Abstract: Wear resistant articles, especially valve seat inserts for internal combustion engines, are produced as sintered metal compacts comprising interspersed microzones of prealloyed austenitic stainless steel and softer ferrous metal, the microzones of austenitic stainless steel containing carbides and carbonitrides. The sintered compacts can be made by forming a green compact from prealloyed austenitic stainless steel powder atomizate blended with softer powdered ferrous metal component and powdered carbon, and sintering the green compact.

Abstract: A method for utilizing a powder metallurgy ("P/M") slurry by employing water atomized metallic powders and subsequently reducing the oxide levels therein to acceptable levels. The slurry comprises a carbon containing binder. The slurry is consolidated and sintered under controlled conditions to reduce the oxide levels.

Abstract: The present invention relates to an iron-base powder containing Ni, Mo and C for producing highly resistant sintered bodies under normal pressing and sintering conditions. The powder contains 7-12% by weight of Ni, 0.4-1.5% by weight of Mo, and 0.3-0.7% by weight of C.

Abstract: An electrical contact material characterized by a pressed and sintered powder of silver composite with about 5 weight percent of graphite fibers.

Abstract: This invention relates to high-hardness, high-toughness, high-density composite materials containing diamond, and a process for making such materials comprising applying shock compression to the composite powders and inducing an exothermic chemical reaction. The process is useful in making metal, ceramic and cermet diamond composite materials.

Abstract: An electrical contact comprises 5 to 20 weight percent tungsten carbide, 0.5 to 3 weight percent graphite, balance silver. The contact has low erosion rate, low contact resistance, and anti-welding properties.

Abstract: A composite compact component made of a composite compact consisting of a diamond or BN powder bonded to a hard sintered alloy base during a sintering operation, and a substrate composed of steel or a hard sintered alloy bonded to the base of the composite compact through a high strength filler metal or alloy having a melting point of at least the liquidus point of the hard sintered alloy base. A process of making set composite compact component is also disclosed as well as a drill bit containing said composite compact component and variations thereof.

Abstract: A wear resistant iron alloy article is preferably formed by compacting and sintering a predominantly iron powder mixture containing additions of carbon, copper and nickel boride. The product microstructure comprises hard borocementite particles dispersed in a martensite or pearlite matrix. The particles have a cross-sectional dimension greater than 1 micron and are present in an amount preferably between 10 and 30 volume percent to improve wear resistance.

Abstract: A polycrystalline diamond (PCD) body with improved thermal stability is disclosed which comprises a PCD body which has had at least one of its previously empty pores infiltrated by a silicon containing alloy. According to the process of the invention, a porous PCD body is obtained, preferably by acid leaching a PCD body which was formed in the presence of a metal catalyst such as cobalt. The porous PCD body is then surrounded by either the desired silicon containing alloy, or by the constituents of that alloy, each preferably in powdered form. The PCD body with its surrounding material is then heated and pressed to temperatures sufficient to melt the surrounding material (thereby forming the silicon alloy if not already formed) and to cause it to infiltrate into the pores. After the infiltration, it is preferred to remove the excess silicon containing alloy from the external surfaces of the PCD body, such as by an acid bath. It is also preferred to include several porous PCD bodies per process cycle.

Abstract: Alloy powder is packed into a mold which comprises a complex-shaped solid aphite inner core and a similarly complex-shaped thin glass outer wall. The mold is evacuated, sealed, and then heated to the alloy sintering temperature, the glass softens and applies an isostatic pressure on the alloy as the alloy particles consolidate. After the consolidation step, the mold and its contents are cooled and the glass and graphite materials are removed from the alloy object. This method is particularly useful for preparing complex fittings of Nitinol shape memory alloys.

Abstract: This invention relates to internal combustion engine liners having a base of aluminum-silicon alloys and of silicon grains and processes for obtaining them.It is characterized in that these grains are carefully graded in size and dispersed in the alloy matrix. These liners can also contain at least an intermetallic compound such as Ni.sub.3 Sn, for example.These liners are obtained by extrusion or sintering of a mixture of powders.The invention has its application particularly in the automobile industry and in any type of industry where it is desired to have liner-piston units from aluminum alloys having a good compatability.

Abstract: A process for the production of a reinforced metal plate comprising forming a slurry of metal coated carbon fibers, binder fibers and metal powder, laying down a mat from said slurry, drying the resultant mat and then sintering said, is disclosed. The dried sintered mat may be made stronger by contacting the mat with a silicate before sintering.

Abstract: A method for producing high technology ceramics with minimal porosity comsing the steps of filling a can with a constituent powder of a ceramic, creating a vacuum in the can and maintaining the vacuum throughout the entire process; outgassing the powder in the can by placing a furnace around the area of the can that encloses the powder and heating the furnace to at least 100.degree. C.; removing the furnace after a minimum of five minutes of heating; cold rolling the can in a rolling system; igniting the powder so a localized propagation reaction front is created; and hot rolling the can in the rolling system so the propagation reaction front is maintained between the rolls of the rolling system.

Abstract: A diamond sintered body for tools contains a diamond content in excess of 93 percent and not more than 99 percent by volume and a residue including at least one of a metal or a carbide selected from groups IVa, Va and VIa of the periodic table and an iron group metal of 0.1 to 3 percent by volume in total and pores at least 0.5 percent and not more than 7 percent by volume.

Abstract: A wear-resistant member and method for producing the same which member may form a movable member in an internal combustion engine which is subjected to high pressure such as a rocker arm, tappet, cam, valve or valve seat. The member is formed as a combination of a ferrous sintered body and a ferrous base body having a common surface. The sintered body is formed from a compressed powder body disposed in contact with the ferrous base body. The powder body, in a preferred embodiment, consists of 0.5 to 7.0% by weight carbon, 0.1 to 5.0% phosphorus, the balance being iron, and having a porosity of 12 to 20% by volume at least 40% of which is pores having a pore size of not more than 300.mu.. The combined powder body and ferrous base body are heated to a temperature higher than the liquid-phase temperature of the powder body but lower than the melting point of the ferrous body to sinter the powder body.

Abstract: Aluminum-base alloys and a method of preparing aluminum-base alloys by mechanical alloying in the presence of a carbidiferous processing aid wherein a strong carbide former such as titanium is included so as to produce carbides in the final alloy more thermally stable at temperatures in excess of 100.degree. C. than Al.sub.4 C.sub.3.

Abstract: A method of manufacturing by a powder metallurgy process a rotary drill bit including a bit body having a plurality of cutting elements mounted on the outer surface thereof comprises the steps of forming a hollow mould for moulding at least a portion of the bit body, packing the mould with powdered matrix material, and infiltrating the material with a metal alloy in a furnace to form a matrix. Before packing the mould with powdered matrix material, there are positioned in spaced locations on the interior surface of the mould a plurality of cutting elements, each of which is formed of a material, such as a polycrystalline diamond material, which is thermally stable at the temperature necessary to form the matrix. Also positioned in the mould, adjacent the rearward side of each cutting element, is a support material such that, at least after formation of the matrix, the support material has a higher modulus of elasticity than the matrix.

Abstract: A method for forming an iron alloy article having increased toughness comprises compacting and sintering a powder mixture composed of predominantly iron powder and carbon powder and containing a powder of a liquating nickel boride compound. Limited nickel diffusion into the iron structure during sintering produces metastable retained austenite in regions about pores in the product structure that retards crack formation and thereby improves mechanical properties.

Abstract: An improved bond between diamond and a metallic matrix can be achieved by hot pressing the metallic matrix onto a cleaned polycrystalline diamond (PCD) element. The PCD is degreased and then maintained substantially free from subsequent oxidation. The cleaned nonoxidized PCD is then disposed within a hot press and bonded under pressure and temperature with a conventional metallic matrix to form a cutting element. The cutting element thus formed is comprised of a PCD portion and a metallic portion with a high strength bond formed therebetween, on at least one surface of the diamond and, preferably, two adjacent surfaces. Typically, the metallic matrix is a carbide-forming metal or mixture of carbide-forming metals, and the diamond is a thermally stable porous, sintered polycrystalline product. The insert is subsequently placed within a bit mold and a bit is fabricated according to conventional powder metallurgical infiltration techniques.

Abstract: A process for the preparation of an iron base sintered alloy well suited for use in valve mechanism members or parts of internal combustion engines, which has a porosity of 5 to 15% and throughout the iron matrix of which is dispersed an Fe-Mo intermetallic compound in the form of a phase harder than the said matrix, by using a powder mixture obtained by incorporating into finely divided iron powders having a particle size of not more than 30 microns the given amounts of copper powders, phosphorus-containing alloy powders, carbon powders and Fe-Mo alloy powders, or the given amounts of bronze powders and/or a mixture of copper powders and tin powders, phosphorus-containing alloy powders, carbon powders and Fe-Mo alloy powders.

Abstract: A composite material for a sliding member has a back metal layer and a graphite-containing phosphor bronze sintered layer bonded to the back metal layer. The graphite-containing phosphor bronze sintered layer consists essentially of 0.03 to 1 wt % phosphorus, 7.5 to 16 wt % tin, 1 to 8 wt % graphite and the balance copper, and is constituted by phosphor bronze powder passing through a 200-mesh screen and a graphite powder passing through a 350-mesh screen. Also disclosed is a method of manufacturing the above-mentioned composite material for a sliding member.

Abstract: A sintered ferrous alloy which is high in wear resistance and relatively weak in the tendency to abrade another metal material with which the sintered alloy makes rubbing contact. The sintered alloy is produced by compacting and sintering 100 parts by weight of a powder mixture of 5-35 parts by weight of a Fe-Cr-B-Si alloy powder, which contains 10-35% of Cr, 1.0-2.5% of B and 0.5-3.0% of Si, such an amount of a Cu-P alloy powder that the powder mixture contains 0.2-1.5% of P and 1.0 to 20.0% of Cu, and the balance of a cast iron powder. Preferably the cast iron powder contains 2.5-3.5% of C, 1.8-2.2% of Si and 0.6-1.0% of Mn. For example, the sintered alloy is suitable for rocker arm tips in automotive engines.

Abstract: Process for the preparation of a composite material incorporating an inorganic matrix in which are distributed inclusions of carbon-containing material, where it comprises the following stages:(a) mixing an inorganic powder with a liquid or viscous resin, which can be transformed into vitreous carbon by heat treatment,(b) subjecting the mixture of resin and inorganic powder to a first heat treatment performed under conditions such that the resin is hardened by crosslinking or polycondensation, and(c) subjecting the thus obtained hardened product to a second heat treatment for transforming the resin into vitreous carbon and thus forming said vitreous carbon inclusions.The composite material obtained comprises a copper matrix in which are uniformly and homogeneously dispersed vitreous carbon inclusions, the vitreous carbon content being at the most 8% by weight.The material is used in the production of electric contacts.

Abstract: A base powder mixture consisting of diamond material and solid support is inserted into the recess of a mold block for the manufacture of cutting elements for, in particular, deep drill bits, the mold block is then externally hermetically enclosed and hot isostatically pressed. The base powder mixture is, first of all, inserted directly into the recess, the mold block is then enclosed as a whole in a capsule and placed in a high pressure furnace in which pressure is applied to the mold block by a liquid or gaseous pressure medium and, finally, after cooling and lowering of the pressure, the capsule is removed and the finished cutting elements are taken out of the recess.

Abstract: Sintering method and apparatus. A pre-sintered or compacted mass of particulate material is densified by loading the mass into a substantially closed three-dimensional space defined by three pairs of punches juxtaposed thereacross in three respective directions, and then by multi-axially compressing the mass by advancing the punches of each pair toward each other while energizing the mass with thermal energy. The axes of action of pressures applied thereto by the three pairs of punches intersect substantially at a point substantially constituting the center of the three-dimensional space.

Abstract: A process improvement is disclosed for making diamond wire die compacts of the type which are generally described as an inner polycrystalline diamond mass surrounded by and bonded to a mass of metal bonded carbide, such as cobalt cemented tungsten carbide. It is known to make these dies by high pressure-high temperature processes, typical conditions being 50 kbar and temperatures in excess of 1300.degree. C. The improvement comprises disposing within the reaction sub-assembly (e.g. metal carbide and diamond within a zirconium cup) a set of discs of specific materials in specified arrangements. For example, on one side of the mass of metal carbide and diamond is disposed one disc of a diamond catalyst/solvent and one disc of a refractory metal such as molybdenum, and on the other side are disposed at least two discs of one or more transition metals such as zirconium. These discs are generally placed inside the sub-assembly cup.

Abstract: The high pressure/high temperature catalyst sweep through process for making diamond and cubic boron nitride compacts has been improved by adding an intermediate metal or metal alloy. The added metal (whether alone or contained in an alloy) has a melting point below that of the catalyst (e.g. cobalt), is miscible with the catalyst, and preferably sweeps through the mass of abrasive crystals first. This modification has reduced flaw formation in such compacts.

Abstract: A fiber-reinforced metal composite material comprising a reinforcing material and a matrix, said reinforcing material being inorganic fibers containing at least two components selected from carbon (as a simple substance), metal oxides, metal carbides, metal nitrides and metal borides, and said matrix being metal alloys containing zinc and aluminum, or zinc and magnesium as main component.

Abstract: An improved diamond compact of the present invention comprises 20 to 85% by volume of diamond grains with a grain size of at least 3 .mu.m and the balance of a binder consisting of 20 to 95% by volume of ultra-fine diamond grains with a grain size of at most 1 .mu.m, at least one member with a grain size of at most 1 .mu.m, selected from the group consisting of carbides, carbonitrides, nitrides, borides of Group 4a, 5a and 6a elements of Periodic Table, solid solutions thereof and mixed crystals thereof and at least one member selected from the group consisting of iron group metals.

Abstract: A highly wear-resistant sintered ferrous alloy which consists essentially of 2.0-8.0% of Cr, 0.1-1.0% of B, 1.0-2.5% of Si, 0.3-1.2% of Mn, 1.2-3.8% of C, by weight, and the balance of Fe. The alloy is produced by compacting and sintering a powder mixture, which is preferably prepared by mixing 75-90 parts by weight of a cast iron powder with 25-10 parts by weight of a Fe--Cr--B--Si alloy powder.

Abstract: An anti-wear sintered alloy comprising from 2.5 to 25.0% of Cr, from 0.10 to 3.0% of Mn, from 0.1 to 0.8% of P, from 1.0 to 5.0% of Cu, from 0.5 to 2.0% of Si, from 0 to 3% of Mo, 1.5 to 3.5% of C, one selected from the group consisting of from 0.5 to 3.0% of S and from 1.0 to 5.0% of Pb, and the balance being Fe with less than 2% of impurities, wherein S or Pb is distributed uniformly in the sintered alloy in form of sulfide or lead particle of less than 100 .mu.m and a manufacturing process thereof.

Abstract: An alloy steel is provided along with a method of making the same. The alloy is heat, wear, corrosion and oxidation resistant, and is preferably made utilizing powder metallurgy techniques. The method involves the addition of carbon and silicon to an iron base alloy containing chromium to improve the properties of the steel.

Abstract: To provide piston rings which are ductile, can be heavily thermally loaded, and are not attacked by corrosive residues occurring upon combustion of residual oil or other sulfur-containing heavy Diesel oils, a powder mixture is sintered in an isostatic hot-pressure sintering process in which a hard metal and a soft filler material are combined; in accordance with one embodiment, the base is a hard metal using nickel or cobalt-based alloys present in 40-80% by weight, the remainder filler which, for example, is unrefined or galvanically coated graphite; in a second embodiment, the base is a soft material such as a high-copper content bronze, and the filler is a nickel or cobalt-based alloy, with the base metal being present in 60-80%, the filler being the remainder (all percentages by weight).

Abstract: A method of producing a rotary dresser include forming a core piece of an iron-base powder and filling in tungsten or like metal powder between the core and an outer mold member containing diamond grit or the like. The construction is then heated to melt and infiltrate a metal alloy, such that a network structure is formed about the powdered metal particles. In a further embodiment, the metal materials may be arranged in concentric form about a metal bushing such that the bushing is included in the final structure.

Abstract: A method for producing compact of diamond particles, comprising: providing a mass of diamond particles and a metallic material capable of dissolving carbon, as infiltrant, with a substantially identical cross section, placing said diamond and infiltrant metal close to but separated with each other with an intervening layer of high melting metal, as barrier, which has a cross section of 85 to 97% relative to that of the diamond and infiltrant metal, and subjecting the whole to an elevated pressure and temperature condition within the diamond stability region of carbon phase diagram, thus allowing a regulated amount of fused infiltrant metal to flow in among the mass of diamond to join adjacent particles with each other, and recovering a compact of thus joined diamond particles.

Abstract: A metallurgically bonded diamond-metal composite sintered material suitable for lapping comprises a Ni and/or Co base, an intermetallic compound dispersed in said base and diamond powder, and the method of making said material comprises specifying the particle size of the base powder and then sintering same at a low temperature not exceeding a diamond graphitization temperature.

Abstract: A method for making magnetic crystallized implements based on glassy metal alloys. Metallic glass alloy powder of suitable ferromagnetic composition is compacted by mechanical, by adhesive bonding or by thermomechanical processes. The resulting compacts can be heat treated to enhance magnetic properties. Compacted bodies exhibit excellent ferromagnetic properties, low remanence, low coercivity and high permeabilities.

Abstract: A process for improving alloying efficiency in making powder alloy sintered compacts is disclosed. A master alloy (non-iron-based) powder is formulated for admixture in small amounts (2.5-6.0%) to a relatively pure iron based powder and free carbon powder to provide liquid phase sintering and production of a substantially homogeneous product having the characteristics of a wrought alloy product. The master alloy powder is inert gas atomized and chemically constituted to contain at least two elements selected from the group consisting of and in the percentage ranges for the alloy powder of manganese (40-72%), nickel (12-30%), molybdenum (5-11%), chromium (3-20%), copper and iron (1-40%. The master alloy powder may contain additions of a wetting agent, silicon up to 3% and rare earth metals up to 2%, either of which assist to speed up diffusion and create a more favorable liquidus-solidus relationship within the master alloy powder.

Abstract: A polycrystalline diamond body infiltrated by a silicon atom-containing metal (e.g., silicon alloy) is bonded to a substrate comprising cemented carbide with a barrier of refractory material extending between the diamonds cemented together with silicon atom-containing binder and the substrate substantially precluding migration of the cementing medium (e.g., cobalt) from the carbide substrate into contact with the silicon atom-containing bonding medium in the diamond body. The process comprises subjecting a mass of diamond powder, a quantity of silicon atom-containing metal binder material, a cemented carbide body and a barrier made of material selected from the group consisting of tantalum, vanadium, molybdenum, zirconium, tungsten and alloys thereof to the simultaneous application of elevated temperature and pressure.

Abstract: The present invention relates to a composite diamond compact for a wire drawing die, in which a part or all of the circumference of a diamond sintered body is surrounded by a cermet consisting of a hard compound of (Mo, W)C type carbide crystals containing molybdenum as a predominant component, bonded by an iron group metal, and the binder phase of the diamond sintered body contains an iron group metal and fine carbide crystals containing molybdenum as a predominant component.