Nonmetal Is Elemental Carbon Patents (Class 419/11)
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Patent number: 5531957Abstract: A mounting object comprises a combination of a mounting object body wherein engaging portions of fastener elements of a metallic heat-resistant two-dimensional fastener are projected outside from a mounting surface, and base portions are embedded and integrally molded, and a mating fastener element base object wherein mating fastener elements in detachably engagement with said fastener elements are projected and integrally molded. Said mounting object body is obtained as a heat-resistant material integral with a metallic two-dimensional fastener by covering and fixing part of the fastener elements of the metallic two-dimensional fastener with a carbon powder having a high melting temperature and covering bases thereof with a metallic powder, a ceramics powder or a mixed powder of them to mold and sinter it.Type: GrantFiled: April 12, 1995Date of Patent: July 2, 1996Assignee: National Aerospace Laboratory of Science & Technology AgencyInventors: Osamu Okamoto, Teruomi Nakaya
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Patent number: 5522914Abstract: A powder-metallurgy produced tool steel article of a hot worked, fully dense, consolidated mass of prealloyed particles of a tool steel alloy having a sulfur content within the range of 0.10 to 0.30 weight percent and a maximum sulfide size below about 15 microns.Type: GrantFiled: February 7, 1995Date of Patent: June 4, 1996Assignee: Crucible Materials CorporationInventors: William Stasko, Kenneth E. Pinnow
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Patent number: 5516483Abstract: A process of forming a sintered article for powder metal comprising blending carbon and ferro alloys and lubricant with compressible elemental iron powder, pressing said blended mixture to form sintering said article, and then high temperature sintering said article in a reducing atmosphere to produce a sintered article having a high density from a single compression.Type: GrantFiled: February 8, 1994Date of Patent: May 14, 1996Assignee: Stackpole LimitedInventors: Rohith Shivanath, Peter Jones, Danny T. D. Thieu
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Patent number: 5512236Abstract: A process of coining sintered articles of powder metal comprising: blending carbon, ferro manganese, and lubricant with compressible elemental iron powder, pressing the blended mixture to form the articles, high temperature sintering of the articles in a reducing atmosphere and then coining the sintered articles to final shape so as to narrow the tolerance variability of coined articles and substantially eliminate secondary operations.Type: GrantFiled: August 25, 1994Date of Patent: April 30, 1996Assignee: Stackpole LimitedInventors: Peter Jones, Roger Lawcock
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Patent number: 5490968Abstract: A compacted, single phase or multiphase composite article. Particles for use in the compacted article are produced by providing a precursor compound containing at least one or at least two metals and a coordinating ligand. The compound is heated to remove the coordinating ligand therefrom and increase the surface area thereof. It may then be reacted so that at least one metal forms a metal-containing compound. The particles may be consolidated to form a compacted article, and for this purpose may be used in combination with graphite or diamonds. The metal-containing compound may be a nonmetallic compound including carbides, nitrides and carbonitrides of a refractory metal, such as tungsten. The metal-containing compound may be dispersed in a metal matrix, such as iron, nickel or cobalt. The dispersed nonmetallic compound particles are no larger than about 0.1 micron in particle size and have a volume fraction greater than about 0.15 within the metal matrix.Type: GrantFiled: March 17, 1995Date of Patent: February 13, 1996Assignee: Exxon Research and Engineering CompanyInventors: Richard S. Polizzotti, Larry E. McCandlish, Edwin L. Kugler
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Patent number: 5476632Abstract: A process of forming a sintered article of powder metal comprising: selecting elemental iron powder; determining the desired properties of said sintered article and selecting, a quantity of carbon, and ferro alloy from the group of ferro manganese, ferro chromium, ferro molybdenum, ferro vanadium, ferro silicon and ferro boron; grinding said ferro alloy to a mean particle size of approximately 8 to 12 microns; introducing a lubricant while blending the carbon, ferro alloy, with said elemental iron powder; pressing the mixture to form the article; and then high temperature sintering the article at a temperature between 1,250.degree. C. and 1,350.degree. C. in a neutral or reducing atmosphere; so as to produce the sintered article of powdered metal; and includes the product formed thereby.Type: GrantFiled: January 14, 1994Date of Patent: December 19, 1995Assignee: Stackpole LimitedInventors: Rohith Shivanath, Peter Jones
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Patent number: 5470371Abstract: Articles having improved strength at high temperature are made from near-eutectic nickel-base superalloys. In such alloys, the improved properties are achieved by preventing the formation of a dispersed second phase during the production of alloy powder. After the powder is consolidated, a dispersion of the second phase is developed through thermal treatment. Consolidation may be achieved by direct application of pressure, or by incremental solidification processes. Some of these alloys are formulated to achieve additional strengthening by precipitation hardening.Type: GrantFiled: March 12, 1992Date of Patent: November 28, 1995Assignee: General Electric CompanyInventor: Ramgopal Darolia
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Patent number: 5466414Abstract: A process for fabrication of sintered metal components having improved mechanical, physical and wear-resistent properties.Type: GrantFiled: September 1, 1994Date of Patent: November 14, 1995Assignee: TecSyn, Inc.Inventor: Bjorn O. A. Pettersson
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Patent number: 5462575Abstract: A powder metallurgy article formed from a Co--Cr--Mo alloy powder and a method for making the article are disclosed. The Co--Cr--Mo alloy powder contains, in weight percent, about 0.35% max. C, about 1.00% max. Mn, about 1.00% max. Si, about 26.0-30.0% Cr, about 5.0-7.0% Mo, about 3% max. Ni, about 0.25% max. N, about 1.00% max. Fe, about 0.01% max. of oxide forming metals, and the balance is essentially Co. Within their respective weight percent limits C and N are controlled such that they satisfy the relationship:62.866+360.93.times.(%C)+286.633.times.(%N)-682.165.times.(%C).sup.2 -641.702.times.(%N).sup.2 .gtoreq.120.Type: GrantFiled: December 23, 1993Date of Patent: October 31, 1995Assignee: CRS Holding, Inc.Inventor: Gregory J. Del Corso
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Patent number: 5460640Abstract: A fully dense ceramic-metal body including 40-88 v/o of an oxide hard phase of, in v/o of the body, 4-88 v/o M-aluminum binary oxides, where the binary oxide has a C-type rare earth, garnet, .beta.-MAl.sub.11 O.sub.18, or perovskite crystal structure, and M is a lanthanide or indium, and 0-79 v/o .alpha.-alumina; about 10-50 v/o of a hard refractory carbide, nitride, or boride as a reinforcing phase; and about 2-10 v/o of a dispersed metal phase combining Ni and Al mostly segregated at triple points of the microstructure. The preferred metal phase contains a substantial amount of the Ni.sub.3 Al ordered crystal structure. In the preferred body, the reinforcing phase is silicon carbide partially incorporated into the oxide grains, and bridges the grain boundaries. The body including a segregated metal phase is produced by densifying a mixture of the hard phase components and the metal component, with the metal component being present in the starting formulation as Ni powder and Al powder.Type: GrantFiled: August 17, 1992Date of Patent: October 24, 1995Assignee: Valenite Inc.Inventor: Sergej-Tomislav Buljan
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Patent number: 5453241Abstract: The present invention relates to cemented carbide bodies preferably for rock drilling and mineral cutting. Due to the fact that the bodies are built up of a core of eta-phase-containing cemented carbide surrounded by a surface zone free of eta-phase with low Co-content in the surface zone and successively increasing Co-content to a maximum in the outer part of the eta-phase-core they have obtained an increase in toughness and life at practical use.Type: GrantFiled: September 22, 1993Date of Patent: September 26, 1995Assignee: Sandvik ABInventors: Jan Akerman, Udo K. R. Fischer, E. Torbjorn Hartzell
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Patent number: 5451244Abstract: A process for preparing a consolidated nickel-base superalloy compact suitable for tensile force inducing high strain rate deformation. It includes the steps of: preparing a melt of a nickel-base superalloy in a vacuum; atomizing the melt into powder in a protective atmosphere; collecting the powder; screening the powder to proper size; introducing the powder into a container; evacuating and sealing the container in a vacuum; and consolidating the powder under pressure at a temperature below the solidus temperature of the alloy and at a temperature at which grain boundaries grow past prior particle boundaries.Type: GrantFiled: April 6, 1994Date of Patent: September 19, 1995Assignee: Special Metals CorporationInventor: B. Wayne Castledine
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Patent number: 5447681Abstract: A method for manufacturing a metal graphite brush comprises steps of preparing natural graphite powders of 60-70 wt %, electrolytic copper powders of 30-40 wt %, molybdenum disulfide and lead of 2.5 wt % and the mixed resin of novolak phenol resin and furfural resin powders of 1-15 wt % which are adhesives, wet-mixing graphite powders with adhesives, pulverizing mixed powders to diameters of less than 200 .mu.m, press-molding all the powders under a pressure of 2-3 ton/cm.sup.2 and heating at a temperature 700.degree. C., and attaching a lead wire thereto, simultaneously, wherein the average particle distribution of the powders is 27 .mu.m. The compound ratio of graphite powders: copper powders: molybdenum disulfide: lead is 62.5 wt %: 35 wt %: 1.5 wt %: 1.0 wt %, the adhesives comprising the mixed resin of novolak phenol resin and furfural resin by 50:50 is added by a weight ratio of 7.5 wt % to the graphite powders.Type: GrantFiled: December 27, 1993Date of Patent: September 5, 1995Assignee: Mando CorporationInventors: Chung Tai Seung, Kim Seong Soo, Lee Jae Sung
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Patent number: 5437833Abstract: This invention relates generally to a novel method of manufacturing a composite body, such as a ZrB.sub.2 --ZrC--Zr (optional) composite body, by utilizing a post-treatment process and to the novel products made thereby. More particularly, the invention relates to a method of modifying a composite body comprising one or more boron-containing compounds (e.g., a boride or a boride and a carbide) which has been made by the reactive infiltration of a molten parent metal into a bed or mass containing boron carbide, and optionally one or more inert fillers, to form the body.Type: GrantFiled: March 25, 1994Date of Patent: August 1, 1995Assignee: Lanxide Technology Company, LPInventors: Terry D. Claar, Gerhard H. Schiroky, William B. Johnson
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Patent number: 5427600Abstract: A low alloy sintered steel contains at least 0.15 percent by weight and less than 0.8 percent by weight of carbon. Its matrix is formed by a tempered martensite containing prior austenite crystal grains of not more than 15 .mu.m in mean grain size. Pores and nonmetallic inclusions contained in the matrix are not more than 50 .mu.m in maximum diameter, and the density of the low alloy sintered steel is at least 96 percent of theoretical density. A raw material powder for forming the low alloy sintered steel includes iron alloy powder which is prepared by an atomizing process, and is treated with a dry mill in an inert gas atmosphere or in the atmospheric air. Thus, dislocations are introduced into the raw material powder, and nonmetallic inclusions contained in the raw material powder are pulverized to be not more than 50 .mu.m in maximum diameter. Not only static characteristics but also dynamic characteristics, such as fatigue strength, of the low alloy sintered steel are improved.Type: GrantFiled: November 30, 1993Date of Patent: June 27, 1995Assignee: Sumitomo Electric Industries, Ltd.Inventors: Yoshiaki Itoh, Kozo Ito, Yoshinobu Takeda
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Patent number: 5403670Abstract: The crack-resistant compound sleeve roll having a shell portion made of a sintered alloy and a core portion made of steel is produced by (a) charging an alloy powder consisting essentially, by weight, of 1.0-3.5% of C, 2% or less of Si, 2% or less of Mn, 10% or less of Cr, 3.0-15.0% of W, 2.0-10.0% of Mo and 1.0-15.0% of V, the balance being substantially Fe and inevitable impurities, into a metal capsule disposed around a roll core; (b) after evacuation and sealing, subjecting the alloy powder to a HIP (hot isostatic pressing) treatment at 1100.degree.-1300.degree. C. to form a shell portion; (c) after removing the metal capsule, subjecting the sintered shell portion to a heat treatment having hardening at 1140.degree.-1220.degree. C. and annealing at 540.degree.-620.degree. C.; and (d) chamfering edge portions of the roll on both axial ends thereof such that a boundary of the shell portion and the core portion exists in a chamfered surface.Type: GrantFiled: December 21, 1993Date of Patent: April 4, 1995Assignee: Hitachi Metals, Ltd.Inventors: Takuya Ohsue, Akira Noda, Hiroshi Fukuzawa, Itsuo Korenaga
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Patent number: 5403372Abstract: Vane material, vane and method of producing a vane to be used in a compressor using a substitute freon, improving the wear resistance thereof. The vane material has a composition consisting of by weight: 1.0-2.5% of C; not more than 1.5% of Si; not more than 1.0% of Mn; 3-6% of Cr; one or two of not more than 20% W and not more than 12% Mo where "W+2Mo" being 15-28%; 3.5-10% of one or two of V and Nb; and the balance of Fe and incidental impurities. Carbides are uniformly dispersed in the matrix thereof where their average diameter does not exceed 1.5 .mu.m and the maximum diameter thereof does not exceed 6 .mu.m. A method of producing a vane is also disclosed, in which an atomized powder having the composition as described is compacted and it is then subjected to hot working, or to hot working and cold working.Type: GrantFiled: June 18, 1992Date of Patent: April 4, 1995Assignee: Hitachi Metals, Ltd.Inventor: Norimasa Uchida
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Patent number: 5401461Abstract: The present invention relates to cemented carbide bodies preferably for wear demanding rock drilling and mineral cutting. The bodies are built up of a core of eta-phase-containing cemented carbide surrounded by a surface zone free of eta-phase where the binder phase content in the outer pan of said zone is lower than the nominal and, in addition, constant or near constant, and the binder phase content in the inner part of the eta-phase free zone closer to the eta-phase core is higher than the nominal. According to the method of the invention, bodies comprising evenly distributed eta-phase are subjected to a partly carburizing treatment with a carbon activity, a.sub.c, close to 1.Type: GrantFiled: September 22, 1993Date of Patent: March 28, 1995Assignee: Sandvik ABInventors: E. Torbjorn Hartzell, Jan Akerman, Udo K. R. Fischer
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Patent number: 5393483Abstract: A nickel based superalloy composition is disclosed that provides increased high temperature stress-rupture strength and improved resistance to fatigue crack propagation at elevated temperatures up to about 760.degree. C. The composition is comprised of, by weight percent, about 10% to 12% chromium, about 17% to 19% cobalt, about 1.5% to 3.5% molybdenum, about 4.5% to 6.5% tungsten, about 3.25% to 4.25% aluminum, about 3.25% to 4.25% titanium, about 2.5% to 3,5% tantalum, about 0.02% to 0.08% zirconium, about 0.005% to 0.03% boron, less than 0.1% carbon, and the balance essentially nickel. Thermomechanical processing including isothermal forging at controlled strain rates and temperature ranges, supersolvus annealing, and slow cooling are disclosed for producing an enlarged grain structure that provides the improved properties in the alloy of this invention.Type: GrantFiled: April 2, 1990Date of Patent: February 28, 1995Assignee: General Electric CompanyInventor: Keh-Minn Chang
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Patent number: 5378426Abstract: Metal particulates and porous metal media, which have enhanced resistance to undesirable oxidation, and methods of producing the same are provided. The porous metal media comprise sintered metal particulates each typically having a core and a surface and a diameter in the range of 0.25 to 50 micrometers, the particulates comprising at least about 60 wt. % of a base metal including at least one of iron and nickel, at least about 11 wt. % chromium and no more than about 0.03 wt. % carbon. The surfaces of the particulates are enriched with at least one treatment element in an amount and depth sufficient to enhance the resistance of the particulates to undesirable oxidation. The invention also includes a fine metal filter medium formed from sintered metal fibers, which has enhanced resistance to corrosion and/or to high temperature oxidation.Type: GrantFiled: October 21, 1992Date of Patent: January 3, 1995Assignee: Pall CorporationInventors: Stephen A. Geibel, John L. Hurley, Sandra L. Brosious
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Patent number: 5304342Abstract: A sintered product useful for abrasion- and impact-resistant tools and the like is provided comprising an iron-group metal binder and refractory metal carbide particles, e.g. tungsten carbide, formed in situ during sintering by the exothermic reaction of a carbide-forming refractory metal powder with a carbon source mixed therewith. The sintering is carried out at an elevated temperature and at a pressure at which diamond is stable in the presence of a liquid phase comprised substantially of an iron-group binder metal, refractory metal, and dissolved carbon. The product may optionally contain diamond, up to about 95% in volume, enabling its properties to be tailored for a wide range of applications.Type: GrantFiled: June 11, 1992Date of Patent: April 19, 1994Inventors: H. Tracy Hall, Jr., David R. Hall
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Patent number: 5298052Abstract: An Ni-based bearing alloy consisting, by weight, of 9-30% Cr, 5-19% Fe, 0.1-1.5% Si, 2-22% Co, 1.4-11.0% Mo, and the balance Ni and incidental impurities, said alloy having a matrix in which hard particles of a Co-Mo-Cr-Si alloy and/or BN are uniformly dispersed in weight ratios of 5 to 35% and not more than 5.0, respectively. The Ni-based alloy matrix provides superior heat resistance. Hard particles of Co-Mo-Cr-Si alloy uniformly dispersed in the matrix improve sliding characteristic with or without uniform dispersion of Bn as a solid lubricant, whereby the bearing alloy exhibits superior heat resistance and sliding characteristic when used in high temperature oxidizing atmosphere.Type: GrantFiled: June 11, 1992Date of Patent: March 29, 1994Assignee: Daido Metal Company, Ltd.Inventors: Tadashi Tanaka, Masaaki Sakamoto, Koichi Yamamoto, Kenji Sakai
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Patent number: 5271890Abstract: A coating film of a carbon allotrope is formed on a substrate by continuously supplying a fine carbon powder onto the substrate and simultaneously irradiating the fine carbon powder with a laser beam of a high output level thereby inducing sublimation of the fine carbon powder, and quenching the sublimated fine carbon powder to cause deposition thereof on the substrate.Type: GrantFiled: October 30, 1992Date of Patent: December 21, 1993Assignee: Agency of Industrial Science & Technology, Ministry of International Trade & IndustryInventors: Hirofumi Shimura, Shinya Sasaki, Yuji Enomoto
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Patent number: 5259860Abstract: A sintered metal part has a magnesium metasilicate mineral, or a magnesium metasilicate mineral and a magnesium orthosilicate mineral, or at least one of a magnesium metasilicate mineral and a magnesium orthosilicate mineral and at least one of boron nitride and manganese sulfide dispersed throughout the metal matrix. An iron-based sintered sliding member is of a structure that free graphite and an intercrystalline inclusion have been dispersed throughout the metal matrix that consists essentially of, in weight ratio, 1.5 to 4% of carbon, 1 to 5% of copper, 0.1 to 2% of tin, 0.1 to 0.5% of phosphorus, 0.Type: GrantFiled: October 9, 1991Date of Patent: November 9, 1993Assignee: Hitachi Powdered Metals Co., Ltd.Inventors: Yutaka Ikenoue, Ryoji Satoh, Koichiro Hayashi, Katsunao Chikahata
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Patent number: 5256368Abstract: A pressure-reaction synthesis process for producing increased stiffness and improved strength-to-weight ratio titanium metal matrix composite materials comprising exothermically reacting a titanium powder or titanium powder alloys with non-metal powders or gas selected from the group consisting of C, B, N, BN, B.sub.4 C, SiC and Si.sub.3 N.sub.4 at temperatures from about 900.degree. to about 1300.degree. C., for about 5 to about 30 minutes in a forming die under pressures of from about 1000 to 5000 psi.Type: GrantFiled: July 31, 1992Date of Patent: October 26, 1993Assignee: The United States of America as represented by the Secretary of the InteriorInventors: Laurance L. Oden, Thomas L. Ochs, Paul C. Turner
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Patent number: 5252119Abstract: A high speed tool steel produced by sintering powder, consisting essentially, by weight, of more than 1.5% but not more than 2.2% C, not more than 1.0% Si, not more than 0.6% Mn, 3.0 to 6.0% Cr, an amount of W and Mo in which the content of W+2Mo is in the range of 20 to 30% and in which the ratio of W/2Mo is not less than 1, not more than 5.0% V, 2.0 to 7.0% Nb, the ratio of Nb/V being not less than 0.5, and the balance Fe and incidental impurities, the value of C-Ceq, which Ceq is defined by 0.24+0.033.times.W+0.063.times.Mo+0.2.times.V+0.1.times.Nb, being in a range of -0.20 to 0.05, the density of carbides in the sintered steel having grain size of 2 to 5 .mu.m being in a range of 10,000 to 30,000 pieces/mm.sup.2.Type: GrantFiled: October 29, 1991Date of Patent: October 12, 1993Assignee: Hitachi Metals, Ltd.Inventors: Junichi Nishida, Norimasa Uchida
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Patent number: 5240513Abstract: An isotropic permanent magnet is made by mixing a thermally responsive, low viscosity binder and atomized rare earth-transition metal (e.g., iron) alloy powder having a carbon-bearing (e.g., graphite) layer thereon that facilitates wetting and bonding of the powder particles by the binder. Prior to mixing with the binder, the atomized alloy powder may be sized or classified to provide a particular particle size fraction having a grain size within a given relatively narrow range. A selected particle size fraction is mixed with the binder and the mixture is molded to a desired complex magnet shape. A molded isotropic permanent magnet is thereby formed. A sintered isotropic permanent magnet can be formed by removing the binder from the molded mixture and thereafter sintering to full density.Type: GrantFiled: October 9, 1990Date of Patent: August 31, 1993Assignee: Iowa State University Research Foundation, Inc.Inventors: R. William McCallum, Kevin W. Dennis, Barbara K. Lograsso, Iver E. Anderson
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Patent number: 5221321Abstract: A Fe-base sintered alloy for a valve seat for use in internal combustion engines, which constitutes a chemical composition of 0.4 to 2% of C, 0.5 to 5% of Cr, 5 to 15% of Mo, 0.2 to 2% of Ni, 0.4 to 2% of Co, 8 to 20% of Cu, 0.01 to 0.5% of S, and the balance Fe, wherein percentages are by weight. The Fe-base sintered alloy possesses high strength and high rigidity, and hence exhibits excellent abrasive and corrosion wear resistance properties, as well as excellent lubricity.Type: GrantFiled: June 18, 1991Date of Patent: June 22, 1993Assignee: Hyundai Motor CompanyInventor: Jong Dae Lim
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Patent number: 5217683Abstract: A steel powder composition useful in the production, by powder-metallurgical methods, of sintered parts with high density, good dimensional accuracy, hardenability, and strength is prepared from an admixture of two pre-alloyed iron powders of different compositions, the first being a pre-alloy of iron and molybdenum, and the second being a pre-alloy of iron with carbon and at least one transition element including chromium, manganese, vanadium, or columbium.Type: GrantFiled: October 21, 1991Date of Patent: June 8, 1993Assignee: Hoeganaes CorporationInventor: Robert J. Causton
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Patent number: 5211766Abstract: Additions of carbon or tantalum ranging between about 0.1 to about 0.15 weight percent are added to an iron-rare earth metal permanent magnet alloy. The permanent magnet alloy contains the magnetic phase consisting of Fe.sub.14 Nd.sub.2 B (or the equivalent) tetragonal crystals, which is primarily based on neodymium and/or praseodymium, iron and boron. The isotropic melt-spun ribbons of the preferred alloy are characterized by generally improved magnetic properties. The anisotropic magnetic bodies formed from these ribbons are hot worked at temperatures substantially lower than the conventional alloy which does not contain the carbon or tantalum additions, with an improvement in magnetic properties observed.Type: GrantFiled: January 21, 1992Date of Patent: May 18, 1993Assignee: General Motors CorporationInventor: Viswanathan Panchanathan
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Patent number: 5199971Abstract: The present invention relates to parts, such as a drive gear and driven gear, for use in a rotary gear pump exhibiting good sliding characteristics against a pump case made of light metals such as aluminum alloys. These parts are obtained by subjecting aluminum alloy powders, which have been solidified at a cooling rate of 100.degree. C./sec or more, or aluminum alloy powders having particle diameters of 350 .mu.m or less, to powder compacting and hot extrusion and optionally further to hot forging, or subjecting the aluminum alloy powders to powder forging.Type: GrantFiled: December 19, 1989Date of Patent: April 6, 1993Assignee: Sumitomo Electric Industries, Ltd.Inventor: Kiyoaki Akechi
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Patent number: 5167914Abstract: An (Fe, Co)-B-R tetragonal type magnet having a high corrosion resistance, which has a boundary phase stabilized by Co and Al against corrosion, and which consists essentially of:0.2-3.0 at % Dy and 12-17 at % of the sum of Nd and Dy;5-10 at % B;0.5-13 at % Co;0.5-4 at % Al; andthe balance being at least 65 at % Fe.0.1-1.0 at % of Ti and/or Nb may be present. Alloy powders therefor can be also stabilized.Type: GrantFiled: May 22, 1991Date of Patent: December 1, 1992Assignee: Sumitomo Special Metals Co., Ltd.Inventors: Setsuo Fujimura, Masato Sagawa, Hitoshi Yamamoto, Satoshi Hirosawa
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Patent number: 5162063Abstract: A magnetically anisotropic R-T-B magnet having crystal grains having aspect ratios of 2 or more and showing a substantially uniform maximum energy product distribution is produced by (a) rapidly quenching an alloy melt; (b) finely pulverizing the rapidly quenched alloy to provide magnetic powder; (c) mixing the magnetic powder with a carbon-containing additive; (d) coating the resulting mixture with a protective layer of a first lubricant such as BN substantially unreactive with the alloy components; (e) compressing it; (f) further coating the resulting compressed body with a second lubricant such as graphite or graphite+glass; and (g) further compressing it.Type: GrantFiled: November 14, 1990Date of Patent: November 10, 1992Assignee: Hitachi Metals Ltd.Inventors: Makoto Shinoda, Katsunori Iwasaki, Shigeho Tanigawa, Masaaki Tokunaga
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Patent number: 5158695Abstract: Antifriction material includes sintered intermetallides of copper with zinc and tin, and ultradispersed diamond powder having grain size below 0.1 micrometer.Type: GrantFiled: October 29, 1991Date of Patent: October 27, 1992Inventors: Nikolay K. Yashchenko, Vladimir V. Ogorodnik
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Patent number: 5139720Abstract: In a method of manufacturing a sintered ceramic material using the heat generated in a thermit reaction as a heating source, a pre-heating is applied preceding to the sintering step or a mixture comprising: (A) at least one ceramic powder, (B) at least one non-metallic powder selected from the group consisting of carbon, boron and silicon, and (C) a metal powder and/or a non-metallic powder other than the above-mentioned (B) is used. Homogeneous and dense sintered ceramic material or sintered composite ceramic material can be obtained by this method, and the fine texture thereof, and the phase constitution, the phase distribution and the like of the composite ceramic phase can be controlled sufficiently.Type: GrantFiled: February 12, 1991Date of Patent: August 18, 1992Assignee: Kabushiki Kaisha Komatsu SeisakushoInventors: Shuichi Takeda, Hideki Shishiba
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Patent number: 5120495Abstract: A thermally conductive diamond metal composite comprising 5 to 80 volume percent diamond particles having a particle size ranging from about 1 to 50 .mu.m and a metal matrix comprising a thermally conductive metal. Preferably, a fine metal powder having particle size below 53 microns is utilized as the source for the metal matrix.Type: GrantFiled: June 3, 1991Date of Patent: June 9, 1992Assignee: The Standard Oil CompanyInventors: Edward C. Supan, Joseph F. Dolowy, Jr., Bradley A. Webb
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Patent number: 5118341Abstract: The invention provides a sinterable brass powder blend, comprising about 90% to about 99% by weight of brass powder, about 0.2% to about 6.0% by weight manganese sulfide, and 0% to about 5.0% by weight of lubricants, binders, graphite, sintering enhancing additives and mixtures thereof.The invention also provides methods for making lead-free but machinable sintered brass powder metal parts.Type: GrantFiled: March 28, 1991Date of Patent: June 2, 1992Assignee: Alcan Aluminum CorporationInventors: Edul M. Daver, Krishnakant B. Patel
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Patent number: 5116568Abstract: An improved temperature stable synthetic polycrystalline diamond (PCD) product includes at least one temperature stable PCD integrally and chemically bonded to a matrix carrier support through a carbide forming layer which is of a thickness of at least about 1 micron, the layer on at least one surface of the PCD is in turn is bonded to the matrix carrier. A wide variety of shapes, sizes and configurations of such products is achieved through relatively low temperature and relatively low pressure processing. Various products of various geometries are described as well as the details of the processing to achieve chemical bonding of the PCD elements in a variety of support matrix carrier materials to form a unitary structure having a temperature stability up to about 1,200 degrees C.Type: GrantFiled: May 31, 1991Date of Patent: May 26, 1992Assignee: Norton CompanyInventors: Chien-Min Sung, Sy-Hwa Chen
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Patent number: 5106576Abstract: A wear-resistant compound roll having a shell portion produced by sintering a uniform mixture of alloy powder consisting essentially, by weight, of 1.2-3.5% of C, 2% or less of Si, 2% or less of Mn. 10% or less of Cr, 3-35%, as W+2Mo, of one or two of W and Mo, 1-12% of V, and balance Fe and inevitable impurities, and 1-15%, based on the weight of said alloy powder, of VC powder dispersed therein. This compound roll is produced by (a) uniformly mixing the alloy powder with the VC powder; (b) charging the resulting mixed powder into a metal capsule disposed around a roll core; and (c) after evacuation and sealing, subjecting said mixing powder to a HIP treatment.Type: GrantFiled: February 25, 1991Date of Patent: April 21, 1992Assignee: Hitachi Metals, Ltd.Inventors: Akira Noda, Kenji Maruta
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Method of optimizing composite preparation for electrical properties: maximum capacitance electrodes
Patent number: 5096663Abstract: Composites of a matrix of metal fibers and carbon fibers interlocked in and interwoven among a network of fused metal fibers are inherently capable of displaying a broad range of values of a particular physical property. Where the composite is made by sintering a preform of the fiber network dispersed in a matrix of an organic binder, the value of the physical property of the resulting composite is a function of several independent variabiles which can be controlled during composite fabrication. With particular regard to the capacitance of a stainless steel-carbon fiber electrode, there is described a method of optimizing capacitance during electrode fabrication.Type: GrantFiled: May 29, 1990Date of Patent: March 17, 1992Assignee: Auburn UniversityInventor: Bruce J. Tatarchuk -
Patent number: 5096661Abstract: A porous intermediate compact is first prepared from metal particles, carbon and a temporary binder. The compact is then heated to remove the binder and then infiltrated with the vapor of a metal having a melting point lower than the compact.Type: GrantFiled: April 2, 1991Date of Patent: March 17, 1992Assignee: Raybestos Products CompanyInventor: Richard D. Lang
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Patent number: 5082433Abstract: Molded articles, particularly cams for camshafts of internal combustion engines, are subjected to high wear conditions. In order to make them resistant to wear, they are produced from a sintered alloy, which has been fabricated by powder metallurgical means. The alloy has a hardened matrix with interstitial copper and consists of 0.5 to 16% by weight of molybdenum, 1 to 20% by weight of copper, 0.1 to 1.5% by weight of carbon and, optionally, of admixtures of chromium, manganese, silicon and nickel totalling, at most, 5% by weight, the remainder being iron.Type: GrantFiled: December 17, 1990Date of Patent: January 21, 1992Assignee: Etablissement SupervisInventor: Karl Leithner
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Patent number: 5080712Abstract: Methods for preparing sintered components from iron-containing and alloy steel powder are provided. The methods includes compacting a powder mixture in a die set at a pressure of at least about 25 tsi to produce a green compact which is then presintered at a temperature of about 1100.degree.-1600.degree. F. (593.degree.-870.degree. C.) for at least about 5 minutes to produce a presintered preform. The presintered preform is then compacted at a pressure of at least about 25 tsi to produce a double-pressed presintered preform, which is, in turn, sintered at a temperature of at least about 1000.degree. C. for at least about 5 minutes to produce a sintered component having improved transverse rupture strength and a higher density.Type: GrantFiled: May 16, 1990Date of Patent: January 14, 1992Assignee: Hoeganaes CorporationInventors: William B. James, Robert J. Causton, John J. Fulmer
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Patent number: 5053284Abstract: A wear-resistant compound roll having a shell portion produced by sintering a uniform mixture of alloy powder consisting essentially, by weight, of 1.2-3.5% of C, 2% or less of Si, 2% or less of Mn, 10% or less of Cr, 3-35%, as W+2Mo, of one or two of W and Mo, 1-12% of V, and balance Fe and inevitable impurities, and 1-15%, based on the weight of said alloy powder, of VC powder dispersed therein. This compound roll is produced by (a) uniformly mixing the alloy powder with the VC powder; (b) charging the resulting mixed powder into a metal capsule disposed around a roll core; and (c) after evacuation and sealing, subjecting said mixed powder to a HIP treatment.Type: GrantFiled: February 1, 1990Date of Patent: October 1, 1991Assignee: Hitachi Metals, Ltd.Inventors: Akira Noda, Kenji Maruta
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Patent number: 5049183Abstract: A method of manufacturing a sintered machine part, by which the machine part can be manufactured to be sufficiently strong, wear and abrasion resistive, and durable against the fatigue caused by recursive impacts, without the heat treatments. In the method, a machine part composed of 0.1 to 0.8% of carbon by weight, 2 to 6% of nickel by weight, 0.6 to 1.6% of molybdenum by weight, 1 to 3% of copper by weight and balance iron is manufactured by mixing partially diffused alloy powder composed of 2 to 6% of nickel by weight, 0.4 to 0.6% of molybdenum by weight, 1 to 3% of copper by weight and balance iron with graphite powder amounting to 0.1 to 0.8% by weight and molybdenum simple powder having 2 to 7 .mu.m mean particle size amounting to 0.2 to 1% by weight, and then by compacting the mixed powder and sintering the compact.Type: GrantFiled: September 28, 1990Date of Patent: September 17, 1991Assignees: Hitachi Powdered Metals Co., Ltd., Honda Giken Kogyo Kabushiki KaishaInventors: Tsutomu Saka, Akira Fujiwara, Tadayuki Tsutsui, Osamu Murai, Kei Ishii
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Patent number: 5045972Abstract: A thermally conductive diamond metal composite consisting essentially of 5 to 80 volume percent diamond particles having a particle size ranging from about 1 to 50 .mu.m and a metal matrix comprising a thermally conductive metal. Preferably, a fine metal powder having particle size below 53 microns is utilized as the source for the metal matrix.Type: GrantFiled: August 27, 1990Date of Patent: September 3, 1991Assignee: The Standard Oil CompanyInventors: Edward C. Supan, Joseph F. Dolowy, Jr., Bradley A. Webb
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Patent number: 5041158Abstract: Powdered metal parts, especitally valve parts of an internal combustion engine which are subject to adhesive wear in service, withstand such wear substantially better when they have substantially uniformly dispersed through them from about 0.75% to about 7.0% by weight of hydrate magnesium silicate (talc).Type: GrantFiled: July 12, 1990Date of Patent: August 20, 1991Assignee: Eaton CorporationInventor: Jay M. Larson
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Patent number: 5041261Abstract: A method for manufacturing a dense cermet article including about 80-95% by volume of a granular hard phase and about 5-20% by volume of a metal binder phase. The hard phase is (a) the hard refractory carbides, nitrides, carbonitrides, oxycarbides, oxynitrides, carboxynitrides, borides, and mixtures thereof of the elements selected from the group consisting of Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, W, and B, or (b) the hard refractory carbides, nitrides, carbonitrides, oxycarbides, oxynitrides, and carboxynitrides, and mixtures thereof of a cubic solid solution of Zr--Ti, Hf--Ti, Hf--Zr, V--Ti, Nb--Ti, Ta--Ti, Mo--Ti, W--Ti, W--Hf, W--Nb, or W--Ta. The binder phase is a combination of Ni and Al having a Ni:Al weight ratio of from about 85:15 to about 88:12, and 0-5% by weight of Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, W, Co, B, and/or C. The method involves presintering the hard phase/binder phase mixture in a vacuum or inert atmosphere at about 1475.degree.-1675.degree. C., then HIPing at about 1575.degree.-1675.degree. C.Type: GrantFiled: December 21, 1990Date of Patent: August 20, 1991Assignee: GTE Laboratories IncorporatedInventors: Sergej T. Buljan, Helmut Lingertat, Steven F. Wayne
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Patent number: 5041339Abstract: A multilayered sliding material of lead bronze containing graphite in the form of a bimetal, comprising a steel plate or a steel plate having a copper plating coating and a sintered copper alloy bonded to the steel plate, the sintered copper alloy having a composition consisting of 5 to 16 wt % Sn, 2 to 20 wt % Pb, 0.03 to 1 wt % P, 0.5 to 3.9 wt % graphite, and the balance Cu, wherein hardness of the alloy exceeds Hv 100.Type: GrantFiled: August 21, 1989Date of Patent: August 20, 1991Assignee: Daido Metal CompanyInventors: Sanae Mori, Masaaki Sakamoto, Koichi Yamamoto, Kenji Sakai
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Patent number: 5039476Abstract: A method for the production of a metallic powder molding material is disclosed which comprises a step of imparting mechanical energy due to at least one of such physical actions as vibration, pulverization, attrition, rolling, shocks, agitation, and mixing a metallic particles in a vessel whose interior is held under vacuumized atmosphere or an atmosphere of inert gas thereby enabling the metallic particles to contact each other and acquire improvement in surface quality and a step of hot molding the metallic particles thereby producing a molding material.Type: GrantFiled: July 19, 1990Date of Patent: August 13, 1991Assignee: Ube Industries, Ltd.Inventors: Mitsuru Adachi, Akio Okamoto, Hideki Iwai, Yoshiharu Waku