Abstract: A composite spray coating comprises an iron base material, a spray coating film applied thereon and a diffusion layer of aluminum or aluminum-zinc alloy, and is used for hot-dip galvanization.

Abstract: A process for producing from iron materials a sintered molded part which is pore-free in individual zones or boundary zones but porous in the other zones. The process is based on a molded part brought to a residual porosity of about 10% by volume by conventional powder pressing and sintering processes. By additional process steps such as zonal introduction of additional materials or local mechanical recompacting, certain zones or local areas are brought to a residual porosity of 5% by volume or less; at the same time, a closed pore structure is produced in these zones. Under these preconditions, in a final HIP or sintering HIP process step the sintered molded part can be brought to 100% material density in the pretreated zones so that they substantially completely free from pores. The major advantages include local improvement in material properties and calibratability of the finished sintered molded part.

Abstract: An impregnated cathode comprising three layers: a very thin emitting surface layer of metal such as an alloy of tungsten with a high fraction of an activating metal of the platinum group to provide low workfunction; an underlying, thin buffer layer of porous tungsten alloyed with a fraction of activating metal, to retard diffusion loss of activating metal from the emitting layer; and a substrate of porous tungsten impregnated with barium aluminate.

Abstract: A density element (12) for use in ruminal delivery devices (10) which is manufactured by partial sintering in such a manner as to fragment upon contact with the many parts in rendering machinery without damage to the blades. The density element (12) has density of at least about 1.5 gm/cm.sup.3 and a transverse rupture strength greater than about 3000 psi no greater than about 30,000 psi. The part is sintered under conditions which do not permit full weld bond strength to be obtained and may thereafter be heat treated or impregnated with an inert hydrophobic material to increase corrosion resistance.

Abstract: The friction lining for disk brakes comprises a carrier plate (10) and a block (16) of a compressed friction material secured to the latter, wherein the carrier plate, on the side bearing the block of friction material, is provided with a sinter-fused mounting bed (12) for the block of friction material of individual shaped members (13) forming frictional and positive connections with the block of friction material, in which, prior to the block of friction material is pressed onto the carrier plate (10) with the mounting bed sinter-fused thereupon, a galvanically, thermally or in some other suitable way produced metallic coating (50) is applied to the carrier plate as a corrosion protection.

Abstract: Gas turbine engines employ a variety of abradable liners to decrease the clearance between the rotating components and the surrounding casing. There is normally a trade-off between porosity, (and concomitant permeability) and the abradability of the liner material, such that materials with good abradability are permeable to gas flow--resulting in performance losses. Permeability of porous liners is decreased by infiltrating the liner with a low-viscosity liquid containing a metal or metal oxide. After infiltration, the viscosity of the liquid is substantially increased to prevent its egress from the porous liner. Thereafter, the liner is heated at an elevated temperature to drive off the remaining liquid and provide an oxide which blocks the passages and decreases the permeability of the liner.

Abstract: A machine component has a wear surface along which excessive friction will develop unless the surface receives adequate lubrication. To provide lubrication for the wear surface in the absence of any other lubricating medium, the component is formed from powdered metal compacted to less than theoretical density so as to contain pores, and the pores hold oil. Even though the component is mechanically machined along its wear surface, the pores are nevertheless open at the wear surface to enable the entrapped oil to exude from the ring and lubricate that surface. During manufacture of the ring, the mechanical machining creates a Bielby layer at the wear surface, that is it smears the metal and closes the pores at that surface, but the Bielby layer is removed by electro-discharge machining This procedure erodes the Bielby layer with electrical arcs so that the pores at the wear surface are again exposed and open.

Abstract: Disclosed is a process for preparing a cathode structure for impregnated cathodes having desired dimensions by a simplified process without experiencing machining etc. A high-melting-point metal powder is introduced into a mold, and heated with the heater to effect isostatic press molding to provide a cathode structure for impregnated cathodes having a predetermined shape and dimensions by one operation.

Abstract: This invention relates generally to a novel method of preparing self-supporting bodies, and to novel products made thereby. In its more specific aspects, this invention relates to a method of producing self-supporting bodies comprising one or more boron-containing compounds, e.g., a boride or a boride and a carbide, by reactive infiltration of a molten parent metal actinide into (1) a bed or mass containing boron carbide and, optionally, (2) at least one of a boron donor material (i.e., a boron-containing material) and a carbon donor material (i.e., a carbon-containing material), (3) a bed or mass comprising a mixture of a boron donor material and a carbon donor material and, optionally, (4) one or more inert fillers in any of the above masses, to form the body.

Abstract: Infiltrate a porous, self-reinforced .beta.-Si.sub.3 N.sub.4 preform with a metal or a crystallizable glass to yield a composite material. The preform possesses a low glass phase and has a density of from about 50 to about 70 percent of theoretical density. Prepare the .beta.-Si.sub.3 N.sub.4 preform by subjecting a porous body formed from an .alpha.-Si.sub.3 N.sub.4 powder composition to two sequential heat treatments. The first heat treatment occurs below the .alpha.- to .beta.- conversion temperature and results in a strengthened body that can be machined. The second heat treatment occurs above that temperature and yields the self-reinforced .beta.-Si.sub.3 N.sub.4 preform. Conventional infiltration procedures with an infiltrant that is a metal or a glass results in a Si.sub.3 N.sub.4 /metal or Si.sub.3 N.sub.4 /glass composite material that has 50 to 70 percent of its volume occupied by .beta.-Si.sub.3 N.sub.4 whiskers.

Abstract: A ceramic oxide superconductive composite material comprising a ceramic oxide superconductor and a non-superconductive material comprising at least one element which does not react with any of the elements of the ceramic oxide superconductor has improved superconductive properties such as a higher critical temperature and a larger critical current density.

Abstract: A method of manufacturing an aluminum-base composite disc rotor comprising the steps of preparing a rough-shaped disc rotor made of a mixture of aluminum powder or aluminum alloy powder with reinforcing particles or aluminum alloy, placing a mixture of aluminum powder or aluminum alloy powder with reinforcing particles or a preform made thereof on each of fixed positions of the rough-shaped disc rotor, and heating the mixture or the preform to at least a region of mashy state temperature to mold under pressure. Thereby the heat resistance and the wear resistance of the aluminum-base composite disc rotor for light-duty cars and industrial machinery are improved.

Abstract: A substrate material for mounting a semiconductor device thereon, comprises a skeleton prepared by liquid-phase presintering the composition of W and/or Mo powder in which Cu and/or Ag powder is uniformly dispersed, and a Cu and/or Ag phase infiltrated into the pores of the skeleton. The total amount of Cu and/or Ag in the product is adjusted to 10-50 vol. %. The substrate material is manufactured by two steps of: presintering the Cu and/or Ag-contng. powdery composition to form a porous skeleton, and infiltrating Cu and/or Ag into the pores of the skeleton. Since the skeleton contng. Cu and/or Ag exhibits an excellent affinity to molten Cu and/or Ag, the infiltration of molten Cu and/or Ag is performed uniformly into every nook and corner of the skeleton. Consequently, the obtained product is free from pores which would deteriorate a junction plane between the substrate and a semiconductor device mounted thereon.

Abstract: This invention relates generally to a novel method of preparing self-supporting bodies, and to novel products made thereby. In its more specific aspects, this invention relates to a method of producing self-supporting bodies comprising one or more boron-containing compounds, e.g., a boride or a boride and a carbide, by reactive infiltration of a molten parent metal actinide into (1) a bed or mass containing boron carbide and, optionally, (2) at least one of a boron donor material (i.e., a boron-containing material) and a carbon donor material (i.e., a carbon-containing material), (3) a bed or mass comprising a mixture of a boron donor material and a carbon donor material and, optionally, (4) one or more inert fillers in any of the above masses, to form the body.

Abstract: A method for manufacturing an impregnated cathode comprising the steps of forming a porous pallet having a plurality of pores by sintering metal powder at a high temperature in a reducing atmosphere and fitting the porous pallet tightly in a cathode ring made of a metal containing an oxidizable material such as silicon, nickel or chromium. In the porous pallet, an electron radiating material is impregnated which is able to react with the oxidizable material of the cathode ring, so that an fixing between the pallet and the cathode ring is achieved by the reaction between the electron radiating material and the oxidizable material. In accordance with the method, the thickness of the cathode body can be greatly reduced, thereby enabling the performance of the impregnated cathode to be improved. Also, the manufacturing process can be simplified, thereby improving the productivity.

Abstract: The present invention is directed to a method of preparing a composite material excellent in joint strength and heat conductivity, and more specifically to a method of preparing a composite material composed of a high-melting material W and low-melting material Cu. The method comprising a first step of forming pores in the high-melting material W, to obtain a substrate material having a porosity distribution, with a high porosity at at least one region of the surface of the substrate material and the porosity gradually decreasing outward from the region; and a second step of impregnating the low melting material Cu to the substrate material obtained in the first step from the region of the highest porosity gradually downward. The substrate material being formed to have a gradient distribution of a composite ratio of the high-melting material and the low-melting material.

Abstract: A beryllium metal matrix phase includes up to 70% by volume of beryllium oxide single crystals dispersed therein. The composites are useful for electronics applications because of their light weight, high strength and effective thermal properties.

Abstract: A method and apparatus for manufacturing a superconductor wire has a wire take-up spool and a feed speed control spool. A wire substrate is taken from the feed speed control spool and onto the take-up spool as the wire take-up spool is rotated. The wire passes through a container which holds a diffusion barrier material, where the diffusion barrier material is electrophoretically deposited onto the wire substrate and subsequently sintered. The wire is also passed through a container which holds a superconductor material suspended in solution, and a layer of the superconductor material is electrophoretically deposited onto the diffusion barrier. The grains of the superconductor layer are then magnetically aligned and sintered. Also, a silver coating is electrophoretically deposited onto the superconductor layer and sintered. A diffusion bonding inhibitor material is then applied to the silver coating. Then, the silver-coated superconductor wire is spooled and heated to four hundred degrees centigrade (400.

Abstract: The present invention relates to a method of fabricating various types of bearing materials and the bearing materials produced thereby. The processes of the invention may be used to produce porous self-lubricating bearings, laminated composite bearings (babbitt bearings) and bearings for high temperature application. The processes of the invention involve the use of micro-pyretic synthesis to achieve bearing materials with improved bearing properties, including higher bearing capacity and toughness.

Abstract: A porous intermediate compact is first prepared from metal particles, carbon and a temporary binder. The compact is then heated to remove the binder and then infiltrated with the vapor of a metal having a melting point lower than the compact.

Abstract: A highly corrosion-resistant rare earth-, e.g., neodymium-, based sintered permanent magnet is proposed which is characterized by the specific chemical composition of the magnet alloy including cobalt and/or chromium in a specified atomic percentage, by the density of the sintered body of at least 95% of the density of the alloy ingot and by the corrosion-resistant surface film formed on the surface of the sintered body by a specific method. By virtue of the favorable conditions against corrosion including the specific chemical composition of the magnet alloy and the high density of the sintered body, these conditions are also favorable for enhancing the adhesion of the corrosion-resistant coating film to the surface of the sintered body.

Abstract: The separation of two or more forged powder metal components is facilitated by forming a compacted and sintered powder metal preform with at least one slit that separates the component pieces. An anti-bonding agent such as graphite is introduced into the slit and the preform is then forged to final shape. The anti-bonding agent prevents the complete bonding of the powder metal pieces to each other thereby facilitating separation of the pieces at the slit. This method is particularly suited for the manufacture of piston connecting rod assemblies of the type including a connecting rod and cap.

Abstract: An injection molded powder metallurgy product of highly satisfactory quality is obtained by a method which comprises injection molding mixture obtained by kneading a metal powder with a binder, depriving the molded mass of the binder while keeping the molded mass at least in contact with ceramic powder, projecting beads on the molded mass free from the binder, and thereafter sintering the molded mass studded with the beads.

Abstract: Reactive ceramic-metal compositions are described that include a ceramic phase of at least 70 percent by volume, 95 percent of theoretical density and a metal phase that retains its chemical reactivity with the ceramic phase after the composition has been fully densified. The composition may be heat treated after densification to form additional ceramic phases in a controllable manner. Preferred ceramic metal compositions wherein the metal and ceramic components retain reactivity after densification include boron carbide ceramic and Al or Mg metals. The process employed in forming said compositions requires first forming a sintered porous body of the ceramic material followed by contacting with the metal component, which may be in chip or solid bar form. The system is then heated to the melting point of the metal and a pressure of at least 200 MPa is employed such that the porous body is filled with metal and the composition is substantially fully densified.

Abstract: The invention relates to a method of making permanent magnets, especially rare-earth ion permanent magnets composed of compacted Fe-B-R type alloy particles. Accordingly, the method provides compacting the magnetic particles into a desired shape having voids between some of the compacted particles. The voids between the particles are filled with a sealing agent and the compact is further coated with either an organic coating or metallic coating.

Abstract: The improved friction facing has a porous, resilient fused metallic matrix with a second metal having a lower boiling point being infused into and alloyed with the matrix.

Abstract: Self-supporting bodies are produced by reactive infiltration of a parent metal into a boron carbide material which may contain one or both of a boron donor material and a carbon donor material. The reactive infiltration typically results in a composite comprising a boron-containing compound, a carbon-containing compound and residual metal, if desired. The mass to be infiltrated may contain one or more inert fillers admixed with the boron carbide material, boron-containing compound and/or carbon-containing compound. The relative amounts of reactants and process conditions may be altered or controlled to yield a body containing varying volume percents of ceramic, metal, ratios of one ceramic to another and porosity.

Abstract: Composite magnetic compacts having good conductivity and excellent mechanical and magnetic properties and their forming methods. The composite magnetic compacts are basically made by forming mixtures consisting essentially of 1 to 50 percent by weight of a magnetic powder and the remaining percentage of a powder of superplastic Zn-22Al alloy. A drop in the strength of the compacts that occurs when the mixing percentage of the magnetic powder increases is made up for by the impregration of plastic in the compacts or the simpler addition of a plastic powder to the mixture of the powders of magnetic material and superplastic Zn-22Al alloy. The forming methods of the composite magnetic compacts are carried out at different temperatures and under different conditions depending on the composition of the powder mixtures and so on.

Abstract: Disclosed is a fragrance emitting metal composed of a sintered metallic body prepared by press-molding a metal powder for sintering within a mold having a required shape, followed by sintering of the resulting molded product at a required temperature, characterized by the constitution wherein the molding pressure is controlled so that the resulting sintered product may have a porosity which permits infiltration of a liquid perfumery therethrough; and the surface of the sintered metallic body is partially polished so as to reduce the porosity of the polished surface, thereby improving the property of sustaining the diffusion of the fragrance from the liquid perfumery infiltrated therethrough and also to impart gloss and luster thereto.

Abstract: A method of making a golf club head and golf club heads produced by said method which involves filling a mold with material selected from the group consisting of metal powders, castings, wrought metal, and green compact metal powders and combinations thereof so as to achieve the desired properties in the particular areas of the club head, compressing the material in the mold to form a green compact of the material, removing the green compact of the material from the mold land then heating the green compact to an elevated temperature to form a sintered product. Thereafter, the sintered product may be further heated under pressure to improve its density.

Abstract: A self-sustaining combustion synthesis process for producing hard, tough, lightweight, low exothermic potential product (LEPP)/high exothermic potential product (HEPP) composites is based on the thermodynamic dependence of adiabatic temperature and product composition on the stoichiometry of the LEPP and HEPP reactants. For lightweight products the composition must be relatively rich in the LEPP component. LEPP rich composites are obtained by varying the initial temperature of the reactants. The product is hard, porous material whose toughness can be enhanced by filling the pores with aluminum or other metal phases using a liquid metal infiltration process. The process can be extended to the formation of other composites having a low exothermic component.

Abstract: It is disclosed a method for preparing a large-sized powder metallurgical sintered product having a superior characteristic by charging mixtures of three types of metallic powder composed of coarse particles, middle particles and fine particles into the molding die while vibrating it, heating the charged material together with the molding die, sintering them, and infiltrating metal of low melting point into the sintered body. According to this method, it is possible to get a large-sized sintered body having a superior strength and surface smoothness or a sintered body prohibiting any cracks or slits by arranging the proper particle size.

Abstract: Sintered ferrous materials are described having a composition in wt % lying within the ranges of C 0.8-1.5/W 1-4.4/Mo 1-4.4/V 1-2.6/Cr 1.3-3.2/Others 3 max./Fe balance. The material may be made by a method comprising the steps of mixing between 40 and 70 wt % of a powder having a composition in wt % within the ranges C 0.45-1.05/W 2.7-6. 2/Mo 2.8-6.2/V 2.8-3.2/Cr 3.8-4.5/Others 3.0 max./Fe balance with between 60 and 30 wt % of an iron powder and from 0.4 to 0.9 wt % of carbon powder, pressing a green body of the article from the mixed powder and then sintering the green body. The material may optionally contain sulphur, metallic sulphides. The material may be infiltrated.

Abstract: A moulded body having an inner support matrix is enveloped at least partially with a plastic envelope making up the mould. The support matrix is formed at least partially from metal wire pieces and/or metal chips, which are compression moulded and sintered.

Abstract: A process for producing clad products that utilizes wrought or cast components eliminating the need for costly metal powders and a can to contain them. A sleeve circumscribes a core leaving a space therebetween. Powder is introduced into the space and is sealed therein. The resultant billet is extruded generating a clean metallurgical bond between the core and the sleeve. The space need not be evacuated prior to heating the billet. Resultant clad welding rod permits higher operating amperages.

Abstract: A metal-metal matrix composite magnet including a magnetic material such as a neodymium-iron-boron magnetic phase bonded by a metal matrix, preferably copper an a method of making the magnet which involves plating a thin metal layer, for example, a layer having a thickness of less than 1000 angstrom average, from a magnetic phase, pressing the powder, with or without magnetic alignment, into the desired shape and then sintering the pressed powder at a temperature below about 400.degree. C.

Abstract: A cathode is made from tungsten powder using as an impregnant the product rmed from adding about 1 mole of a member selected from the group consisting of zirconium, zirconium dioxide, hafnium, hafnium dioxide, uranium, uranium dioxide, titanium, and titanium dioxide to about 50 to about 100 moles of a compound selected from the group consisting of Ba.sub.3 Al.sub.2 O.sub.6, Ba.sub.3 WO.sub.6, and Ba.sub.4 Al.sub.2 O.sub.7.

Abstract: The invention is related to a bearing material having multiple layers therein and a method for manufacturing the same. The invention features that a bearing layer consisting mainly of an integrated resin powder is formed on a porous layer covering a back metal, such as a steel plate of like, that the integrated resin powder consists of P T F E resin precipitate and F E P resin precipitate and/or P F A resin precipitate and that each particle of the integrated resin powder is covered with Pb-Sn alloy powders.Accordingly, the integrated resin powder independently provides a predetermined lubricating property. In addition, since these resin precipitates are in unity, it is possible to maintain excellent cavitation resistance property and load resistance property, even under severe boundary conditions.Furthermore, since each of the integrated resin powder is covered with the Pb-Sn alloy powder, an uniform and deep penetration of the alloy powder into pores of the porous layer can be easily obtained.

Abstract: A method of producing powder forged components produces parts which precisely fit together, the method including the steps of: forming a one-piece preform by pressing from powder; forming at least one tear notch in the preform at a selected location; sintering the preform; providing a protective layer on each tear notch; forging the preform into a component, including closing each tear notch during the forging to form a corresponding slit; cooling the component; and separating the component at the corresponding selected location into a plurality of individual parts by breaking.

Abstract: The present invention relates to porous powder metal (P/M) parts having improved dynamic properties such as impact and fatigue strength. These properties are achieved by the use of finer metal powders.

Abstract: A high temperature wear resistant sintered alloy suitable for the material of a valve seat in an automotive vehicle engine. The matrix of the sintered alloy consists essentially of carbon ranging from 0.45 to 1.15% by weight, nickel ranging from 5.4 to 27% by weight, molybdenum ranging form 0.4 to 2.7% by weight, cobalt ranging from 4.2 to 7.2% by weight and balance being substantially iron. The matrix is formed of a mixture of at least one of sorbite structure and bainite structure and austenite structure. Furthermore, the matrix includes hard phase dispersed therein and containing at least silicon, molybdenum and cobalt. The sintered alloy of such a structure can exhibit high strength and wear resistance at high temperatures regardless of type of engine and kind of fuel in case of being used as the material of the valve seat, while maintaining production cost thereof lower.

Abstract: This invention relates to a method of producing a corrosion-, heat- and wear-resistant member which comprises packing an atomized powder of a high-carbon high-chromium steel into a capsule, heating the capsule packed with the powder, then extruding the capsule packed with the powder to obtain a stock not containing carbide grains greater than 3 .mu.m, working the stock, polishing a surface of the stock, and evaporating a film of TiC and/or TiN onto the polished surface, and further a corrosion-, heat- and wear-resistant member produced by the method. The corrosion-, heat- and wear-resistant member according to this invention is suitable for being members for tools used under extremely severe conditions, such as various tools for can manufacturing, molding tools for reinforced plastics, etc.

Abstract: A long life high current density cathode is made from a mixture of tungsten nd iridium powders by processing the mixture of powders with an activator into a porus billet, and then impregnating the billet with a mixture of barium peroxide and a coated emitter by firing the billet in a dry hydrogen furnace at a temperature at which the impregnant melts.

Abstract: A mirror having optical quality reflective faces is prepared by pressing of metallurgical powders. An optical quality surface, free of scratches and irregularities, is formed by pressing the faces with an optical quality tool face, applied to the face at an acute angle to achieve a degree of metal flow. The mirror is progressively formed, by first pressing an assembly of powder to a "green" powder mirror, sintering the pressed powder, and then repressing the sintered mirror using a tool having optical quality surfaces on the faces contacting the mirror faces. The mirror is annealed, repressed with the tool having optical quality surfaces, and coated on the reflective surfaces with a thin metallic coating. This technique is particularly effective for preparing large numbers of mirrors with multiple facets requiring precise facet intersections, as the pressing tool can be adjusted to produce highly exact facet intersections which are then reproduced exactly in subsequent mirrors.

Abstract: A cathode is made from a mixture of tungsten and iridium powders using a ction product formed from reacting barium peroxide with an excess of tungsten as the impregnant.

Abstract: A process for making a porous mass of a metal of iron- or titanium-group comprises steps of forming a sinter of solvent-soluble particles, pressing in a molten metal of the iron- or titanium- group into open interstices in the sinter, and eluting the particles from the composite of the sinter and metal. Solvent-soluble magnesia particles whose surface is either covered or not with a film of boric anhydride or solvent-soluble calcia particles whose surface is either covered or not with film of calcium chloride are sintered and machined into the desired shape. The formed sinter is put in a case of a heat-insulating material that can withstand the melting temperature of a metal of iron- or titanium-group. After being heated to a given temperature together with the case, the sinter is immediately put in a metal mold where a molten metal of iron- or titanium-group is pressed into open interstices in the sinter. Then, only the particles are eluted from the sinter-metal composite by a solvent.

Abstract: A composite is produced by depositing a slurry of infiltration-promoting material and organic binding material on a layer of boron nitride coated fibrous material forming a tape therewith on drying, firing the tape to burn out organic binding material and infiltrating the resulting porous body with a solution of boron and silicon.

Abstract: A method of manufacturing a scandate dispenser cathode having a matrix (1) at least the top layer of which consists substantially of a mixture of tungsten with scandium oxide or with a mixed oxide comprising scandium oxide. When sintering of the matrix is carried out at a temperature between 1300.degree. and 1700.degree. C., preferably at approximately 1500.degree. C. and in a hydrogen atmosphere, cathodes are obtained having a better recovery after ion bombardment compared with cathodes sintered at 1900.degree. C. Sintering in hydrogen results in a better reproducibility.

Abstract: The present invention relates to an infiltrated ferrous powder metal part containing certain additives, yielding a radically improved unnotched impact strength without sacrificing tensile strength. Fatigue strength is also improved. In addition, improved dimensional control is obtained during infiltration. The microstructure is also improved, with smoothing or rounding of the formerly sharp angled copper filled pores. The invention also comprises the method of achieving these results.

Abstract: A dental material and method for forming, reinforcing or repairing a dental restoration comprising a combination of a high fusing temperature metal component in a major proportion and a low fusing temperature component in a minor proportion. A binder may be added to form a putty-like consistency. The dental material is molded into a predetermined shape and heat treated at a temperature which will substantially melt the low fusing metal components but below the melting temperature of the high fusing metal component for forming a porous, sponge-like mass of interconnected particles of the high fusing temperature metal component. A filler material having a low melting temperature is then added to the porous mass and the mass is again treated to form a solid mass.