a metallic structure in which 15 to 45% of a hard phase is dispersed in a matrix. The hard phase consists of, by mass %, 15 to 35% of Mo, 1 to 10% of Si, 10 to 40% of Cr, and the balance of Co and inevitable impurities.Type: ApplicationFiled: June 30, 2009Publication date: January 14, 2010Applicant: HITACHI POWDERED METALS CO., LTD.Inventor: Hideaki Kawata
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Patent number: 7637981Abstract: Provided are a composite wear-resistant member which can be manufactured with a lowered sintering temperature, and thus can prevent the carbonization of a material around super hard particles such as diamond; and a method for manufacturing the member. The member, characterized in that it comprises hard particles comprising diamond particles and WC particles and an iron group metal containing phosphorus as a binding material, wherein the content of phosphorus is 0.01 to 2.0 wt % relative to the total weight of the WC particles and the binding material.Type: GrantFiled: January 24, 2006Date of Patent: December 29, 2009Assignees: TIX Corporation, Nagaoka University of TechnologyInventors: Nobuhiro Kuribayashi, Kozo Ishizaki, Koji Matsumaru
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Publication number: 20090269235Abstract: A production method for sintered machine components, includes preparing an Fe alloy powder A, an Fe alloy powder B, an Fe—P powder, and a graphite powder. The Fe alloy powder A consists of, by mass %, 25 to 45% of Cr, 1.0 to 3.0% of Mo, 1.0 to 3.0% of Si, 0.5 to 1.5% of C, and the balance of Fe and inevitable impurities. The Fe alloy powder B consists of, by mass 15 to 35% of Cr, 15 to 30% of Ni, and the balance of Fe and inevitable impurities, and the Fe—P powder consists of 10 to 30 mass % of P and the balance of Fe and inevitable impurities. The production method further includes mixing 40 to 60 mass % of the Fe alloy powder B, 1.0 to 5.0 mass % of the Fe—P powder, and 0.5 to 3.5 mass % of the graphite powder with the Fe alloy powder A into a mixed powder. The production method further includes compacting the mixed powder into a green compact and sintering the green compact.Type: ApplicationFiled: April 21, 2009Publication date: October 29, 2009Applicant: HITACHI POWDERED METALS CO., LTD.Inventors: Daisuke Fukae, Hideaki Kawata
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Publication number: 20090257903Abstract: The present invention relates to a high speed steel with a chemical composition that comprises, in % by weight: 0.6-2.1 C 3-5 Cr 4-14 Mo max 5 W max 15 Co 0.5-4 V, balance Fe and impurities from the manufacturing of the material, which steel is powder metallurgically manufactured and has a content of Si in the range of 0.7<Si?2.Type: ApplicationFiled: September 7, 2006Publication date: October 15, 2009Inventor: Stefan Sundin
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Patent number: 7585459Abstract: The present invention concerns a process for the preparation of high density green compacts comprising the steps of providing an iron-based powder essentially free from fine particles; optionally mixing said powder with graphite and other additives; uniaxially compacting the powder in a die at a compaction pressure of at least about 800 MPa and ejecting the green body. The invention also concerns the powder used in the method.Type: GrantFiled: October 22, 2003Date of Patent: September 8, 2009Assignee: Höganäs ABInventors: Mikhail Kejzelman, Paul Skoglund, Hilmar Vidarsson
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Patent number: 7559494Abstract: Nanotechnology methods for creating stoichiometric and non-stoichiometric substances with unusual combination of properties by lattice level composition engineering are described.Type: GrantFiled: October 31, 2003Date of Patent: July 14, 2009Assignee: PPG Industries Ohio, Inc.Inventors: Tapesh Yadav, John Alexander
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High-strength and highly-wear-resistant sintered diamond object and manufacturing method of the same
Patent number: 7553350Abstract: A high-strength and highly-wear-resistant sintered diamond object according to the present invention includes sintered diamond particle having an average particle size of not larger than 2 ?m and a binder phase as a remaining portion. The content of the sintered diamond particle in the sintered diamond object is not smaller than 80 volume % and not larger than 98 volume %. The binder phase contains at least one element selected from the group consisting of titanium and the like, of which content is not smaller than 0.5 mass % and less than 50 mass %, and contains cobalt, of which content is not smaller than 50 mass % and less than 99.5 mass %. A part of the element or the element as a whole is present as carbide particle having an average particle size of not larger than 0.8 ?m. A texture of the carbide particle is discontinuous, and adjacent diamond particles are bound to each other.Type: GrantFiled: July 26, 2005Date of Patent: June 30, 2009Assignee: Sumitomo Electric Industries, Ltd.Inventors: Yoshihiro Kuroda, Satoru Kukino, Tomohiro Fukaya -
Publication number: 20090136707Abstract: An object of the present invention is to provide a metal-based carbon fiber composite material that exhibits an improved thermal expansion coefficient and an improved thermal conductivity, and is smaller in weight. The metal-based carbon fiber composite material of the present invention comprises a metal and a carbon fiber comprising a micron carbon fiber and a nanofiber; the composite material having a first surface; the micron-size carbon fiber being oriented in one direction parallel to the first surface of the composite material, and being continuous from one end to the other end; at least 80% of the nanofiber being oriented at an angle within 30° with respect to the first surface; and the nano-size carbon fiber being oriented randomly in a plane parallel to the first surface.Type: ApplicationFiled: November 24, 2006Publication date: May 28, 2009Applicant: Shimane Prefectural GovernmentInventor: Toshiyuki Ueno
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Publication number: 20090060772Abstract: A method of manufacturing a metal-graphite brush material for a motor, which allows high-density formation of copper particles on the surfaces of graphite particles. The method: attaches copper complex to graphite particles; heat-treats the graphite particles attached with the copper particles, thereby to pyrolyze the copper complex to form copper particles on the surfaces of the graphite particles; forms the graphite particles having the copper particles formed thereon, together with a resin, into a formed product; and reduction-sinters the formed product under a reducing atmosphere to pyrolyze the resin, thereby to form a sintered body and also to reduce copper oxide formed in surface layers of the copper particles during the heat-treating.Type: ApplicationFiled: February 24, 2006Publication date: March 5, 2009Applicant: AISIN SEIKI KABUSHIKI KAISHAInventor: Hiroshi Kobayashi
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Publication number: 20090060771Abstract: A method of forming a crankshaft bushing or similar component is provided. A compaction die is provided having an axial, generally cylindrical internal opening. An upper and a lower punch are provided with exterior surfaces corresponding to the internal opening of the compaction die. An upper core rod passes through an axial opening in the upper punch. A lower core rod passes through an axial opening in the lower punch. The upper core rod and the lower core rod each may have a generally flat external surface section. A metal powder is compacted in the compaction die by the combined action of the upper and lower punches and the upper and lower core rods.Type: ApplicationFiled: September 4, 2007Publication date: March 5, 2009Inventors: John Engquist, Bret E. Viant, Mark R. Haas, Kurt Kujawski, Matthew D. Bowman, Kevin J. Skibinski
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Patent number: 7488512Abstract: In a solid precursor evaporation system configured for use in a thin film deposition system, such as thermal chemical vapor deposition (TCVD), a method for preparing one or more trays of solid precursor is described. The solid precursor may be formed on a coating substrate, such as a tray, using one or more of dipping techniques, spin-on techniques, and sintering techniques.Type: GrantFiled: December 9, 2004Date of Patent: February 10, 2009Assignee: Tokyo Electron LimitedInventors: Kenji Suzuki, Emmanuel P. Guidotti, Gerrit J. Leusink, Masamichi Hara, Daisuke Kuroiwa, Sandra G. Malhotra, Fenton McFeely, Robert R. Young, Jr.
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Publication number: 20090032309Abstract: Earth-boring tools comprise a bit body comprising a face and a plurality of blades extending radially outward over the face and forming gage regions. A shank is coupled to the bit body and includes a threaded portion for connecting to a drill string. A sleeve structure is positioned adjacent to the bit body and surrounds a portion of the shank, the sleeve structure extending from adjacent the bit body to proximate the threaded portion of the shank. An outer surface of the sleeve structure comprises a plurality of circumferentially spaced gage pads extending thereover and may comprise a plurality of breaker flats.Type: ApplicationFiled: July 30, 2008Publication date: February 5, 2009Applicant: BAKER HUGHES INCORPORATEDInventors: Thorsten Schwefe, Henning Finke, Thomas Ganz
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Patent number: 7473296Abstract: A wear-resistant iron-based sintered contact material is provided which is sintered by powder sintering so as to have high density, high seizure resistance and wear resistance. A wear-resistant iron-based sintered composite contact component composed of the wear-resistant iron-based sintered contact material sinter-bonded to a backing metal and its producing method are also provided. To this end, at least Cr7C3-type carbide and/or M6C-type carbide which have an average particle diameter of 5 ?m or more are precipitately dispersed in an amount of 20 to 50% by volume within an iron-based martensite parent phase which has a hardness of HRC 50 or more even when tempered at up to 600° C.Type: GrantFiled: September 2, 2005Date of Patent: January 6, 2009Assignee: Komatsu, Ltd.Inventors: Takemori Takayama, Kazuo Okamura, Yoshikiyo Tanaka, Tetsuo Ohnishi
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Publication number: 20080292899Abstract: A titanium alloy composite material including dispersed carbon fibers coated with a layer containing an element which forms a carbide in reaction with carbon, and the carbide formed thereby, in crystal grains of the titanium alloy. The element which forms a carbide in reaction with carbon is preferably at least one of silicon (Si), chromium (Cr), titanium (Ti), vanadium (V), tantalum (Ta), molybdenum (Mo), zirconium (Zr), boron (B), and calcium (Ca). The carbon fibers are preferably carbon nanotubes, vapor-grown carbon fibers, or a mixture thereof. The titanium alloy composite material has excellent mechanical strength, such as tensile strength, Young's modulus, toughness, and hardness.Type: ApplicationFiled: August 22, 2006Publication date: November 27, 2008Applicants: E&F CORPORATION, NAGANO PREFECTUREInventors: Toshio Tanimoto, Hidekazu Takizawa
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Patent number: 7449144Abstract: A process for manufacturing a sliding contact piece for medium to high current densities including a step of warm premixing of graphite and plastic binder, a step of cold mixing of the resulting premixture with copper, a step of pressing of the resulting main mixture into the sliding contact piece, and finally a step of sintering of it; and so as to improve the operating characteristics of the sliding contact piece, which is free of any environmentally harmful additives, a metal such as zinc, tin, bismuth or an alloy of such metals is added during the premixing of the graphite and plastic binder.Type: GrantFiled: January 17, 2003Date of Patent: November 11, 2008Assignee: Deutsche Carbone AGInventors: Wilhelm Latz, Jürgen Spangenberg, Arwed Uecker
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Publication number: 20080202651Abstract: An iron-based compact having a high density and also an iron-based sintered body having a high strength and a high density are manufactured with a high productivity by pre-compacting an iron-based mixed powder prepared by mixing an iron-based metal powder and a graphite powder; pre-sintering the resulting pre-compacted iron-based mixed powder at a temperature higher than 1000° C. but not higher than 1300° C. to produce a sintered iron-based powder preform containing C: 0.10 to 0.50 mass %, O: 0.3 mass % or less, and N: 0.010 mass % or less and having a density of 7.2 Mg/m3 or more; and subjecting the sintered iron-based powder preform to high-velocity compaction at a compaction energy density of 1.8 MJ/m2 or more (1.4 MJ/m2 or more for a sintered pure-iron based powder preform).Type: ApplicationFiled: November 24, 2005Publication date: August 28, 2008Applicant: JFE Steel CorporationInventors: Satoshi Uenosono, Naomichi Nakamura
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Publication number: 20080187661Abstract: Discontinuous diamond particulate containing metal matrix composites of high thermal conductivity and methods for producing these composites are provided. The manufacturing method includes producing a thin reaction formed and diffusion bonded functionally graded interactive SiC surface layer on diamond particles. The interactive surface converted SiC coated diamond particles are then disposed into a mold and between the particles and permitted to rapidly solidify under pressure. The surface conversion interactive SiC coating on the diamond particles achieves minimal interface thermal resistance with the metal matrix which translates into good mechanical strength and stiffness of the composites and facilitates near theoretical thermal conductivity levels to be attained in the composite. Secondary working of the diamond metal composite can be performed for producing thin sheet product.Type: ApplicationFiled: October 8, 2007Publication date: August 7, 2008Inventors: Sion M. Pickard, James C. Withers, Raouf O. Loutfy
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Patent number: 7396505Abstract: CoCrMo can be used to enhance biocompatibility of a sintered polycrystalline diamond compact.Type: GrantFiled: August 27, 2004Date of Patent: July 8, 2008Assignee: Diamicron, Inc.Inventors: Bill J. Pope, Richard H. Dixon, Jeffery K. Taylor, Clayton F. Gardinier, Troy Medford, Dean C. Blackburn, Michael A. Vail, Louis M. Pope, Kenneth M. Jensen
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Publication number: 20080146467Abstract: The iron-based sintered sliding material comprises: a sintered structure which contains 10-50 wt. % copper and 1-15 wt. % carbon and has been formed by sintering a powder mixture obtained by mixing at least one of an Fe—Cu alloy powder containing copper in an amount which is the solid solubility or larger and is 5-50 wt. %, excluding 50 wt. %, and an Fe—Cu—C alloy powder containing copper in an amount which is the solid solubility or larger and is 5-50 wt. %, excluding 50 wt. %, and containing carbon in an amount of 0-5 wt. %, excluding 0 wt. %, with a graphite powder and at least one of a copper powder and a copper alloy powder; and graphite particles dispersed in the sintered sliding material in an amount of 1-14 wt. % or 3-50 vol. %.Type: ApplicationFiled: January 26, 2006Publication date: June 19, 2008Inventor: Takemori Takayama
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Publication number: 20080080938Abstract: A cutting tool for processing a nonferrous metal member by rotation has a body portion and a cutting edge arranged at the body portion. The body portion has a coolant supply hole through which a coolant is supplied for the nonferrous metal member in processing, and a chip evacuation groove which has a substantially helical shape and through which chip of the nonferrous metal member generated in the processing is expelled. The cutting edge is made of diamond grains and a binder material. An opening of the coolant supply hole is arranged at the cutting edge.Type: ApplicationFiled: September 25, 2007Publication date: April 3, 2008Applicant: DENSO CorporationInventors: Yukitaka Makino, Hideki Hayashi, Toshiki Hirukawa
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Patent number: 7341689Abstract: The invention concerns a new pre alloyed steel powder comprising in addition to iron and inevitable impurities, by wt %, 1.3-1.7% by weight of Cr, 0.15-0.3% by weight of Mo, 0.09-0.3% by weight of Mn, not larger than 0.01 by weight of C, not larger than 0.25% of O.Type: GrantFiled: December 27, 2005Date of Patent: March 11, 2008Assignee: Höganäs ABInventors: Ulf Engström, Sigurd Berg
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Publication number: 20080054708Abstract: Systems and methods for electrical component, e.g., brush, manufacture are provided that control grain orientation. The systems and methods utilize hot pressing techniques to enhance the properties and functionalities of the electrical components/brushes. An intermediate work product characterized by a grain orientation is initially formed through a conventional pressing technique. The conventionally-pressed intermediates are positioned within a cavity/die with the grain orientation in a predetermined orientation relative to the hot press force to be applied thereto. The hot pressed final product exhibits superior resistivity, strength and apparent density/durability. Surface features may be formed on the face(s) of the final work product during the hot pressing step that cannot be achieved in conventional processing techniques. Advantageous articles of manufacture, e.g., brushes and brush assemblies, are also disclosed.Type: ApplicationFiled: August 28, 2007Publication date: March 6, 2008Applicant: ENERGY CONVERSION SYSTEMS HOLDINGS, LLCInventors: Shepard Lynn Hockaday, Candace Stephenson Barefoot, George Dane Goodson, Timothy Glenn King, Ray John Matthews, John David Reece, Jr., Jeffrey Shaw Smith, Pimol Ballard Vonkchalee
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Publication number: 20080038140Abstract: The present invention relates to fullerene, nanotube, or nanofiber filled metals and polymers. This invention stems from a cross-disciplinary combination of electromagnetic and acoustic processing and property enhancement of materials through fullerene or nanofiber additives. Containerless processing (CP) in the form of electromagnetic field enduced and/or acoustic mixing leads to controlled dispersion of fullerenes, nanotubes, or nanofibers in various matrices. The invention provides methods of mixing that highly disperse and align the fullerenes, nanotubes, or nanofibers within the matrices of metals and polymers. The invention provides new compositions of matter and multifunctional materials based on processing, composition, and degree of in situ processing.Type: ApplicationFiled: February 1, 2001Publication date: February 14, 2008Inventors: Enrique V Barrera, Yildiz Bayazitoglu
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Patent number: 7329380Abstract: The invention concerns a method of controlling the dimensional change to a predetermined value including the steps of providing a first powder (A) consisting of an iron based powder (1) and copper in the form of elemental copper (2), or copper diffusion-bonded to the iron-based powder (3); providing a second powder (B) consisting of the iron-based powder (1) and a pre-alloyed iron-copper powder (4); mixing the first and second powder mixtures (A) and (B) in proportions resulting in the desired dimensional change adding graphite and lubricant and optionally hard phase materials and other alloying elements to the obtained mixture; compacting the obtained mixture; and sintering the compacted body.Type: GrantFiled: October 15, 2003Date of Patent: February 12, 2008Assignee: Höganäs ABInventor: Yang Yu
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Publication number: 20080025863Abstract: A powder mixture alloy is provided for manufacturing surface densified high carbon sintered steel articles containing iron or iron pre-alloyed powder, which has been preliminary mixed with at least 0.4 wt % graphite, lubricant and optionally at least one alloying element from the group of nickel, chromium, copper, manganese and molybdenum. Components are manufactured utilizing the alloy mixture comprising the steps of: a) compacting the metallic powder to obtain a compact; b) pre-sintering the compact at a low temperature to prevent graphite from diffusing into the iron; c) surface densifying of the pre-sintered compact to a predetermined densification depth; d) sintering under neutral gas or carburizing atmosphere; e) heat treating the sintered compact.Type: ApplicationFiled: July 27, 2006Publication date: January 31, 2008Inventors: Salvator Nigarura, Rick Ellingsworth, Eric Riley, Juan R.L. Trasorras
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Patent number: 7323136Abstract: The present invention relates to fullerene, nanotube, or nanofiber filled metals and polymers. This invention stems from a cross-disciplinary combination of electromagnetic and acoustic processing and property enhancement of materials through fullerene or nanofiber additives. Containerless processing (CP) in the form of electromagnetic field enduced and/or acoustic mixing leads to controlled dispersion of fullerenes, nanotubes, or nanofibers in various matrices. The invention provides methods of mixing that highly disperse and align the fullerenes, nanotubes, or nanofibers within the matrices of metals and polymers. The invention provides new compositions of matter and multifunctional materials based on processing, composition, and degree of in situ processing.Type: GrantFiled: February 1, 2001Date of Patent: January 29, 2008Assignee: William Marsh Rice UniversityInventors: Enrique V. Barrera, Yildiz Bayazitoglu
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Patent number: 7309465Abstract: A sintered sprocket for a silent chain is obtained from a material with few addition elements by a simple densifying method. The sintered sprocket is made of an ferrous material having an ovarall composition containing Cu at 1 to 2%, C at 0.5 to 0.8%, Mn as an inevitable impurity at 0.10% or less, and balance of Fe and other inevitable impurities by mass and has a density of 7.1 Mg/m3 or higher, 65 HRA or higher as a hardness in the gear teeth, and a martensite, sorbite, bainite, or their mixed structure as a cross-sectional microscopic structure in at least the gear teeth and the peripheral area of the gear teeth.Type: GrantFiled: April 5, 2006Date of Patent: December 18, 2007Assignees: Nissan Motor Co., Ltd., Hitachi Powdered Metals Co., Ltd.Inventors: Akira Fujiki, Yukihiro Maekawa, Yutaka Mabuchi, Takashi Murata, Takashi Suzuki, Jyun-ichi Yamada, Tadayuki Tsutsui, Kei Ishii
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Patent number: 7300488Abstract: The present invention concerns a powder metal composition for producing powder metal components comprising a Co-based pre-alloyed powder, with irregularly shaped particles comprising at least 15% by weight Cr and less than 0.3% by weight C, admixed with graphite. The invention also concerns a method for producing PM components by pressing of articles to shape from the powder metal composition according to the invention and sintering them.Type: GrantFiled: March 17, 2004Date of Patent: November 27, 2007Assignee: Höganäs abInventors: Christophe Szabo, Owe Mårs
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Patent number: 7244318Abstract: A blended powder including a first powder containing an R2T14B phase as a main phase, and a second powder containing an R2T17 phase at 25 wt % or more of the whole is prepared. Herein, R is at least one element selected from the group consisting of all rare-earth elements and Y (yttrium), T is at least one element selected from the group consisting of all transition elements, and Q is at least one element selected from the group consisting of B (boron) and C (carbon). The blended powder is sintered, so as to manufacture a permanent magnet having a structure in which a rare-earth element included in the second powder is concentrated in a grain surgace region of a main phase.Type: GrantFiled: January 22, 2002Date of Patent: July 17, 2007Assignee: Neomax Co., Ltd.Inventors: Takao Sekino, Yuji Kaneko
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Patent number: 7077883Abstract: The present invention relates to a pre-alloyed powder and its use as a bond powder in the manufacture of powder metallurgy parts and of diamond tools in particular. A pre-alloyed powder is disclosed, based on the iron-copper dual phase system, additionally containing Co, Ni, Mo, W, oxides or carbides as reinforcing elements in the iron phase, and Sn in the copper phase.Type: GrantFiled: September 28, 2004Date of Patent: July 18, 2006Assignee: UmicoreInventors: Bert-Jan Kamphuis, Janneck Peersman
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Patent number: 7074247Abstract: There is provided a method of making a composite abrasive compact which comprises an abrasive compact bonded to a substrate. The abrasive compact will generally be a diamond compact and the substrate will generally be a cemented carbide substrate. The composite abrasive compact is made under known conditions of elevated temperature and pressure suitable for producing abrasive compacts. The method is characterised by the mass of abrasive particles from which the abrasive compact is made. This mass has three regions which are: (i) an inner region, adjacent the surface of the substrate on which the mass is provided, containing particles having at least four different average particle sizes; (ii) an outer region containing particles having at least three different average particle sizes; and (iii) an intermediate region between the first and second regions.Type: GrantFiled: October 15, 2001Date of Patent: July 11, 2006Inventors: Klaus Tank, Moosa Mahomed Adia, Roy Derrick Achilles, Paul Machael Daniel
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Patent number: 6960319Abstract: Disclosed is a flow-softening tungsten alloy having the general formula: W100-pAiBjCkDe wherein W is tungsten; A is one or more elements selected from the group consisting of nickel, iron, chromium and cobalt; B is in or more elements selected from the group consisting of molybdenum, niobium and tantalum; C is one or more of the elements selected from the groups consisting of titanium and aluminum; D is one or more elements selected from the group consisting of boron, carbon, and silicon; i is from about 5 to about 8 weight percent; j is from 0 to about 4 weight percent; k is from about 0.1 to about 4 weight percent; 1 is from 0 to about 0.1 weight percent; and p is greater than or equal to about 7 weight percent and less than or equal to about 20 weight percent. In this alloy p is approximately equal to the sum of i, j, k and 1. A method of preparing this alloy and a kinetic energy penetrator manufactured from it are also disclosed.Type: GrantFiled: October 27, 1995Date of Patent: November 1, 2005Assignee: The United States of America as represented by the Secretary of the ArmyInventor: Deepak Kapoor
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Patent number: 6951578Abstract: PCD materials of this invention comprise diamond crystals that are bonded together with a catalyst/binder material. The PCD material is prepared by combining diamond grains with a catalyst/binder material either as a premixture or by infiltration during sintering. The PCD material comprises 15 percent by volume or less diamond grains sized 20 micrometers or less. The diamond grains are pressurized under elevated temperature conditions to form the desired PCD material. PCD materials of this invention can constitute the exclusive material phase of a PCD construction, or can form one or more material phase in a multi-phase material microstructure, wherein the multiple material phase can be arranged in an ordered/oriented or random fashion. PCD materials of this invention display improved properties of impact and fatigue resistance, and functional toughness, when used in complex wear environments, when compared to conventional PCs materials comprising intentionally added fine-sized diamond grains.Type: GrantFiled: August 10, 2000Date of Patent: October 4, 2005Assignee: Smith International, Inc.Inventors: Daniel J. Belnap, Nathan R. Anderson, Zhigang Fang, Anthony Griffo, Brian A. White
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Patent number: 6949216Abstract: A system for fabricating a free form structure of a composite material including carbon nanotubes. The system includes a discharge assembly and a composite formation device operatively linked with the discharge assembly. The discharge assembly dispenses a fusing agent such as for example a high energy density emission, a laser emission or a particle beam emission. The composite formation device includes a composite generator and an arranger in operative engagement with a composite generator. The composite generator engages with the fusing agent so as to create a composite nodal element. The composite nodal element includes a matrix and a multiplicity of fibers formed of carbon nanotubes dispersed throughout the matrix. The arranger positions one node relative to another to define the free form structure.Type: GrantFiled: October 24, 2001Date of Patent: September 27, 2005Assignee: Lockheed Martin CorporationInventors: Craig A. Brice, Frederick J. Herman
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Patent number: 6905530Abstract: In a preliminary molding step 1, a metallic powder mixture 7 obtained by blending an iron-based metal powder 7a with graphite 7b such that the graphite is present in an amount of preferably not less than 0.1% by weight, more preferably not less than 0.3% by weight, is compacted into a preform 8 having a density of not less than 7.3 g/cm3. In a provisional sintering step 2, the preform 8 is provisionally sintered at a predetermined temperature to form a metallic powder-molded body 9 having a structure in which the graphite remains along a grain boundary of the metal powder. In a re-compaction step 3, the metallic powder-molded body 9 is re-compacted into a re-compacted body 10. In a re-sintering step 4, the re-compacted body 10 is re-sintered to obtain a sintered body 11. In a heat treatment step 5, the sintered body 11 is heat-treated to obtain a heat-treated sintered body 11.Type: GrantFiled: June 27, 2002Date of Patent: June 14, 2005Assignees: Unisia Jecs Corporation, Kawasaki Steel CorporationInventors: Takashi Yoshimura, Hiroyuki Amma, Masashi Fujinaga, Mitsumasa Iijima, Yasuo Hatai, Takayuki Matsumoto, Satoshi Uenosono, Shigeru Unami
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Patent number: 6872356Abstract: The residual stresses that are experienced in polycrystalline diamond cutters, which lead to cutter failure, can be effectively modified by selectively thinning the carbide substrate subsequent to high temperature, high pressure (sinter) processing, by selectively varying the material constituents of the carbide substrate, by subjecting the PDC cutter to an annealing process during sintering, by subjecting the formed PDC cutter to a post-process stress relief anneal, or a combination of those means.Type: GrantFiled: November 15, 2002Date of Patent: March 29, 2005Assignee: Baker Hughes IncorporatedInventors: Trent N. Butcher, Ralph M. Horton, Stephen R. Jurewicz, Danny E. Scott, Redd H. Smith
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Patent number: 6827755Abstract: A high-strength and high-toughness ferritic steel having a tensile strength of not less than 1,000 MPA and a Charpy impact value of not less than 1 MJ/m2 is provided. A ferritic steel comprising, by weight, not more than 1% Si, not more than 1.25% Mn, 8 to 30% Cr, not more than 0.2% C, not more than 0.2% N, not more than 0.4% O, a total amount of not more than 12% of at least one compound-forming element selected from the group of Ti, Zr, Hf, V and Nb in amounts of not more than 3% Ti, not more than 6% Zr, not more than 10% Hf, not more than 1.0% V and not more than 2.0% Nb, also containing where necessary not more than 0.3% Mo, not more than 4% W and not more than 1.6% Ni, and the balance consisting of Fe and unavoidable impurities, and having an average crystal grain size of not more than 1 &mgr;m, can be obtained by a method comprising encapsulating a steel powder produced by mechanical alloying, and subjecting the encapsulated steel powder to plastic deformation.Type: GrantFiled: July 2, 2002Date of Patent: December 7, 2004Assignee: Hitachi, Ltd.Inventors: Masami Taguchi, Ryo Ishibashi, Yasuhisa Aono, Hidehiko Sumitomo, Hiroki Masumoto, Masakuni Fujikura
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Patent number: 6805835Abstract: A process for sintering green powder metal, metal alloy or metal composition parts employing microwave energy is described.Type: GrantFiled: January 25, 2001Date of Patent: October 19, 2004Assignee: The Penn State Research FoundationInventors: Rustum Roy, Dinesh K. Agrawal, Jiping Cheng
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Patent number: 6793876Abstract: A valve seat is produced by (a) using, as a raw material powder for forming a matrix, an Fe-based alloy powder with an average particle size of 20 to 50 &mgr;m, and using, as a raw material powder for forming a hard dispersion phase, a Co-based alloy powder with an average particle size of 20 to 50 &mgr;m, (b) conducting solid phase sintering, under vacuum, of a pressed compact formed from a mixed powder generated by mixing the Co-based alloy powder into the Fe-based alloy powder in sufficient quantity to account for 25 to 35% by weight of the combined weight with the Fe-based alloy powder, and causing the Co, Cr and Si components of the Co-based alloy powder to diffuse and migrate into the matrix, and the Fe component of the Fe-based alloy powder to diffuse and migrate concurrently into the hard dispersion phase, thereby markedly improving adhesion of the hard dispersion phase to the matrix, and forming, as a result, an Fe-based sintered alloy substrate with a porosity of 10 to 20%, and comprising an Fe&mdasType: GrantFiled: September 30, 2003Date of Patent: September 21, 2004Assignee: Mitsubishi Materials CorporationInventors: Atsushi Kawakami, Kazuyuki Hoshino, Kunio Hanata
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Patent number: 6773482Abstract: A cold work steel alloy for the manufacture of parts, comprising the elements C, Si, Mn, Cr, W, Mo, V, Nb, Co, S, N, Ni and accompanying elements in the concentration ranges recited in claim 1 and having an oxygen content of less than 100 ppm and a content of nonmetallic inclusions corresponding to a K0 value of a maximum of 3 when tested according to DIN 50 602, as well as a method of making a part of said steel alloy by powder metallurgy.Type: GrantFiled: April 9, 2002Date of Patent: August 10, 2004Assignee: Bohler Edelstahl, GmbHInventors: Werner Liebfahrt, Roland Rabitsch
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Publication number: 20040146423Abstract: Scrolls made from one or more near-net shaped powder metal processes either wholly or fabricated together from sections. Both “conventional” press and sinter methods and metal injection molding methods will be described.Type: ApplicationFiled: January 20, 2004Publication date: July 29, 2004Inventor: Marc J. Scancarello
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Patent number: 6759005Abstract: The present invention relates to a method of manufacturing sputtering targets doped with non-metal components including boron, carbon, nitrogen, oxygen and silicon. A powder process is utilized whereby alloyed powders, which contain non-metal elements of B/C/N/O/Si and non-metal containing phases of less than ten microns in microstructure, are blended, canned and subjected to hot isostatic press consolidation. The sputtering targets of the present invention avoid spitting problems during sputtering of the target material on a substrate.Type: GrantFiled: July 23, 2002Date of Patent: July 6, 2004Assignee: Heraeus, Inc.Inventor: Wenjun Zhang
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Publication number: 20040123696Abstract: The invention concerns a powder composition including an iron or iron based powder and a lubricating amount of an alkylalkoxy or polyetheralkoxy silane, wherein the alkyl or polyether group has between 8 and 30 carbon atoms and the alkoxi group includes 1-3 carbon atoms.Type: ApplicationFiled: October 22, 2003Publication date: July 1, 2004Inventors: Mikhail Kejzelman, Paul Skoglund, Hilmar Vidarsson, Per Knutsson
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Publication number: 20040123697Abstract: The present invention concerns a process for the preparation of high density green compacts comprising the steps of providing an iron-based powder essentially free from fine particles; optionally mixing said powder with graphite and other additives; uniaxially compacting the powder in a die at a compaction pressure of at least about 800 MPa and ejecting the green body. The invention also concerns the powder used in the method.Type: ApplicationFiled: October 22, 2003Publication date: July 1, 2004Inventors: Mikhail Kejzelman, Paul Skoglund, Hilmar Vidarsson