Powder Shape Or Size Characteristics Patents (Class 419/23)
  • Patent number: 10864577
    Abstract: The present invention relates to granular composite density enhancement, and related methods and compositions. The application where these properties are valuable include but are not limited to: 1) additive manufacturing (“3D printing”) involving metallic, ceramic, cermet, polymer, plastic, or other dry or solvent-suspended powders or gels, 2) concrete materials, 3) solid propellant materials, 4) cermet materials, 5) granular armors, 6) glass-metal and glass-plastic mixtures, and 7) ceramics comprising (or manufactured using) granular composites.
    Type: Grant
    Filed: December 28, 2018
    Date of Patent: December 15, 2020
    Assignee: Uniformity Labs Inc.
    Inventors: Adam Bayne Hopkins, Salvatore Torquato
  • Patent number: 10823600
    Abstract: A system for estimating a flowable substrate level in a storage unit is disclosed. In one embodiment, the system includes a transmitter and a conductor that extend downwardly into a grain storage bin, which cycles through a range of frequencies in order to determine the resonant frequency of the conductor which changes depending on the amount of grain in the bin.
    Type: Grant
    Filed: January 7, 2019
    Date of Patent: November 3, 2020
    Assignee: Extron Company
    Inventor: Randall G. Honeck
  • Patent number: 10807162
    Abstract: A system for additive metal manufacturing, including a deposition mechanism, a translation mechanism mounting the deposition mechanism to the working volume, and a stage. A method for additive metal manufacturing including: selectively depositing a material carrier within the working volume; removing an additive from the material carrier; and treating the resultant material.
    Type: Grant
    Filed: August 13, 2018
    Date of Patent: October 20, 2020
    Assignee: Mantle Inc.
    Inventors: Stephen T. Connor, Theodore C. Sorom, James R. Groves
  • Patent number: 10500639
    Abstract: A method of making an article includes depositing a plurality of layers to form a three-dimensional preform, sintering the preform to form a sintered preform, and infiltrating the preform with at least one metal to form the article. At least one layer of the plurality of layers is formed from a beryllium-containing composition including beryllium powder. The infiltrating metal can be selected from aluminum and magnesium.
    Type: Grant
    Filed: December 10, 2015
    Date of Patent: December 10, 2019
    Assignee: Materion Corporation
    Inventor: James Andrew Yurko
  • Patent number: 10493524
    Abstract: A method for processing a powder material includes feeding a powder material through an additive processing machine to deposit multiple layers of the powder material onto one another and using an energy beam to thermally fuse selected portions of the layers to one another with reference to data relating to a particular cross-section of an article being formed. The powder material has spherical metal particles and a spaced-apart distribution of ceramic nanoparticles attached to the surfaces of the particles. The ceramic nanoparticles form a dispersion of reinforcement through the formed article.
    Type: Grant
    Filed: August 16, 2017
    Date of Patent: December 3, 2019
    Assignee: UNITED TECHNOLOGIES CORPORATION
    Inventors: Ying She, John A. Sharon, James T. Beals, Aaron T. Nardi
  • Patent number: 10441390
    Abstract: The invention shows a dental press furnace comprising a pressing punch (36) which acts on a green product (32) made of in particular a ceramic mass—possibly by means of an interposed ram (28)—, the green product (32) being guided in a press channel (30) which is configured in a muffle (24), and a pressure, distance and/or speed sensor detecting at least one motion parameter of the pressing punch (36), and comprising a control device for controlling the pressing process based on the output signal of the sensor, the trigger criterion for the start of the pressing process being a change of at least one motion parameter of the pressing punch upon heating and/or softening of the green product which change is detected by means of the sensor.
    Type: Grant
    Filed: March 1, 2016
    Date of Patent: October 15, 2019
    Assignee: Ivoclar Vivadent AG
    Inventor: Rudolf Jussel
  • Patent number: 10311182
    Abstract: Embodiments provide methods and systems for modifying a finite element mesh representation of a three-dimensional model. A method according to an embodiment defines a symmetric constraint of a finite element mesh where the finite element mesh represents a subject 3D model and the symmetric constraint comprises two asymmetric zones of the finite element mesh to be modified symmetrically. Next, corresponding finite elements between the two asymmetric zones are identified and a topological manipulation to at least one of the identified corresponding finite elements is performed. In response, the topological manipulation is performed symmetrically on the identified finite element corresponding to the at least one finite element. In such an embodiment, performing the manipulation symmetrically results in the two asymmetric zones being modified symmetrically and represents a symmetrical topological modification in the subject 3D model.
    Type: Grant
    Filed: August 16, 2016
    Date of Patent: June 4, 2019
    Assignee: Dassault Systemes
    Inventors: Frederic Letzelter, Jean-Marc Chauvet, Christophe Dufau
  • Patent number: 10301509
    Abstract: A sheet for thermal bonding which has a tensile modulus of 10 to 3,000 MPa and contains fine metal particles in an amount in the range of 60-98 wt % and which, when heated from 23° C. to 400° C. in the air at a heating rate of 10° C./min and then examined by energy dispersive X-ray spectrometry, has a carbon concentration of 15 wt % or less.
    Type: Grant
    Filed: December 11, 2015
    Date of Patent: May 28, 2019
    Assignee: NITTO DENKO CORPORATION
    Inventors: Yuki Sugo, Nao Kamakura, Tsuyoshi Ishizaka, Mitsuaki Fusumada
  • Patent number: 10266435
    Abstract: A composite material, method and device for preparing particle-energy multifunctional active water. The composite material contains Si, Re, Pt, Ge, Nb, Ni, Se and Mg, and is prepared from nanometer-sized particles of these elements by magnetization, sintering and remagnetization. The composite material contacts and interacts with water to convert the water into the particle-energy multifunctional active water. The particle-energy multifunctional active water is smaller than small molecule group water, with specific gravity at normal temperature of 1.002-1.004 g/cm3. The water is sterile, with stability and activity better than small molecule group water. The water has a long shelf life. After bottled water is stored for three years, its diameter, solvency, penetrability and activity do not change, and it is still sterile.
    Type: Grant
    Filed: May 12, 2015
    Date of Patent: April 23, 2019
    Assignee: JINGHUAN PARTICLE ENERGY TECHNOLOGY DEVELOPMENT CO., LTD.
    Inventors: Jinghuan Huang, Yaoquan Huang
  • Patent number: 10245639
    Abstract: A powder metallurgy method includes (a) forming a metallic powder into a shape, (b) thermo-mechanically forming the shape into an article having a polycrystalline microstructure, (c) heat treating the article to cause coarsening of the polycrystalline microstructure, and (d) controlling the grain size homogeneity and distribution in the article formed during coarsening in step (c) by selecting the metallic powder in step (a) to include a metallic powder particle size distribution that is truncated on fine and coarse particle size sides, the selected metallic powder particle size distribution reducing abnormal grain growth such that the polycrystalline microstructure coarsens to a predefined target grain size range.
    Type: Grant
    Filed: July 31, 2012
    Date of Patent: April 2, 2019
    Assignee: UNITED TECHNOLOGIES CORPORATION
    Inventors: Agnieszka M. Wusatowska-Sarnek, Ronald S. Mace, Harpreet Wasan, Ruston M. Moore, John M. Wezalis, Larry G. Housefield
  • Patent number: 10094007
    Abstract: A method of manufacturing a ferrous alloy article is disclosed and includes the steps of melting a ferrous alloy composition into a liquid, atomizing and solidifying of the liquid into powder particles, outgassing to remove oxygen from the surface of the powder particles, and consolidating the powder particles into a monolithic article.
    Type: Grant
    Filed: May 20, 2014
    Date of Patent: October 9, 2018
    Assignee: CRS Holdings Inc.
    Inventors: David E. Wert, Timothy R. Armstrong, David A. Helmick, Michael L. Schmidt
  • Patent number: 9945018
    Abstract: Aluminum iron based alloys and methods for producing the same are provided. In an exemplary embodiment, a method for producing an aluminum iron based alloy includes melting an aluminum iron based alloy to form a melt. The aluminum iron based alloy includes iron at about 2.0 to about 7.5 weight percent, silicon at about 0.5 to about 3.0 weight percent, aluminum at about 86 to about 97.5 weight percent, and one or more of manganese, vanadium, chromium, molybdenum, tungsten, niobium, zirconium, cerium, erbium, magnesium, calcium, scandium, ytterbium, yttrium, or tantalum at about 0.05 to about 3.5 weight percent. The melt is solidified at about 105 degrees centigrade per second of faster to form particulates. The particulates are degassed at a degassing temperature of about 400 to about 500 degrees centigrade.
    Type: Grant
    Filed: November 26, 2014
    Date of Patent: April 17, 2018
    Assignee: HONEYWELL INTERNATIONAL INC.
    Inventor: Krish Krishnamurthy
  • Patent number: 9863024
    Abstract: A Ni-based bulk metallic glass forming alloy is provided. The alloy includes Ni(100-a-b-c-d)CraNbbPcBd, where an atomic percent of chromium (Cr) a ranges from 3 to 13, an atomic percent of niobium (Nb) b is determined by x?y*a, where x ranges from 3.8 to 4.2 and y ranges from 0.11 to 0.14, an atomic percent of phosphorus (P) c ranges from 16.25 to 17, an atomic percent of boron (B) d ranges from 2.75 to 3.5, and the balance is nickel (Ni), and where the alloy is capable of forming a metallic glass object having a lateral dimension of at least 6 mm, where the metallic glass has a stress intensity factor at crack initiation when measured on a 3 mm diameter rod containing a notch with length between 1 and 2 mm and root radius between 0.1 and 0.15 mm, the stress intensity factor being at least 70 MPa m1/2.
    Type: Grant
    Filed: October 30, 2013
    Date of Patent: January 9, 2018
    Assignees: Glassimetal Technology, Inc., Apple Inc.
    Inventors: Jong Hyun Na, Michael Floyd, Marios D. Demetriou, William L. Johnson, Glenn Garrett, Maximilien Launey
  • Patent number: 9844806
    Abstract: The present disclosure provides a method of dual-phase hot metal extrusion comprising (i) providing a load carrier made of a first metal material, wherein the load carrier comprises one or more load chambers containing a second metal material, wherein the melting point of the second metal material is lower than the melting point of the first metal material, (ii) heating the load carrier to a temperature above the melting point of the second metal material and suitable for extrusion of the load carrier, and (iii) extruding the load carrier to form an extruded product. The present disclosure also provides apparatuses for accomplishing the dual-phase hot extrusion of metals and products resulting from such processes.
    Type: Grant
    Filed: March 14, 2013
    Date of Patent: December 19, 2017
    Assignee: THE ELECTRIC MATERIALS COMPANY
    Inventors: Philip O. Funk, Douglas S. Winner, Seth Lafountain Wyse, Benjamin Anthony Laemmerhirt
  • Patent number: 9751792
    Abstract: A portion of a submerged combustion burner is disposed into a pressure vessel. The portion of the submerged combustion burner has a welded area that has a first microstructure defined by a first number of voids. The vessel is filled with an inert gas, pressurized, and heated. Pressurizing and heating operations are performed for a time and at a temperature and a pressure sufficient to produce a second microstructure in the welded area of the burner. The second microstructure is defined by a second number of voids less than the first number of voids.
    Type: Grant
    Filed: August 12, 2015
    Date of Patent: September 5, 2017
    Assignee: Johns Manville
    Inventors: Juan Carlos Madeni, John Wayne Baker
  • Patent number: 9548148
    Abstract: An R-T-B based sintered magnet maintains high magnetic properties and decreases usage of heavy rare earth elements. The magnet includes main phase grains and grain boundary phases, the main phase grain containing a core portion and a shell portion. X in the main phase LR(2-x)HRxT14B of the core portion ranges from 0.00 to 0.07; x in the main phase LR(2-x)HRxT14B of the shell portion ranges from 0.02 to 0.40; and the maximum thickness of the shell portion ranges from 7 nm to 100 nm. LR contains Nd and one or more light rare earth elements consisting of Y, La, Ce, Pr and Sm; HR contains Dy or/and Tb and one or more heavy rare earth elements consisting of Gd, Ho, Er, Tm, Yb and Lu; T contains Fe or/and Co and one or two kinds of Mn and Ni; and B represents boron partly replaced by C (carbon).
    Type: Grant
    Filed: October 4, 2012
    Date of Patent: January 17, 2017
    Assignee: TDK CORPORATION
    Inventors: Ryota Kunieda, Takuma Hayakawa, Tetsuya Chiba, Kenichi Nishikawa, Yoshinori Fujikawa
  • Patent number: 9486848
    Abstract: The present disclosure provides a method of dual-phase hot metal extrusion comprising (i) providing a load carrier made of a first metal material, wherein the load carrier comprises one or more load chambers containing a second metal material, wherein the melting point of the second metal material is lower than the melting point of the first metal material, (ii) heating the load carrier to a temperature above the melting point of the second metal material and suitable for extrusion of the load carrier, and (iii) extruding the load carrier to form an extruded product. The present disclosure also provides apparatuses for accomplishing the dual-phase hot extrusion of metals and products resulting from such processes.
    Type: Grant
    Filed: August 19, 2015
    Date of Patent: November 8, 2016
    Assignee: THE ELECTRIC MATERIALS COMPANY
    Inventors: Philip O. Funk, Douglas S. Winner, Seth Lafountain Wyse, Benjamin Anthony Laemmerhirt
  • Patent number: 9459050
    Abstract: A heat pipe apparatus having a sintered lattice wick structure includes a plurality of wicking walls having respective length, width and heights and spaced in parallel to wick liquid in a first direction along the respective lengths, the respective lengths being longer than the respective widths and the respective heights, the plurality of wicking walls being adjacent to one another and spaced apart to form vapor vents between them, a plurality of interconnect wicking walls to wick liquid between adjacent wicking walls in a second direction substantially perpendicular to the first direction, and a vapor chamber encompassing the sintered lattice wick structure, the vapor chamber having an interior condensation surface and interior evaporator surface, wherein the plurality of wicking walls and the plurality of interconnect wicking walls are configured to wick liquid in first and second directions and the vapor vents communicate vapor in a direction orthogonal to the first and second directions.
    Type: Grant
    Filed: December 24, 2012
    Date of Patent: October 4, 2016
    Assignee: Teledyne Scientific & Imaging, LLC
    Inventors: Yuan Zhao, Chung-Lung Chen
  • Patent number: 9409234
    Abstract: A one-piece component includes a first subregion made of a base material, and a second subregion made of the base material as binder with intercalated hard material particles, the second subregion being injection-molded onto the first subregion by means of MIM injection molding, so that an integral connection is formed between the first subregion and the second subregion. Furthermore, a method for producing the one-piece component by means of MIM injection molding is described.
    Type: Grant
    Filed: February 6, 2013
    Date of Patent: August 9, 2016
    Assignee: ROBERT BOSCH GMBH
    Inventors: Tilla Haubold, Matthias Schumacher
  • Patent number: 9359662
    Abstract: An iron-carbon master alloy is described, with a C content of 0.3 to 8 wt % and an upper limit of alloying metals Ni<10 wt %, P<4 wt %, Cr<5 wt %, preferably<1 wt %, Mn<5 wt %, preferably<1 wt %, Mo<3 wt %, W<3 wt %, Cu<1 wt %, a particle size of >20 ?m and a hardness of <350 HV 0.01, and a method for the manufacture of said master alloy.
    Type: Grant
    Filed: December 17, 2009
    Date of Patent: June 7, 2016
    Assignee: TECHNISCHE UNIVERSITÄT WIEN
    Inventors: Christian Gierl-Mayer, Herbert Danninger, Yousef Hemmatpour
  • Patent number: 9316253
    Abstract: A maximum diameter (d) of each of surface openings formed in a bearing surface through melting of Sn metal powder as a binder is set within a range of 0 ?m<d?25 ?m. In order to attain the range, binder metal powder having a maximum particle diameter of 25 ?m or less is used.
    Type: Grant
    Filed: January 21, 2009
    Date of Patent: April 19, 2016
    Assignee: NTN CORPORATION
    Inventors: Kazuo Okamura, Fuyuki Ito
  • Patent number: 9192993
    Abstract: A family of materials wherein nanostructures and/or nanotubes are incorporated into a multi-component material arrangement, such as a metallic or ceramic alloy or composite/aggregate, producing a new material or metallic/ceramic alloy. The new material has significantly increased strength, up to several thousands of times normal and perhaps substantially more, as well as significantly decreased weight. The new materials may be manufactured into a component where the nanostructure or nanostructure reinforcement is incorporated into the bulk and/or matrix material, or as a coating where the nanostructure or nanostructure reinforcement is incorporated into the coating or surface of a “normal” substrate material. The nanostructures are incorporated into the material structure either randomly or aligned, within grains, or along or across grain boundaries.
    Type: Grant
    Filed: June 22, 2012
    Date of Patent: November 24, 2015
    Assignees: Consolidated Nuclear Security, LLC, UT-Battelle, LLC
    Inventors: Roland D. Seals, Edward B. Ripley, Gerard M. Ludtka
  • Patent number: 9090469
    Abstract: To provide a method of producing a spherical aluminum nitride powder which has a large thermal conductivity and excellent filling property, and is useful as a filler for heat-radiating materials. [Means for Solution] The spherical aluminum nitride powder is produced by reductively nitriding a mixture of 100 parts by mass of an alumina or an alumina hydrate, 0.5 to 30 parts by mass of a rare earth metal compound and 38 to 46 parts by mass of a carbon powder at a temperature of 1620 to 1900° C. for not less than 2 hours.
    Type: Grant
    Filed: September 27, 2011
    Date of Patent: July 28, 2015
    Assignee: TOKUYAMA CORPORATION
    Inventors: Takatoshi Muneoka, Kazutaka Watanabe
  • Patent number: 9073755
    Abstract: [Problems] To provide a spherical aluminum nitride powder that features high thermal conductivity and filling property, and that is useful as a filler for a heat radiating material, and a method of producing the same. [Means for Solution] A spherical aluminum nitride powder comprising aluminum nitride particles having an average particle diameter of 3 to 30 ?m, a sphericalness of not less than 0.75, and an oxygen content of not more than 1% by weight wherein, when the average particle diameter is d (?m), the specific surface area S (m2/g) satisfies the following formula (1), (1.84/d)?S?(1.84/d+0.5)??(1).
    Type: Grant
    Filed: August 31, 2011
    Date of Patent: July 7, 2015
    Assignee: TOKUYAMA CORPORATION
    Inventors: Takatoshi Muneoka, Kazutaka Watanabe
  • Patent number: 9056774
    Abstract: [Problem] To provide a method of producing aluminum nitride that has high conducting property and can be excellently filled and is useful as a filler for heat-radiating materials, and an aluminum nitride powder obtained by the same method.
    Type: Grant
    Filed: November 30, 2011
    Date of Patent: June 16, 2015
    Assignee: TOKUYAMA CORPORATION
    Inventors: Takatoshi Muneoka, Kazutaka Watanabe
  • Publication number: 20150147590
    Abstract: A new Enhanced High Pressure Sintering (EHPS) method for making three-dimensional fully dense nanostructures and nano-heterostructures formed from nanoparticle powders, and three-dimensional fully dense nanostructures and nano-heterostructures formed using that method. A nanoparticle powder is placed into a reaction chamber and is treated at an elevated temperature under a gas flow to produce a cleaned powder. The cleaned powder is formed into a low density green compact which is then sintered at a temperature below conventional sintering temperatures to produce a fully dense bulk material having a retained nanostructure or nano-heterostructure corresponding to the nanostructure of the constituent nanoparticles. All steps are performed without exposing the nanoparticle powder to the ambient.
    Type: Application
    Filed: November 14, 2014
    Publication date: May 28, 2015
    Applicant: The Government of the United States of America, as represented by the Secretary of the Navy
    Inventors: Boris N. Feigelson, James A. Wollmershauser
  • Publication number: 20150147217
    Abstract: An article having a nanocomposite magnetic component and method of forming a nanocomposite magnetic component are disclosed. The article includes a plurality of nanocrystalline flake particles bonded along their prior particle boundaries. The nanocrystalline flake particles have a median grain size less than about 30 nanometers and include a first set of grains comprising predominantly permanent magnet phase and a second set of grains comprising predominantly soft magnet phase.
    Type: Application
    Filed: November 27, 2013
    Publication date: May 28, 2015
    Applicant: General Electric Company
    Inventors: Francis Johnson, Wanming Zhang, Min Zou, Christina Hongbing Chen
  • Publication number: 20150130573
    Abstract: An eddy current loss at a frequency of 3,000 Hz is set to less than 150 W/kg by setting a single particle diameter-equivalent diameter dS of soft magnetic metal powder represented by the following formula to 210 ?m or less. In the formula, dS represents a single particle diameter-equivalent diameter of the soft magnetic metal powder [m], dMN represents a number average particle diameter of the soft magnetic metal powder [m], and ? represents a standard deviation of the particle diameter of the soft magnetic metal powder [m].
    Type: Application
    Filed: April 25, 2013
    Publication date: May 14, 2015
    Applicant: NTN CORPORATION
    Inventors: Hikaru Araki, Norikazu Muneda, Eiichirou Shimazu
  • Patent number: 9028624
    Abstract: Provided is a NdFeB sintered magnet which can be used in the grain boundary diffusion method as a base material in which RH can be easily diffused through the rare-earth rich phase and which itself has a high coercive force, a high maximum energy product and a high squareness ratio, as well as a method for producing such a magnet. A NdFeB system sintered has an average grain size of the main-phase grains magnet is equal to or smaller than 4.5 ?m, the carbon content of the entire NdFeB system sintered magnet is equal to or lower than 1000 ppm, and the percentage of the total volume of a carbon rich phase in a rare-earth rich phase at a grain-boundary triple point in the NdFeB system sintered magnet to the total volume of the rare-earth rich phase is equal to or lower than 50%.
    Type: Grant
    Filed: December 27, 2012
    Date of Patent: May 12, 2015
    Assignee: Intermetallics Co., Ltd.
    Inventors: Masato Sagawa, Tetsuhiko Mizoguchi
  • Patent number: 9017599
    Abstract: There is provided a sliding part in which a surface coverage ratio of copper in the sliding part increases. A bearing which is the sliding part is formed by filling the raw powder into the filling portion of the forming mold, compacting the raw powder to form a powder compact, which is sintered. A copper-based raw powder is composed of a copper-based flat raw powder whose diameter is smaller than that of an iron-based raw powder and an aspect ratio larger than that of the iron-based raw powder, and a copper-based small-sized raw powder whose diameter is smaller than that of the copper-based flat raw powder. The copper is allowed to segregate at the surface of the sliding part. The surface of the bearing is covered with the copper-based small-sized raw powder and the copper-based flat raw powder, thereby the surface coverage ratio of copper can be increased.
    Type: Grant
    Filed: June 1, 2012
    Date of Patent: April 28, 2015
    Assignee: Diamet Corporation
    Inventors: Teruo Shimizu, Tsuneo Maruyama
  • Patent number: 9011763
    Abstract: The present invention is generally directed to nanocomposite thermoelectric materials that exhibit enhanced thermoelectric properties. The nanocomposite materials include two or more components, with at least one of the components forming nano-sized structures within the composite material. The components are chosen such that thermal conductivity of the composite is decreased without substantially diminishing the composite's electrical conductivity. Suitable component materials exhibit similar electronic band structures. For example, a band-edge gap between at least one of a conduction band or a valence band of one component material and a corresponding band of the other component material at interfaces between the components can be less than about 5kBT, wherein kB is the Boltzman constant and T is an average temperature of said nanocomposite composition.
    Type: Grant
    Filed: September 20, 2012
    Date of Patent: April 21, 2015
    Assignees: Massachusetts Institute of Technology, Trustees of Boston College
    Inventors: Gang Chen, Mildred Dresselhaus, Zhifeng Ren
  • Patent number: 8999225
    Abstract: First, an ionic liquid is placed on a glass slide, which is then installed in an evaporation apparatus, and a metal (for example, indium) is mounted as a target material at a position facing the ionic liquid, followed by sputter deposition of the metal. After sputtering, the ionic liquid containing nanoparticles dispersed therein is recovered. The nanoparticles are solid nanoparticles. Next, the ionic liquid containing the solid nanoparticles dispersed therein is placed in a test tube and then oxidized by heating in air at 250° C. for 1 hour. As a result, hollow nanoparticles having cavities formed in core portions of the solid nanoparticles are produced.
    Type: Grant
    Filed: November 9, 2010
    Date of Patent: April 7, 2015
    Assignees: National University Corporation Nagoya University, Osaka University
    Inventors: Tsukasa Torimoto, Ken-ichi Okazaki, Toshimasa Suzuki, Yousuke Tomita, Susumu Kuwabata
  • Publication number: 20150071809
    Abstract: The present invention relates to a method for forming a three-dimensional article through successive fusion of parts of at least one layer of a powder bed provided on a work table. Said method comprising the steps of: providing at least a first and second powder tank, providing a first type of powder in said first powder tank having a first particle size distribution, providing a second type of powder in said second powder tank having a second particle size distribution, providing a first sub-layer of said first type of powder on said work table, providing a second sub-layer of said second type of powder on top of said first layer of said first type of powder, fusing said first and second sub-layers simultaneously with a high energy beam from a high energy beam source for forming a first cross section of said three-dimensional article.
    Type: Application
    Filed: April 15, 2014
    Publication date: March 12, 2015
    Applicant: Arcam AB
    Inventors: Johan Nordkvist, Ulf Ackelid, Anders Snis
  • Publication number: 20150071810
    Abstract: A method for preparing a Nd—Fe—B-based sintered magnet. The method includes: 1) providing a master alloy and an auxiliary alloy, the master alloy being a Nd—Fe—B alloy ingot or cast strip, the auxiliary alloy being a heavy rare earth alloy; 2) breaking up the master alloy using a hydrogen decrepitation process to yield a crude powder, conducting hydrogen absorption treatment on the auxiliary alloy and breaking up the hydrogenated auxiliary alloy to yield hydride particles; 3) uniformly mixing and stirring the crude powder of the master alloy and the hydride particles of the auxiliary alloy to yield a mixture; 4) milling the mixture obtained in step 3) to yield powders; 5) uniformly stirring the powders obtained in step 4) and conducting orientation forming treatment on the powders, to yield a raw body of a Nd—Fe—B based magnet; and 6) sintering the raw body of the Nd—Fe—B based magnet.
    Type: Application
    Filed: November 14, 2014
    Publication date: March 12, 2015
    Inventors: Xiangke LV, Min ZHANG, Xike OUYANG, Yong DING, Zhao WANG, Shengye LIU
  • Patent number: 8961647
    Abstract: The invention is a process for manufacturing a nano aluminum/alumina metal matrix composite and composition produced therefrom. The process is characterized by providing an aluminum powder having a natural oxide formation layer and an aluminum oxide content between about 0.1 and about 4.5 wt. % and a specific surface area of from about 0.3 and about 5 m2/g, hot working the aluminum powder, and forming a superfine grained matrix aluminum alloy. Simultaneously there is formed in situ a substantially uniform distribution of nano particles of alumina. The alloy has a substantially linear property/temperature profile, such that physical properties such as strength are substantially maintained even at temperatures of 250° C. and above.
    Type: Grant
    Filed: December 4, 2012
    Date of Patent: February 24, 2015
    Inventors: Thomas G. Haynes, III, Martin Walcher, Martin Balog
  • Patent number: 8961868
    Abstract: In a nanocomposite bulk magnet according to the present invention, nanocomposite magnet powder particles, including an Nd2Fe14B crystalline phase and an ?-Fe phase, are combined together. The composition of the magnet is represented by T100-x-y-z-n(B1-qCq)xRyTizMn, where T is at least one transition metal element selected from the group consisting of Fe, Co and Ni and always including Fe, R is at least one rare-earth element including substantially no La or Ce, M is an additive metallic element, and x, y, z, n and q satisfy 4 at %?x?10 at %, 6 at %?y?10 at %, 0.05 at %?z?5 at %, 0 at %?n?10 at %, and 0?q?0.5, respectively. The powder particles have a minor-axis size of less than 40 ?m. And powder particles, of which the major-axis size exceeds 53 ?m, account for at least 90 mass % of the entire magnet. And those powder particles are directly combined with each other. Consequently, a full-dense magnet, of which the density is 96% or more of the true density of its material alloy, is realized.
    Type: Grant
    Filed: March 30, 2010
    Date of Patent: February 24, 2015
    Assignee: Hitachi Metals, Ltd.
    Inventor: Toshio Miyoshi
  • Publication number: 20150041974
    Abstract: A sintered body of silver fine particles for a bonding member to bond components of a semiconductor device, wherein an activation energy for creep of the sintered body of the silver fine particles is from 0.4 to 0.75 times that of an activation energy for a lattice diffusion of bulk silver.
    Type: Application
    Filed: February 26, 2013
    Publication date: February 12, 2015
    Inventors: Makoto Kobayashi, Koji Sasaki
  • Publication number: 20150033894
    Abstract: A sintered gear serving as a mechanical structure component is a mechanical structure component made of a metal sintered body, and includes a base region; and a high density region formed so as to include a maximum stress position at which a maximum tensile stress or a maximum shear stress is applied, and to include a surface, in which the high density region is lower in porosity than the base region. A surface hardened layer is formed in a region including the surface by performing a hardening process.
    Type: Application
    Filed: February 27, 2013
    Publication date: February 5, 2015
    Applicant: NTN CORPORATION
    Inventors: Takahiro Okuno, Eiichirou Shimazu, Hikaru Araki
  • Publication number: 20150023831
    Abstract: The present invention provides a method for producing an R-T-B-M sintered magnet having an oxygen content of less than 0.07 wt. % from R-T-B-M raw materials. The composition of R-T-B-M includes R being at least one element selected from a rare earth metal including Sc and Y. The composition also includes T being at least one element selected from Fe and Co. B in the composition is defined as Boron. The composition further includes M being at least one element selected from Ti, Ni, Nb, Al, V, Mn, Sn, Ca, Mg, Pb, Sb, Zn, Si, Zr, Cr, Cu, Ga, Mo, W, and Ta. The present invention provides for a step of creating an inert gas environment in the steps of casting, milling, mixing, molding, heating, and aging to prevent the powder from reacting with the oxygen in anyone of the above mentioned steps.
    Type: Application
    Filed: July 17, 2014
    Publication date: January 22, 2015
    Inventors: Xifeng Lin, Kaihong Ding, Yongjie Wang, Shengli Cui, Zhong Jie Peng, Wenchao Li
  • Publication number: 20150014156
    Abstract: Provided is a sputtering target which contains Na in high concentration and, despite this, is inhibited from discoloration, generating spots, and causing abnormal electrical discharge and which has high strength and rarely breaks. Also provided is a method for producing the sputtering target. The sputtering target has a component composition that contains 10 to 40 at % of Ga and 1.0 to 15 at % of Na as metal element components other than F, S, and Se, with the remainder composed of Cu and unavoidable impurities, wherein the Na is contained in the form of at least one Na compound selected from sodium fluoride, sodium sulfide, and sodium selenide. The sputtering target has a theoretical density ratio of 90% or higher, a flexural strength of 100 N/mm2 or higher, and a bulk resistivity of 1 m?·cm or less. The number of 0.05 mm2 or larger aggregates of the at least one of sodium fluoride, sodium sulfide, and sodium selenide present per cm2 area of the target surface is 1 or less on average.
    Type: Application
    Filed: February 15, 2013
    Publication date: January 15, 2015
    Inventors: Shoubin Zhang, Keita Umemoto, Masahiro Shoji
  • Publication number: 20140377119
    Abstract: A titanium alloy comprising an elevated level of oxygen is disclosed. The alloy may have 5.5 to 6.75 weight percent of aluminum, 3.5 to 4.5 weight percent of vanadium, 0.21 to 0.30 weight percent of oxygen, and up to 0.40% of weight percent of iron. The alloy may also have a minimum ultimate tensile strength of 130,000 psi, a minimum tensile yield strength of 120,000 psi, and a minimum ductility of 10% elongation. Also disclosed is a method for manufacturing components having the aforementioned alloy.
    Type: Application
    Filed: January 25, 2013
    Publication date: December 25, 2014
    Inventors: Stanley Abkowitz, Susan M. Abkowitz, Patrick Connors, David Main, Harvey Fisher
  • Patent number: 8916091
    Abstract: Disclosed is a method for producing semi-finished products from a shape memory alloy, particularly an NiTi shape memory alloy, wherein a powder is first produced from a shape memory alloy, and subsequently the powder is divided into a coarse fraction and a fine fraction in a separating cut T. While the fine fraction is required, in particular, for the production of a first semi-finished product, employing the metal injection molding (MIM) method, the coarse fraction can be used for the production of a second semi-finished product, employing the hot isostatic pressing (HIP) method. The advantages of the invention can be summarized as follows. The MIM method for producing semi-finished products from a shape memory alloy is qualitatively improved and more cost-effective to implement if the coarse fraction that is typically obtained during powder production, but not used for the MIM process, can advantageously be supplied to a further process, in this case the HIP process.
    Type: Grant
    Filed: August 27, 2008
    Date of Patent: December 23, 2014
    Assignee: Forschungszentrum Juelich GmbH
    Inventors: Manuel Koehl, Martin Bram, Berthold Coenen, Hans Peter Buchkremer, Detlev Stoever
  • Patent number: 8911663
    Abstract: The present invention relates to ferromagnetic powders with an electrically insulating layer on iron particles intended for the manufacture of components having improved soft magnetic properties at low and medium frequencies. The invention comprises an iron powder coated with a dielectric insulating layer comprising boron bearing compounds to form an insulated ferromagnetic powder. The present invention also relates to a method of making these insulated ferromagnetic powders. The present invention further relates to a method of synthesizing a product made from insulated ferromagnetic powders via a post-heat treatment at a moderate temperature (300° C. to 700° C.), to form a glass-like coating which acts as an electrical insulator. A preferred embodiment of the present invention is obtained when small amounts of alkali bearing compounds are added to the precursors to modify the coating chemistry and significantly increase the electrical resistivity after heat treatment.
    Type: Grant
    Filed: March 5, 2009
    Date of Patent: December 16, 2014
    Assignee: Quebec Metal Powders, Ltd.
    Inventors: Guillem Vachon, Claude Gelinas
  • Publication number: 20140355178
    Abstract: A capacitor anode including a tungsten sintered body having an average pore diameter of 0.3 ?m or less; and a method for producing the anode. The method includes forming tungsten powder into a molded body having a density (Dg) of 8 g/cm3 or more and then sintering the molded body to a density (Ds) of at least 1.15 times the density (Dg) to form a tungsten sintered body having an average pore diameter of 0.3 ?m or less.
    Type: Application
    Filed: August 30, 2012
    Publication date: December 4, 2014
    Applicant: SHOWA DENKO K.K.
    Inventor: Kazumi Naito
  • Publication number: 20140356216
    Abstract: In various embodiments, powders with engineered particle-size distributions are slip or pressure casted to produce homogeneous parts without the need for additives such as flocculating or deflocculating agents.
    Type: Application
    Filed: May 28, 2014
    Publication date: December 4, 2014
    Inventors: MICHAEL T. STAWOVY, Maria Bozena Winnicka
  • Patent number: 8882975
    Abstract: Provided is an Sb—Te base alloy sinter sputtering target having Sb and Te as its primary component and comprising a structure in which Sb—Te base alloy particles are surrounded by fine carbon or boron particles; wherein, if the mean diameter of the Sb—Te base alloy particles is X and the particle size of carbon or boron is Y, Y/X is within the range of 1/10 to 1/10000. The present invention seeks to improve the Sb—Te base alloy sputtering target structure, inhibit the generation of cracks in the sintered target, and prevent the generation of arcing during the sputtering process.
    Type: Grant
    Filed: October 5, 2007
    Date of Patent: November 11, 2014
    Assignee: JX Nippon Mining & Metals Corporation
    Inventors: Masataka Yahagi, Hideyuki Takahashi, Hirohisa Ajima
  • Publication number: 20140327503
    Abstract: Provided is a NdFeB sintered magnet which can be used in the grain boundary diffusion method as a base material in which RH can be easily diffused through the rare-earth rich phase and which itself has a high coercive force, a high maximum energy product and a high squareness ratio, as well as a method for producing such a magnet. A NdFeB system sintered has an average grain size of the main-phase grains magnet is equal to or smaller than 4.5 ?m, the carbon content of the entire NdFeB system sintered magnet is equal to or lower than 1000 ppm, and the percentage of the total volume of a carbon rich phase in a rare-earth rich phase at a grain-boundary triple point in the NdFeB system sintered magnet to the total volume of the rare-earth rich phase is equal to or lower than 50%.
    Type: Application
    Filed: December 27, 2012
    Publication date: November 6, 2014
    Inventors: Masato Sagawa, Tetsuhiko Mizoguchi
  • Patent number: 8871142
    Abstract: Provided are methods for processing a green body that includes compacted metal powder, comprising impacting the green body with a particulate material for a time and under conditions effective to displace a portion of the metal powder from the green body. The present methods can be used to prepare green bodies that have “roughened” surfaces and that can be used to make orthopedic implants displaying low movement relative to bone when installed in situ, which corresponds to higher stability upon implantation and decreases the time required for biological fixation of the implant. Also provided are implants comprising a metallic matrix, and methods comprising surgically installing an implant prepared from a “surface roughened” green body in accordance with the present invention.
    Type: Grant
    Filed: May 21, 2009
    Date of Patent: October 28, 2014
    Assignee: DePuy Synthes Products, LLC
    Inventors: Bryan Smith, Jeffrey A. Rybolt, Derek Hengda Liu, Andrew James Martin
  • Publication number: 20140294651
    Abstract: A thermal mechanical treatment method includes consolidating a powder by a severe plastic deformation process and ageing the consolidated powder at low temperature. The method may include cryomilling the powder before consolidating the powder by a severe plastic deformation process; hot isostatic pressing the consolidated powder into a dense powder before aging the consolidated powder; hot extruding the dense powder into a stock shape before aging the consolidated powder; hot-working the stock shape on a gyrating forge at a predetermined temperature before aging the consolidated powder; or heating the consolidated powder to a predetermined temperature, and maintaining the consolidated powder at the predetermined temperature for a predetermined time.
    Type: Application
    Filed: March 31, 2014
    Publication date: October 2, 2014
    Applicant: SCHLUMBERGER TECHNOLOGY CORPORATION
    Inventors: Indranil Roy, Rashmi Bhavsar
  • Patent number: 8834786
    Abstract: Carbide pellets including relatively small amounts of metallic binder are produced by steps of pressing, comminuting, shaping and sintering. The carbide pellets may be used as wear resistant hard facing materials that are applied to various types of tools. The carbide pellets provide improved mechanical properties such as hardness and abrasiveness while maintaining required levels of toughness and strength.
    Type: Grant
    Filed: June 30, 2010
    Date of Patent: September 16, 2014
    Assignee: Kennametal Inc.
    Inventors: Terry Wayne Kirk, Hongbo Tian, Xin Deng, Debangshu Banerjee, Qingjun Zheng