Powder Pretreatment (prior To Consolidation Or Sintering) Patents (Class 419/30)
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Patent number: 7655182Abstract: A metallic article made of metallic constituent elements is fabricated from a mixture of nonmetallic precursor compounds of the metallic constituent elements. The mixture of nonmetallic precursor compounds is chemically reduced to produce an initial metallic material, without melting the initial metallic material. The initial metallic material is consolidated to produce a consolidated metallic article, without melting the initial metallic material and without melting the consolidated metallic article.Type: GrantFiled: August 6, 2007Date of Patent: February 2, 2010Assignee: General Electric CompanyInventors: Andrew Philip Woodfield, Eric Allen Ott, Clifford Earl Shamblen
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Publication number: 20100021335Abstract: A method of making a rare-earth alloy granulated powder according to the present invention includes the steps of: preparing a rare-earth alloy powder; generating remnant magnetization in the powder; and granulating the powder by utilizing agglomeration force produced by the remnant magnetization of the powder. Since the agglomeration force produced by the remnant magnetization is utilized, the addition of a granulating agent may be omitted.Type: ApplicationFiled: October 5, 2009Publication date: January 28, 2010Applicant: HITACHI METALS, LTD.Inventors: Futoshi KUNIYOSHI, Tomoiku OTANI
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Patent number: 7648552Abstract: A low-cost filled skutterudite for advanced thermoelectric applications is disclosed. The filled skutterudite uses the relatively low-cost mischmetal, either alone or in addition to rare earth elements, as a starting material for guest or filler atoms.Type: GrantFiled: November 1, 2004Date of Patent: January 19, 2010Assignee: GM Global Technology Operations, Inc.Inventors: Jihui Yang, Gregory P. Meisner
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Publication number: 20090285712Abstract: The present invention relates to a metal powder mixture that is suitable for producing sintered bodies. The powder mixture is suitable as a binder for hard metals and contains: a) at least one prealloyed powder selected from the group of iron/nickel, iron/cobalt, iron/nickel/cobalt and nickel/cobalt; b) at least one element powder selected from the group of iron, nickel and cobalt or a prealloyed powder selected from the group consisting of iron/nickel, iron/cobalt, iron/nickel/cobalt and nickel/cobalt which is different from component a). The invention also relates to a cemented hard material which uses the inventive powder mixture and a hard material powder, wherein the overall composition of the components a) and b) together contains not more than 90% by weight of cobalt and not more than 70% by weight of nickel and the iron content.Type: ApplicationFiled: September 21, 2007Publication date: November 19, 2009Applicant: H.C. Starck GmbHInventors: Benno Gries, Leo Prakash
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Patent number: 7601296Abstract: A method of forming a sputtering target and other metal articles having controlled oxygen and nitrogen content levels and the articles so formed are described. The method includes surface-nitriding a deoxidized metal powder and further includes consolidating the powder by a powder metallurgy technique. Preferred metal powders include, but are not limited to, valve metals, including tantalum, niobium, and alloys thereof.Type: GrantFiled: May 10, 2006Date of Patent: October 13, 2009Assignee: Cabot CorporationInventors: Christopher A. Michaluk, Shi Yuan, James Maguire
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Patent number: 7597840Abstract: The formation of amorphous porous bodies and in particular to a method of manufacturing such bodies from amorphous particulate materials. The method allows for the control of the volume fraction as well as the spatial and size distribution of gas-formed pores by control of the size distribution of the powder particulates. The method allows for the production of precursors of unlimited size, and because the softened state of the amorphous metals used in the method possesses visco-plastic properties, higher plastic deformations can be attained during consolidation as well as during expansion.Type: GrantFiled: January 23, 2006Date of Patent: October 6, 2009Assignee: California Institute of TechnologyInventors: Marios Demetriou, William L. Johnson, Christopher Thomas Veazey, Jan Schroers
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Publication number: 20090212089Abstract: 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: ApplicationFiled: May 4, 2009Publication date: August 27, 2009Inventor: Denis Christopherson, JR.
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Publication number: 20090185942Abstract: A novel method to prepare an advanced thermoelectric material has hierarchical structures embedded with nanometer-sized voids which are key to enhancement of the thermoelectric performance. Solution-based thin film deposition technique enables preparation of stable film of thermoelectric material and void generator (voigen). A subsequent thermal process creates hierarchical nanovoid structure inside the thermoelectric material. Potential application areas of this advanced thermoelectric material with nanovoid structure are commercial applications (electronics cooling), medical and scientific applications (biological analysis device, medical imaging systems), telecommunications, and defense and military applications (night vision equipments).Type: ApplicationFiled: December 4, 2008Publication date: July 23, 2009Applicants: National Institute of Aerospace Associates, Space AdminstrationInventors: Sang Hyouk Choi, SR., Yeonjoon Park, Sang-Hyon Chu, James R. Elliott, Glen C. King, Jae-Woo Kim, Peter T. Lillehei, Diane M. Stoakley
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Publication number: 20090181179Abstract: A method for producing a composite metal powder according to one embodiment of the invention may comprise: Providing a supply of molybdenum metal powder; providing a supply of a sodium compound; combining the molybdenum metal powder and the sodium compound with a liquid to form a slurry; feeding the slurry into a stream of hot gas; and recovering the composite metal powder.Type: ApplicationFiled: January 11, 2008Publication date: July 16, 2009Applicant: CLIMAX ENGINEERED MATERIALS, LLCInventors: Naresh Goel, Carl Cox, Dave Honecker, Eric Smith, Chris Michaluk, Adam DeBoskey, Sunil Chandra Jha
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Metal Matrix Material Based On Shape-Memory Alloy Powders, Production Method Thereof and Use of Same
Publication number: 20090123329Abstract: The invention relates to a metal matrix material based on shape-memory alloy powders, to the production method thereof and to the use of same. More specifically, the invention relates to a metal matrix material which is characterised in that it is based on particles of shape-memory alloy powder, having a base of copper at a concentration of between 45 vol.-% and 70 vol.-% in relation to the total volume of the material, said powder particles being supported by a metal matrix. The invention also relates to a method of producing the aforementioned material and to the use of same for absorbing vibrations, particularly acoustic and mechanical vibrations.Type: ApplicationFiled: August 30, 2006Publication date: May 14, 2009Applicant: Universidad Del Pais Vasco Euskal Herriko UnibertsitateaInventors: Jose Maria San Juan Nunez, Maria Luisa No Sanchez -
Patent number: 7527752Abstract: A method for surface treatment of nickel nanoparticles using an organic solution, including dispersing nickel nanoparticles in a reductive organic solvent to obtain homogeneity; heating the dispersion of nickel nanoparticles; and separating the solution after treatment, washing and drying. Nickel nanoparticles treated by this method are preferably substantially free of impurities remaining on particle surfaces and thus have smooth surfaces and increased tap density, and the use thereof enables efficient production of a multi-layer ceramic capacitor.Type: GrantFiled: June 24, 2005Date of Patent: May 5, 2009Assignee: Samsung Electro-Mechanics Co., Ltd.Inventors: Seon Mi Yoon, Jae Young Choi, Yong Kyun Lee, Hyun Chul Lee
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Publication number: 20090107837Abstract: A method of recycling ruthenium (Ru) and Ru-based alloys comprises steps of: providing a solid body of Ru or a Ru-based alloy; segmenting the body to form a particulate material; removing contaminants, including Fe, from the particulate material; reducing the sizes of the particulate material to form a powder material; removing contaminants, including Fe, from the powder material; reducing oxygen content of the powder material to below a predetermined level to form a purified powder material; and removing particles greater than a predetermined size from the purified powder material. The purified powder material may be utilized for forming deposition sources, e.g., sputtering targets.Type: ApplicationFiled: October 29, 2007Publication date: April 30, 2009Applicant: HERAEUS INC.Inventors: Wuwen Yi, William Heckman, Bernd Kunkel, Carl Derrington, Patrick Griffin
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Patent number: 7473296Abstract: A wear-resistant iron-based sintered contact material is provided which is sintered by powder sintering so as to have high density, high seizure resistance and wear resistance. A wear-resistant iron-based sintered composite contact component composed of the wear-resistant iron-based sintered contact material sinter-bonded to a backing metal and its producing method are also provided. To this end, at least Cr7C3-type carbide and/or M6C-type carbide which have an average particle diameter of 5 ?m or more are precipitately dispersed in an amount of 20 to 50% by volume within an iron-based martensite parent phase which has a hardness of HRC 50 or more even when tempered at up to 600° C.Type: GrantFiled: September 2, 2005Date of Patent: January 6, 2009Assignee: Komatsu, Ltd.Inventors: Takemori Takayama, Kazuo Okamura, Yoshikiyo Tanaka, Tetsuo Ohnishi
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Publication number: 20080274002Abstract: A powder injection molding composition is disclosed. The composition comprises caprolactam and a plurality of particles, where that plurality of particles is selected from a metal powder, a metal hydride powder, a ceramic powder, a ferrite powder, and mixtures thereof. The composition optionally firther comprises a wax and polymeric material.Type: ApplicationFiled: July 7, 2008Publication date: November 6, 2008Inventor: JOHN LOMBARDI
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Patent number: 7431808Abstract: An electrically conductive titanium dioxide sputter target with an electrical resistivity of less than 5 ?-cm, which contains as an additive at least one doping agent or a mixture of doping agents in an amount of less than 5 mole %. The doping agent or agents are selected from the group including indium oxide, zinc oxide, bismuth oxide, aluminum oxide, gallium oxide, antimony oxide, and zirconium oxide. This treatment renders the titanium dioxide sputter target suitable for use in a direct-current sputtering process without any negative effects on the properties of the coating.Type: GrantFiled: August 19, 2002Date of Patent: October 7, 2008Assignee: W.C. Heraeus GmbH & Co., KGInventors: Markus Schultheis, Christoph Simons, Martin Weigert
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Publication number: 20080226488Abstract: The present invention relates to high-purity niobium monoxide powder (NbO) produced by a process of combining a mixture of higher niobium oxides and niobium metal powder or granules; heating and reacting the compacted mixture under controlled atmosphere to achieve temperature greater than about 1945° C., at which temperature the NbO is liquid; solidifying the liquid NbO to form a body of material; and fragmenting the body to form NbO particles suitable for application as capacitor anodes. The NbO product is unusually pure in composition and crystallography, and can be used for capacitors and for other electronic applications. The method of production of the NbO is robust, does not require high-purity feedstock, and can reclaim value from waste streams associated with the processing of NbO electronic components. The method of production also can be used to make high-purity NbO2 and mixtures of niobium metal/niobium monoxide and niobium monoxide/niobium dioxide.Type: ApplicationFiled: May 24, 2007Publication date: September 18, 2008Inventors: Charles A. Motchenbacher, James W. Robison, Brian J. Higgins, Thomas J. Fonville
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Publication number: 20080213122Abstract: Molybdenum metal powder has surface-area-to-mass-ratios in a range of between about 1.0 meters2/gram (m2/g) and about 3.0 m2/g, as determined by BET analysis, in combination with a particle size wherein at least 30% of the particles are larger than a size +100 standard Tyler mesh sieve. A method for producing molybdenum metal powder includes providing a supply of ammonium molybdate and a reducing gas; causing an exothermic reaction between the ammonium molybdate and the reducing gas at a first temperature to produce an intermediate reaction product and a supplemental reducing gas; causing an endothermic reaction between the intermediate reaction product and the reducing gas at a final temperature to produce the molybdenum metal powder.Type: ApplicationFiled: August 14, 2007Publication date: September 4, 2008Applicant: CLIMAX ENGINEERED MATERIALS, LLCInventors: Loyal M. Johnson, Sunil Chandra Jha, Carl Cox, Patrick Ansel Thompson
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Publication number: 20080213119Abstract: When producing tooth replacements from metal, the conventional method of casting is almost exclusively employed, even though said method is a relatively complicated one. The object of the invention is therefore to make available a method that is considerably simpler. In this method, an aqueous suspension, still containing microcrystalline wax and ethoxylated alcohols, is generated with the dental-grade metal powder. The metal powder is deposited on a model by electrophoresis, resulting, for example, in the formation of a cap (4). This cap (4) is filled with investment compound (5) and placed on a firing support (6), where it is sintered in this position. A cap is obtained which, in terms of its strength characteristics, is the equal of a cap that has been produced by casting. Alternatively, the cap (4) can be stabilized, during sintering, on a plated stump or in a muffle filled with a temperature-resistant powder.Type: ApplicationFiled: January 31, 2006Publication date: September 4, 2008Inventor: Stefan Wolz
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Patent number: 7416697Abstract: A method for preparing an article of a base metal alloyed with an alloying element includes the steps of preparing a compound mixture by the steps of providing a chemically reducible nonmetallic base-metal precursor compound of a base metal, providing a chemically reducible nonmetallic alloying-element precursor compound of an alloying element, and thereafter mixing the base-metal precursor compound and the alloying-element precursor compound to form a compound mixture. The compound mixture is thereafter reduced to a metallic alloy, without melting the metallic alloy. The step of preparing or the step of chemically reducing includes the step of adding an other additive constituent. The metallic alloy is thereafter consolidated to produce a consolidated metallic article, without melting the metallic alloy and without melting the consolidated metallic article.Type: GrantFiled: May 17, 2004Date of Patent: August 26, 2008Assignee: General Electric CompanyInventors: Andrew Philip Woodfield, Eric Allen Ott, Clifford Earl Shamblen, Michael Francis Xavier Gigliotti
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Publication number: 20080181805Abstract: A nanocomposite comprising a plurality of nanoparticles dispersed in a molybdenum-based matrix, and an x-ray tube component formed from such a nanocomposite. The nanocomposite contains volume fraction of nanoparticle dispersoids in a range from about 2 volume percent to about 20 volume percent. A method of making such molybdenum-based nanocomposites is also disclosed.Type: ApplicationFiled: June 28, 2007Publication date: July 31, 2008Applicant: GENERAL ELECTRIC COMPANYInventors: Pazhayannur Ramanathan Subramanian, Judson Sloan Marte, Paul Leonard Dupree
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Publication number: 20080166255Abstract: A method of making Re and Re-based materials comprises steps of: providing a Re powder starting material or a Re powder starting material and at least one additional powder material; subjecting at least the Re powder to a first degassing treatment for reducing the oxygen content thereof; increasing the density of the degassed Re powder or a mixture of the degassed Re powder and the at least one additional powder material to form a green billet; subjecting the billet to a second degassing treatment to further reduce the oxygen content; and consolidating the billet to form a consolidated material with greater than about 95% of theoretical density and low oxygen content below about 200 ppm for Re and below about 500 ppm for Re-based materials formed from the mixture, excluding oxygen from non-metallic compounds and ceramics. Materials so produced are useful in the manufacture of deposition sources such as sputtering targets.Type: ApplicationFiled: January 3, 2008Publication date: July 10, 2008Applicant: HERAEUS INC.Inventors: Fenglin YANG, Carl Derrington, Bernd Kunkel
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Publication number: 20080159905Abstract: A controlled combustion synthesis apparatus comprises an ignition system, a pressure sensor for detecting internal pressure, a nitrogen supply, a gas pressure control valve for feeding nitrogen and exhausting reaction gas, means for detecting the internal temperature of the reaction container, a water cooled jacket, and a cooling plate. A temperature control system controls the temperature of the reaction container by controlling the flow of cooling water supplied to the jacket and the cooling plate in response to the detected temperature. By combustion synthesizing, while controlling the internal pressure and temperature, the apparatus can synthesize a silicon alloy including 30-70 wt. % silicon, 10-45 wt. % nitrogen, 1-40 wt. % aluminum, and 1-40 wt % oxygen.Type: ApplicationFiled: April 19, 2007Publication date: July 3, 2008Applicant: ISMAN J CorporationInventors: Toshiyuki Watanabe, Masafumi Matsushita, Toshitaka Sakurai, Kazuya Sato, Yoko Matsushita
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Patent number: 7390345Abstract: The invention concerns a powder metallurgical composition comprising a major amount of an iron-based metal powder and a minor amount of carbon black. The amount of carbon black is between 0.001 and 0.2% by weight, preferably between 0.01 to 0.1% by weight.Type: GrantFiled: July 1, 2005Date of Patent: June 24, 2008Assignee: Höganäs ABInventor: Naghi Solimnjad
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Publication number: 20080138235Abstract: A (CoFe)ZrNb/Ta/Hf based target material is provided which is capable of achieving a high sputtering efficiency and a high sputtering effect by increasing the leakage magnetic flux in the magnetron sputtering, and a method for producing the target material. This target material is made of an Fe—Co based alloy comprising not less than 80 atomic % in total of Fe and Co having an Fe:Co atomic ratio of 80:20 to 0:100, and less than 20 atomic % of one or more selected from the group consisting of Zr, Hf, Nb and Ta. The Fe—Co based alloy comprises a Co—Fe phase being a ferromagnetic phase, and the one or more selected from the group consisting of Zr, Hf, Nb and Ta are solid-solved into the Co—Fe phase in a total amount of 0.5 to 2 atomic %.Type: ApplicationFiled: November 16, 2007Publication date: June 12, 2008Applicant: SANYO SPECIAL STEEL CO., LTD.Inventors: Toshiyuki Sawada, Akihiko Yanagitani, Ryoji Hayashi, Yoshikazu Aikawa
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Patent number: 7384596Abstract: A method for preparing a metallic article made of metallic constituent elements includes furnishing a mixture of nonmetallic precursor compounds of the metallic constituent elements. The method further includes chemically reducing the mixture of nonmetallic precursor compounds to produce an initial metallic material, without melting the initial metallic material, and consolidating the initial metallic material to produce a consolidated metallic article, without melting the initial metallic material and without melting the consolidated metallic article.Type: GrantFiled: July 22, 2004Date of Patent: June 10, 2008Assignee: General Electric CompanyInventors: Andrew Philip Woodfield, Clifford Earl Shamblen, Eric Allen Ott, Michael Francis Xavier Gigliotti
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Publication number: 20080083616Abstract: The present invention relates to a Co—Fe—Zr based alloy target material for forming a soft magnetic film of the Co—Fe—Zr based alloy used in a perpendicular magnetic recording medium, and provides a Co—Fe—Zr based alloy target material having a low magnetic permeability and good sputtering characteristics and a process for producing this target material. A Co—Fe—Zr based alloy sputtering target material represented by the compositional formula based on the atomic ratio: (Cox—Fe100-X)100-(Y+Z)—ZrY-MZ (20?X?70, 2?Y?15 and 2?Z?10) in which the element(s) M is one or more elements selected from the group consisting of Ti, V, Nb, Ta, Cr, Mo, W, Si, Al and Mg, wherein a phase composed of HCP-Co and an alloy phase composed mainly of Fe are finely dispersed in the microstructure of the target material.Type: ApplicationFiled: October 9, 2007Publication date: April 10, 2008Applicant: HITACHI METALS, LTD.Inventors: Jun Fukuoka, Hiroshi Takashima, Tomonori Ueno, Mitsuharu Fujimoto, Hide Ueno
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Patent number: 7329381Abstract: A metallic article made of metallic constituent elements is fabricated from a mixture of nonmetallic precursor compounds of the metallic constituent elements. The mixture of nonmetallic precursor compounds is chemically reduced to produce an initial metallic material, without melting the initial metallic material. The initial metallic material is consolidated to produce a consolidated metallic article, without melting the initial metallic material and without melting the consolidated metallic article.Type: GrantFiled: June 14, 2002Date of Patent: February 12, 2008Assignee: General Electric CompanyInventors: Andrew Philip Woodfield, Eric Allen Ott, Clifford Earl Shamblen
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Publication number: 20080019858Abstract: An atomised pre-alloyed iron-based powder which comprises by weight-% 10.5-30 Cr ??3-15 Al ??5-20 Cu max 0.1 C max 0.2 N max 3.0 Mn max 2.5 Si max 3.0 Mo balance essentially only iron and unavoidable impurities.Type: ApplicationFiled: June 25, 2007Publication date: January 24, 2008Inventors: Ove H. Mars, Ingrid Hauer
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Patent number: 7288224Abstract: A sputtering target contains a target material including as constituent elements Ag, In, Te and Sb with the respective atomic percents (atom. %) of ?, ?, ? and ? thereof being in the relationship of 0.5??<8, 5???23, 17???38, 32???73, ???, and ?+?+?+?=100, and a method of producing the above sputtering target is provided.Type: GrantFiled: September 25, 2003Date of Patent: October 30, 2007Assignee: Ricoh Company, Ltd.Inventors: Yukio Ide, Hiroko Iwasaki, Yoshiyuki Kageyama, Yujiro Kaneko, Katsuyuki Yamada, Michiaki Shinotsuka, Makoto Harigaya, Hiroshi Deguchi
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Patent number: 7258812Abstract: A compound magnetic material having high heat resistance is provided. A fabrication method of a compound magnetic material includes the step of preparing mixed powder including an organic resin and compound magnetic particles. The long-period heat resistance temperature of the organic resin is at least 200° C. The containing ratio of the organic resin to the compound magnetic particles exceeds 0 mass % and not more than 0.2 mass %. The compound magnetic particle includes a metal magnetic particles, and a coat layer containing metal oxide, directly bound to the surface of the metal magnetic particle. The fabrication method of a compound magnetic material includes the steps of forming a compact by introducing mixed powder into a die having a lubricant applied to its surface and conducting warm-compacting, and applying heat treatment to the compact.Type: GrantFiled: October 28, 2002Date of Patent: August 21, 2007Assignees: Sumitomo Electric Sintered Alloy, Ltd., DENSO CORPORATIONInventors: Yoshiyuki Shimada, Hitoshi Oyama, Takao Nishioka
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Patent number: 7244287Abstract: The present invention relates to a method of producing a magnetic particle including forming a layer containing an alloy particle that can form a CuAu-type or Cu3Au-type hard magnetic ordered alloy phase on a support, oxidizing the layer, and annealing the layer in a non-oxidizing atmosphere. The invention also relates to a method of producing a magnetic particle including producing an alloy particle that can form a hard magnetic ordered alloy phase, oxidizing the alloy particle, and annealing the particle in a non-oxidizing atmosphere, and a magnetic particle produced by the foregoing production method. Further, the invention relates to a magnetic recording medium comprising a magnetic layer containing a magnetic particle and a method of producing a magnetic recording medium including forming a layer containing an alloy that can form the foregoing hard magnetic ordered alloy phase, oxidizing the layer, and annealing the layer in a non-oxidizing atmosphere.Type: GrantFiled: July 22, 2004Date of Patent: July 17, 2007Assignee: Fujifilm CorporationInventors: Yasushi Hattori, Koukichi Waki, Keizo Ogawa
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System and method for fabricating a three-dimensional metal object using solid free-form fabrication
Patent number: 7220380Abstract: A method for solid free-form fabrication of a three-dimensional metal object includes depositing a particulate blend in a defined region, the particulate blend including a number of metal or metal alloy particulates and a peroxide, and selectively ink-jetting a binder system onto a predetermined area of the particulate blend to form a green part, wherein the liquid phase binder includes a water soluble monofunctional acrylate-based monomer, a water soluble difunctional acrylate-based monomer, an amine, and water.Type: GrantFiled: October 14, 2003Date of Patent: May 22, 2007Assignee: Hewlett-Packard Development Company, L.P.Inventors: Isaac Farr, Terry M. Lambright, Daniel A. Kearl -
Patent number: 7175802Abstract: Spent sputtering targets are refurbished by filling the depleted region of the target with new sputter material using a hot isostatic pressing or HIP'ing technique.Type: GrantFiled: September 16, 2002Date of Patent: February 13, 2007Assignee: Heraeus, Inc.Inventors: Michael Sandlin, Wenjun Zhang, Bernd Kunkel
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Patent number: 7141126Abstract: Rare earth alloy powder having an oxygen content of 50 to 4000 wt. ppm and a nitrogen content of 150 to 1500 wt. ppm is compacted by dry pressing to produce a compact. The compact is impregnated with an oil agent and then sintered. The sintering process includes a first step of retaining the compact at a temperature of 700° C. to less than 1000° C. for a period of time of 10 to 420 minutes and a second step of permitting proceeding of sintering at a temperature of 1000° C. to 1200° C. The average crystal grain size of the rare earth magnet after the sintering is controlled to be 3 ?m to 9 ?m.Type: GrantFiled: June 22, 2004Date of Patent: November 28, 2006Assignee: Neomax Co., Ltd.Inventors: Futoshi Kuniyoshi, Hitoshi Morimoto
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Patent number: 7138019Abstract: In the step of sintering a compact that is finally to be a magnetostrictive element, when the temperature in a furnace is elevated, the atmosphere in the furnace is evacuated by a vacuum pump to keep the pressure in the furnace at negative pressure in a temperature range that allows thermal decomposition of hydride present in the compact to release hydrogen gas to accelerate release of hydrogen from the compact.Type: GrantFiled: July 26, 2004Date of Patent: November 21, 2006Assignee: TDK CorporationInventors: Seigo Tokoro, Shiro Tomizawa, Teruo Mori
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Patent number: 7108830Abstract: A method of production of large Ingots of neutron attenuating composites using a vacuum-bellows system allows for large cross-sectional shapes to be extruded and rolled. This method uses a vacuum-bellows technology which allows the manufacturing of large 8–16 inch diameter ingots (50–450 lbs. each). A variety of primary metal matrix materials can be used in this technology. High specific strength and stiffness can be achieved because the technology allows for final densities of 99% and higher. The vacuum-bellows technology allows metals and ceramics to blend and mesh together at compression pressures of 800 tons with elevated temperatures. The controlled compression movement allows for any oxide layer, on the metal, to be broken up and consolidated with the chosen ceramic particulate. One application is to blend boron-rich ceramics and high purity (99.5–99.99%) aluminum particulates together and produce a large ingot using this vacuum-bellows technology.Type: GrantFiled: September 9, 2002Date of Patent: September 19, 2006Assignee: Talon CompositesInventor: Robin A. Carden
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Patent number: 7056393Abstract: A method of making a sintered body for a rare earth magnet includes the steps of (a) preparing a first coarse powder by coarsely pulverizing a rare earth alloy sintered body by a hydrogen pulverization process, (b) preparing a first fine powder by finely pulverizing the first coarse powder, (c) preparing a second fine powder by pulverizing an alloy block of a rare earth alloy material, and (d) sintering a mixed powder including the first and second fine powders. The first and second fine powders each includes a main phase represented by (LR1-xHRx)2T14A, where T is Fe and/or at least one non-Fe transition metal element; A is boron and/or carbon; LR is at least one light rare earth element; HR is at least one heavy rare earth element; and 0?x<1.Type: GrantFiled: May 28, 2002Date of Patent: June 6, 2006Assignee: Neomax, Co., Ltd.Inventors: Koki Tokuhara, Hitoshi Morimoto
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Patent number: 7037463Abstract: A metallic article is prepared by first furnishing at least one nonmetallic precursor compound, wherein all of the nonmetallic precursor compounds collectively containing the constituent elements of the metallic article in their respective constituent-element proportions. The constituent elements together form a titanium-base alloy having a stable-oxide-forming additive element therein, such as magnesium, calcium, scandium, yttrium, lanthanum, cerium, praseodymium, neodymium, promethium, samarium, europium, gadolinium, terbium, dysprosium, holmium, erbium, thulium, ytterbium, and lutetium, and mixtures thereof. The stable-oxide-forming additive element forms a stable oxide in a titanium-based alloy. At least one additive element is present at a level greater than its room-temperature solid solubility limit in the titanium-base alloy. The precursor compounds are chemically reduced to produce an alloy material, without melting the alloy material. The alloy material may be consolidated.Type: GrantFiled: December 23, 2002Date of Patent: May 2, 2006Assignee: General Electric CompanyInventors: Andrew Philip Woodfield, Clifford Earl Shamblen, Eric Allen Ott, Michael Francis Xavier Gigliotti
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Patent number: 6991686Abstract: To provide a method for producing a magnetostrictive material of excellent magnetostrictive characteristics. The method for producing a magnetostrictive material, wherein a mixture composed of Starting Materials A, B and C is sintered, where A is represented by Formula 1 (TbxDy1-x)Ty (T is at least one metallic element selected from the group consisting of Fe, Ni and Co, 0.35<x?0.50 and 1.70?y?2.00), B is represented by Formula 2 DytT1-t (0.37?t?1.00), and C contains T, to produce a magnetostrictive material represented by Formula 3 (TbvDy1-v)Tw (0.27?v<0.50, and 1.70?w?2.00), wherein oxygen content is set at 500 to 3,000 ppm for Starting Material A and at 2,000 to 7,000 ppm for Starting Material B.Type: GrantFiled: January 25, 2005Date of Patent: January 31, 2006Assignee: TDK CorporationInventors: Seigo Tokoro, Teruo Mori
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Patent number: 6878182Abstract: The present invention relates to economic and environment-friendly slurries and their preparation, handling, and spray drying for the production of cemented carbide based hard metals. The slurry is ethanol-water based and contains metallic and metal carbide raw materials as well as polyethylene glycol (PEG) and a very low concentration of polyethylenimine (PEI). The concentration of PEI is 0.01-<0.1% of the raw material weight. As a result, low-viscous slurries are produced which require less use of ethanol, energy, manpower and equipment time in their preparation, handling, and spray drying.Type: GrantFiled: December 17, 2002Date of Patent: April 12, 2005Assignee: Seco Tools ABInventor: Olof Kruse
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Patent number: 6852274Abstract: A hard metal granulate is produced by wet milling and spray drying in a spray tower using pure water as the liquid phase. The spray tower is configured and operated in such a way that a ratio of the quantity of water added via the slurry (in liters per hour) to tower volume (in m3) is between 0.5 and 1.8 and in that a maximum of 0.17 kg of slurry is atomized per m3 of incoming drying gas. The slurry has a solid particle concentration within a range of 65-85% by weight. Under these conditions, the addition of a water-soluble, long-chain polyglycol to the slurry prior to spraying previously required in order to prevent oxidation of the hard metal granulate is no longer necessary.Type: GrantFiled: November 22, 2002Date of Patent: February 8, 2005Assignee: Ceratizit Austria Gesellschaft m.b.H.Inventors: Gerhard Knünz, Helmut Beirer, Andreas Lackner, Wolfgang Glätzle, Erwin Hartlmayr
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Patent number: 6841121Abstract: 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.Type: GrantFiled: June 15, 2001Date of Patent: January 11, 2005Assignee: Tanaka Kikinzoku Kogyo K.K.Inventors: Toru Shoji, Soichi Hitomi, Yoshikazu Takagi, Yoshinobu Watanabe
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Publication number: 20040258552Abstract: A compound magnetic material having high heat resistance is provided. A fabrication method of a compound magnetic material includes the step of preparing mixed powder including an organic resin and compound magnetic particles. The long-period heat resistance temperature of the organic resin is at least 200° C. The containing ratio of the organic resin to the compound magnetic particles exceeds 0 mass % and not more than 0.2 mass %. The compound magnetic particle includes a metal magnetic particles, and a coat layer containing metal oxide, directly bound to the surface of the metal magnetic particle. The fabrication method of a compound magnetic material includes the steps of forming a compact by introducing mixed powder into a die having a lubricant applied to its surface and conducting warm-compacting, and applying heat treatment to the compact.Type: ApplicationFiled: March 17, 2004Publication date: December 23, 2004Inventors: Yoshiyuki Shimada, Hitoshi Oyama, Takao Nishioka
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Publication number: 20040247478Abstract: A method of manufacturing titanium or titanium alloy semi-finished or ready-to-use products is disclosed. The method includes forming shaped bodies of titanium oxide particles and positioning the shaped bodies in an electrolytic cell which includes: an anode, a cathode, and a molten electrolyte. The shaped bodies are positioned to form at least a part of the cathode. The electrolyte includes cations of a metal that is capable of chemically reducing titanium oxide. The method further includes reducing the titanium oxide to titanium in a solid state in the electrolytic cell so that the shaped bodies become shaped bodies of titanium sponge. Finally, the method includes processing the shaped bodies of titanium sponge to reduce the volume or at least one of the dimensions of the bodies thereby to form the semi-finished or ready-to-use products.Type: ApplicationFiled: July 30, 2004Publication date: December 9, 2004Inventors: Les Strezov, Ivan Ratchev, Steve Osborn, Kannappar Mukunthan
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Patent number: 6820323Abstract: A method of firing magnetic cores includes the steps of attaching a powder to the surface of a plurality of flattened-ring compact bodies made of a magnetic material, arranging the plurality of flattened-ring compact bodies adjacently so that the axes of flattened through-holes of the flattened-ring compact bodies are vertically oriented, and firing the flattened-ring compact bodies while the powder is interposed between the adjacent flattened-ring compact bodies. Alternatively, a method of firing magnetic cores includes the steps of attaching a powder to the surface of a plurality of thin compact bodies made of a magnetic material, vertically arranging the plurality of thin compact bodies adjacently, and firing the thin compact bodies while the powder is interposed between the adjacent thin compact bodies.Type: GrantFiled: March 10, 2000Date of Patent: November 23, 2004Assignee: Murata Manufacturing Co., Ltd.Inventors: Hiroyuki Kino, Nobuaki Ito, Yoshihiro Nishinaga
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Publication number: 20040180217Abstract: A sputtering target including indium oxide and tin oxide, the content by percentage of the tin atoms therein being from 3 to 20 atomic % of the total of the indium atoms and the tin atoms, and the maximum grain size of indium oxide crystal in the sputtering target being 5 &mgr;m or less. When a transparent conductive film is formed by sputtering, this sputtering target makes it possible to suppress the generation of nodules on the surface of the target and to conduct the sputtering stably.Type: ApplicationFiled: January 30, 2004Publication date: September 16, 2004Inventors: Kazuyoshi Inoue, Shigeo Matsuzaki
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Patent number: 6776954Abstract: A process for adjusting the level of water or water soluble additives in aqueous-based powder injection molding compounds for the purpose of recycling scrap material, controlling shrinkage or rehydrating dry feedstock. Depending on the objective, the process may require material granulation equipment, equipment for the addition or removal of water and mixing equipment. The molding compounds may be comprised of either recycled scrap material before being heat-treated or dry, virgin feedstock material.Type: GrantFiled: May 31, 2000Date of Patent: August 17, 2004Assignee: Honeywell International Inc.Inventors: James F. Stevenson, Gary Marsh, Jerry C. LaSalle, Mohammad Behi
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Publication number: 20040118247Abstract: A metallic article is prepared by first furnishing at least one nonmetallic precursor compound, wherein all of the nonmetallic precursor compounds collectively containing the constituent elements of the metallic article in their respective constituent-element proportions. The constituent elements together form a titanium-base alloy having a stable-oxide-forming additive element therein, such as magnesium, calcium, scandium, yttrium, lanthanum, cerium, praseodymium, neodymium, promethium, samarium, europium, gadolinium, terbium, dysprosium, holmium, erbium, thulium, ytterbium, and lutetium, and mixtures thereof. The stable-oxide-forming additive element forms a stable oxide in a titanium-based alloy. At least one additive element is present at a level greater than its room-temperature solid solubility limit in the titanium-base alloy. The precursor compounds are chemically reduced to produce an alloy material, without melting the alloy material. The alloy material may be consolidated.Type: ApplicationFiled: December 23, 2002Publication date: June 24, 2004Inventors: Andrew Philip Woodfield, Clifford Earl Shamblen, Eric Allen Ott, Michael Francis Xavier Gigliotti
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Publication number: 20040118246Abstract: A metallic alloy is prepared from a gaseous mixture of at least two non-oxide precursor compounds, wherein the non-oxide precursor compounds collectively comprise the metallic constituents. The mixture of the non-oxide precursor compounds is oxidized to form a solid mixed metallic oxide. The solid mixed metallic oxide is chemically reduced to produce the metallic alloy.Type: ApplicationFiled: December 23, 2002Publication date: June 24, 2004Inventors: Andrew Philip Woodfield, Eric Allen Ott, William Thomas Carter
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Publication number: 20040120841Abstract: A method of preparing an article made of a metallic material having its constituent elements includes the steps of furnishing at least one nonmetallic precursor compound, wherein all of the nonmetallic precursor compounds collectively include the constituent elements of the metallic material in their respective constituent-element proportions, and thereafter utilizing the nonmetallic precursor compound to produce a metallic injection molded brown article. The nonmetallic precursor compounds may be processed into the metallic material by first chemically reducing them to the metallic material, and then injection molding the metallic material, or first injection molding the nonmetallic precursor compounds and then chemically reducing them to the metallic material.Type: ApplicationFiled: December 23, 2002Publication date: June 24, 2004Inventors: Eric Allen Ott, Andrew Philip Woodfield, Clifford Earl Shamblen