Impregnation Patents (Class 419/27)
  • Patent number: 10518361
    Abstract: A method of manufacturing of a component having the steps of manufacturing of a first segment for the component by a powder-bed manufacturing process, and the manufacturing of a second segment for the component originating from the first segment by an additive manufacturing process, such that the second segment projects by a projecting distance over at least one side face of the first segment. Furthermore, a component has the first segment being manufactured by the powder-bed manufacturing process and the second segment being manufactured by the additive manufacturing process, wherein the second segment projects by a projecting distance over at least one side face of the first segment.
    Type: Grant
    Filed: September 21, 2015
    Date of Patent: December 31, 2019
    Assignee: Siemens Aktiengesellschaft
    Inventors: Jonas Eriksson, Andreas Graichen
  • Patent number: 10399258
    Abstract: There is disclosed herein a method of designing a mold, the mold being at least part of a unitary body to be formed from a plurality of layers by 3D printing, the method including defining an inner surface of the mold corresponding to at least part of an outer surface of an object to be molded in the mold; selecting a first material from which at least part of the mold is to be printed; and selecting a second material from which at least another part of the mold is to be printed, the second material having a higher thermal and/or electrical conductivity than the first material, wherein at least one of the layers from which the mold is to be formed by 3D printing includes areas to be printed from each of the first and second materials.
    Type: Grant
    Filed: December 8, 2015
    Date of Patent: September 3, 2019
    Assignee: Halliburton Energy Services, Inc.
    Inventors: William Brian Atkins, Gary Eugene Weaver, Valerie Sillen
  • Patent number: 10024110
    Abstract: An earth-boring drill bit includes a bit body having a powder component and a binder. The powder component includes a plurality of nanotubes disposed on a surface of at least one particle of the powder component.
    Type: Grant
    Filed: December 18, 2013
    Date of Patent: July 17, 2018
    Assignee: Halliburton Energy Services, Inc.
    Inventors: Garrett T. Olsen, Jeffrey G. Thomas
  • Patent number: 9932841
    Abstract: A workpiece manufactured from an additive manufacturing system (AMS) having a particle separator and a method of operating includes modeling the workpiece into layers and modeling the layers into a plurality of regions. The AMS then deposits one of a plurality of particle types into a respective one of the plurality of regions. In this way, the surface finishes of the component may be controlled and material densities from one region to the next and from one layer to the next are also controlled.
    Type: Grant
    Filed: January 16, 2015
    Date of Patent: April 3, 2018
    Assignee: United Technologies Corporation
    Inventors: Alexander Staroselsky, Sergey Mironets, Thomas N. Slavens, Thomas J. Martin, Brooks E. Snyder
  • Patent number: 9790744
    Abstract: There is disclosed herein a method of molding an object by infiltrating a matrix material with an infiltration material, the method including providing first and second zones of respective different first and second matrix materials arranged substantially adjacent to each other in a mold, including forming a transition region between the two zones through which the composition of the material in the transition region is gradually varied from the composition of the first matrix material adjacent the first zone to the composition of the second matrix material near the second zone.
    Type: Grant
    Filed: November 28, 2011
    Date of Patent: October 17, 2017
    Assignee: Halliburton Energy Services, Inc.
    Inventors: William Brian Atkins, Gary Eugene Weaver
  • Patent number: 9759304
    Abstract: A method of making a worm gear is provided. The method comprises forming a gear hub from a powdered metal material. Thereafter an outer surface of the gear hub is sealed.
    Type: Grant
    Filed: January 28, 2015
    Date of Patent: September 12, 2017
    Assignee: STEERING SOLUTIONS IP HOLDING CORPORATION
    Inventors: Alan G. Turek, Jeffrey E. Beyerlein, Niklaus A. Von Matt
  • Patent number: 9622834
    Abstract: A method by which an orthodontic appliance is automatically designed and manufactured from digital lower jaw and tooth shape data of a patient provides for the scanning of the mouth of a patient to produce a three-dimensional digitized model of the shapes of the patient's teeth and their positions in the patient's mouth. The appliance is automatically designed according to the final design, which also can be interactively modified and approved by the orthodontist, with the computer recalculating the effects on the treatment as a result of the doctor's changes. Brackets are fabricated as an integrated set, either by cutting slots therein or by building the brackets in layers. Three-dimensional custom jigs are automatically made to exactly position the brackets on a patient's teeth.
    Type: Grant
    Filed: December 19, 2011
    Date of Patent: April 18, 2017
    Assignee: Ormco Corporation
    Inventors: Eric Chapoulaud, Craig A. Andreiko, Mark A. Payne
  • Patent number: 9596747
    Abstract: A wiring substrate in which a plating layer is sufficiently plated on a surface metal layer and which has an excellent reliability is provided. A wiring substrate includes an insulating base; a heat dissipation member disposed in the insulating base, the heat dissipation member partially exposed from the insulating base, the heat dissipation member containing Cu; a surface metal layer disposed on a surface of the insulating base, the surface metal layer contacting and covering the heat dissipation member, the surface metal layer containing Mo as a main component, the surface metal layer including a surface portion containing Cu; and a plating layer disposed on the surface metal layer, wherein Cu contained in the heat dissipation member and Cu contained in the surface portion are bonded to each other.
    Type: Grant
    Filed: June 29, 2012
    Date of Patent: March 14, 2017
    Assignee: KYOCERA CORPORATION
    Inventors: Hiroshi Kawagoe, Kazuhiko Yagi
  • Patent number: 9309767
    Abstract: A stator for a progressive cavity pump or motor comprises a tubular housing having a central axis. In addition, the stator comprises a stator insert coaxially disposed within the housing. The stator insert has a radially outer surface that engages the housing and a radially inner surface defining a helical-shaped through bore extending axially through the stator insert. The stator insert includes an insert body and an insert liner attached to the insert body. The insert body is radially positioned between the housing and the insert liner. The insert body comprises a reinforcement structure and a plurality of voids dispersed within the reinforcement structure.
    Type: Grant
    Filed: August 15, 2011
    Date of Patent: April 12, 2016
    Assignee: NATIONAL OILWELL VARCO, L.P.
    Inventors: Harold A. Sreshta, Jiinjen Albert Sue, Stefan M. Butuc, Jan Edgar Marshall
  • Patent number: 9272331
    Abstract: A porous and permeable composite for treatment of contaminated fluids, said composite including a body of iron particles and 0.01-10% by weight of at least one functional ingredient distributed and locked in the pores and cavities of the iron body. Also, methods of making a permeable porous composite for water treatment. Also, use of a permeable porous composite for reducing the content of contaminants in a fluid, wherein said fluid is allowed to pass through the permeable composite.
    Type: Grant
    Filed: August 4, 2010
    Date of Patent: March 1, 2016
    Assignee: HOGANAS AB
    Inventor: Bo Hu
  • Patent number: 8962147
    Abstract: A powder metal component is made of compacted and sintered powder metal particles such as chromium-containing ferrous-based metal and is porous. Following sintering, the pores are impregnated with relatively smaller particles of ceria and/or yttria. The component is then heat treated and the presence of the impregnated ceria and/or yttria serve as nucleation sites for the formation of desirable oxides, such as chromium oxide, on the surface. The impregnated particles that lie below the protective oxide layer remain available throughout the life of the component in the event the original oxide layer becomes worn or damaged, wherein a renewed protective oxide is formed in such regions due to the presence of the impregnated particles.
    Type: Grant
    Filed: December 5, 2011
    Date of Patent: February 24, 2015
    Assignee: Federal-Mogul Corporation
    Inventors: Denis Christopherson, Jr., Jeremy Koth
  • 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
  • Patent number: 8936665
    Abstract: The present invention relates to a method for producing diamond-metal composites comprising mixing diamond particles with metal-filler particles forming a diamond/metal-filler mixture, forming a green body of the diamond/metal-filler mixture, optionally green machining the green body to a work piece before or after pre-sintering by heating the green body to a temperature ?500° C., infiltrating the green body or the work piece with one or more wetting elements or infiltrating the green body or the work piece with one or more wetting alloys, which infiltration step being carried out under vacuum or in an inert gas atmosphere at a pressure ?200 Bar. The invention relates further to a green body, a diamond metal composite, and use of the diamond metal composite.
    Type: Grant
    Filed: October 30, 2008
    Date of Patent: January 20, 2015
    Assignee: Alfa Laval Corporate AB
    Inventor: Jie Zheng
  • Publication number: 20140341773
    Abstract: A magnetic refrigeration material includes alloy represented by a composition formula of La(Fe, Si)13H, and the alloy includes ?-Fe by a weight ratio lower than 1 wt % and a plurality of pores so that a packing fraction of the alloy is within a range from 85% to 99%.
    Type: Application
    Filed: September 12, 2012
    Publication date: November 20, 2014
    Applicant: DENSO CORPORATION
    Inventors: Tomonori Fujinaka, Nobuyoshi Sakakibara
  • Publication number: 20140328712
    Abstract: A vacuum heat treatment method for NdFeB rare earth permanent magnetic devices and an equipment thereof are disclosed. A rotary vacuum heat treatment equipment is for processing the NdFeB rare earth permanent magnetic devices with a vacuum heat treatment and obviously improves magnetic performance of the NdFeB rare earth permanent magnetic device, especially coercivity, which facilitates reducing a usage of heavy rare earth elements and protecting rare earth resources. Thus the vacuum heat treatment method and the equipment thereof are able to manufacture high-performance rare earth permanent magnetic devices.
    Type: Application
    Filed: September 11, 2013
    Publication date: November 6, 2014
    Applicant: China North Magnetic & Electronic Technology Co., LTD
    Inventor: Haotian Sun
  • Patent number: 8858869
    Abstract: A method of treating a porous work piece includes infiltrating a liquid metallic alloy into surface porosity of a work piece and isothermally solidifying the liquid metallic alloy to at least partially fill the surface porosity.
    Type: Grant
    Filed: February 4, 2011
    Date of Patent: October 14, 2014
    Assignee: Aerojet Rocketdyne of DE, Inc.
    Inventor: Clifford C. Bampton
  • Publication number: 20140286813
    Abstract: A method for manufacturing a high melting point metal based object includes providing pure high melting point metal based powder, fabricating a green object from the powder, by way of a laser sintering technique, providing infiltration treatment to the green object, and providing heating pressure treatment to the green object. The temperature to the green object is controlled to the re-sintering point of the green object.
    Type: Application
    Filed: March 20, 2014
    Publication date: September 25, 2014
    Applicant: General Electric Company
    Inventors: Rui Guo, Zhixue Peng, Yanmin Li, Wen Tan, Abdelaziz Ikhlef
  • Patent number: 8795584
    Abstract: A small diameter, elongated steel article, comprising fully consolidated, prealloyed metal powder is disclosed. The consolidated metal powder has a microstructure that has a substantially uniform distribution of fine grains having a grain size of not larger than about 9 when determined in accordance with ASTM Standard Specification E 112. The microstructure of the consolidated metal powder is further characterized by having a plurality of substantially spheroidal carbides uniformly distributed throughout the consolidated metal powder that are not greater than about 6 microns in major dimension and a plurality of sulfides uniformly distributed throughout the consolidated metal powder wherein the sulfides are not greater than about 2 microns in major dimension. A process for making the elongated steel article is also disclosed.
    Type: Grant
    Filed: August 23, 2012
    Date of Patent: August 5, 2014
    Assignee: CRS Holdings, Inc.
    Inventors: Olivier Schiess, Pierre Marechal, Gregory J. Del Corso
  • Publication number: 20140132377
    Abstract: An alloy for R-T-B-based rare earth sintered magnets which contains R which is a rare earth element; T which is a transition metal essentially containing Fe; a metallic element M containing one or more metals selected from Al, Ga and Cu; B and inevitable impurities, in which R accounts for 13 at % to 15 at %, B accounts for 4.5 at % to 6.2 at %, M accounts for 0.1 at % to 2.4 at %, T accounts for balance, a proportion of Dy in all rare earth elements is in a range of 0 at % to 65 at %, and the following Formula 1 is satisfied, 0.0049Dy+0.34?B/TRE?0.0049Dy+0.36??Formula 1 wherein Dy represents a concentration (at %) of a Dy element, B represents a concentration (at %) of a boron element, and TRE represents a concentration (at %) of all the rare earth elements.
    Type: Application
    Filed: July 6, 2012
    Publication date: May 15, 2014
    Applicant: SHOWA DENKO K.K.
    Inventors: Kenichiro Nakajima, Takashi Yamazaki
  • Publication number: 20140127071
    Abstract: In a manufacturing method of a magnetic refrigeration material, a powder material made of La (Fe, Si)13 is molded by applying a pressure equal to or higher than 286 MPa and heating at a temperature equal to or lower than 600 degrees Celsius. Thus, a molded product of the magnetic refrigeration material is produced.
    Type: Application
    Filed: November 5, 2013
    Publication date: May 8, 2014
    Applicant: DENSO CORPORATION
    Inventors: Tomonori Fujinaka, Yasuo Kitou
  • Patent number: 8701970
    Abstract: A method of forming and assembling at least two parts together that may be metal, ceramic, or a combination of metal and ceramic parts. Such parts may have different CTE. Individual parts that are formed and sintered from particles leave a network of interconnecting porosity in each sintered part. The separate parts are assembled together and then a fill material is infiltrated into the assembled parts using a method such as capillary action, gravity, and/or pressure. The assembly is then cured to yield a bonded and fully or near-fully dense part that has the desired physical and mechanical properties for the part's intended purpose. Structural strength may be added to the parts by the inclusion of fibrous materials.
    Type: Grant
    Filed: June 17, 2011
    Date of Patent: April 22, 2014
    Assignee: Babcock & Wilcox Technical Services Y-12, LLC
    Inventor: Edward B. Ripley
  • Patent number: 8636948
    Abstract: The present invention provides iron-based infiltration methods for manufacturing powder metallurgy components, compositions prepared from those methods, and methods of designing those infiltration methods. Iron-based infiltration methods table include the steps of providing an iron-based infiltrant composed of a near eutectic liquidus composition of a first iron based alloy system and an iron-based base compact composed of a near eutectic solidus powder composition of a second iron based alloy system. The base compact is placed in contact with the infiltrant and heated to a process temperature above the melting point of the infiltrant to form a liquid component of the infiltrant. Lastly, the base compact is infiltrated with the liquid component of the infiltrant. During infiltration, the liquid component of the infiltrant flows into the pores of the base compact.
    Type: Grant
    Filed: December 3, 2004
    Date of Patent: January 28, 2014
    Assignee: Hoeganaes Corporation
    Inventors: Frederick J. Semel, Kalathur S. Narasimhan
  • Publication number: 20130323109
    Abstract: A method for producing a bonded rare-earth magnet according to an embodiment of the present invention includes the steps of: providing a rapidly solidified rare-earth magnet alloy powder; providing a solution in which a resin that is in solid phase at an ordinary temperature is dissolved in an organic solvent; mulling the rapidly solidified rare-earth magnet alloy powder and the solution together and vaporizing the organic solvent, thereby making a bonded rare-earth magnet compound in which magnet powder particles that form the rapidly solidified rare-earth magnet alloy powder are coated with the resin; making a compressed compact by compressing the bonded rare-earth magnet compound under a pressure of 1000 MPa to 2500 MPa; and thermally treating the compressed compact. If the rapidly solidified rare-earth magnet alloy powder to be mulled is 100 mass %, the solution includes 0.4 mass % to 1.0 mass % of the resin and 1.2 mass % to 20 mass % of the organic solvent.
    Type: Application
    Filed: February 27, 2012
    Publication date: December 5, 2013
    Applicant: HITACHI METALS, LTD.
    Inventors: Kazuhiro Takayama, Toshio Miyoshi
  • Publication number: 20130302202
    Abstract: An iron-based powder composition for metal injection molding having an average particle size of 20-60 ?m, and having 99% of the particles less than 120 ?m wherein the iron-based powder composition includes, by weight percent of the iron-based powder composition: Mo: 0.3-1.6, P: 0.1-0.6, optionally Cu: up to 3.0, optionally Si: up to 0.6, optionally Cr: up to 5, optionally, unavoidable impurities: up to 1.0, whereof carbon is less than 0.1, the balance being iron, and wherein the sum of Mo and 8*P content is within the range of 2-4.7.
    Type: Application
    Filed: December 29, 2011
    Publication date: November 14, 2013
    Applicant: HOGANAS AB (PUBL)
    Inventor: Anna Larsson
  • Publication number: 20130252004
    Abstract: The present invention provides a rare earth-iron-nitrogen-based alloy material which can produce a rare earth magnet having excellent magnetic characteristics and a method for producing the same, a rare earth-iron-based alloy material suitable as a raw material of the rare earth magnet and a method for producing the alloy material. A rare earth-iron-based alloy material is heat-treated in a hydrogen-containing atmosphere to produce a multi-phase powder 1 in which a phase 3 of a hydrogen compound of a rare earth element is dispersedly present in a phase 2 of an iron-containing material. A powder compact 4 produced by compression-molding the multi-phase powder 1 is heat-treated in a vacuum with a magnetic field of 3 T or more applied, thereby forming a rare earth-iron-based alloy material 5. The rare earth-iron-based alloy material 5 is heat-treated in a nitrogen atmosphere with a magnetic field of 3.5 T or more applied, thereby forming a rare earth-iron-nitrogen-based alloy material 6.
    Type: Application
    Filed: May 22, 2012
    Publication date: September 26, 2013
    Applicant: SUMITOMO ELECTRIC INDUSTRIES, LTD.
    Inventors: Toru Maeda, Asako Watanabe, Motoi Nagasawa, Takeshi Kato
  • Publication number: 20130195710
    Abstract: Provided is a manufacturing method of a rare-earth magnet capable of penetrant-diffusing a modifier alloy to increase a coercive force (especially a coercive force under a high-temperature atmosphere) at a temperature lower than the conventional method for manufacturing a rare-earth magnet without using heavy rare-earth metals such as Dy and Tb, and accordingly capable of manufacturing a high coercivity rare-earth magnet at the lowest cost possible.
    Type: Application
    Filed: January 25, 2013
    Publication date: August 1, 2013
    Inventors: Kazuaki HAGA, Noritaka MIYAMOTO, Tetsuya SHOJI, Noritsugu SAKUMA, Shinya OMURA, Motoki HIRAOKA
  • Publication number: 20130149184
    Abstract: A powder material, a method for manufacturing a communication device, and a communication device are disclosed. The powder material according to an embodiment of the present invention includes quartz glass powder, tungsten powder, and an auxiliary material, where a weight proportion of the quartz glass powder is 5% to 90%, a weight proportion of the tungsten powder is 5% to 90%, and a weight proportion of the auxiliary material is 0 to 20%. The powder material according to another embodiment of the present invention includes titanium powder, tungsten powder, and iron powder, where a weight proportion of the titanium powder is 4% to 80%, a weight proportion of the tungsten powder is 5% to 90%, and a weight proportion of the iron powder is 4% to 80%.
    Type: Application
    Filed: February 7, 2013
    Publication date: June 13, 2013
    Applicant: HUAWEI TECHNOLOGIES CO., LTD.
    Inventor: Huawei Technologies Co., Ltd.
  • Publication number: 20130135069
    Abstract: A permanent magnet has a grain structure that includes a main phase and a grain boundary phase that is primarily composed of a first metal. A second metal that enhances the coercivity of the permanent magnet and a third metal that has a lower standard free energy of oxide formation than the first metal and the second metal are diffused in the permanent magnet, and the third metal is present in the form of an oxide in the grain boundary phase.
    Type: Application
    Filed: July 13, 2011
    Publication date: May 30, 2013
    Inventors: Noritaka Miyamoto, Shinya Omura
  • Publication number: 20130127569
    Abstract: A method for manufacturing a resonant tube is provided in the present invention, which comprises: mechanically mixing 88-98 wt. % of iron-nickel alloy powder, 1-8 wt. % of carbonyl iron powder, and 1-8 wt. % of carbonyl nickel powder to form a uniform powder mixture; molding the uniform powder mixture to form a resonant tube blank; and continuously sintering and annealing the resonant tube blank. Also provided in the present invention are a resonant tube and a cavity filter. The method for manufacturing a resonant tube provided in the present invention significantly enhances production efficiency while greatly reducing consumption of raw materials. Moreover, the resonant tube provided in the present invention reduces, to the greatest extent, segregation of alloy components and coarse and uneven microstructures, thereby increasing the performance and stability of the corresponding products.
    Type: Application
    Filed: June 1, 2011
    Publication date: May 23, 2013
    Applicant: Shenzhen Tatfook Network Technology Co., Ltd.
    Inventors: Kelun Zhao, Fengping Shen, Bingbing Wan, Yanzhao Zhou
  • Publication number: 20130039796
    Abstract: A master alloy used to produce the steel part and a process for producing a sinter hardened steel part from the master alloy are described. The powdered master alloy having a composition of iron, about 1 to less than 5 weight % C, about 3 to less than 15 weight % Mn, and about 3 to less than 15 weight % Cr, wherein the master alloy comprises a microstructure composed of a solid solution of the alloying elements and carbon, the microstructure comprising at least 10 volume % austenite and the remainder as iron compounds. The process comprises: preparing the master alloy, mixing the master alloy with a steel powder to produce a mixture wherein the weight % of the master alloy is from 5 to 35 weight % of the mixture, compacting the mixture into a shape of a part and sintering the mixture to produce the steel part, and controlling the cooling rate after sintering to produce sinter hardening. The master alloy powder can also be used as a sinter hardening enhancer when mixed with low-alloy steel powders.
    Type: Application
    Filed: February 15, 2011
    Publication date: February 14, 2013
    Inventors: Gilles L'Esperance, Ian Bailon-Poujol, Denis Christopherson, JR.
  • Publication number: 20120306308
    Abstract: An R—Fe—B based porous magnet according to the present invention has an aggregate structure of Nd2Fe14B type crystalline phases with an average grain size of 0.1 ?m to 1 ?m. At least a portion of the magnet is porous and has micropores with a major axis of 1 ?m to 20 ?m.
    Type: Application
    Filed: August 16, 2012
    Publication date: December 6, 2012
    Applicant: HITACHI METALS, LTD.
    Inventors: Takeshi NISHIUCHI, Noriyuki NOZAWA, Satoshi HIROSAWA, Tomohito MAKI, Katsunori BEKKI
  • Publication number: 20120304694
    Abstract: In a method for producing jewelry articles, forming a predetermined shape from a plurality of sinterable materials, heating the plurality of sinterable materials to a first temperature and for a first time period sufficient to produce a substrate that retains the predetermined shape during manipulation, cooling the substrate to a second temperature at which the substrate is manipulable, manipulating the substrate to incorporate at least one design feature in the substrate, heating the substrate to a third temperature and for a second time period sufficient to sinter the substrate, and cooling the substrate to obtain the jewelry article.
    Type: Application
    Filed: June 1, 2012
    Publication date: December 6, 2012
    Applicant: FREDERICK GOLDMAN INC.
    Inventor: Andrew Derrig
  • Publication number: 20120299675
    Abstract: A method for producing an anisotropic rare earth magnet according to the present invention comprises a forming step of obtaining a formed body by press-forming a mixed raw material of a magnet raw material capable of generating R2TM14B1-type crystals of a tetragonal compound of a rare earth element (R), boron (B), and a transition element (TM), and a diffusion raw material to serve as a supply source of at least a rare earth element (R?) and Cu; and a diffusing step of diffusing at least R? and Cu onto surfaces or into crystal grain boundaries of the R2TM14B1-type crystals by heating the formed body. In this production method, the diffusion raw material having a low melting point and high wettability envelops the R2TM14B1-type crystals, and therefore an anisotropic rare earth magnet having high coercivity can be obtained without decreasing magnetization which should be inherently exhibited by the magnet raw material.
    Type: Application
    Filed: August 27, 2010
    Publication date: November 29, 2012
    Applicant: AICHI STEEL CORPORATION
    Inventors: Yoshinobu Honkura, Chisato Mishima
  • Publication number: 20120269671
    Abstract: A process for producing a weldable titanium or titanium alloy wire characterised in that full consolidation of the wire is achieved via solid-state processing entailing compaction, extrusion, and rolling, whereby melting of the constituent titanium sponge particles does not occur.
    Type: Application
    Filed: October 21, 2010
    Publication date: October 25, 2012
    Inventor: Kevin Dring
  • Publication number: 20120230859
    Abstract: A fully dense, powder-metallurgy produced maraging steel alloy article of prealloyed powder for use as a tool for high temperature applications. The article in the as-produced condition having a hardness less than 40 HRC to provide machinability and thereafter the article upon maraging heat treatment having a hardness greater than 45 HRC. A method for producing this article comprises compacting prealloyed powder to produce a fully dense article having a hardness less than 40 HRC and thereafter maraging heat treating to a hardness greater than 45 HRC.
    Type: Application
    Filed: February 23, 2012
    Publication date: September 13, 2012
    Inventors: Joseph F. MUHA, Andrzej L. WOJCIESZYNSKI, Brian J. MCTIERNAN
  • Publication number: 20120228361
    Abstract: An ultrasonic welding tool fabricated of powder metal material includes a body and a welding tip extending axially from the body to a working end. The powder metal material can be ferrous-based and admixed with additives, such as alumina, carbide, ferro-molybdenum, ferro-nickel, chrome or tribaloy. An exposed surface of the welding tip can comprise Fe3O4 oxides. The tool is compacted to the desired shape and sintered. The body can include a different second material compacted separately from the welding tip and then joined to the tip and sintered.
    Type: Application
    Filed: May 21, 2012
    Publication date: September 13, 2012
    Inventor: Denis CHRISTOPHERSON, JR.
  • Publication number: 20120146759
    Abstract: A coil component comprising a first split magnetic core and a second split magnetic core, each having an outer core leg, an inner core leg and a back yoke connecting the outer core leg and the inner core leg, and a coil block mounted to the inner core leg, wherein the outer core leg has a sectional area smaller than a sectional area of the inner core leg, a density of magnetic body in the outer core leg is different from a density of the magnetic body in any of the inner core leg and the back yoke, and the first split magnetic core and the second split magnetic core are butted against each other to form a magnetic core of a closed magnetic circuit.
    Type: Application
    Filed: September 2, 2010
    Publication date: June 14, 2012
    Applicant: Panasonic Corporation
    Inventors: Tomonori Shibuya, Tsunetsugu Imanishi
  • Publication number: 20120055316
    Abstract: A scented article manufactured from a sintered metal powder. The metal powder may be one or more metals, one or more alloys, or any combination or mixture thereof. The scented article is of a weight sufficient to sink to a depth in the water and shaped such that, when urged through the water, the lure moves in a substantially oscillating motion. The scented article is impregnated with a scent, such as a fish attractant, that is slowly diffused in the water as the scented article is urged through the water. A method of manufacturing a scented article is also disclosed.
    Type: Application
    Filed: November 10, 2011
    Publication date: March 8, 2012
    Applicant: CONTINUOUS METAL TECHNOLOGY INC.
    Inventors: Timothy G. Smith, Ivan R. Smith
  • Patent number: 8124245
    Abstract: A direct metal laser sintered material including a substrate formed from a laser sintering process, the substrate having at least one surface, and a cladding material brazed onto at least a portion of the surface.
    Type: Grant
    Filed: May 7, 2010
    Date of Patent: February 28, 2012
    Assignee: General Electric Company
    Inventors: David Edwin Budinger, Ronald Lance Galley, Ashwin Sreekant Raghavan, David Allen Kastrup
  • Publication number: 20110311389
    Abstract: A method is provided for manufacturing a turbine component. The method includes forming a first intermediate turbine article with an additive manufacturing process; encapsulating the first intermediate turbine article with an encapsulation layer to form a second intermediate turbine article; and consolidating the second intermediate turbine article to produce the turbine component.
    Type: Application
    Filed: June 22, 2010
    Publication date: December 22, 2011
    Applicant: HONEYWELL INTERNATIONAL INC.
    Inventors: Daniel Ryan, Mark C. Morris, Donald G. Godfrey, Steve Starr
  • Patent number: 8079762
    Abstract: Crankshaft bearing cap presenting on one of its faces a semi-cylindrical notch, formed by powder metallurgy with an iron powder blend molded by compaction and sintering, and partially infiltrated with Cu, being the area adjacent to the area around the notch, the one with highest Cu content. A method for manufacturing main bearing caps by infiltration of Cu including the steps of placing the molded cap so that the axis of the semi-cylindrical notch extends in a horizontal direction and the notch cavity is in the upwards position. Placing high Cu content tablets on the upper face of the cap and on the cylindrical arch and sintering of the cap and Cu tablets system.
    Type: Grant
    Filed: August 27, 2004
    Date of Patent: December 20, 2011
    Inventors: Antonio Romero Fernandez, Brian Daniel Kaminski
  • Patent number: 8066937
    Abstract: Discontinuous diamond particulate containing metal matrix composites of high thermal conductivity and methods for producing these composites are provided. The manufacturing method includes producing a thin reaction formed and diffusion bonded functionally graded interactive SiC surface layer on diamond particles. The interactive surface converted SiC coated diamond particles are then disposed into a mold and between the particles and permitted to rapidly solidify under pressure. The surface conversion interactive SiC coating on the diamond particles achieves minimal interface thermal resistance with the metal matrix which translates into good mechanical strength and stiffness of the composites and facilitates near theoretical thermal conductivity levels to be attained in the composite. Secondary working of the diamond metal composite can be performed for producing thin sheet product.
    Type: Grant
    Filed: October 8, 2007
    Date of Patent: November 29, 2011
    Assignee: Nano Materials International Corporation
    Inventors: Sion M. Pickard, James C. Withers, Raouf O. Loutfy
  • Publication number: 20110284792
    Abstract: The present invention features a steel-base sintering alloy having a high wear-resistance for a valve seat of an engine. In preferred embodiments, the steel-base sintering alloy may include a chief element of Ferrum (Fe); and a powder-alloy which are composed of Carbon (C) of 0.6˜1.2 wt %, Nickel (Ni) of 1.0˜3.0 wt %, Cobalt (Co) of 15.0˜25.0 wt %, Chrome (Cr) of 3.0˜9.0 wt %, Molybdenum (Mo) of 8.0˜15.0 wt %, Tungsten (W) of 1.0˜4.0 wt %, Manganese (Mn) of 0.5˜2.0 wt %, and Calcium (Ca) of 0.1˜0.5 wt %.
    Type: Application
    Filed: October 18, 2010
    Publication date: November 24, 2011
    Applicants: KOREA SINTERED METAL CO., LTD., HYUNDAI MOTOR COMPANY
    Inventors: Jong Myung Kim, Ki Bum Kim, Dong Jin Kang, Hyung Oh Ban, Hong Kil Baek, Won-Seog Koo, Jong-Kwan Park, Sung-Tae Choi
  • Patent number: 8061580
    Abstract: A method of forming and assembling at least two parts together that may be metal, ceramic, or a combination of metal and ceramic parts. Such parts may have different CTE. Individual parts that are formed and sintered from particles leave a network of interconnecting porosity in each sintered part. The separate parts are assembled together and then a fill material is infiltrated into the assembled parts using a method such as capillary action, gravity, and/or pressure. The assembly is then cured to yield a bonded and fully or near-fully dense part that has the desired physical and mechanical properties for the part's intended purpose. Structural strength may be added to the parts by the inclusion of fibrous materials.
    Type: Grant
    Filed: November 23, 2010
    Date of Patent: November 22, 2011
    Assignee: Babcock & Wilcox Technical Services Y-12, LLC
    Inventor: Edward B. Ripley
  • Patent number: 8051566
    Abstract: A method for manufacturing a rigid internal gear of a wave gear device in which an internally toothed portion formed with internal teeth and a gear main body portion are joined integrally, the method including preforming an internal teeth-forming ring or disc for forming the internally toothed portion by using a first aluminum alloy powder; manufacturing a forging in which the internal teeth-forming ring or disc is placed in a forging die and is integrally formed on its outer side with the gear main body portion using a second aluminum alloy powder, the first aluminum alloy powder being harder and having higher abrasion resistance than the second aluminum alloy powder; and applying post-processing including cutting teeth to the forging.
    Type: Grant
    Filed: May 27, 2010
    Date of Patent: November 8, 2011
    Assignees: Harmonic Drive Systems, Inc., Sumitomo Electric Sintered Alloy, Ltd.
    Inventors: Masaru Kobayashi, Toshihiko Kaji
  • Patent number: 8048366
    Abstract: From tungsten or molybdenum powders, a tungsten or molybdenum compact is pressurized and molded into the same dimensions as or slightly larger than the end product and sintered into tungsten or molybdenum skeleton. After copper infiltration, chemical copper etching is applied to remove excess surface copper. A machining allowance with an absolute value >0-?0.1 mm may be applied for the machining of uneven surfaces resulting from the chemical process of copper removal.
    Type: Grant
    Filed: October 10, 2008
    Date of Patent: November 1, 2011
    Assignee: Torrey Hills Technologies, LLC
    Inventors: Dejun Zhu, Hong Wu, York Yuan Chang, Ken Kuang
  • Publication number: 20110168363
    Abstract: A composite article (1; 10; 40) comprises a plurality of inclusions (5) of a magnetocalorically active material embedded in a matrix (4) of a magnetocalorically passive material. The inclusions (5) and the matrix (4) have a microstructure characteristic of a compacted powder.
    Type: Application
    Filed: December 27, 2007
    Publication date: July 14, 2011
    Inventors: Georg Werner Reppel, Matthias Katter
  • Publication number: 20110142387
    Abstract: Impregnation of a resin into a sintered body (15) enables reduction in an amount of oil to be impregnated into inner pores. Further, by forming pores into which the resin is unimpregnated in a bearing surface (inner peripheral surface (15a)), it is possible to supply oil retained in the pores into bearing gaps and to cause the pores to function as filters for catching contaminants such as abrasion powder in a bearing.
    Type: Application
    Filed: August 31, 2009
    Publication date: June 16, 2011
    Applicant: NTN CORPORATION
    Inventors: Norihide Sato, Akihiro Omori, Katsutoshi Muramatsu, Kazutoyo Murakami
  • Patent number: 7931856
    Abstract: A method of forming a crankshaft bushing or similar component is provided. A compaction die is provided having an axial, generally cylindrical internal opening. An upper and a lower punch are provided with exterior surfaces corresponding to the internal opening of the compaction die. An upper core rod passes through an axial opening in the upper punch. A lower core rod passes through an axial opening in the lower punch. The upper core rod and the lower core rod each may have a generally flat external surface section. A metal powder is compacted in the compaction die by the combined action of the upper and lower punches and the upper and lower core rods.
    Type: Grant
    Filed: September 4, 2007
    Date of Patent: April 26, 2011
    Assignee: Burgess-Norton Mfg. Co., Inc.
    Inventors: John Engquist, Bret E. Viant, Mark R. Haas, Kurt Kujawski, Matthew D. Bowman, Kevin J. Skibinski
  • Publication number: 20110056691
    Abstract: A shaped charge includes a casing defining an interior volume, wherein the casing is prepared by sintering a metal powder or a mixture of metal powders; a liner located in the interior volume; and an explosive between the liner and the casing. A method for manufacturing a shaped charge casing includes the steps of mixing a metal powder or a metal powder mixture with a binder to form a pre-mix; pressing the pre-mix in a mold to form a casing green body; heating the casing green body to a first temperature to vaporize the binder; raising the temperature to a second temperature in an inert or reducing atmosphere to sinter the metal powder or the metal powder mixture to produce the shaped charge casing.
    Type: Application
    Filed: September 9, 2010
    Publication date: March 10, 2011
    Applicant: SCHLUMBERGER TECHNOLOGY CORPORATION
    Inventors: Allan W. King, Richard Caminari