Abstract: A process for making an arc tube comprises the steps of sintering an arc tube composition to form the arc tube; annealing the arc tube in a vacuum; and sealing the arc tube with at least one electrode. Preferably, the arc tube annealed according to the present process is a ceramic arc tube. The annealing of the arc tubes in a vacuum preferably occurs at a temperature of between about 1000° C. and 1500° C.

Abstract: A heat-resistant, creep-resistant aluminum alloy containing from 10 to 30 mass % of silicon, from 3 to 10 mass % of at least either iron or nickel in total, from 1 to 6 mass % of at least one rare earth element in total, and from 1 to 3 mass % of zirconium, preferably excluding titanium, magnesium and copper, with the rest substantially consisting of aluminum, is prepared by a method including providing a rapidly cooled aluminum alloy powder, molding the powder into a pressurized powder compact, and performing hot plastic working on the compact to form a product shape such as a billet. The compact is exposed to a temperature of at least 450° C. for at least 10 seconds and not more than 30 minutes before forming the product shape by the hot plastic working.

Abstract: A titanium based composite which includes a Ti(Al,O) base matrix, discrete ceramic particles, and an oxide layer on the surface of the composite. The discrete ceramic particles are integrally associated with the Ti(Al,O) base matrix and the oxide layer, so that at a temperature of above about 600° C., the composite is substantially resistant to oxidation and spallation.

Abstract: A method of producing parts from powdered metal comprising the steps of providing a metallurgic powder comprising iron, 0-1.5 weight percent silicon, 0.4-0.9 weight percent carbon, 0.5-4.5 weight percent nickel, 0.5-1.0 weight percent molybdenum, 0-0.5 weight percent manganese, and 0-1.5 weight percent copper, the weight percentages calculated based on the total weight of the powder. Next, the metallurgic powder is compressed at a pressure of 25 to 65 tsi to provide a green compact with a density if 6.4 g/cc to 7.4 g/cc. The compact is high temperature sintered at a temperature of 2100° F. to 2400° F. Then, the compact is selectively densified to greater than 7.6 g/cc. The compact is sinter hardened to obtain a mainly Martensite microstructure. The compact can be directly high temperature sinter hardened if selective densification is not necessary. Material made by this method is also disclosed.

Abstract: An R—Fe—B permanent magnet wherein R is Nd or a combination of Nd with a rare earth element is prepared by casting an R—Fe—B alloy, crushing the alloy in an oxygen-free atmosphere of argon, nitrogen or vacuum, effecting comminution, compaction, sintering, aging, and cutting and/or polishing the magnet to give a finished surface. The magnet is then heat treated in an argon, nitrogen or low-pressure vacuum atmosphere having a limited oxygen partial pressure, obtaining a highly oil resistant sintered permanent magnet having corrosion resistance and hydrogen barrier property even in a high pressure hot environment of refrigerant and/or lubricant as encountered in compressors.

Abstract: There are provided an intermetallic-compound superconductor that is high in superconducting transition temperature, and an alloy superconductor that is high in superconducting transition temperature and excels in malleability and ductility, as well as a method of making such a superconductor with good reproducibility and at a low cost of manufacture. This entirely new intermetallic compound superconductor is made of magnesium (Mg) and beryllium (Be) and has a chemical composition expressed by formula: Mg1Be2, has a hexagonal AlB2 type crystallographic structure and has a superconducting transition temperature (Tc) of 35 K. An alloy containing this intermetallic compound excels in malleability and ductility and constitutes the alloy superconductor having a superconducting transition temperature (Tc) of 35 K and being low in specific resistance for normal conduction at a temperature ranging from the superconducting transition temperature to a room temperature.

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.

Abstract: A sintered, magnetically soft composite is proposed, especially for use in solenoid valves, and a process for producing such a composite, in which initially a starting mixture from which the magnetically soft composite is formed after sintering is produced, having a ferromagnetic, especially powdery first starting component (11) as main constituent, and a ferritic second starting component (12) as secondary constituent, as well as possibly a pressing aid. After the starting mixture is sintered, the second starting component (12) is present in the produced composite at least largely as grain boundary phase. The proposed manufacturing process includes the process steps: provision of the starting mixture; mixing of the starting mixture; compression of the starting mixture in a cavity mold under increased pressure; removal of the binder from the compressed starting mixture; and sintering of the compressed starting mixture to form the composite.

Abstract: A sintered alloy composition for automotive engine valve seats, and a method for producing the same, are described. An iron base sintered alloy composition comprising vanadium carbide particles, Fe—Co—Ni—Mo alloy particles, and Cr—W—Co—C alloy particles in which the composition is dispersed in a structure of sorbite is particularly suitable for use as materials of valve seats for automotive engines which requires excellent wear resistance, high-performance, high-rotation-speed, and low-fuel-consumption.

Abstract: A composite strip of compacted powders, which has a three layers structure, is continuously obtained by means of a rolling machine for powder compacting. The composite strip is sintered at a temperature of 460° C. to 550° C. to form a sintered composite strip. The sintered composite strip is continuously bonded by rolling to a steel strip. The bonded composite strip is optionally subjected to a heat treatment of heating at a temperature of 250° C. to 400° C. followed by heating to a temperature of 400° C. to 510° C., holding the strip under the temperature for not less than 30 seconds, and rapidly cooling down to 300° C. at a cooling rate of not lower than 50° C./minute, whereby obtaining a multi-layered composite material consisting of the steel strip, a sintered bonding layer, a sintered sliding layer and a sintered sacrificial layer.

Abstract: A sintered iron-based powder metal body with lower re-compacting load and having a high density and a method of manufacturing an iron-based sintered component with fewer pores of a sharp shape and having high strength and high density.

Abstract: A copper-based sliding material produced by sintering, comprising at least two phases of copper and/or copper alloys which phases have hardness levels different form each other, and hard particles with an average particle size of 0.1 to 10 &mgr;m which are dispersed in at least one phase with the exception of a softest phase in an amount of 0.1 to 10 vol. % of the whole copper-based sliding material, said sliding material satisfying (H2/H1)≧1.2 in which H1 is the Vickers hardness of the softest phase and in which H2 is the Vickers hardness of a phase hardest in hardness including said hard particles.

Abstract: A method for forming a copper-infiltrated iron powder metal article comprises compacting and sintering a predominately iron powder to form an iron-base matrix that contains between about 1 and 7 weight percent nickel and about 0.1 and 1.2 weight percent phosphorus. A copper metal is infiltrated into pores within the iron-base matrix. The product article comprises between about 2.0 and 23 weight percent copper infiltrant. Preferably, infiltration is carried out concurrently with sintering of the iron powder compact. The resulting product exhibits a particularly useful combination of mechanical properties, including high tensile strength and elongation.

Abstract: A sintered sprocket is provided in which surface pressure resistance can be improved without using a forging processing. An Fe-based sintered alloy which contains C at 0.2 to 0.5% by weight, Mo at 0.2 to 1.0% by weight, and Ni at 0.2 to 1.0% by weight, and which exhibits a metallic structure in which an internal base layer comprises ferrite and bainite and in which the ferrite adjoins voids, is subjected to a rolling and is then subjected to carburizing and hardening.

Abstract: A powder metallurgical process of preparing a sheet from a powder having an intermetallic alloy composition such as an iron, nickel or titanium aluminide. The sheet can be manufactured into electrical resistance heating elements having improved room temperature ductility, electrical resistivity, cyclic fatigue resistance, high temperature oxidation resistance, low and high temperature strength, and/or resistance to high temperature sagging. The iron aluminide has an entirely ferritic microstructure which is free of austenite and can include, in weight %, 4 to 32% Al, and optional additions such as ≦1% Cr, ≧0.05% Zr ≦2% Ti, ≦2% Mo, ≦1% Ni, ≦0.75% C, ≦0.1% B, ≦1% submicron oxide particles and/or electrically insulating or electrically conductive covalent ceramic particles, ≦1% rare earth metal, and/or ≦3% Cu.

Abstract: A heat treatment assembly and heat treatment methods are disclosed for producing different microstructures in the bore and rim portions of nickel-based superalloy disks, particularly suited for gas turbine applications. The heat treatment assembly is capable of being removed from the furnace and disassembled to allow rapid fan or oil quenching of the disk. For solutioning heat treatments of the disk, temperatures higher than that of this solvus temperature of the disk are used to produce coarse grains in the rim of each disk so as to give maximum creep and dwell crack resistance at the rim service temperature. At the same time, solution temperature lower than the solvus temperature of the disk are provided to produce fine grain in the bore of the disk so as to give maximum strength and low cycle fatigue resistance.

Abstract: A method for manufacturing a sliding part for a hermetic compressor is disclosed. Since the abrasion resistance and corrosion resistance of the sliding part is increased, the energy consumption efficiency is improved and the performance of the compressor can be enhanced. In addition, since the manufacturing process is shortened, the production cost can be reduced and the manufacturing time can be reduced. Moreover, since the thickness change of the sliding part is minimized, the defective rate of the part size can be reduced and its quality can be improved.

Abstract: A high-speed steel article, particularly a cutting tool, produced by powder metallurgy and its production, the steel having a high degree of purity corresponding to a K0 value of no higher than 3 according to DIN 50 602 and being of a particular composition which comprises the elements C, Si, Mn, Cr, W, Mo, V, Co, S and N. Also provided is a process for the high-speed machining of metal parts without lubricants.

Abstract: A high density iron based forged part such as a mechanical part is produced by a method comprising the following steps in the sequence set forth: (a) preparing iron based powder mixture containing iron based metal powder and graphite powder; (b) preliminarily compacting the iron based powder mixture to form a preliminary compact; (c) sintering the preliminary compact in a non-oxidizing atmosphere whose nitrogen partial pressure is 30 kPa or less, at a temperature of 950° C. or more and of 1300° C. or less to form a forming material; and (d) forging the forming material by closed die forging or enclosed die forging to produce a high density forged part.

Abstract: Bodies for heating, for example electric sealing jaws, are produced according to the present invention by a method which includes compaction and densification or consolidation of pulverulent, metallic material in a mould. The mould (6) is first supplied with the pulverulent material (10) which is compacted, as well as treated with an impregnating solution (12). Thereafter, the body (2) is heated to dry the solution and to sinter the pulverulent material. The method gives a dense body possessing superior thermal conductivity.

Abstract: A method of producing a gear from a metallurgical powder includes molding at least a portion of the powder to provide a gear preform. The gear preform is sintered and hot formed, and subsequently may be carburized. The gear preform is resintered and cooled at a cooling rate suitable to provide a bainitic microstructure in at least a surface region of the preform. The gear teeth of the preform may be shaved to, for example, adjust dimensions, and enhance dimensional uniformity.

Abstract: The invention relates to a process for the powder metallurgical production of material having improved isotropy of its mechanical properties with a rectangular or flat elliptical cross section, so-called broad-flat material, in particular raw material for producing cutting or piercing tools, in which process a powder of an alloy produced with gas, in particular pulverized with nitrogen, is placed into a capsule, compressed, and the capsule is closed, optionally after an evacuation, whereupon a heating and isostatic pressing (HIPing) of the powder capsules occur and the hot isostatically pressed slug produced in this manner is subjected to a forming by forging.

Abstract: A method for easily sintering a magnetic core while preventing damage to the magnetic core caused by deformation or other problems, includes preparing a flattened tubular compact by forming the compact to have a flattened tubular shape and a through hole. A supporting plate made from a baked porcelain material or a metal material having a dimension that allows for insertion into the through hole of the flattened tubular compact, as well as a length that is sufficiently longer than that of the flattened tubular compact, is inserted through the through hole. The flattened tubular compact is placed inside of a sintering container having highly pure alumina powder spread therein so that the axial direction of the compact is horizontal. The flattened tubular compact is then sintered in a sintering furnace to produce the magnetic core.

Abstract: A sintered rare earth magnet consisting essentially of 20-30% by weight of R (wherein R is Sm or a mixture of Sm and another rare earth element), 10-45% by weight of Fe, 1-10% by weight of Cu, 0.5-5% by weight of Zr, and the balance of Co has on its surface a composite layer containing Sm2O3 and/or CoFe2O4 in Co or Co and Fe. The magnet is resistant to hydrogen embrittlement.

Abstract: Lightweight metal matrix composites containing a skeleton structure of titanium, titanium aluminide, or Ti-based alloy are manufactured by low temperature infiltration with molten Mg-based alloy or Mg—Al alloy at 450-750° C., with molten In, Pb, or Sn at 300-450° C., or with molten Ag and Cu at 900-1100° C. The skeleton structure with a density of 25-35% is produced by loose sintering of Ti or Ti-based alloy powders. A primary deformation of the Ti skeleton structure before the infiltration is carried out by cold or hot rolling or forging to obtain a porous flat or shaped preform with a porosity <50% and pores drawn out in one direction such as the direction of future rolling of the composite plate.

Abstract: The invention provides a process for forging a titanium-based material comprises the steps of: preparing a titanium-based sintered workpiece including at least one of ceramics particles and pores in a total amount of 1% or more by volume, the ceramics particles being thermodynamically stable in a titanium alloy; and heating the workpiece to a forging temperature and forging the same. In the production process, the pores or the ceramics particles inhibit the grain growth during forging. Accordingly, it is possible to carry out the forging at a relatively high temperature at which the titanium-based material exhibits a small resistance to deformation. Moreover, the titanium-based material can maintain an appropriate microstructure even after the forging. Consequently, the impact value and the fatigue strength are inhibited from decreasing.

Abstract: These forged articles are useful as connecting rods. The bushing is assembled during the forging operation of the powder metal connecting rod. This reduces the number of manufacturing operations required to process a powder metal article. The main components of this article are a sintered powder metal perform and preferably a bronze bushing. The bronze bushing is inserted in the bore of the sintered perform of a connecting rod and thereafter forged in during forging then heated to provide bonding between the bushing and connecting rod.

Abstract: Blank for a gun barrel, consisting of a steel bar, which bar, in one or more hot working steps, has been repeatedly wrung about its own longitudinal axis.

Abstract: The invention relates to a method for producing a sintered material offering improved corrosion protection by activation and coating of the surface with a metal, followed by a heat treatment. Said method is characterized in that during activation and before coating with said metal the following steps are carried out: removal of particles adhering to the surface of the sintered material by treating said surface with a stripper; passivation of the surface; and drying of the sintered material. The invention also relates to a magnetic body with greater corrosion resistance.

Abstract: The present invention allows the obtaining of a condenser having high electrostatic capacitance by optimizing the anodic oxidation treatment voltage and particle size of the metal powder for the condenser during production of an electrolytic condenser anode body, and forming an anodic oxide film of a thickness that is suitable for the particle size of the metal powder. In the present invention, and electrolytic condenser anode body is produced by using the metal powder containing 50 wt % or more of particles, in which the primary particle diameter as determined by image analysis is within the range of 2.7×Vf to 10×Vf (units: nm), when the anodic oxidation treatment voltage during formation of an anodic oxide film on an anode sintered body composed of the metal powder is Vf (units: V).

Abstract: A nickel base powder metallurgy superalloy gas turbine engine disk for a compressor or turbine. The wrought powder metallurgy gas turbine engine disk has desirable fatigue crack growth resistance and a superior balance of tensile, creep rupture and low cycle fatigue strength characteristics. In one embodiment the disk defines a segregation free homogenous structure.

Abstract: The present invention relates to a method of controlling the microstructures of Cu—Cr-based contact materials for vacuum interrupters, in which a heat-resistant element is added to the Cu—Cr-based contact materials to obtain an excellent current interrupting characteristic and voltage withstanding capability, and contact materials manufactured thereby. The method of controlling the microstructures of Cu—Cr-based contact materials includes the steps of mixing a copper powder used as a matrix material, a chromium powder improving an electrical characteristic of the contact material and a heat-resistant element powder making the chromium particles in the matrix material fine to thereby obtain mixed powder, and subjecting the mixed powder to one treatment selected from sintering, infiltration and hot pressing to thereby obtain a sintered product.

Abstract: The invention relates to a steel with a high wear resistance, high hardness and good notched bar impact strength, useful for the manufacture of products, in the use of which at least some of the features are desirable, preferably for the manufacture of tools intended to be used at temperatures up to at least 500 ° C. The steel is produced powder-metallurgically and consists in percent by weight essentially of 0.55-0.65 C, 0.7-1.5 Si, 0.1-1.0 Mn, 3.5-4.5 Cr, 1.5-2.5 Mo, 1.5-2.5 W, 1.2-1.8 V, 0-0.2 Nb, balance iron and impurities in normal amounts. After hardening and tempering the steel contains 1.5-2.5 percent by volume of MC carbides, in which M consists essentially only of vanadium, the carbides being evenly distributed in the steel matrix. The invention also relates to use of the steel, manufacture and products manufactured from the steel.

Abstract: A method is provided for manufacturing a form tool used for forming threaded fasteners. The method utilizes powdered metal technology and processes to produce densified parts having at least the near net shape of the desired threaded fastener form tool.

Abstract: A method for the hardening treatment of a sintered alloy includes compressing an iron-based sinterable material to form a compact, providing a surface of the compact with a coating material containing aluminum or an aluminum alloy that melts at a temperature lower than the sintering temperature of the compact, and sintering the compact provided with the coating material, so as to form an intermediate compound of iron and aluminum in a surface layer of the compact.

Abstract: Aluminum alloy containing a fraction of uniformly distributed particles, preferably silicon particles, of less than 20% by weight, so as to increase the wear resistance, prior to processing or machining under hot conditions, and process for producing wear-resistant objects from such an aluminum alloy.

Abstract: Highly dense shaped parts are produced with a powder metallurgic process. The parts are formed of an alloy that, besides of at least 20 weight % chromium, consists of iron and one or several additional alloy portions that in sum do not amount to more than 10 weight %. The part is produced by pressing and sintering to near final shape a ready-to-press powder where the additional alloy portions are introduced in form of a master-alloy powder. The master-alloy may contain the following variations: the additional alloy portions and the iron portions; or the additional alloy portions, the iron parts, and the chromium portions; or additional alloy portions and the chromium portions.

Abstract: The present invention is aimed at providing a platinum material in which creep strength is elevated by improving a metal grain shape in an oxide-dispersion strengthened platinum material in which zirconium oxide is dispersed, and providing a process for producing the platinum material. The present invention provides an oxide-dispersion strengthened platinum material in which zirconium oxide is dispersed in platinum and which can be obtained through rolling and thermal recrystallization, in which platinum grains constituting the platinum material have an average grain size in a rolling direction in the range of 200 to 1500 &mgr;m and an average grain aspect ratio of 20 or more.

Abstract: A method for coating a surface of a substrate, includes providing a substrate having a surface, and coating the surface with a foam suspension containing a powder suspended in a foam to form a coating on the surface. The substrate is then heat treated to densify the coating along the surface.

Abstract: The present invention provides a process for the hardening treatment of sintered members which can impart sufficient wear resistance thereto at low cost without causing a reduction in dimensional accuracy due to heat distortion. This process for the hardening treatment of sintered members comprises the steps of coating an iron-based sinterable member with a Ni—P alloy powder containing 7 to 13% by weight of phosphorus so as to give a coating weight of 0.1 to 1.2 mg/mm2; sintering the iron-based sinterable member coated with the Ni—P alloy powder at a temperature in the range of 1,000 to 1,300° C.; and hardening the iron-based sintered member by cooling it at a cooling rate of not less than 10° C./min. until a temperature of 200° C. is reached.

Abstract: A sintered metal sprocket for a silent chain is produced by the following steps. A base mixture is prepared, which contains a powder metallurgical iron powder, a lubricant and a graphite powder. Then, the base mixture is subjected to a compression molding while being heated at above approximately 100° C. thereby to produce a green compact. Then, the green compact is subjected to a sintering at a temperature above approximately 1180° C. For much improving the mechanical performance of the sprocket thus sintered, the same may be subjected to a carbonizing hardening or an induction hardening.

Abstract: A method of producing a powder metal material includes providing a metallurgical powder including at least one low alloy steel powder and 0.3 up to 1.0 weight percent carbon. At least portions of the powder are molded to provide compacts, and the compacts are then sintered at 1800° F. to 2400° F. The sintered compacts are hot formed and are subsequently heated to 1000° F. to 2300° F. and held at temperature for a predetermined time period. Material produced by the method may have tensile strength greater than 100 ksi, yield strength greater than 80 ksi, Rockwell C hardness of at least 20, and elongation greater than 2%, properties that are similar to ductile cast iron. Accordingly, parts produced by the method may be used in applications in which ductile cast iron parts are conventional. Such applications include, for example, parts for automotive engines and transmissions.

Abstract: The method for manufacturing an R—Fe—B rare earth magnet of the present invention includes the steps of: compacting rare earth alloy powder having an oxygen content of 4000 wt. ppm or less by dry compacting under compression to produce a compact; impregnating the compact with an oil agent from the surface of the compact; and sintering the compact.

Abstract: A case according to the present invention is used in a sintering process to produce a rare-earth magnet. The case includes: a body with an opening; a door for opening or closing the opening of the body; and supporting rods for horizontally sliding a sintering plate, on which green compacts of rare-earth magnetic alloy powder are placed. The supporting rods are secured inside the body. At least the body and the door are made of molybdenum.

Abstract: A coated body that has a substrate of tungsten, carbon, and cobalt, and wherein the substrate presents a surface. Eta phase is present at the surface of the substrate. Fibrous tungsten carbide grains are present at the surface of the substrate. The surface of the substrate has a surface roughness, Ra, of greater than about 12 microinches. A coating layer is on the surface of the substrate.

Abstract: The present invention relates to a coated cemented carbide insert with a binder phase enriched surface zone. The WC-grains have an average grain size in the range 1.0-3.5 &mgr;m, preferably 1.3-3.0 &mgr;m and the number of WC-grains larger than 2 times the average grain size is less than 10 grains/cm2 measured on a representative polished section 0.5 cm2 large, preferably less than 5 grains/cm2, and the number larger than 3 times the average grain size is less than 5 grains/cm2, preferably less than 3 grains/cm2. The cemented carbide is made by powder metallurgical methods and is in particular characterized in that the cooling rate, CR, from the sintering temperature, ST, exhibits the relationship 10<CR·(ST-1300)/1000<17.

Abstract: This invention aims to provide a process for producing an oxide-dispersion strengthened platinum material which allows zirconium oxide to be more finely dispersed in a platinum material, and to further improve creep strength in an oxide-dispersion strengthened platinum material.

Abstract: A pellet for use in electrolytic capacitors is comprised of a powder selected from one of Tantalum and Niobium. The pellet is porous, free from oxygen, annealed by heat, and diffused with nitrogen with all these attributes being achieved in an oxygen free environment. The method of producing the pellet involves the steps of taking a powder selected from one of Tantalum and Niobium pressing the powder into a self-contained pellet; removing any oxygen in the pellet; annealing the pellet; and subjecting the pellet to nitrogen gas so that the nitrogen diffuses into the pellet to reduce DLC, with all these steps taking place in an oxygen free environment.

Abstract: A method of preparing a biaxially textured alloy article comprises the steps of preparing a mixture comprising Ni powder and at least one powder selected from the group consisting of Cr, W, V, Mo, Cu, Al, Ce, YSZ, Y, Rare Earths, (RE), MgO, CeO2, and Y2O3; compacting the mixture, followed by heat treating and rapidly recrystallizing to produce a biaxial texture on the article. In some embodiments the alloy article further comprises electromagnetic or electro-optical devices and possesses superconducting properties.

Abstract: A method of making a metal foam object includes the steps of mixing a gasifier with metal powder and subjecting the mixture to an elevated temperature T1 and pressure P1 to form a sintered sheet; placing at least a portion of the sintered sheet into a mold and subjecting the mold to a temperature T2 where T2 is greater than T1 at which the metal melts and the gas is released from the gasifier; quenching the metal foam object thus formed in the mold; and passing a hot inert gas through the metal foam object.