Abstract: A method is disclosed of forming a powder metal compact. Powder metal is placed in an annular space of a compaction die tool set in which the annular space has inner and outer cylindrical surfaces that form inner and outer cylindrical surfaces of the powder metal compact. An elastomeric tool has a first cylindrical surface adjacent to a fixed cylindrical surface of the compaction die tool set that is radially fixed and further has a second cylindrical surface, opposite to the first cylindrical surface, that touches the powder metal. The powder metal is compressed to form the powder metal compact by applying an external axial force on the elastomeric tool while maintaining the diameter of the fixed cylindrical surface so as to cause the elastomeric tool to compress the second cylindrical surface of the elastomeric tool against the powder metal.

Abstract: A method of sintering a 17-4PH alloy powder and a sintered 17-4PH sintered part are disclosed. The part is formed by selective laser sintering a 17-4PH alloy powder and binder mixture to form a green part that is sintered to form a part having a substantially pure martensitic structure. The metal powder includes boron. The sintered part may be further processed by shot peening to improve crack resistance.

Abstract: The present invention is directed to improved compaction techniques for use in powder metallurgical applications using lower temperatures and pressures than are traditionally used in the field.

Abstract: A method of sintering a 17-4PH alloy powder and a sintered 17-4PH sintered part are disclosed. The part is formed by selective laser sintering a 17-4PH alloy powder and binder mixture to form a green part that is sintered to form a part having a substantially pure martensitic structure. The metal powder includes boron. The sintered part may be further processed by shot peening to improve crack resistance.

Abstract: A method for forming an interconnect of a solid oxide fuel cell includes the following steps. First of all, a powder mixture substantially including equal to or more than 90 wt % chromium powder, with the balance being iron powder and inevitable impurities, is provided. Then the powder mixture is pressurized by a pressing process with a pressure equal to or over 8 mt/cm2 to form a green interconnect with a density being equal to or over 90% of the theoretical density. Next the green interconnect is sintered by a sintering process to form an interconnect body. Finally, a protection process is performed on at least one surface of the interconnect body to form an interconnect.

Abstract: The invention relates to a method for manufacturing a massive component substantially wholly made of intermetallic material, comprising the steps of: a) preparing a mixture of powders of at, least two metallic elements, the powders being present in the mixture in a proportion by weight corresponding to the atomic percentage in which the at least two metallic elements are present in a corresponding intermetallic compound which may be formed from these metallic elements; b) applying a plurality of layers of such a mixture of powders by cold spraying on a substrate so as to obtain, on the substrate, a preform of metallic mixture of predetermined thickness; c) thermally treating at least the preform of metallic mixture so as to cause the reaction between the at least two metallic elements to form the corresponding intermetallic compound; and d) removing the substrate, thus obtaining the massive component made of intermetallic material.

Abstract: A carbonaceous support member for a high-temperature heat-treated metal molding object, particularly a setter for heat-treatment in powder metallurgy, is formed as a carbon-ceramic composite shaped product having a bulk density of 1.2-1.6 g/ml and including a carbonaceous matrix and 3-20 wt. % of ceramic particles which are uniformly dispersed in the carbonaceous matrix and partly exposed to the surface of the composite. The support member can effectively prevent carburization of a metal molding object supported thereby during the heat-treatment without causing a problem of peeling of coating layer as encountered in a ceramic-coated support member. The support member may be prepared by compression molding of a powdery mixture of a fine carbon precursor and ceramic particles, followed by heating at 1000-2000° C. to carbonize the fine carbon precursor.

Abstract: A method of manufacturing a metal component from metal powder comprises preparing (12) a metal powder, providing (14) gallium on at least part of the surface of at least some of the metal powder particles, encapsulating (16) the metal powder in a container, evacuating (18) the container to remove air and/or gas from the container, sealing (20) the container, hot isostatically pressing (22) the container to consolidate the metal powder particles to produce the metal component and removing (24) the container from the metal component. The process is used to produce gas turbine engine metal components, for example turbine discs with improved fatigue properties.

Abstract: A bearing stiffness of a sintered metal sleeve is prevented from lowering. A sleeve includes an inner section formed of metal powder for sintering and a resin for impregnation, and a surface deformation section which covers a surface of the inner section and is formed by shot blast process. Since the surface deformation section is formed by the shot blast process, the number of pores formed between the metal powder for sintering near the surface can be reduced. In this way, a supporting pressure at a bearing portion can be prevented from being released out through the pores, and the bearing stiffness can be prevented from lowering.

Abstract: Dental prostheses are fabricated as a metallic alloy body by a technique that produces scrap alloy. Suitable gold base alloys have only base metal alloying additions which are more readily oxidized than gold and when combined with the gold can be age hardened. Exemplary metals include titanium, zirconium, yttrium and chromium. Scrap from fabricating a dental prosthesis is melted in air so that the base metals are all oxidized and substantially pure gold is reclaimed for reuse in new alloys.

Abstract: A method of making a combustion turbine component includes forming a metallic powder including at least one metal and at least one rare-earth element and processing the metallic powder including at least one metal and at least one rare-earth element to form a cohesive metallic mass. A primary aging heat treatment may be performed on the cohesive metallic mass. A homogenization heat treatment may be performed on the cohesive metallic mass prior to the primary aging heat treating. Furthermore, a secondary aging heat treatment may be performed on the cohesive metallic mass after the primary aging heat treating.

Abstract: The present invention relates to a cutting tool insert for turning consisting of a cemented carbide substrate and a coating. The cemented carbide substrate comprises WC, binder phase, and vanadium containing cubic carbide phase with a binder phase enriched surface zone essentially free of cubic carbide phase. The thermal properties of the vanadium-containing cubic phase, has turned out to give excellent resistance to thermal cracking of the insert.

Abstract: A process comprising: (a) forming a feature comprising uncoalesced silver-containing nanoparticles; (b) heating the uncoalesced silver-containing nanoparticles to form coalesced silver-containing nanoparticles; and (c) subjecting to a plasma treatment the uncoalesced silver-containing nanoparticles or the coalesced silver-containing nanoparticles, or both the uncoalesced silver-containing nanoparticles and the coalesced silver-containing nanoparticles, wherein the feature prior to the action (c) exhibits a low electrical conductivity but the electrical conductivity of the feature subsequent to the actions (b) and (c) is increased by at least about 100 times, wherein the action (c) is undertaken during one or more of prior to the heating, or during the heating, or after the heating.

Abstract: The present invention provides a continuous powder extrusion method for making an article having a profile including an outer shape and optionally including one or more inner hollows. One or more bulk material powders and one or more binders are provided, and the bulk material powders and the binders are mixed to form a mixture. A die is provided, the die optionally including a mandrel having one or more shapes. The mixture is extruded through the die and the optional mandrel to produce a green form. The green form is debound to produce a brown form and the brown form is sintered to produce a densified form. The densified form is optionally processed using thermal, mechanical, and/or thermomechanical processing to produce a wrought form. The densified or wrought form is optionally cut to a length and/or finished using traditional metal finishing processes.

Abstract: The invention relates to high purity MoO2 powder by reduction of ammonium molybdate or molybdenum trioxide using hydrogen as the reducing agent in a rotary or boat furnace. Consolidation of the powder by press/sintering, hot pressing, and/or HIP is used to make discs, slabs, or plates, which are used as sputtering targets. The MoO2 disc, slab, or plate form is sputtered on a substrate using a suitable sputtering method or other physical means to provide a thin film having a desired film thickness. The thin films have properties such as electrical, optical, surface roughness, and uniformity comparable or superior to those of indium-tin oxide (ITO) and zinc-doped ITO in terms of transparency, conductivity, work function, uniformity, and surface roughness.

Abstract: A member for a semiconductor device of low price, capable of forming a high quality plating layer on a surface, having heat conductivity at high temperature (100° C.) of more than or equal to 180 W/m·K and toughness that will not cause breaking due to screwing, and will not cause solder breaking due to heat stress when it is bonded to other member with solder, and a production method thereof are provided. A member for a semiconductor device (1) having a coefficient of thermal expansion ranging from 6.5×10?6/K to 15×10?6/K inclusive, and heat conductivity at 100° C.

Abstract: A manufacturing method of a clad material composed of a bronze alloy and a steel is provided, including: scattering a bronze alloy powder on a steel back metal; sintering the bronze alloy powder to obtain a bilayer material having a porous bronze alloy layer on the steel; dry-rolling and a sintering the bilayer material so that the bronze alloy layer has a porosity of 3% or less; and wet-rolling the bilayer material with supplying a rolling oil to surfaces of rolling rolls. The clad manufactured according to this method can be heat-treated without an disadvantage in a conventional wet-rolling that entering rolling oil vaporizes in the bronze alloy layer during the heat treatment to form new voids. Therefore, it becomes possible to make a bronze alloy layer high in density in small times of rolling, thus enabling an increase in production efficiency.

Abstract: The invention relates to implantable medical devices, particularly, to porous structures for such devices. In one aspect, the invention provides a porous metal scaffold comprising a porous metal network having pores defined by metal webs, the metal webs covered with at least one layer of metal particles bonded to the metal webs. In other aspects, the invention provides methods of forming porous scaffolds. In one such aspect, the method includes providing a polymer foam; forming a skin of biocompatible metal on the polymer foam by low temperature arc vapor deposition; and heating the polymer foam and the metal skin above the decomposition temperature of the polymer foam in an inert gas atmosphere; thereby the polymer foam decomposes producing a green metal foam. In yet other aspects, the invention provides methods of improving stability of porous scaffolds.

Abstract: A method for obtaining a selectively non-carburized powdered metal part. The steps include compacting, sintering, removing, forging and cooling. A metal powder is compacted to form a preform having at least one first surface in which a forged part is required to have a case depth and at least one second surface in which a carburized portion is required to be removed prior to forging. The preform is then sintered and carburized. After carburizing the at least one second surface of the preform is removed and subsequently forged and cooled. The forged part has at least one second surface having improved post forging properties and at least one first surface having improved performance features. A part made from the present method is also provided.

Abstract: The invention provides a method of fabricating a turbine stator casing, the method comprising the operations consisting in: between the walls of portions of a mold, forming a cavity of shape corresponding to the shape of the shroud of said casing, securing soluble cores to at least one of said mold portions, said cores being held at a distance from the wall of said mold portion and representing empty spaces that are to be formed inside said shroud; putting soluble inserts into place between the cores to represent flow paths between said empty spaces; filling said cavity with a metal alloy powder; sintering said powder by hot isostatic pressing; eliminating the cores and the inserts by dissolving them; and extracting the shroud as molded in this way. The invention is applicable to fabricating a turbine stator casing for an airplane turbojet.

Abstract: A cemented carbide cutting tool insert/button for mining and construction comprising hard constituents in a binder phase of Co and/or Ni and at least one surface portion and an interior portion in which surface portion the grain size is smaller than in the interior portion is disclosed. The surface portion with the smaller grain size has a lower binder phase content than the interior portion. A method to form the cemented carbide cutting tool insert/button is also disclosed.

Abstract: Disclosed is a manufacturing method of sinter forged aluminum-based parts with high strength. In the manufacturing method, prepared is a raw material powder comprising, by mass: 3.0 to 10% zinc; 0.5 to 5.0% magnesium; 0.5 to 5.0% copper; inevitable amount of impurities; and the balance aluminum. The raw material powder is formed into a compact by pressing the raw material powder, sintered in a non-oxidizing atmosphere in such a manner as to heat the compact at a sintering temperature of 590 to 610 degrees C. for 10 minutes or more, before cooling the sintered compact. It is then forged by pressing the sintered compact in a pressing direction to compress the sintered compact in the pressing direction and produce plastic flow of material in a direction crossing to the pressing direction.

Abstract: The formation of amorphous porous bodies and in particular to a method of manufacturing such bodies from amorphous particulate materials. The method allows for the control of the volume fraction as well as the spatial and size distribution of gas-formed pores by control of the size distribution of the powder particulates. The method allows for the production of precursors of unlimited size, and because the softened state of the amorphous metals used in the method possesses visco-plastic properties, higher plastic deformations can be attained during consolidation as well as during expansion.

Abstract: The method is suitable for the manufacture of flat or shaped titanium aluminide articles and layered metal matrix composites such as lightweight plates and sheets for aircraft and automotive applications, thin cross-section vanes and blades, composite electrodes, heat-sinking lightweight electronic substrates, bulletproof structures for vests, partition walls and doors, as well as for sporting goods such as helmets, golf clubs, sole plates, crown plates, etc.

Abstract: An electrolytic capacitor anode treated with a surfactant during anodic oxidation is provided. Without intending to be limited by theory, it is believed that the surfactant may lower the surface tension of an electrolyte, which inhibits the clustering of grown oxides and allows the dielectric layer to become more homogeneous and uniformly spread over the anode body. The resulting dielectric layer may thus have a substantially homogeneous thickness, smooth surface, and improved leakage current stability.

Abstract: Hollow metal spheres are heated in a high vacuum in the presence of an organic substance, at a temperature at least equal to the melting point of a eutectic between carbon and the metallic constituents of the said spheres.

Abstract: In one aspect of the present invention, an insert comprises a sintered polycrystalline diamond body bonded to a cemented metal carbide substrate. The diamond body comprises a substantially conical shape with conical side wall terminating at an apex. The diamond body comprises a first region with a metallic catalyst dispersed through interstices between the diamond grains and a second region proximate the apex with the characteristic of higher thermal stability than the first region.

Abstract: A method for producing a powder metal article having a three dimensional shape and having at least one densified surface comprising: a) providing a blend of powdered metals; b) compacting said blend to form a pre-form having a general shape of said article; c) sintering said pre-form; d) densifying at least one cylindrical surface region of said pre-form; and, e) forming said pre-form to a final density and into the three dimensional shape of said article.

Abstract: In a method of refurbishing a deposition target, a surface of the target is provided in a process zone. An electrical arc is generated in the process zone, and a consumable metal wire is inserted into the process zone to form liquefied metal. A pressurized gas is injected into the process zone to direct the liquefied metal toward the surface of the target to splatter the liquefied metal on the surface, thereby forming a coating having the metal on at least a portion of the surface of the target that exhibits reduced contamination from the environment.

Abstract: A honeycomb seal which is manufactured by powder metallurgical injection molding is disclosed. The honeycomb seal is composed preferably of several segments. Each segment is embodied as a single piece and has a base element as well as honeycomb elements that are embodied as a single piece with the base element.

Abstract: A coated cutting insert for metal machining, in particular of short chipping materials, includes a tungsten carbide-based substrate with a binder phase enriched surface zone having at least one rake face and at least one clearance face intersecting to form a cutting edge. The binder phase enriched surface zone is at least partly missing on the rake face including at least a part of the surface extending from the cutting edge. As a result, an optimum combination of edge strength and wear resistance has been achieved.

Abstract: An electroluminescence device comprising at least one electroluminescence light source (2) for emitting a primary radiation, preferably having wavelengths between 200 nm and 490 nm, and at least one light-converting element (3), arranged in the path of the rays of the primary radiation, for partial absorption of the primary radiation and emission of a secondary radiation, wherein the light-converting element (3) has a dilatation in the radiation direction (5) of the primary radiation, which is less than an average scattering length of the primary radiation in the light-converting element (3).

Abstract: Magnesium composite powder which is a starting raw material to manufacture a particle-dispersion type of magnesium group composite material comprises magnesium alloy coarse particles (7) serving as a main component which constitutes a matrix of a magnesium alloy and fine-grained powder (8) comprising a component which reacts with magnesium to form a compound and attached on a surface of the magnesium alloy coarse particle (7) through a binder (9).

Abstract: Clutch components for automotive use usually include a pair of clutch members with operative faces. In particular, planar one way clutches include a pair of clutch members whose operative faces are enclosed spaced opposition, with each clutch face including a plurality of recessed defining respective load bearing shoulders. A plurality of struts are disposed between the coupling face of the members, and such struts are moveable between the coupling position and non coupling position. A preferable method of manufacturing such clutch components includes powder metal operations comprising die compacting a metal powder into a metal blank, placing the die compacted metal blank in a machined flat ceramic support, sintering the metal blank to form a sintered metal blank, and cooling the sintered metal blank to form a cooled metal blank. The preferred metallic structure of the cooled metal blank is 50-80% martensite and 20-50% bainite and fine pearlite.

Abstract: Methods are provided for manufacturing a magnetizable core component for use in an electric motor. The method includes forming a green body from a powdered metal-ceramic composite. The method also includes heating the green body to form a core. The method further includes applying a magnetic field to the core to produce paths in a predetermined orientation, where the paths are configured to allow flux to flow therealong. The magnetizable core component is also provided.

Abstract: A method includes fabricating an energy detector using a sol-gel process.

Abstract: A method for manufacturing valve metal anodes of electrolytic capacitors by deoxidizing the anodes using Mg vapor in a deoxidizing furnace, removing the anodes from deoxidizing furnace, placing them in sintering furnace, sintering at temperature lower than the temperature conventionally used for sintering in vacuum, and leaching of Mg oxide off the anode surface. The process limits free oxygen and improves morphology of valve metal anodes, which results in improved performance of electrolytic capacitors with these anodes. The process does not require any special equipment or maintenance operations and, thereby, is highly productive due to performing deoxidizing and sintering in traditional deoxidizing and sintering furnaces.

Abstract: A sheet is prepared by mixing a mass of metallic powders with a temporary thermoplastic binder to form an injection-moldable mixture, thereafter injection molding the injection-moldable mixture to form a sheet precursor. The sheet precursor is consolidated to a relative density of substantially 100 percent to form the sheet, and thereafter heat treated. The final sheet is preferably a nickel-base superalloy having more than about 30 volume percent of gamma prime phase, or an intermetallic such as a titanium aluminide.

Abstract: An iron-based sintered powder metal article for cam lobe and other high temperature, high wear applications requiring excellent net-shape stability during sintering comprises a powder metal mixture consisting essentially of, by weight, 0.5–3.0% Mo, 1–6.5% Cr, 1–5% V, and the balance Fe and impurities. These articles also have a carburized case having 0.7–1.2% C by weight. Following carburization of the case, the articles are quenched to form a martensitic matrix having a network of disbursed carbides of Cr and V. The resulting sintered articles have good mechanical strength and wear resistance and possess excellent machineability and dimensional stability.

Abstract: A sintered sprocket for a silent chain is obtained from a material with few addition elements by a simple densifying method. The sintered sprocket is made of an ferrous material having an ovarall composition containing Cu at 1 to 2%, C at 0.5 to 0.8%, Mn as an inevitable impurity at 0.10% or less, and balance of Fe and other inevitable impurities by mass and has a density of 7.1 Mg/m3 or higher, 65 HRA or higher as a hardness in the gear teeth, and a martensite, sorbite, bainite, or their mixed structure as a cross-sectional microscopic structure in at least the gear teeth and the peripheral area of the gear teeth.

Abstract: The temporary compacting of the powder for use in sintering is carried out, the temporary sintering is carried out, the main compacting is carried out, the main sintering is carried out, and the thickness of the radius direction of the base part of the cam before the heat-treatment is set to 3.0 mm or more.

Abstract: A method of production of large Ingots of neutron attenuating composites using a vacuum-bellows system allows for large cross-sectional shapes to be extruded and rolled. This method uses a vacuum-bellows technology which allows the manufacturing of large 8–16 inch diameter ingots (50–450 lbs. each). A variety of primary metal matrix materials can be used in this technology. High specific strength and stiffness can be achieved because the technology allows for final densities of 99% and higher. The vacuum-bellows technology allows metals and ceramics to blend and mesh together at compression pressures of 800 tons with elevated temperatures. The controlled compression movement allows for any oxide layer, on the metal, to be broken up and consolidated with the chosen ceramic particulate. One application is to blend boron-rich ceramics and high purity (99.5–99.99%) aluminum particulates together and produce a large ingot using this vacuum-bellows technology.

Abstract: A method of producing a sintered rare earth magnetic alloy wafer comprises a step of using a cutter to slice a wafer of a thickness of not greater than 3 mm from a sintered rare earth magnetic alloy having ferromagnetic crystal grains surrounded by a more readily grindable grain boundary phase and a step of surface-grinding at least one cut surface of the obtained wafer with a grindstone to form at a surface layer thereof flat ferromagnetic crystal grain cross-sections lying parallel to the wafer planar surface. The method enables high-yield production of a sintered rare earth magnetic alloy wafer having flat surfaces.

Abstract: To provide a substrate material made of an aluminum/silicon carbide composite alloy which has a thermal conductivity of 100 W/m×K or higher and a thermal expansion coefficient of 20×10?6/° C. or lower and is lightweight and compositionally homogeneous. A substrate material made of an aluminum/silicon carbide composite ally which comprises Al—SiC alloy composition parts and non alloy composition part and dispersed therein from 10 to 70% by weight silicon carbide particles, and in which the fluctuations of silicon carbide concentration in the Al—SiC alloy composition parts therein are within 1% by weight. The substrate material is produced by sintering a compact of an aluminum/silicon carbide starting powder at a temperature not lower than 600° C. in a non-oxidizing atmosphere.

Abstract: A method for making aerospace face seal rotors reinforced by rhenium metal, alloy, or composite in combination with silicon carbide or other ceramic. The resulting rotor also is disclosed. Ceramic grains, preferably silicon carbide (SiC), are mixed with powdered metallic (PM) binder that may be based on a refractory metal, preferably rhenium. The mixture is applied to a rotor substrate. The combined ceramic-metal powder mixture is heated to sintering temperature under pressure to enable fusion of the ceramic in the resulting metal-based substrate. A load may then be applied under an elevated temperature. The resulting coated rotor can exhibit high hot hardness, increased durability and/or high hot wear resistance, as well as high thermal conductivity.

Abstract: An article has a metallic matrix made of its constituent elements with a dispersoid distributed therein. The article is prepared by furnishing at least one nonmetallic matrix precursor compound. All of the nonmetallic matrix precursor compounds collectively include the constituent elements of the metallic matrix in their respective constituent-element proportions. A mixture of an initial metallic material and the dispersoid is produced. The matrix precursor compounds are chemically reduced to produce the initial metallic material, without melting the initial metallic material, and the dispersoid is distributed in the initial metallic material. The mixture of the initial metallic material and the dispersoid is consolidated to produce a consolidated article having the dispersoid distributed in the metallic matrix comprising the initial metallic material. The initial metallic material, the dispersoid, and the consolidated article are not melted during the consolidation.

Abstract: Mounting plates used to mount filter elements within cylindrical canisters are made from sintered powdered materials, such as sintered powdered metal in order to reduce engineering and tooling lead time as well as to reduce costs. By making a mounting plate of sintered metal, the mounting plate can have a varying thickness which is an advantage not obtainable with a mounting plate stamped from steel sheet.

Abstract: A nanostructured tungsten carbide bulk material, sintered from tungsten carbide and metal such as cobalt nano-powders, comprises a tungsten carbide and a metallic binder such as cobalt phases. The tungsten carbide phase has nanostructures comprising a plurality of dislocations, twins, stacking faults, dislocation cells, nano-subgrains with preferred orientation or texture, or a combination thereof.

Abstract: A method of manufacturing a piezoelectric/electrostrictive device includes the following steps. An integrated layered body is obtained by laminating at least one green sheet that is to be a thin plate, at least one green sheet having at least one rectangular-shaped hole portion, and at least one green sheet that is to be another thin plate. A piezoelectric/electrostrictive element is formed on a surface of the green sheets that form the thin plates by one of a thick film method or a thin film method. The layered body is cut in the laminating direction of the green sheets such that the rectangular-shaped hole portion is open on the side of the layered body after sintering the layered body.

Abstract: A method to produce a sintered metal with an improved abrasion resistance and durability, and a rotary compressor flange produced by use of the method. The sintered metal is produced by kneading metal powder, pressure molding the kneaded powder, and sintering the molded powder. The sintered metal is further produced by subzero treating the sintered metal powder for a predetermined time and tempering the resulting sintered metal powder under a predetermined compression residual stress.