Powder Pretreatment (prior To Consolidation Or Sintering) Patents (Class 419/30)
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Patent number: 5901337Abstract: A method and apparatus for loading tool steel and high speed steel powder to a deformable mold for compacting is disclosed. The particles are exposed to a uniform vacuum during transfer from a sealed container through a sealed conduit and into a sealed deformable mold. By this method and apparatus, the particles are uniform throughout the container and substantially free of impurities, without requiring conventional outgassing.Type: GrantFiled: July 29, 1998Date of Patent: May 4, 1999Assignee: Crucible Materials CorporationInventors: Terry C. Rhodes, Henry E. Brinzer, Jr., Frank J. Rizzo
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Patent number: 5897962Abstract: A method of making flowable tungsten/copper composite powder by milling an aqueous slurry of a mixture of the desired weight ratio of tungsten powder and copper oxide powder and, optionally, a small amount of cobalt powder, spray-drying the slurry to form spherical, flowable agglomerates, and reducing the agglomerates in a hydrogen atmosphere.Type: GrantFiled: July 13, 1995Date of Patent: April 27, 1999Assignee: Osram Sylvania Inc.Inventors: David L. Houck, Nelson Kopatz, Muktesh Paliwal, Sanjay Sampath
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Patent number: 5878322Abstract: Heatsinks for microcircuit packages are formed by first mold-pressing a composite powder of free-flowing spray-dried particles of copper and at least one other denser material such as tungsten and/or molybdenum breakably agglutinated in nodules grouping sub-nodules of surface alloyed pairs of particles of each metal, the proportions of which are adjusted to match the thermal expansion characteristics of the microcircuit material. The pressed compacts are then heated in a sintering furnace at 1090.degree. C. to 1150.degree. C. in order to effect an homogeneous distribution of the melting copper throughout the structure. The process results in a readily usable component having good thermal conductivity and matched thermal expansion that requires no further machining.Type: GrantFiled: October 10, 1997Date of Patent: March 2, 1999Inventor: Frank J. Polese
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Patent number: 5826159Abstract: The sinterability of a copper/tungsten green compact is improved by using copper oxide, tungsten oxide or both as the copper and/or tungsten source. Sinterability is further enhanced by including steam in the sintering atmosphere. Spontaneous combustion of the source powders used to form the sintering compacts can be reduced or eliminated by including corrosion inhibitor in the powders.Type: GrantFiled: April 29, 1997Date of Patent: October 20, 1998Assignee: Brush Wellman, Inc.Inventors: David E. Jech, Juan L. Sepulveda, Anthony B. Traversone
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Patent number: 5822674Abstract: A material for electric contacts based on silver-tin oxide is obtained by mixing a powder of silver or an alloy mainly containing silver with a powder consisting mainly of tin oxide and 0.01 to 10 wt. % (in relation to the quantity of tin oxide) of an additive consisting of one or more compounds containing silver, oxygen and a metal from sub-groups II to VI of the periodic system and/or antimony, bismuth, germanium, indium and gallium, compacting the mixture and sintering it. The tin oxide may be replaced by zinc oxide.Type: GrantFiled: May 18, 1995Date of Patent: October 13, 1998Assignee: Doduco GmbH + Co. Dr. Eugen DurrwachterInventors: Volker Behrens, Thomas Honig
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Patent number: 5774780Abstract: A process for the production of a shaped part which is produced from a high-melting point metal powder with crystalline sinter-activating additives. The process includes the steps of preparing, compressing and sintering the metal powder. Prior to the sintering step, the final contour of the shaped part is substantially shaped. The process is primarily directed for the production of shields for radiation protection, as melting crucibles or as electrodes.Type: GrantFiled: November 22, 1995Date of Patent: June 30, 1998Assignee: Bayerische Metallwerke GmbHInventor: Oliver Prause
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Patent number: 5742891Abstract: A wire for fabrication of a vibration resistant filament for an incandescent lamp. The wire includes about 0.05-1.00 weight percent lanthanum oxide dispersed in a tungsten matrix and has a microstructure including stringers of fine particles of lanthanum oxide extending parallel to the wire axis. During primary recrystallization of a vibration resistant lamp filament from the filament wire, the stringers produce a microstructure in the filament exhibiting sufficient grain boundary segments extending generally axially along the length of the filament to render the filament resistant to vibration. A method for producing a vibration resistant filament for an incandescent lamp is also disclosed.Type: GrantFiled: April 4, 1996Date of Patent: April 21, 1998Assignee: Osram Sylvania Inc.Inventors: Thomas J. Patrician, Harry D. Martin, III
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Patent number: 5710384Abstract: The invention provides a magneto-optical recording medium target and a manufacture method thereof which target can produce the leakage magnetic flux in sufficient density and has the high mechanical strength. The target is a sintered body containing 15 to 30 atomic % at least one rare earth metal and the balance at least one transition metal, in which alloy powder having such a composition is sintered so that the original morphology of the alloy powder essentially remains. Specifically, the target has a micro structure in which the alloy powder particles consisted of the rare earth metal and the transition metal are interconnected through grain boundary phases. The target is able to have the deflective strength not less than 50 MPa, the relative density not less than 99%, and the content of oxygen not more than 1000 ppm. Particulate micro structures preferably have a grain size d.ltoreq.250 .mu.m and a volume mean size d.sub.av of 50.ltoreq.d.sub.ad .ltoreq.120 .mu.m.Type: GrantFiled: March 8, 1996Date of Patent: January 20, 1998Assignee: Hitachi Metals, Ltd.Inventor: Kaoru Masuda
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Patent number: 5697043Abstract: The present invention is a novel method for freeform fabrication. Specifically, the method of solid freeform fabrication has the steps of:(a) preparing a slurry by mixing powder particles with a suspension medium and a gelling polysaccharide;(b) making a layer by depositing an amount of said powder slurry in a confined region;(c) hardening a selected portion of the layer by applying a gelling agent to the selected portion; and(d) repeating steps (b) and (c) to make successive layers and forming a layered object. In many applications, it is desirable to remove unhardened material followed by heating to remove gellable polysaccharide then sintering.Type: GrantFiled: May 23, 1996Date of Patent: December 9, 1997Assignee: Battelle Memorial InstituteInventors: Suresh Baskaran, Gordon L. Graff
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Patent number: 5604919Abstract: The preferred sintered parts made of oxygen-sensitive, non-reducible powders and their production by injection-molding are distinguished by the powders used being freed of their oxide layer by attritor milling in a water-free organic solvent, in the presence or absence of an additional reductant, the oxide particles being removed if necessary by filtration or screening in the presence of the organic solvent, the oxide-free powder being mixed as suspension with a polyacetal as binder under a protective gas, the organic solvent being distilled off, the mixture of powder and polyacetal being heated above the melting point of the polyacetal and being compounded to give a homogeneous composition, the granular material thus obtained being processed in an injection-molding machine made inert with argon to give shaped bodies, the shaped bodies being freed of binder under the action of oxalic acid in a closed ceramic container which nevertheless allows pressure equilibration under protective gas at atmospheric pressurType: GrantFiled: July 29, 1996Date of Patent: February 18, 1997Assignee: BASF AktiengesellschaftInventors: Hans-Josef Sterzel, Hans Wohlfromm
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Patent number: 5594930Abstract: A brazeable aluminum material is composed of an aluminum core and a brazing agent layer consisting of a brazing agent thermally sprayed onto covering a surface of the core. A number of unmolten minute particles of the brazing agent are present in the brazing agent layer, which contains at least an aluminum-silicon alloy and/or a mixture of aluminum and silicon. Characteristic features of a method of producing the brazeable aluminum material are the steps of: preparing a powder composed of minute particles; and thermally spraying the powder onto the aluminum core in such a state that only a surface of each minute particle is molten, with a pith of the particle remaining unmolten. The powder is an Al-Si alloy and/or a mixture of Al powder and Si powder.Type: GrantFiled: October 27, 1993Date of Patent: January 14, 1997Assignee: Showa Aluminum CorporationInventors: Takashi Terada, Masahiro Kojima, Taizo Morita, Katsuyuki Arakawa, Ichiro Iwai, Masakazu Furuta
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Patent number: 5594932Abstract: In a method for the manufacture of an encased high critical temperature superconducting wire by the "powder in tube" method, prior to the introduction of a compressed rod of superconducting material into a silver tube, the rod is heat treated so that grains of unwanted phase are reabsorbed. The tube can be drawn more easily, and strands can be produced with a regular geometry and no defects. The wire is constituted by 15 .mu.m to 20 .mu.m thick filaments (30) with a form factor of more than 60.Type: GrantFiled: June 9, 1994Date of Patent: January 14, 1997Assignee: Alcatel Alsthom Compagnie General d'ElectriciteInventors: Gerard Duperray, Denis Legat
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Patent number: 5574959Abstract: A metal casing for a semiconductor device is manufactured by a powder metallurgy injection molding process which uses infiltration. The metal casing includes a base member and an enclosure member arranged on the base member. The base member and the enclosure member are formed of an alloy including 20 to 50 percent by volume of copper, equal to or less than 1 percent by weight of nickel and remainder of tungsten or molybdenum. The metal casing is manufactured as a net-shape product by a process which includes the steps of mixing tungsten powder and nickel powder having average particles sizes equal to or less than 40 .mu.Type: GrantFiled: September 16, 1994Date of Patent: November 12, 1996Assignee: Sumitomo Electric Industries, Ltd.Inventors: Masanori Tsujioka, Junzoh Matsumura
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Patent number: 5574955Abstract: A method and a device for heating powder, especially for preheating powder in view of subsequent compacting, are disclosed. The powder is divided into partial flows which are heated separately to a predetermined temperature. Then, the partial flows are brought together to form a common flow of heated powder. The partial flows are so heated that an uniform temperature is attained over essentially the entire cross-section of each of the partial flows before these are brought together. The device comprises a storage container (10) for the powder, and a heating unit (20) for receiving powder from the storage container (10) and heating it. The heating unit (20) comprises a plurality of spaced-apart heating surfaces (27) defining between them a plurality of flow channels (28) for the powder.Type: GrantFiled: April 11, 1995Date of Patent: November 12, 1996Assignee: Hoganas ABInventors: Mats Stromgren, Michael Johansson
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Patent number: 5556719Abstract: This invention disclosures a method to make an improved hydrogen/hydride electrode for electro-chemical applications. The method comprises the steps of: (1) preparing the slurry of hydrogen storage material; (2) pasting the slurry onto and/or into a substrate current collector to make a wet pasted electrode; (3) drying the wet pasted electrode; and (4) sintering the pasted electrode. The aforementioned method is very useful for the hydrogen storage alloy comprising of Ti, 2-70 at. %; Zr, 2-70 at. % and Ni, 5-80 at. %. It is also useful for a pseudo AB.sub.5 - or AB.sub.2 -type alloy. In particular, a high capacity hydrogen storage electrode comprising a multicomponent hydrogen storage alloy having composition represented by the formula: Ti.sub.a Zr.sub.b Ni.sub.c Nb.sub.y R.sub.z M.sub.Type: GrantFiled: June 27, 1994Date of Patent: September 17, 1996Inventors: Kuochih Hong, Kuoshiu Hong, Huiyim Hong
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Patent number: 5554338Abstract: The invention relates to a method of preparing a composite sintered body having inner and outer portions fitted with each other. The method includes the steps of: (a) preparing an inner powder compact; (b) preparing an outer powder compact; (c) fitting the inner and outer powder compacts with each other so as to prepare a composite powder compact; and (d) sintering the composite powder compact so as to prepare the composite sintered body. The inner and outer powder compacts are respectively selected such that, during the step (d), the amount of growth of the inner powder compact becomes greater than that of the outer powder compact. Each of the inner and outer composite powder compacts is made of one member selected from the group consisting of a wax-type segregation prevention powder mixture and a metal-soap-type segregation prevention powder mixture. At least one of the inner and outer composite powder compacts is made of the wax-type segregation prevention powder.Type: GrantFiled: April 18, 1995Date of Patent: September 10, 1996Assignees: Nissan Motor Co., Ltd., Hitachi Powdered Metals Co., Ltd.Inventors: Hiroshi Sugihara, Hiroyuki Ishikawa, Tsutomu Uemura, Akira Fujiki, Hiromasa Imazato, Shinichi Umino
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Patent number: 5555481Abstract: A method of producing parts from two distinct classes of materials utilizes depositing a first class material and a second class material on a deposition surface where the first class material forms a three-dimensional shape defined by the interface of the first class material and the second class material. The first class material is unified and the second class material is removed therefrom to form a three-dimensional part of the first class material. Preferably, the first and second class materials are deposited in layers.Type: GrantFiled: August 1, 1995Date of Patent: September 10, 1996Assignee: Rensselaer Polytechnic InstituteInventors: Stephen J. Rock, Charles R. Gilman
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Patent number: 5545323Abstract: A filter assembly and a method of making a filter assembly is described wherein a filter pack is seated in an end cap and contacted with a particulate material and a settling liquid of low viscosity to form a filter assemblage. The filter assemblage is sintered to form a strong, virtually impermeable bond therebetween.Type: GrantFiled: January 17, 1995Date of Patent: August 13, 1996Assignee: Pall CorporationInventors: Paul C. Koehler, Michael B. Whitlock, Lawrence J. Noble, George C. Jenkins
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Patent number: 5532069Abstract: A dispersion-strengthened aluminum alloy having a composite structure containing a matrix of .alpha.-aluminum and a precipitation deposited phase of an intermetallic compound with the intermetallic compound in a volume ratio of not more than 35 vol. %, has both high strength and high toughness. The precipitation phase of the intermetallic compound has an aspect ratio of not more than 3.0, the .alpha.-aluminum has a crystal grain size which is at least twice the grain size of the precipitation phase of the intermetallic compound, and the crystal grain size of the .alpha.-aluminum is not more than 200 nm. It is possible to obtain an aluminum alloy having the aforementioned limited structure by carrying out first and second heat treatments on gas-atomized powder containing at least 10 vol. % of an amorphous phase or a green compact thereof and thereafter carrying out hot plastic working.Type: GrantFiled: December 22, 1994Date of Patent: July 2, 1996Assignees: Tsuyoshi Masumoto, Akihisa InoueInventors: Tsuyoshi Masumoto, Akihisa Inoue, Toshihiko Kaji, Junji Iihara, Yoshishige Takano
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Patent number: 5527624Abstract: The invention relates to a process for preparing sintered shapes, comprising the steps of:(1) forming a green body from a mixture comprising a major amount of at least one inorganic powder; and one or more additives selected from the group consisting of: (A) at least one reaction product of a hydroxy compound with a carboxylic acylating agent; (B) at least one Mannich reaction product; (C) at least one hydrocarbyl-substituted amine; (D) at least one aminophenol; (E) at least one reaction product of a nitrophenol and amino compound; (F) at least one basic nitrogen-containing polymer; (G) at least one carboxylic acylating agent; (H) at least one aromatic acid or derivative thereof; (I) at least one aromatic oxime; and (J) at least one overbased or gelled overbased metal salt of an acidic organic compound provided that when the carboxylic acylating agent is a hydrocarbyl-substituted carboxylic acylating agent and the hydrocarbyl group contains less than an average of 40 carbon atoms, then the carboxylic acylatinType: GrantFiled: April 5, 1995Date of Patent: June 18, 1996Assignee: The Lubrizol CorporationInventors: William Higgins, Fred E. Heller, Reed H. Walsh, Ralph E. Kornbrekke, Stephen A. DiBiase
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Patent number: 5489343Abstract: An R-Fe-B-based, sintered magnet, wherein R is one or more of rare earth elements including Y, is produced by the method including the steps of mixing fine R-Fe-B-based magnet powder with a mineral oil and/or a synthetic oil having a fractional distillation temperature range of 150.degree.-400.degree. C. and a kinetic viscosity of 10 cSt or less to prepare a mixture; charging the mixture under pressure into a die cavity equipped with a filter, to which an orientated magnetic field is applied, while removing a mineral oil and/or a synthetic oil from the mixture; compressing the mixture in the die cavity to carry out a wet molding while orientating the powder to prepare a green body; heating the green body to a temperature up to 500.degree. C. at a speed of 10.degree. C./min or less under pressure of 10.sup.-1 Torr or less for 30 minutes or more to remove a mineral oil and/or a synthetic oil from the green body; and then sintering the green body.Type: GrantFiled: January 27, 1994Date of Patent: February 6, 1996Assignee: Hitachi Metals, Ltd.Inventors: Kimio Uchida, Masahiro Takahashi, Masamichi Ozaki, Akira Kikuchi
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Patent number: 5487865Abstract: A complex body and method of making same which includes forming an assembly of green bodies, each body having an inlet end and an outlet end and having a multiplicity of cells extending from inlet to outlet end, and sintering the assembly at a temperature and time sufficient to cause interdiffusion of the metals between the bodies to join them and form the complex body.Type: GrantFiled: September 2, 1994Date of Patent: January 30, 1996Assignee: Corning IncorporatedInventors: Leslie E. Hampton, David S. Weiss
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Patent number: 5484468Abstract: Cemented carbide inserts are available containing WC and cubic phases of carbide and/or carbonitride in a binder phase based on cobalt and/or nickel with a binder phase enriched surface zone. The binder phase content along a line essentially bisecting the rounded edge surfaces increases toward the edge and cubic phase is present. As a result, the edge toughness of the cutting inserts is improved.Type: GrantFiled: February 7, 1994Date of Patent: January 16, 1996Assignee: Sandvik ABInventors: Ake Ostlund, Ulf Oskarsson, Per Gustafson, Leif Akesson
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Patent number: 5484568Abstract: Electrical heating elements and related articles having oxidation resistance at high temperatures, produced by a method involving micropyretic synthesis. A composition subjected to micropyretic synthesis comprises a filler material, a reactive system capable of undergoing micropyretic synthesis, and (optionally) a plasticizer or extrusion agent. The method of preparation of articles includes slurry techniques, plastic extrusion, slip casting, or coating.Type: GrantFiled: January 3, 1994Date of Patent: January 16, 1996Assignee: University of CincinnatiInventors: Jainagesh A. Sekhar, Naiping Zhu
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Patent number: 5482672Abstract: The process for extruding tantalum or niobium includes sealing a cold isostatically pressed charge of tantalum or niobium powder in a first metal cylinder and then sealing the first cylinder in a second metal cylinder with a metal powder of spherical shape in a gap between the cylinders. Thereafter, the second cylinder is cold isostatically pressed to prevent the metal powder in the gap from segregating. This is followed by heating and extrusion of the second container to form, e.g. an extruded bar. The ends of the bar and the skin on the bar can be removed to obtain a rod of tantalum (or niobium) with a yield of from 95% to 96% of the original powder.Type: GrantFiled: February 9, 1995Date of Patent: January 9, 1996Inventors: Ira Friedman, Christer Aslund
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Patent number: 5478522Abstract: The present invention relates to a method for manufacturing a heating element, the method including the steps of: a) providing powders of two metals; b) mixing the powders; c) grinding the mixed powders; d) compacting the mixed powders to form a green compact; e) sintering the green compact in a first atmosphere; f) plastically working and process annealing the green compact; g) etching a surface of the green compact to cause pores thereon; and h) sintering the etched green compact in an oxidizing atmosphere. A Ni-Cr heating element manufactured by the present method has improved high temperature properties and a fusion temperature 300.degree. C. greater than those of conventional Ni-Cr heating elements.Type: GrantFiled: November 15, 1994Date of Patent: December 26, 1995Assignee: National Science CouncilInventor: S. Wang
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Patent number: 5472661Abstract: Method of distributing and retaining insoluble additive particles uniformly throughout a mass of moldable metal particles. The additive particles are suspended in a solution of a polymeric binder and spray-coated onto the metal particles. When the solvent evaporates, the additives remain glued to the metal particles by the binder.Type: GrantFiled: December 16, 1994Date of Patent: December 5, 1995Assignee: General Motors CorporationInventor: David E. Gay
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Patent number: 5466311Abstract: A method of manufacturing an Ni--Al intermetallic compound matrix composite comprising steps of a) providing an aluminum powder, b) providing a reinforced material, c) providing a reducing solution containing a reducing agent and nickel ions to be reduced, d) adding the aluminum powder and the reinforced material into the reducing solution, and e) permitting the reducing agent to reduce the nickel ions to be respectively deposited on the aluminum powder and the reinforced material. Such method permits the Ni--Al, Ni--Al+B intermetallic compound matrix composite to be produced inexpensively/efficiently/fastly.Type: GrantFiled: February 10, 1994Date of Patent: November 14, 1995Assignee: National Science CouncilInventors: Chen-Ti Hu, Wen-Chih Chiou
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Patent number: 5460775Abstract: The invention provides aluminum sintered alloys with high dimensional accuracy and high density which are superior in mechanical and physical characteristics as well as wear resistance, and a method of producing such alloys not by plastic working but by atmospheric sintering with high economy. Rapidly solidified aluminum alloy powder resulting from solidifying aluminum alloy molten metal containing 0.4 to 4.0% by weight of Mg at a solidification rate of 10.sup.2 .degree. C./sec or more is press molded in the cold, after annealing in the temperature range of 250 to 450.degree. C. if necessary, and then the molded product is sintered by generating nitrogen compounds on the powder surface at atmospheric pressure with a nitrogen partial pressure of 0.8 atm or more and a steam partial pressure of 0.01 atm or less in which a reducing gas component has been added as a nitrogen-combining acceleration gas component by 0.01 atm or more. Thus, a nitrogen-combined aluminum sintered alloy containing 0.4 to 4.Type: GrantFiled: July 2, 1993Date of Patent: October 24, 1995Assignee: Sumitomo Electric Industries, Ltd.Inventors: Tetsuya Hayashi, Yoshinobu Takeda
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Patent number: 5456877Abstract: A method for producing a high solids content, low viscosity ceramic slurry composition comprises turbomilling a dispersion of a ceramic powder in a liquid to form a slurry having a viscosity less than 100 centipoise and a solids content equal to or greater than 48 volume percent.Type: GrantFiled: March 4, 1994Date of Patent: October 10, 1995Assignee: Martin Marietta Energy Systems, Inc.Inventors: Terry N. Tiegs, Dale E. Wittmer
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Patent number: 5455001Abstract: A method for manufacturing an intermetallic compound comprises (a) preparing a powder, (b) canning said powder in a tube, (c) executing a first heat treatment to said tube-canned powder, and (d) treating said tube-canned powder for obtaining an intermetallic compound. This invention offers a simple, efficient, and inexpensive method for producing an intermetallic compound possessing excellent mechanical properties.Type: GrantFiled: July 7, 1994Date of Patent: October 3, 1995Assignee: National Science CouncilInventor: Chen-Ti Hu
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Patent number: 5448447Abstract: A process for producing capacitor grade powder, electrodes, and finished capacitors therefrom having reduced electrical leakage characteristics. The powder is prepared by reacting Group V-B base materials with quantities of between 500 to 7000 ppm of nitrogen and 700 to 3000 ppm of oxygen. Electrical leakage is reduced by at least 28% for electrodes anodized at 100 volts or greater in comparison with electrodes and finished capacitors made from undoped materials. A range of specific charge of up to 25,000 uFV/g is achieved for sintering temperatures of 1400.degree. C. to 1800.degree. C.Type: GrantFiled: April 26, 1993Date of Patent: September 5, 1995Assignee: Cabot CorporationInventor: Hongju Chang
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Patent number: 5445789Abstract: A plunger charged as an electrode is received in a trough charged as a counter-electrode in order to heat material in the trough above the annealing temperature of metal material or the sintering temperature of ceramic-material. The trough and plunger are situated in a vacuum chamber separated from a condenser and pump stand by a valve. The plunger can be retracted into a cover of the chamber by a hydraulic drive on the cover. The cover, drive, and plunger are removable from the lower part of the chamber as a unit.Type: GrantFiled: March 16, 1994Date of Patent: August 29, 1995Assignee: Leybold Durferrit GmbHInventors: Erwin Wanetzky, Franz Hugo
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Patent number: 5443788Abstract: The subject invention relates to method for briquetting fines and ultrafines comprising mixing the fines and ultrafines on a continuous basis with a binder system having low viscosity of up to about 200 cps and at least 50% solids, such that the resulting briquette contains less than about 3% binder by weight of the briquette.Type: GrantFiled: December 9, 1993Date of Patent: August 22, 1995Assignee: Palsat International, Inc.Inventors: Francis S. Palowitz, Sudarshan R. Sathe
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Patent number: 5439638Abstract: A method of making flowable tungsten/copper composite powder by milling an aqueous slurry of a mixture of the desired weight ratio of tungsten powder and copper oxide powder and, optionally, a small amount of cobalt powder, spray-drying the slurry to form spherical, flowable agglomerates, and reducing the agglomerates in a hydrogen atmosphere.Type: GrantFiled: July 16, 1993Date of Patent: August 8, 1995Assignee: OSRAM Sylvania Inc.Inventors: David L. Houck, Nelson Kopatz, Muktesh Paliwal, Sanjay Sampath
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Patent number: 5439637Abstract: Brazed structures are disassembled with little or no physical damage to the components by coating the brazed joints with a powdered wicking agent, preferably mixed with a fugitive liquid binder to form an adherent slurry, then heating the joint to allow the brazing alloy to melt and be drawn into the powdered wicking agent by capillary action. After cooling, the powder and braze alloy are mixed together to form a loosely consolidated mass which can be readily removed by mechanical and/or chemical means so that the components can then be separated for repair or reuse.Type: GrantFiled: July 20, 1994Date of Patent: August 8, 1995Assignee: Pyromet Group, Inc.Inventor: Craig R. Moyer
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Patent number: 5413751Abstract: High density heatsinks for microcircuit packages are formed by first mold-pressing a composite powder of free-flowing spray-dried particles of copper and at least one other denser material such as tungsten and/or molybdenum, the proportions of which are adjusted to match the thermal expansion characteristics of the microcircuit material. The pressed compacts are then heated in a sintering furnace at 1,200.degree. C. to 1,350.degree. C. in order to effect an homogeneous distribution of the melting copper throughout the structure. The process results in a readily usable component having good thermal conductivity and matched thermal expansion that requires no further machining.Type: GrantFiled: May 20, 1993Date of Patent: May 9, 1995
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Patent number: 5409518Abstract: A sintered titanium alloy is composed of a titanium matrix or titanium alloy matrix and hard particles dispersed in the matrix, the sintered titanium alloy comprises: 4-8 mass % of aluminum (Al); 2-6 mass % of vanadium (V); 0.15-0.8 mass % of oxygen (O); at least one element selected from the group consisting of 0.2-9 mass % of boron (B), 0.5-3 mass % of at least one of molybdenum (Mo), tungsten (W), tantalum (Ta), zirconium (Zr), niobium (Nb), and hafnium (Hf), 0.05-2 mass % of at least one of Ia Group elements, IIa Group elements, and IIIa Group elements, 0.05-0.5 mass % of at least one of halogens; with the balance being titanium (Ti) and inevitable impurities.Type: GrantFiled: November 8, 1991Date of Patent: April 25, 1995Assignee: Kabushiki Kaisha Toyota Chuo KenkyushoInventors: Takashi Saito, Tadahiko Furuta
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Patent number: 5397530Abstract: A method for heating metal powder, e.g., iron powder, comprises irradiating the powder with microwaves. The powder may be coated with various materials to enhance the heating effects of the microwave. For example, the powder may be coated with a non-emissive material, such as a ceramic material. The powder may also be coated with a dipole material, such as water or plastic, or a dielectric material.Type: GrantFiled: February 2, 1994Date of Patent: March 14, 1995Assignee: Hoeganaes CorporationInventors: K. S. V. L. Narasimhan, Johan Arvidsson, Howard G. Rutz, W. John Porter, Jr.
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Patent number: 5397532Abstract: A sintered electrode having fine pores and coarse pores and intended for use in a voltaic cell is made from reduced iron powder granules, which have been made from an iron(III) oxide powder having a particle size up to 10 micrometers and have a particle size not in excess of 500 micrometers and are compacted to form an electrode body, which is sintered under a reducing atmosphere at a sintering temperature up to 750.degree. C. The iron powder granules are derived from the agglomerated iron powder that is formed as the iron powder is reduced at 600.degree. to 800.degree. C. and optionally after the agglomerated iron powder has been reduced in size, and the iron powder granules before being compacted are mixed with an organic solid expanding agent, which volatilizes during the sintering process and is used in such a proportion and has such a particle size that the resulting sintered electrode has coarse pores in the desired number and the desired size.Type: GrantFiled: July 7, 1993Date of Patent: March 14, 1995Assignee: Miba Sintermetall AktiengesellschaftInventor: Franz Blaimschein
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Patent number: 5395464Abstract: A method for obtaining a product from pre-alloyed powders in which the powders are subjected to compaction treatment. The powders are first subjected to pre-treatment under low pressure (or without pressure) at a temperature such that segregating materials precipitate out in stable phases.Type: GrantFiled: April 7, 1994Date of Patent: March 7, 1995Assignee: TECPHYInventor: James Davidson
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Patent number: 5382405Abstract: A method of manufacturing a shaped article from a powdered precursor, wherein the components of the powdered precursor are subjected to a self-propagating high-temperature synthesis (SHS) reaction and are consolidated essentially simultaneously. The shaped article requires essentially no machining after manufacture.Type: GrantFiled: September 3, 1993Date of Patent: January 17, 1995Assignee: Inland Steel CompanyInventors: Kenneth F. Lowrance, II, Eric C. Knorr, William M. Goldberger, Daniel Boss, Doreen Edwards
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Patent number: 5354535Abstract: An article and method of manufacture of (Bi,Pb)-Sr-Ca-Cu-O superconductor. The superconductor is manufactured by preparing a first powdered mixture of bismuth oxide, lead oxide, strontium carbonate, calcium carbonate and copper oxide. A second powdered mixture is then prepared of strontium carbonate, calcium carbonate and copper oxide. The mixtures are calcined separately with the two mixtures then combined. The resulting combined mixture is then subjected to a powder in tube deformation and thermal processing to produce a substantially phase pure (Bi,Pb)-Sr-Ca-Cu-O superconductor.Type: GrantFiled: April 6, 1993Date of Patent: October 11, 1994Assignee: University of ChicagoInventors: Stephen E. Dorris, Roger B. Poeppel, Barton C. Prorok, Michael T. Lanagan, Victor A. Maroni
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Patent number: 5342575Abstract: Billets are produced from powdery alloys by a process which comprises densely packing in a can a powdery metal or alloy easy of plastic working and a powdery alloy difficult of plastic working in that order, sealing hermetically the can and thereafter degassing the same; or a process which comprises densely packing a powdery alloy difficult of plastic working in a can and, then, densely packing a powdery metal or powdery alloy easy of plastic working in the can to make the powdery metal or alloy into a lid of the can, wherein the powdery alloy easy of plastic working is coarse powder, while the powdery alloy difficult of plastic working is fine powder, and the powdery alloy is a rapidly solidified powdery alloy comprising an Al-base, Mg-base, Ni-base, Ti-base or Fe-base alloy.Type: GrantFiled: July 20, 1993Date of Patent: August 30, 1994Assignee: Yoshida Kogyo K.K.Inventor: Yoshitaka Nagai
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Patent number: 5338507Abstract: A method for making metal/ceramic superconductor thick film structures including the steps of preparing a silver/superconductor ink, applying the ink to a substrate, evaporating the ink's binder, decomposing a silver compound in the residue to coat the superconductor grains, sintering the coated superconductor grains, and oxygenating the superconductor grains through the silver coating. The resultant inter-granular silver increases the critical current and mechanical strength of the superconductor.Type: GrantFiled: August 29, 1991Date of Patent: August 16, 1994Assignee: Hewlett-Packard CompanyInventors: John T. Anderson, V. K. Nagesh, Richard C. Ruby
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Patent number: 5338617Abstract: A method for insulating metal powder particles comprises steps of placing the metal powder particles in a mixing container and adding a monomer in solution to the metal powder particles to form a mixture. The mixture is then stirred to provide an even consistency and is baked to remove solvents. The mixture is then stirred and the monomer is polymerized by exposing the monomer coated carbonyl iron particles to moist gas. The mixture is then ground to form a powder. The powder is suitable for incorporation into plastic resins for subsequent casting to form radio frequency shields having high DC resistance.Type: GrantFiled: November 30, 1992Date of Patent: August 16, 1994Assignee: Motorola, Inc.Inventors: David M. Workinger, Robert D. Fraser
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Patent number: 5314658Abstract: Tungsten and molybdenum powders are advantageously conditioned for metal injection molding by fluid energy milling the powder prior to batching. A preferred method of conditioning, jet milling, has been found to beneficially effect the particle characteristics to render the metal powder more suitable for injection molding.Type: GrantFiled: April 3, 1992Date of Patent: May 24, 1994Assignee: AMAX, Inc.Inventors: David N. Meendering, Deepak Malhotra, Linda K. Baltich
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Patent number: 5284615Abstract: The present invention presents a method of processing ferrous powder materials to produce small component parts exhibiting excellent soft magnetic properties, in particular, residual magnetic flux density. The processing steps involve, in part, mixing with a binder, dewaxing or presintering at a temperature higher than in the conventional dewaxing process, followed by final sintering and a further conversion sintering, at a temperature lower than in the conventional sintering process, to produce parts having density values of over 96% theoretical density and excellent soft magnetic properties. The invented method is suitable for producing small component parts having sufficient strength and excellent soft magnetic properties to make them suitable for miniaturized electrical and electronic equipment.Type: GrantFiled: July 15, 1992Date of Patent: February 8, 1994Assignee: Mitsubishi Materials CorporationInventors: Koshiro Ueda, Mutsumi Moribayashi, Tohru Kohno
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Patent number: 5268233Abstract: The invention relates to a method of preparing sintered shapes, comprising the steps of forming a green body from a mixture comprising (A) a major amount of at least one inorganic powder with (B) at least one reaction product of an amine other than an alkanolamine with a hydrocarbyl-substituted carboxylic acylating agent or alkylalkyleneglycolacetic acylating agent; provided the reaction product is other than an alkylene oxide treated fatty monocarboxylic amide and provided that when the hydrocarbyl-substituted carboxylic acylating agent is a nonaromatic acylating agent, then the hydrocarbyl group is other than hydrocarbyl groups having an average of about 55 to about 110 carbon atoms; and sintering the body. Sintered shapes made from the methods of the present invention have relatively high fired densities and small uniform grain sizes; and low porosity. The reaction products of the present invention help disperse the inorganic powder.Type: GrantFiled: November 22, 1991Date of Patent: December 7, 1993Assignee: The Lubrizol CorporationInventors: Fred E. Heller, William Higgins, Robert E. Quinn
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Patent number: 5244510Abstract: This invention relates to a process for producing a rare earth-containing powder comprising crushing a rare earth-containing alloy in a passivating gas at a temperature from ambient temperature to a temperature below the phase transformation temperature of the material.Additionally, this invention relates to a process for producing a rare earth-containing powder compact comprising crushing a rare earth-containing alloy in water, compacting the crushed alloy material, drying the compacted alloy material at a temperature below the phase transformation temperature of the material, and treating the compacted alloy material with a passivating gas at a temperature from ambient temperature to a temperature below the phase transformation temperature of the material.Rare earth-containing alloys suitable for use in producing magnets utilizing the powder metallurgy technique, such as Nd-Fe-B and Sm-Co alloys, can be used.Type: GrantFiled: July 18, 1991Date of Patent: September 14, 1993Inventor: Yakov Bogatin