Abstract: A copper-rich metal shape is produced by forming a coherent forerunner shape consisting essentially of cupreous powder, said powder containing a proportion of copper oxide sufficient for facilitating the obtaining of a high sinter density in sintered porous mass, and in a reducing atmosphere at temperature that will sinter copper present, converting said forerunner shape into a porous sintered mass virtually devoid of copper oxide. Said porous mass can be worked so virtually full density if desired.

Abstract: A magnetic powder core, suitable for use in a low frequency power device, is prepared by a method including the steps of coating an atomized iron powder from an aqueous solution of potassium dichromate, drying the powder, compressing the powder to form a compact and heat treating the compact until it becomes partially sintered. Cores having coercivities below 240.sup.A /m, saturation inductions exceeding 1.3 Tesla and resistivities exceeding 500 microhm cm are disclosed.

Abstract: The disclosure relates to a feedstock of particulate material for use in formation of articles therefrom, the feedstock including a homogeneous combination of large particles, small particles and a binder. The large particles comprise less than about 60% by volume of the feedstock and are defined as particles having a diameter greater than their diffusion length. The fine particles and binder combined comprise more than about 40% by volume of the feedstock, the fine particles being defined as particles having a diameter less than their diffusion length.

Abstract: A powder metallurgical method is described for producing precision components of sintered steel having high strength and high ductility by compressing a powder to form a green compact and sintering the latter at a temperature from 950.degree. to 1250.degree. C. for 5 to 90 minutes in a reducing atmosphere of partially combusted hydrocarbons, sufficient carbon being present to impart a carbon content of 0.05 to 0.6% by weight in the sintered steel; said powder consisting essentially of iron powder containing 0.65 to 0.8% phosphorus, 0.1 to 0.5% graphite or carbon powder, and 0 to 1.5% of a solid lubricant.

Abstract: A sintered Fe-Cr-Co type magnetic alloy consisting essentially of 20-35% Cr, 3-15% Co and the balance substantially of Fe and a method of producing an article made of the alloy are disclosed. The method comprises the steps of blending at least one of an Fe-Cr powder and Fe-Cr-Co powder with a carbonyl Fe-powder and a Co-powder, if necessary to make up to said alloy composition, to provide a powder blend, the average particle size of said Fe-Cr powder and Fe-Cr-Co powder being 200 mesh or smaller in size, and the surface of these powders having been activated; compacting the resulting powder blend to provide a compact; sintering the resulting compact in an atmosphere in which the total amount of oxygen and nitrogen has been restricted to not more than 3 ppm; and effecting the heat treatment and magnetization of the resulting sintered alloy.

Abstract: A process for forming a titanium base alloy comprises compacting a powder formed of particles of titanium or of a mother alloy thereof and of a dispersion of fine particles of a product curbing the growth of the grain size, in a proportion per volume which is less than that which would lead to the formation of a continuous layer of fine particles about the particles of titanium powder. Then the alloy is heat treated at a temperature higher than the point of transformation into phase .beta. and quenched. The product is typically selected among S, P, B, As, Se, Te, Y and the lanthanides.

Abstract: Permanent magnetic materials of the Fe-B-R type are produced by:preparing an metallic powder having a mean particle size of 0.3-80 microns and a composition of, by atomic percent, 8-30% R (rare earth elements), 2-28% B, and the balance Fe, compacting, sintering at a temperature of 900-1200 degrees C., and aging at a temperature ranging from 350 degrees C. to the temperature for sintering. Co and additional elements M (Ti, Ni, Bi, V, Nb, Ta, Cr, Mo, W, Mn, Al, Sb, Ge, Sn, Zr, Hf) may be present.

Abstract: In a method of producing unbaked agglomerates, green pellets or briquettes are produced by adding 5 to 30% of reduced iron powder, mill scale powder or iron sand and also adding a binder consisting of a cement or granulated blast furnace slag and then the green pellets or briquettes are dry cured thereby producing agglomerates having excellent reducing performance.

Abstract: High strength and high toughness are combined in an aluminum-based metallic product by dispersing particles of an aluminum-based metal having a toughness of at least about 20 foot-pounds through a matrix of aluminum-based metal having a yield strength of at least about 30 ksi.

Abstract: Permanent magnet materials of the Fe-B-R type are produced by:preparing a metallic powder having a mean particle size of 0.3-80 microns and a composition of 8-30 at % R, 2-28 at % B, and the balance Fe,compacting, andsintering, at a temperature of 900-1200 degrees C.Co up to 50 at % may be present. Additional elements M (Ti, Ni, Bi, V, Nb, Ta, Cr, Mo, W, Mn, Al, Sb, Ge, Sn, Zr, Hf) may be present. The process is applicable for anisotropic and isotropic magnet materials.

Abstract: A process for forming a wear-resistant, sintered layer on an iron based substrate which comprises steps of providing a first alloy sheet containing 94 to 99 weight % of Fe-Cr type alloy particles and 6 to 1 weight % of acryl binder and a second alloy sheet containing 94 to 99 weight % of eutectic alloy particles and 6 to 1 weight % of acryl binder, placing the first and second alloy sheets in a superposed condition on the substrate, and heating in a non-oxidating atmosphere to a temperature which is higher than a solidus temperature of the eutectic alloy but lower than a solidus temperature of the Fe-Cr type alloy.

Abstract: A method of producing a composite compact of cBN and WC-Co, comprising: mixing fine particles of cBN with a minor part of titanium carbide, the former being in an amount of 60-80% and the latter 40-20%, correspondingly, of the combined volume, putting the mixture in an intimate contact with a composite of WC-Co, heating the whole to a temperature high enough to cause an outflow of a liquid phase from said composite and infiltration thereof into said mixture under a pressure-temperature condition where cubic boron nitride is crystallographically stable, interjoining adjacent particles of cBN and titanium carbide, and as a whole to the composite of WC-Co, and recovering the integrated product of cBN, titanium carbide and WC-Co.

Abstract: A metal powder sheet for use for forming a sintered layer on a metal substrate. The sheet includes powders of a metal which provides a required physical property such as wear-resistance and ultra-fine powders of a metal having a powder size finer than 1 micron. These powders are kneaded with an addition of an acryl resin as a binder. The ultra-fine powders make it possible to carry out the sintering process at a lower temperature.

Abstract: Broadly, the present invention provides for improvements in the manufacture of compacted or molded articles of blended mixtures of additive metals for use in the preparation of alloys of base metals. The improvements comprise the addition to blended mixtures of additive metals of at least one processing aid comprising at least one polyglycol or a derivative thereof to the blended mixture of metals in a stabilizing and lubricating amount.

Abstract: A process for making a strip or sheet comprising dispersion strengthened metal or dispersion strengthened metal alloy which comprises rolling directly from dispersion strengthened metal powder to a green strip or sheet density of from at least 90% to 95% of theoretical density, sintering the green strip or sheet in an inert atmosphere at a temperature and for a period of time sufficient to form a rigid body; reducing the thickness of the strip or sheet by at least 25% by cold rolling or hot rolling and resintering at sintering temperature of at least about 1800.degree. F. for 40 to 75 or more minutes.

Abstract: A fine aluminum metallurgical powder suitable for compacting and sintering into densified articles which includes a dispersed phase is produced by directing a stream of molten droplets at a repellent surface to produce smooth surfaced and melt solidified particles having an average particle size of less than about ten micrometers.

Abstract: Pressure assisted sintering achieves full densification in short sinter times with low grain growth. This result is enabled by a stage of sintering to a condition of closed porosity (14) followed by a pressure assisted sinter (PAS) stage (16) carried out at a temperature close to, but just below, sinter temperature. Advantageously a small melt formation is induced by a brief temperature spiking (18) during the PAS stage to enable collapse of voids.

Abstract: Manufacture of a workpiece from a creep-resistant nickel superalloy which is hardened by means of an oxide dispersion, by a powder-metallurgical process in which the mechanically alloyed powder is subjected to an isothermal or quasi-isothermal hot-rolling operation, in the course of which the powder particles are converted into a flake-shaped form with a pronounced longitudinal axes, and the rolled powder is introduced into a steel container and is compressed by isostatic hot-pressing. The workpiece is afterwards subjected to an annealing treatment which is designed to develop a coarse grain size. A preferred embodiment comprises the introduction of the powder into the mold or container in an oriented manner, in order to obtain a stratified packing of the powder, and an annealing treatment which is designed to develop a coarse grain size and is performed as a zone-annealing treatment.

Abstract: An article comprising a first portion which is formed porously by sintering of an alloy or cermet material and a second portion which is formed of a metal and intimately bonds to the first portion. For example, the article is a rocker arm for an automotive internal combustion engine, in which first portion is the wear-resistant tip portion and the second portion the body portion. The second portion is formed by molten metal forging, with the sintered first portion set in the mould as an insert, such that the molten metal under pressure is forced to infiltrate into the pores of the sintered first portion at least in a region contiguous to the interface between the first and second portions. This article features very high strength of the bond at the interface between the first and second portions.

Abstract: The present invention provides a method for consolidating rapidly solidified, transition metal alloys which includes the step of compacting a plurality of alloy bodies at a temperature ranging from about 0.90-0.99 Tm (melting temperature in .degree.C.) for a time period ranging from about 1 min to 24 hours. The alloy bodies contain at least two transition metal elements and consist essentially of the formula (Fe,Co and/or Ni).sub.bal (W, Mo, Nb and/or Ta).sub.a (Al and/or Ti).sub.b (Cr).sub.c (B and/or C).sub.d (Si and/or P).sub.e, wherein "a" ranges from about 0-40 at. %, "b" ranges from about 0-40 at. %, "c" ranges from about 0-40 at. %, "d" ranges from about 5-25 at. %, and "e" ranges from about 0-15 at. %. The alloy bodies also have a substantially homogeneous and optically featureless structure.

Abstract: Method for producing molded metallic honeycomb structures of high physical strength and porosity, the method comprising forming a honeycomb structure by extruding through a die a kneaded mixture of a metal powder and a binder capable of forming a supporting bone structure for the metal powder upon application of heat, and, after drying, sintering the honeycomb structure.

Abstract: To increase the creep strength of a titanium-containing alloy which also contains chromium, the alloy powder is heated in the presence of ammonia at a temperature of the order of 700.degree. C. so as to form a layer of chromium nitride(s) on the particles and is then heated further in an inert atmosphere at a temperature between 1000.degree. C. and 1150.degree. C. to dissociate the chromium nitride(s) thereby effecting nitriding of the titanium to titanium nitride which affords dispersion-strengthening of the alloy.

Abstract: An acoustical transducer is provided with an acoustically absorbant backing material having an acoustical impedance precisely matching the impedance of the piezoelectric element in the transducer. The backing material is a multiphase mixture of selected materials, such as a low melting point alloy (InPb) and one or more powders having high impedance characteristics (tungsten and copper). The slope of the curve impedance versus volume fraction of the backing components is low, thus allowing the impedance of the material to be precisely controlled. The backing material is preferably electrically conductive and is fuzed to one surface of the piezoelectric element to further improve the output characteristics of the transducer.

Abstract: A master alloy compacted mass of particulate metal is fabricated using non-spherical particulated aluminum, such as aluminum sawdust from production operations, in combination with metal particles of a brittle and friable principal metal of the master alloy which is non-malleable and, therefore, non-compactable. The compacted mass retains its homogeneity by the interlocking action of the aluminum sawdust and thereby obviates the need for additional binder despite the non-compactability of the metal particles of the non-malleable principal metal of the master alloy.

Abstract: An acoustical transducer is provided with an acoustically absorbant backing material having an acoustical impedance precisely matching the impedance of the piezoelectric element in the transducer. The backing material is a multiphase mixture of selected materials, such as a low melting point alloy (InPb) and one or more powders having high impedance characteristics (tungsten and copper). The slope of the curve impedance versus volume fraction of the backing components is low, thus allowing the impedance of the material to be precisely controlled. The backing material is preferably electrically conductive and is fuzed to one surface of the piezoelectric element to further improve the output characteristics of the transducer.

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: Fully dense consolidated powder alloys of iron, cobalt and/or nickel characterized by having an ultrafine microstructure exhibiting a substantially uniformly dispersed harding phase of particle size essentially less than 3 microns, are produced from prealloyed powders by rapidly quenching an atomized molten alloy charge and subjecting the solidified alloy powder particles to the step of hot consolidation to produce substantially fully dense metal stock directly from prealloyed powder.

Abstract: A powder metallurgical method of producing metal bodies using spherical powder, produced by inert gas atomization, from magnetizable material with a particle size distribution closely approximating the so called Fuller curve for maximum density packing of spherical particles. Said powder is magnetized and filled into a form, which may take place before or after magnetization, said mixed and magnetized powder then sintered in said form with the exclusion of air, to produce a sintered body without communicating porosity.

Abstract: A method is provided for preparing computer disk substrates having low surface amplitude which comprises: (a) forming a liquid suspension containing aluminum powder, an aluminum alloying element and a borate composition by initially admixing the borate composition with a volatile liquid medium to obtain a borate solution and thereafter admixing the aluminum powder and aluminum alloying element with the borate solution to produce the liquid suspension; (b) heating the liquid suspension to remove the liquid medium and to obtain a dry aluminum powder composition; (c) isostatically pressurizing the dry aluminum powder composition and roller compacting the same into sheet form; (d) heating and sintering the sheet form in a non-oxidizing atmosphere; and (e) cutting and compressing the sintered sheet into computer disk substrate configuration.

Abstract: An object is manufactured from a powdered material by isostatic pressing of a body, preformed from the powdered material, with a pressure medium, whereby the preformed body, in which at least the surface layer consists of a ceramic material in the form of a nitride, is surrounded by a casing which is rendered impenetrable to the pressure medium, before the isostatic pressing is carried out and the powder sintered. As the material in the casing there is used boron oxide or a glass containing boron oxide or a material forming glass while being heated, in which the content of boron oxide is sufficiently high for the glass--or the glass formed during heating--to be removable by water. The preformed body surrounded by the casing is subjected to a heat treatment for the formation of boron nitride on the surface of the preformed body, before the isostatic pressing is carried out. The casing is removed from the finished product by means of water or water vapor.

Abstract: A method for producing and distributing wet zinc dust to a zinc sulfate purification system or other zinc plant operation is disclosed. The method comprises atomizing molten zinc with high pressure water or other suitable medium, and feeding a predetermined amount of the wet zinc dust to at least one zinc sulphate purification tank or any other zinc plant operation.

Abstract: A method for producing iron-silicon alloy articles having an improved combination of hot workability and electrical properties; the method comprises taking a molten alloy mass of an iron-silicon alloy from which the article is to be made and gas atomizing it to form alloy particles which are quickly cooled to solidification temperature. These alloy particles are then hot isostatically pressed to form a substantially fully dense article. The fully dense article is then hot rolled to sheet form suitable for example for use as laminates in the manufacture of transformer cores.

Abstract: An electrically conducting cermet for use in a closure assembly in a high pressure sodium discharge lamp which cermet comprises a sintered compact of refractory oxide granules and a conducting network extending throughout the cermet wherein said network is provided by a layer of niobium and, optionally, at least one other specified metal. The cermet is, because of the niobium content of the metallic network, permeable to hydrogen and lamps incorporating this cermet can therefore be stabilized in acceptable times.

Abstract: The present invention relates to a method for manufacturing a high-strength sintered silicon carbide article and more particularly, to a method for a sintered silicon carbide article having high mechanical strength by mixing a finely divided silicon carbide powder with the definite amounts of a specific carbon-containing material, a boron compound and silicon powder as densification aids, shaping and then sintering said shaped article under an inert atmosphere.

Abstract: Porous metallic bodies having a substantially uniform pore size of less than about 200 microns and a density of less than about 25 percent theoretical, as well as the method for making them, are disclosed. Group IIA, IIIB, IVB, VB, and rare earth metal hydrides are heated in a confining container at a controlled rate to a temperature of about greater than the temperature at which the hydride decomposes. Hydrogen is removed from the container and the remaining metal is heated during a second stage to a temperature greater than the temperature at which it was previously heated but not greater than the temperature of 1/2 to 2/3 the temperature at which the metal melts at a controlled rate. The resulting porous metallic body produced has a density less than about 25 percent theoretical and a pore size of less than about 200 microns. The metallic particles of the present invention have high inner surface area and possess minimum resistance to gas flow.

Abstract: A method for improving the handling characteristics of a flaked tantalum powder composition comprising heat treating the flaked powder component of the composition in order to pre-agglomerate the flaked component prior to mixing it with the granular tantalum powder component of the composition.

Abstract: A precision molded article, such as a die cavity, is made by combining granules of a first metal or alloy and a second metal or alloy, the second metal or alloy having a homogeneous appearance at some temperature below its melting point, and a higher Rockwell Hardness than the first metal or alloy, mixing the granules with a heat fugitive organic binder, molding the granule-binder mixture into a green molded preform, thermally degrading and removing essentially all the binder to form a skeletal preform, and infiltrating the preform with a third metal or alloy which will wet the second metal or alloy and has a lower Rockwell Hardness than the second metal or alloy, thereby forming a molded article having granules of first metal or alloy the majority of which are fully enveloped within a single skeleton of the second metal or alloy, the skeleton of second metal or alloy being surrounded by layers or matrices of softer metals.

Abstract: A stainless steel powder is mixed with at least a Ni--Mn and a Ni--Cr powder, and the powder mixture is formed by loose packing into a required configuration. The powder mixture is sintered in a non-oxidizing atmosphere at the melting point of the Ni--Mn powder or at a higher temperature thereby to obtain a porous body.

Abstract: Sponge titanium powder is compacted, advantageously by roll compaction to a density in the range of about 60% to 80% of the density of solid titanium metal, thereafter heat treated in vacuum at about 500.degree. C. to 750.degree. C., cooled in vacuum to 300.degree. C. and quenched to 100.degree. C. to provide a substrate for electrodes useful in electrolytic processes.

Abstract: A thick film conductor material comprising metal particles containing both gold and at least one additional element prealloyed into a single particle. The additional element may preferably be Pd and the prealloying may preferably be accomplished by coprecipitation. The conductor material, when bonded with Al wire, impedes the growth of intermetallic compounds and subsequent Kirkendall voids, even at elevated temperatures.

Abstract: Apparatus for the production of a metal article comprises means for maintaining a reservoir of molten metal with a free surface, means for rotating the free surface of the reservoir about an axis such that the molten metal is atomized and thrown outwardly away from the said surface by centrifugal action, and a substrate in the path of the atomized particles of said molten metal, whereby a solid article may be built up on the substrate by solidifying the atomized particles thereon. The molten metal may be produced by melting an electrode or otherwise.An annular solid metal article is disclosed having excellent mechanical properties. The solid metal article is produced in a single step by a spray deposition process. Molten metal is centrifugally atomized to splat and build up on a cooled mold surface disposed around the centrifuge means. Controlled relative reciprocatory movement in the direction of the rotational axis of the centrifuge is provided.

Abstract: A precision molded article, such as a die cavity, is made by combining iron powder granules and optional manganese granules with a heat fugutive organic binder, molding the granule-binder mixture into a green molded preform, thermally degrading and removing essentially all the binder to form a skeletal preform, and infiltrating the preform with an infiltrant which has a lower melting point than the iron powder granules and which optionally contains manganese, with the proviso that either the above decribed manganese granules are employed or manganese-containing infiltrant is employed, thereby forming a molded article having a skeleton of ferroalloy granules having a martensitic or perlitic core and an outer layer of austenitic manganese steel, the skeleton being surrounded by infiltrant.

Abstract: The cavity of a hollow turbine has its bottom equipped with a temporary means of obturation and is filled with a mixture of metal chips and a powder consisting of low melting metals, said mixture being subjected to a heating operation in order to join the chips with each other and with the walls of the blade by means of diffusion brazing of said fusible metal.

Abstract: An ultrasonic sound absorbing material capable of operating at high temperatures and pressures, said material comprises a dense, rigid, permeable material such as sintered metal filled with a viscous fluid.

Abstract: A porous sintered body, preferably a filter or filter material, with good corrosion resistance and with a pore volume which can be predicted within specified comparatively narrow limits, is made by loose sintering of a preferably gas-atomized spherical powder a ferritic-austenitic stainless steel.

Abstract: A sintered powdered titanium alloy article is provided which has a density approaching theoretical and which is characterized by having physical properties similar to those of a wrought titanium alloy article having the same chemical composition.

Abstract: In production of so-called anisotropic fine grain type hard magnetic material, particles of highly magnetic substance powder are each plated with nonmagnetic substance before compaction, sintering and plastic deformation in order to provide the product with stable magnetic characteristics for reduced production cost.

Abstract: The present invention is directed to a process for preparing a body of polycrystalline silicon doped with aluminum comprising melting a mixture of silicon powder and aluminum powder, rapidly quenching the melt, grinding the solidified silicon-aluminum alloy and hot pressing to form a compact.

Abstract: The invention is directed to the production of non-fragile shaped members from powders comprising spheroidal metal particles.For this purpose, the invention provides a process for the production of shaped parts from powders comprising spheroidal metal particles which are mixed with from 0.2% to 2% of lubricant, comprising the combination of the following successive steps, performed in the below-indicated order:(a) mixing the powder formed by spheroidal metal particles with an amount of water-soluble cellulose gum between 0.2% and 2%, and with an amount of water which is also between 0.2% and 2%;(b) a cold compacting operation;(c) an optional oven drying operation;(d) a two-phase sintering operation, in an atmosphere which is neutral or reducing with respect to the compacted powder, the first phase being effected at a temperature of from 300.degree. to 500.degree. C. and the second phase being effected at a temperature which is substantially higher and variable with the nature of the powder.

Abstract: Electrode material composed of metal encapsulated substrate particles for making into an electrode for a molten carbonate fuel cell is produced by electroless plating of a metal electrochemically active for the reactions of the cell onto a substrate particle which is non-sintering at the operating temperatures of the cell.