Heat Treatment Of Powder Patents (Class 419/31)
  • Patent number: 11133395
    Abstract: A method includes forming a dummy gate stack over a semiconductor substrate, wherein the semiconductor substrate is comprised in a wafer. The method further includes removing the dummy gate stack to form a recess, forming a gate dielectric layer in the recess, and forming a metal layer in the recess and over the gate dielectric layer. The metal layer has an n-work function. A portion of the metal layer has a crystalline structure. The method further includes filling a remaining portion of the recess with metallic materials, wherein the metallic materials are overlying the metal layer.
    Type: Grant
    Filed: April 18, 2019
    Date of Patent: September 28, 2021
    Assignee: Taiwan Semiconductor Manufacturing Company, Ltd.
    Inventors: Chi-Cheng Hung, Kuan-Ting Liu, Jun-Nan Nian
  • Patent number: 11059096
    Abstract: An apparatus for manufacturing a powder has: a chamber; a temperature control system for the chamber interior; and a conveyor within the chamber. First, second, and third powder sources supply respective first, second, and third powders along respective first, second, and third powder flowpaths. The second and third flowpaths merge with the first flowpath along the conveyor. The apparatus comprises a vaporizer for vaporizing a solvent to be delivered to the second and third powders along the second and third powder flowpaths.
    Type: Grant
    Filed: January 11, 2019
    Date of Patent: July 13, 2021
    Assignee: Raytheon Technologies Corporation
    Inventor: Christopher W. Strock
  • Patent number: 11052451
    Abstract: A gear manufacturing method includes a step of preparing a gear blank; a step (teeth cutting step) of cutting the gear blank to form a half-finished gear having a plurality of gear teeth; a step (heat treatment step) of heat-treating the half-finished gear having the gear teeth; and a step (form rolling step) of rolling the half-finished gear which is subjected to the heat treatment, in which the gear teeth of the half-finished gear which is subjected to the teeth cutting step is formed with protuberances on both sides in a circumferential direction, and at the form rolling step, the protuberances are pressed by a rolling die, so that the half-finished gear becomes a gear.
    Type: Grant
    Filed: December 28, 2016
    Date of Patent: July 6, 2021
    Inventor: Kwang Hui Lee
  • Patent number: 10998139
    Abstract: A solid electrolytic capacitor element that includes a porous body, a dielectric layer on a surface of the porous body, and a solid electrolyte layer on a surface of the dielectric layer. The porous body is made from a sintered body of a Ti-alloy-containing grain having a Ti—Zr—X multicomponent alloy on a surface thereof, where X is at least one valve metal element selected from Si, Hf, Y, Al, Mo, W, Ta, Nb, and V, and a composition of the Ti—Zr—X multicomponent alloy is Ti: 50 atm % to 80 atm %, Zr: 8 atm % to 32 atm %, and X: 1 atm % to 20 atm %.
    Type: Grant
    Filed: May 10, 2019
    Date of Patent: May 4, 2021
    Assignee: MURATA MANUFACTURING CO., LTD.
    Inventors: Daisuke Obara, Takeo Arakawa, Takeshi Furukawa, Yuji Yokoyama, Yoshihiro Fujita, Masahiro Matsuo, Hideo Ito
  • Patent number: 10943717
    Abstract: An R-T-B based permanent magnet includes main phase grains composed of R2T14B type compound. R is a rare earth element. T is iron group element(s) essentially including Fe or Fe and Co. B is boron. An average grain size of the main phase grains is 0.8 ?m or more and 2.8 ?m or less. The R-T-B based permanent magnet contains at least C and Zr in addition to R, T, and B. B is contained at 0.75 mass % or more and 0.88 mass % or less. Zr is contained at 0.65 mass % or more and 5.00 mass % or less. A formula (1) of 5.0?[B]+[C]?[Zr]?5.6 is satisfied, where [B] is a B content represented by atom %, [C] is a C content represented by atom %, and [Zr] is a Zr content represented by atom %.
    Type: Grant
    Filed: February 23, 2017
    Date of Patent: March 9, 2021
    Assignee: TDK CORPORATION
    Inventors: Masashi Miwa, Takurou Iwasa
  • Patent number: 10857595
    Abstract: There is provided an additive manufactured (AM) article formed of a Co based alloy having a composition comprising: in mass %, 0.08-0.25% C; 0.1% or less B; 10-30% Cr; 30% or less in total of Fe and Ni, the Fe being 5% or less; 5-12% in total of W and/or Mo; 0.5-2% in total of Ti, Zr, Nb and Ta; 0.5% or less Si; 0.5% or less Mn; 0.003-0.04% N; and the balance being Co and impurities. The AM article comprises crystal grains with an average size of 10-100 ?m. In the crystal grains, segregation cells with an average size of 0.15-1.5 ?m are formed, in which components constituting an MC type carbide phase comprising the Ti, Zr, Nb and/or Ta are segregated in boundary regions of the cells, and/or grains of the MC type carbide phase are precipitated at an average intergrain distance of 0.15-1.5 ?m.
    Type: Grant
    Filed: September 25, 2019
    Date of Patent: December 8, 2020
    Assignee: MITSUBISHI HITACHI POWER SYSTEMS, LTD.
    Inventors: Shinya Imano, Yuting Wang, Shigenobu Eguchi, Yoshitaka Uemura, Norihiko Motoyama, Takanao Komaki
  • Patent number: 10784028
    Abstract: An R-T-B based permanent magnet includes main phase grains composed of R2T14B type compound. R is a rare earth element. T is iron group element(s) essentially including Fe or Fe and Co. B is boron. An average grain size of the main phase grains is 0.8 ?m to 2.8 ?m. The R-T-B based permanent magnet contains at least C and Ga in addition to R, T, and B. B is contained at 0.71 mass % to 0.86 mass %. C is contained at 0.13 mass % to 0.34 mass %. Ga is contained at 0.40 mass % to 1.80 mass %. A formula (1) of 0.14?[C]/([B]+[C])?0.30 is satisfied, where [B] is a B content represented by atom %, and [C] is a C content represented by atom %.
    Type: Grant
    Filed: February 23, 2017
    Date of Patent: September 22, 2020
    Assignee: TDK CORPORATION
    Inventors: Tamotsu Ishiyama, Masashi Miwa, Takashi Watanabe
  • Patent number: 10660573
    Abstract: A sensor guide wire for intravascular measurements of at least one physiological or other variable in a living body, comprising a proximal region, a distal sensor region, and a tip region, and at least one sensor element arranged in said sensor region and configured to measure the variable and to generate a sensor signal in response to the variable. The sensor guide wire further comprises a core wire, with a tip core wire portion, wherein at least part of the tip core wire portion comprises a shape memory material, and the composition of the shape memory material is such that the transformation temperature of the shape memory material is above the body temperature of the living body.
    Type: Grant
    Filed: March 12, 2014
    Date of Patent: May 26, 2020
    Assignee: ST. JUDE MEDICAL COORDINATION CENTER BVBA
    Inventors: Sathees Ranganathan, Anna Norlin-Weissenrieder, Rolf Hill
  • Patent number: 10632532
    Abstract: A mixed powder for powder metallurgy having excellent green compact strength and ejectability is provided. The mixed powder for powder metallurgy includes an iron-based powder; and a copolymerized polyamide, in an amount of 0.3 to 2.0 parts by mass per 100 parts by mass of the iron-based powder, having a melting point of 80° C. to 116° C.
    Type: Grant
    Filed: November 25, 2016
    Date of Patent: April 28, 2020
    Assignee: JFE STEEL CORPORATION
    Inventors: Shigeru Unami, Juuji Hirayama
  • Patent number: 10596625
    Abstract: A mixed powder for powder metallurgy having excellent green compact strength and ejectability is provided. The mixed powder for powder metallurgy includes an iron-based powder; and a copolymerized polyamide, in an amount of 0.3 to 2.0 parts by mass per 100 parts by mass of the iron-based powder, having a melting point of 80° C. to 116° C.
    Type: Grant
    Filed: November 25, 2016
    Date of Patent: March 24, 2020
    Assignee: JFE STEEL CORPORATION
    Inventors: Shigeru Unami, Juuji Hirayama
  • Patent number: 9796137
    Abstract: An additive manufacturing method includes using hydrogenated titanium in forming an object by additive manufacturing, the object having a first microstructure. The method includes heat treating the hydrogenated titanium and, after completing a shape of the object, dehydrogenating the object. The dehydrogenated object has a second microstructure different from the first microstructure. Also, another additive manufacturing method includes forming an object containing Ti-6Al-4V, the object having a first microstructure containing columnar structures along a build direction of the additive manufacturing and the object exhibiting mechanical property anisotropy resulting from the columnar structures. After completing a shape of the object, the method includes hydrogenating the Ti-6Al-4V, heat treating the object containing the hydrogenated titanium, and dehydrogenating the heat treated object.
    Type: Grant
    Filed: June 8, 2015
    Date of Patent: October 24, 2017
    Assignee: THE BOEING COMPANY
    Inventors: Hao Zhang, Ryan P. Quarberg
  • Patent number: 9777347
    Abstract: Disclosed herein is a process that includes: (a) providing a powder blend comprising (1) one or more hydrogenated titanium powders containing around 0.2 to around 3.4 weight % of hydrogen, and (2) one or more master alloys, comprising Al, V, or a combination thereof, (b) consolidating the powder blend by compacting the powder blend to provide a green compact, (c) heating the green compact to a temperature ranging from around 400° C. to around 900° C.
    Type: Grant
    Filed: June 15, 2015
    Date of Patent: October 3, 2017
    Inventors: Vladimir S. Moxson, Mykhailo Matviychuk, Vladimir Duz
  • Patent number: 9289826
    Abstract: In accordance with an exemplary embodiment, a method of manufacturing a stator airfoil assembly includes forming an interior wall of a stator airfoil using an additive manufacturing technique, forming an exterior wall of the stator airfoil using the additive manufacturing technique, and forming a plurality of internal ribs between the interior wall and the exterior wall using the additive manufacturing technique. A cooling air circuit is formed in a space between the interior wall and the exterior wall. Further, the interior wall, the exterior wall, and the internal ribs are formed simultaneously as an integral structure by using the additive manufacturing technique.
    Type: Grant
    Filed: September 17, 2012
    Date of Patent: March 22, 2016
    Assignee: HONEYWELL INTERNATIONAL INC.
    Inventors: Mark C. Morris, Donald G. Godfrey, Harry Lester Kington
  • Patent number: 9285192
    Abstract: A ballistic strike plate assembly comprises a first plate formed from aluminum alloy and having a first surface and a second surface. A titanium plate is has a first surface and a second surface. A sheet of ballistic gap foam is adhered to the first surface of the first plate and the first surface of the titanium plate. A multilayer ballistic fabric plate is adhered to the second surface of the titanium plate. A first sheet of ballistic wrap is disposed over the multilayer ballistic fabric plate, and has edges extending beyond edges of the multilayer ballistic fabric plate that are folded over the edges of the multilayer ballistic fabric plate. A second smaller sheet of ballistic wrap is adhered to the portion of the second surface of the first plate not covered by the folded over edges of the first sheet of ballistic wrap.
    Type: Grant
    Filed: February 19, 2013
    Date of Patent: March 15, 2016
    Assignee: Bourque Industries
    Inventor: John M. Bourque
  • Publication number: 20150122302
    Abstract: According to an embodiment, a thermoelectric conversion material is made of a polycrystalline material which is represented by a composition formula (1) shown below and has a MgAgAs type crystal structure. The polycrystalline material includes a MgAgAs type crystal grain having regions of different Ti concentrations. (AaTib)cDdXe??Composition formula (1) wherein 0.2?a?0.7, 0.3?b?0.8, a+b=1, 0.93?c?1.08, and 0.93?e?1.08 hold when d=1; A is at least one element selected from the group consisting of Zr and Hf, D is at least one element selected from the group consisting of Ni, Co, and Fe, and X is at least one element selected from the group consisting of Sn and Sb.
    Type: Application
    Filed: January 15, 2015
    Publication date: May 7, 2015
    Inventor: Takao SAWA
  • Patent number: 8992828
    Abstract: A method for manufacturing a high ductility Ti-, Ti-alloy or NiTi-foam, meaning a compression strain higher than 10%, includes: preparing a powder suspension of a Ti-, NiTi- or Ti-alloy powder, bringing the said powder suspension into a desired form by gelcasting to form a green artifact. The method also includes a calcination step wherein the green artifact is calcined, and sintering the artifact. The calcination step includes a slow heating step wherein said green artifact is heated at a rate lower or equal to 20° C./hour to a temperature between 400° C. and 600° C. and the Ti-, NiTi- or Ti-alloy powder has a particle size less than 100 ?m. A high ductility Ti-, Ti-alloy or NiTi foam, with a compression higher than 10%, with a theoretical density less than 30%, pore size (cell size) between 50 to 1000 ?m can be obtained with such a method.
    Type: Grant
    Filed: June 7, 2006
    Date of Patent: March 31, 2015
    Assignee: Vlaamse Instelling Voor Technologisch Onderzoek (VITO)
    Inventors: Steven Mullens, Ivo Thijs, Jozef Cooymans, Jan Luyten
  • Patent number: 8992827
    Abstract: A process is provided for producing aluminum-titanium-boron grain refining master alloys containing soluble titanium aluminide and insoluble aluminum boride particles, the process comprising mixing aluminum-boron alloy powder and K2TiF6 salt to obtain a blended mixture, heat treating the mixed powder blend thus obtained in an inert gas furnace just below the melting point of aluminum, at approximately 650 degrees Celcius sufficiently long and compacting the heated powder blend in the form of tablets. The cast grain size of an aluminum- 7 wt % silicon foundry alloy after inoculation with this master alloy at an addition level of 0.02% Ti was less than 200 microns for contact times of upto 15 minutes.
    Type: Grant
    Filed: February 27, 2009
    Date of Patent: March 31, 2015
    Assignee: Tubitak
    Inventor: Yucel Birol
  • Publication number: 20150078951
    Abstract: The present invention relates to a high speed steel with a chemical composition that comprises, in % by weight: 0.6-2.1 C 3-5 Cr 4-14 Mo max 5 W max 15 Co 0.5-4 V, balance Fe and impurities from the manufacturing of the material, which steel is powder metallurgically manufactured and has a content of Si in the range of 0.7<Si?2.
    Type: Application
    Filed: August 4, 2014
    Publication date: March 19, 2015
    Inventor: Stefan Sundin
  • Patent number: 8961867
    Abstract: Refractory metal powders are dehydrided in a device which includes a preheat chamber for retaining the metal powder fully heated in a hot zone to allow diffusion of hydrogen out of the powder. The powder is cooled in a cooling chamber for a residence time sufficiently short to prevent re-absorption of the hydrogen by the powder. The powder is consolidated by impact on a substrate at the exit of the cooling chamber to build a deposit in solid dense form on the substrate.
    Type: Grant
    Filed: May 23, 2013
    Date of Patent: February 24, 2015
    Assignee: H.C. Starck Inc.
    Inventors: Steven A. Miller, Mark Gaydos, Leonid N. Shekhter, Gokce Gulsoy
  • Patent number: 8920712
    Abstract: A process including: (a) forming a powder blend by mixing titanium powders, (b) consolidating the powder blend by compacting to provide a green compact, (c) heating the green compact thereby releasing absorbed water from the titanium powder, (d) forming ?-phase titanium and releasing atomic hydrogen from the hydrogenated titanium by heating the green compact in an atmosphere of hydrogen emitted by the hydrogenated titanium, (e) reducing surface oxides on particles of the titanium powder with atomic hydrogen released by heating of the green compact, (f) diffusion-controlled chemical homogenizing of the green compact and densification of the green compact by heating followed by holding resulting in complete or partial dehydrogenation to form a cleaned and refined compact, (g) heating the cleaned and refined green compact in vacuum thereby sintering titanium to form a sintered dense compact, and (h) cooling the sintered dense compact to form a sintered near-net shaped article.
    Type: Grant
    Filed: August 8, 2011
    Date of Patent: December 30, 2014
    Assignee: Advanced Materials Products, Inc.
    Inventors: Orest M. Ivasishin, Dmitro G. Savvakin, Vladimir S. Moxson, Vladimir A. Duz, Mykola M. Gumenyak
  • Patent number: 8858675
    Abstract: A powder metallurgical combination is provided comprising an iron-based powder A comprising core particles of iron to which core particles nickel is diffusion alloyed and wherein said nickel diffusion alloyed to said core particles comprises 4-7% (preferably 4.5-6%) by weight of said iron-based powder A, and a powder B substantially consisting of particles of pure iron. Further a method is provided for preparing a powder metallurgical combination.
    Type: Grant
    Filed: July 10, 2008
    Date of Patent: October 14, 2014
    Assignee: Hoganas AB (Publ)
    Inventor: Mats Larsson
  • Patent number: 8845957
    Abstract: A method for producing a magnetizable metal shaped body comprising a ferromagnetic starting material that is present in powder and in particulate form, using the following steps: (a) first compaction of the starting material (S3) such that adjoining particles become bonded to each other by means of positive adhesion and/or integral bonding in sections along the peripheral surfaces thereof and while forming hollow spaces, (b) creating an electrically isolating surface coating on the peripheral surfaces of the particles in regions outside the joining sections (S4), and (c) second compaction of the particles (S5) provided with the surface coating, such that the hollow spaces are reduced in size or eliminated.
    Type: Grant
    Filed: April 27, 2009
    Date of Patent: September 30, 2014
    Assignees: ETO Magnetic GmbH, Kennametal Europe GmbH
    Inventors: Paul Guempel, Stefan Glaeser, Beat Hofer
  • Publication number: 20140271326
    Abstract: There is provided improved laser sintering systems that increase the powder density and reduce anomalies of the powder layers that are sintered, that measure the laser power within the build chamber for automatic calibration during a build process, that deposit powder into the build chamber through a chute to minimize dusting, and that scrubs the air and cools the radiant heaters with recirculated scrubbed air. The improvements enable the laser sintering systems to make parts that are of higher and more consistent quality, precision, and strength, while enabling the user of the laser sintering systems to reuse greater proportions of previously used but unsintered powder.
    Type: Application
    Filed: March 14, 2014
    Publication date: September 18, 2014
    Applicant: 3D Systems, Inc.
    Inventors: David H. Cullen, Rafael Enrique Hidalgo
  • Patent number: 8795585
    Abstract: There is provided cryogenic milled nanophase copper alloys and methods of making the alloys. The alloys are fine grained having grains in the size range from about 2 to about 100 nanometers, and greater. The nanophase alloys possess desirable physical properties stemming from the fine grain size, such as potentially high strength. Some embodiments of the cryogenic milled copper alloys may also be tailored for ductility, toughness, fracture resistance, corrosion resistance, fatigue resistance and other physical properties by balancing the alloy composition. In addition, embodiments of the alloys generally do not require extensive or expensive post-cryogenic milling processing.
    Type: Grant
    Filed: December 21, 2006
    Date of Patent: August 5, 2014
    Assignee: The Boeing Company
    Inventors: Barun Majumdar, James D. Cotton, Clifford C. Bampton
  • Patent number: 8784728
    Abstract: There is provided cryogenic milled copper alloys and methods of making the alloys. The alloys are fine grained and possess desirable physical properties stemming from the fine grain size. Embodiments include desirable physical properties, such as potentially high strength. Some embodiments of the cryogenic milled copper alloys may also be tailored for ductility, toughness, fracture resistance, corrosion resistance, fatigue resistance and other physical properties by balancing the alloy composition. In addition, embodiments of the alloys generally do not require extensive or expensive post-cryogenic milling processing.
    Type: Grant
    Filed: December 5, 2006
    Date of Patent: July 22, 2014
    Assignee: The Boeing Company
    Inventors: Clifford C. Bampton, James D. Cotton, Barun Majumdar
  • Publication number: 20140178241
    Abstract: A pulverant material supply system has an outer shell, an inner shell, and a plurality of openings to a passage within the inner shell to allow a reducing fluid into the pulverant material contained therein. The liner is made from a non-evaporable getter alloy.
    Type: Application
    Filed: October 29, 2013
    Publication date: June 26, 2014
    Applicant: United Technologies Corporation
    Inventors: Sergey Mironets, Michael C. Reiter, Agnes Klucha, Youping Gao
  • Patent number: 8728389
    Abstract: A method for producing high strength aluminum alloy tanks and other vessels containing L12 dispersoids from an aluminum alloy powder containing the L12 dispersoids. The powder is consolidated into a billet having a density of about 100 percent. Tanks are formed by rolling consolidated billets into sheets, cutting preforms from said sheets, roll forming the performs into cylindrical shapes and friction stir welding the seams to form cylinders. L12 alloy domes are spin formed from the rolled sheet and friction stir welded to the cylinder. Circular bases are cut from the rolled sheet and friction stir welded to the domed cylinder to form bottoms of the tank.
    Type: Grant
    Filed: September 1, 2009
    Date of Patent: May 20, 2014
    Assignee: United Technologies Corporation
    Inventor: Awadh B. Pandey
  • Publication number: 20140105779
    Abstract: A strip cast alloy containing Nd in excess of the stoichiometry of Nd2Fe14B is subjected to HDDR treatment and diffusion treatment, yielding microcrystalline alloy powder in which major phase crystal grains with a size of 0.1-1 ?m are surrounded by Nd-rich grain boundary phase with a width of 2-10 nm. The powder is finely pulverized, compacted, and sintered, yielding a sintered magnet having a high coercivity.
    Type: Application
    Filed: October 16, 2013
    Publication date: April 17, 2014
    Applicant: SHIN-ETSU CHEMICAL CO., LTD.
    Inventor: Hajime Nakamura
  • Publication number: 20140083847
    Abstract: Provided is a sintered sputtering target having a composition by atomic ratio represented by the formula: (Fe100-X—PtX)100-ACA (wherein A and X satisfy 20?A?50 and 35?X?55, respectively), wherein C particles are finely dispersed in a matrix alloy, and an oxygen content is 300 wt ppm or less. An object of the present invention is to provide an Fe—Pt based sputtering target having finely dispersed C particles and a low oxygen content, which allows manufacture of a granular structure magnetic thin film having excellent corrosion resistance, and further allows facilitation of ordering the L10 structure.
    Type: Application
    Filed: July 20, 2012
    Publication date: March 27, 2014
    Applicant: JX Nippon Mining & Metals Corporation
    Inventor: Atsushi Sato
  • Patent number: 8679220
    Abstract: This invention relates to a ceramic and a cermet each having a second phase for improving toughness via phase separation from a complete solid-solution phase and to a method of preparing them. The ceramic and the cermet may have the second phase phase-separated from the complete solid-solution phase, thereby easily achieving a great improvement in toughness and exhibiting other good properties including high strength, consequently enabling the manufacture of high-strength and high-toughness cutting tools, instead of conventional WC—Co hard materials.
    Type: Grant
    Filed: June 20, 2007
    Date of Patent: March 25, 2014
    Assignee: SNU R&DB Foundation
    Inventor: Shin Hoo Kang
  • Patent number: 8657915
    Abstract: The present invention provides a metal powder composed of tantalum or niobium that achieves both sinterability and fluidity and the manufacturing method thereof. The present invention also provides a tantalum or niobium powder that enables the manufacturing of an anode for a solid electrolytic capacitor in which holes are formed for a conductive polymer-containing solution to pass through, without using a hole molding material or pore forming material. Furthermore, the present invention provides an anode for a solid electrolytic capacitor that enables the manufacturing of a high-volume and low ESR solid electrolytic capacitor. The present invention further provides a manufacturing method of a metal powder that allows the manufacturing of a metal powder of a given diameter range from a raw powder at high yield, without requiring a lot of work and time.
    Type: Grant
    Filed: May 31, 2006
    Date of Patent: February 25, 2014
    Assignee: Global Advanced Metals Japan, K.K.
    Inventors: Yujiro Mizusaki, Isao Sugiyama, Hitoshi Iijima, Osamu Kubota
  • Publication number: 20130315773
    Abstract: The invention relates to energy-saving manufacturing of purified hydrogenated titanium powders or alloying titanium hydride powders, by metallo-thermic reduction of titanium chlorides, including their hydrogenation, vacuum separation of titanium hydride sponge block from magnesium and magnesium chlorides, followed by crushing, grinding, and sintering of said block without need for hydrometallurgical treatment of the produced powders. Methods disclosed contain embodiments of processes for manufacturing high-purity powders and their use in manufacturing near-net shape titanium and titanium-alloy articles by sintering titanium hydride and alloyed titanium hydride powders produced from combined hydrogen-magnesium reduction of titanium chlorides, halides and hydrides of other metals.
    Type: Application
    Filed: May 24, 2012
    Publication date: November 28, 2013
    Applicant: Advance Materials Products, Inc. (ADMA Products, Inc.)
    Inventors: Vladimir S. Moxson, Volodymyr A. Duz, Andrey G. Klevtsov, Viktor D. Sukhoplyuyev, Mihajlo D. Sopka, Yury V. Shuvalov, Mykhailo Matviychuk
  • Publication number: 20130315772
    Abstract: A powder metal composition for high wear and temperature applications is made by atomizing a melted iron based alloy including 3.0 to 7.0 wt. % carbon; 10.0 to 25.0 wt. % chromium; 1.0 to 5.0 wt. % tungsten; 3.5 to 7.0 wt. % vanadium; 1.0 to 5.0 wt. % molybdenum; not greater than 0.5 wt. % oxygen; and at least 40.0 wt. % iron. The high carbon content reduces the solubility of oxygen in the melt and thus lowers the oxygen content to a level below which would cause the carbide-forming elements to oxidize during atomization. The powder metal composition includes metal carbides in an amount of at least 15 vol. %. The microhardness of the powder metal composition increases with increasing amounts of carbon and is typically about 800 to 1,500 Hv50.
    Type: Application
    Filed: March 15, 2013
    Publication date: November 28, 2013
    Applicant: Federal-Mogul Corporation
    Inventor: Federal-Mogul Corporation
  • Publication number: 20130252004
    Abstract: The present invention provides a rare earth-iron-nitrogen-based alloy material which can produce a rare earth magnet having excellent magnetic characteristics and a method for producing the same, a rare earth-iron-based alloy material suitable as a raw material of the rare earth magnet and a method for producing the alloy material. A rare earth-iron-based alloy material is heat-treated in a hydrogen-containing atmosphere to produce a multi-phase powder 1 in which a phase 3 of a hydrogen compound of a rare earth element is dispersedly present in a phase 2 of an iron-containing material. A powder compact 4 produced by compression-molding the multi-phase powder 1 is heat-treated in a vacuum with a magnetic field of 3 T or more applied, thereby forming a rare earth-iron-based alloy material 5. The rare earth-iron-based alloy material 5 is heat-treated in a nitrogen atmosphere with a magnetic field of 3.5 T or more applied, thereby forming a rare earth-iron-nitrogen-based alloy material 6.
    Type: Application
    Filed: May 22, 2012
    Publication date: September 26, 2013
    Applicant: SUMITOMO ELECTRIC INDUSTRIES, LTD.
    Inventors: Toru Maeda, Asako Watanabe, Motoi Nagasawa, Takeshi Kato
  • Publication number: 20130192986
    Abstract: Provided are a method for producing a Cu—Ga alloy powder, by which a high quality Cu—Ga alloy powder to be produced readily; a Cu—Ga alloy powder; a method for producing a Cu—Ga alloy sputtering target; and a Cu—Ga alloy sputtering target. Specifically, a Cu—Ga alloy powder is produced by stirring a mixed powder containing a Cu powder and a Ga in a mass ratio of 85:15 to 55:45 at a temperature of 30 to 700° C. in an inert atmosphere thereby accomplishing alloying. Also a Cu—Ga alloy sputtering target is produced by molding the Cu—Ga alloy powder followed by sintering.
    Type: Application
    Filed: April 7, 2011
    Publication date: August 1, 2013
    Applicant: SUMITOMO METAL MINING CO., LTD.
    Inventors: Toshio Morimoto, Tatsuya Takahashi, Isao Ando, Tetsufumi Komukai, Masanori Takagi, Eriko Sato, Hirotaka Minami
  • Publication number: 20130189145
    Abstract: Provided is a method by which a low-oxygen and high-density molybdenum target can be efficiently obtained, while fully utilizing the characteristics of each molybdenum (Mo) starting material powder. The present invention provides a method for producing a molybdenum target, wherein a mixed powder that is obtained by mixing a molybdenum powder A, which is prepared by reducing molybdenum oxide and then crushing the resulting so as to have an average particle diameter of 2-15 ?m, and a molybdenum powder B, which is prepared by crushing a molybdenum bulk starting material having a density of not less than 6.64×10 (kg/m3) so as to have an average particle diameter of 50-2,000 ?m, is sintered under pressure.
    Type: Application
    Filed: September 14, 2011
    Publication date: July 25, 2013
    Applicant: HITACHI METALS, LTD.
    Inventors: Kazuya Saitoh, Tomoyuki Hata, Masashi Kaminada, Hiroshi Takashima
  • Patent number: 8475711
    Abstract: Processes for producing a nickel-titanium alloy are disclosed. The processes are characterized by the production of nickel-titanium alloy articles having improved microstructure. A pre-alloyed nickel-titanium alloy is melted and atomized to form molten nickel-titanium alloy particles. The molten nickel-titanium alloy particles are cooled to form nickel-titanium alloy powder. The nickel-titanium alloy powder is consolidated to form a fully-densified nickel-titanium alloy preform that is hot worked to form a nickel-titanium alloy article. Any second phases present in the nickel-titanium alloy article have a mean size of less than 10 micrometers measured according to ASTM E1245-03 (2008) or an equivalent method.
    Type: Grant
    Filed: February 14, 2011
    Date of Patent: July 2, 2013
    Assignee: ATI Properties, Inc.
    Inventor: C. Craig Wojcik
  • Publication number: 20130039796
    Abstract: A master alloy used to produce the steel part and a process for producing a sinter hardened steel part from the master alloy are described. The powdered master alloy having a composition of iron, about 1 to less than 5 weight % C, about 3 to less than 15 weight % Mn, and about 3 to less than 15 weight % Cr, wherein the master alloy comprises a microstructure composed of a solid solution of the alloying elements and carbon, the microstructure comprising at least 10 volume % austenite and the remainder as iron compounds. The process comprises: preparing the master alloy, mixing the master alloy with a steel powder to produce a mixture wherein the weight % of the master alloy is from 5 to 35 weight % of the mixture, compacting the mixture into a shape of a part and sintering the mixture to produce the steel part, and controlling the cooling rate after sintering to produce sinter hardening. The master alloy powder can also be used as a sinter hardening enhancer when mixed with low-alloy steel powders.
    Type: Application
    Filed: February 15, 2011
    Publication date: February 14, 2013
    Inventors: Gilles L'Esperance, Ian Bailon-Poujol, Denis Christopherson, JR.
  • Patent number: 8329092
    Abstract: A metal powder for use in a metal laser-sintering wherein a three-dimensional shaped object is produced by irradiating a powder layer of the metal powder with a light beam to form a sintered layer and thereby laminating the sintered layers. The metal powder of the present invention is characterized in that it comprises an iron-based powder and at least one kind of powder selected from the group consisting of a nickel powder, a nickel-based alloy powder, a copper powder, a copper-based alloy powder and a graphite powder; and the iron-based powder has been annealed. In such metal powder, the iron-based powder is in a softened state due to the annealing treatment thereof. Accordingly, the use of the metal powder in a metal laser-sintering process makes it possible to reduce a machining resistance attributable to the residual metal powder adherent to the surface of the shaped object, which leads to an achievement of an extended lifetime of a machining tool.
    Type: Grant
    Filed: August 23, 2007
    Date of Patent: December 11, 2012
    Assignee: Panasonic Corporation
    Inventors: Isao Fuwa, Satoshi Abe
  • Patent number: 8309839
    Abstract: A method of improving the thermoelectric figure of merit (ZT) of a high-efficiency thermoelectric material is disclosed. The method includes the addition of fullerene (C60) clusters between the crystal grains of the material. It has been found that the lattice thermal conductivity (?L) of a thermoelectric material decreases with increasing fullerene concentration, due to enhanced phonon-large defect scattering. The resulting power factor (S2/?) decrease of the material is offset by the lattice thermal conductivity reduction, leading to enhanced ZT values at temperatures of between 350 degrees K and 700 degrees K.
    Type: Grant
    Filed: April 30, 2004
    Date of Patent: November 13, 2012
    Assignees: GM Global Technology Operations LLC, Shanghai Institute of Ceramics, Chinese Academy of Sciences
    Inventors: Lidong Chen, Xun Shi, Jihui Yang, Gregory P. Meisner
  • Patent number: 8273290
    Abstract: A method for producing a composite metal material includes preparing a solution containing a surfactant having both hydrophilicity and hydrophobicity, dispersing a nanosized to micro-sized fine carbonaceous substance into a state of being monodispersed in the solution, bringing the solution having the dispersed fine carbonaceous substance into contact with surface of a metal powder particle, drying the metal powder particle to make the fine carbonaceous substance in the monodispersed state adhere to the surface of the metal powder particle via a component of the solution, and thermally decomposing and removing the solution component adhering to the surface of the metal powder particle by heat-treating the metal powder particle either in a hydrogen-containing reducing atmosphere or in a vacuum atmosphere to partially expose the surface of the metal powder particle out of the adhering fine carbonaceous substance, and thus progress diffusion and sintering among the metal powder particles through exposed parts.
    Type: Grant
    Filed: October 16, 2008
    Date of Patent: September 25, 2012
    Assignees: National University Corporation Hokkaido University
    Inventors: Katsuyoshi Kondoh, Bunshi Fugetsu
  • Publication number: 20120230860
    Abstract: A method for purifying metal M1 particles manufactured by an electrochemical reduction process, the method comprising the steps of introducing the metal M1 particles into a heat source (13) at a temperature substantially equal to or higher than the melting point of M1 so as to cause vaporisation of some or substantially all of the contaminating impurities present, removing the vaporised impurities from the vicinity of the particles, and cooling the purified metal M1 particles. The purified particles can be used directly in lower temperature powder metallurgy processes and have a fully dense spherical particle morphology, imparting good flowability. The purification process can also be incorporated as an integral stage of sheet or stock production processes based on particle feedstocks that have been produced by electrochemical reduction.
    Type: Application
    Filed: May 22, 2012
    Publication date: September 13, 2012
    Applicant: METALYSIS LIMITED
    Inventors: Charles M. WARD-CLOSE, Alastair B. Godfrey, Paul S. Goodwin
  • Patent number: 8246903
    Abstract: Refractory metal powders are dehydrided in a device which includes a preheat chamber for retaining the metal powder fully heated in a hot zone to allow diffusion of hydrogen out of the powder. The powder is cooled in a cooling chamber for a residence time sufficiently short to prevent re-absorption of the hydrogen by the powder. The powder is consolidated by impact on a substrate at the exit of the cooling chamber to build a deposit in solid dense form on the substrate.
    Type: Grant
    Filed: September 9, 2008
    Date of Patent: August 21, 2012
    Assignee: H.C. Starck Inc.
    Inventors: Steven A. Miller, Mark Gaydos, Leonid N. Shekhter, Gokce Gulsoy
  • Patent number: 8197885
    Abstract: A method for producing a metal article according to one embodiment may include: Providing a supply of a sodium/molybdenum composite metal powder; compacting the sodium/molybdenum composite metal powder under sufficient pressure to form a preformed article; placing the preformed article in a sealed container; raising the temperature of the sealed container to a temperature that is lower than a sintering temperature of molybdenum; and subjecting the sealed container to an isostatic pressure for a time sufficient to increase the density of the article to at least about 90% of theoretical density.
    Type: Grant
    Filed: February 25, 2009
    Date of Patent: June 12, 2012
    Assignee: Climax Engineered Materials, LLC
    Inventors: Dave Honecker, Christopher Michaluk, Carl Cox, James Cole
  • Publication number: 20120114961
    Abstract: A bulk nanocomposite thermoelectric material including: a plurality of grains of a thermoelectric material; and a metal nanolayer on a boundary of the plurality of grains, wherein the metal nanolayer is crystalline, and a glass transition temperature and a crystallization temperature of the nanometal are lower than a melting point of the thermoelectric material.
    Type: Application
    Filed: September 23, 2011
    Publication date: May 10, 2012
    Applicants: Chungju National University Industry-Academic Cooperation Foundation, SAMSUNG ELECTRONICS CO., LTD.,
    Inventors: Kyu-hyoung LEE, Hyun-sik KIM, Sang-mock LEE, Eun-sung LEE, Sang-soo JEE, Il-ho KIM
  • Publication number: 20120039740
    Abstract: Processes for producing a nickel-titanium alloy are disclosed. The processes are characterized by the production of nickel-titanium alloy articles having improved microstructure. A pre-alloyed nickel-titanium alloy is melted and atomized to form molten nickel-titanium alloy particles. The molten nickel-titanium alloy particles are cooled to form nickel-titanium alloy powder. The nickel-titanium alloy powder is consolidated to form a fully-densified nickel-titanium alloy preform that is hot worked to form a nickel-titanium alloy article. Any second phases present in the nickel-titanium alloy article have a mean size of less than 10 micrometers measured according to ASTM E1245-03 (2008) or an equivalent method.
    Type: Application
    Filed: February 14, 2011
    Publication date: February 16, 2012
    Applicant: ATI Properties, Inc.
    Inventor: C. Craig Wojcik
  • Publication number: 20110279216
    Abstract: A Mn—Zn—Co ferrite core includes a basic component, sub-components, and unavoidable impurities. As the sub-components, silicon oxide (in terms of SiO2): 50-400 mass ppm and calcium oxide (in terms of CaO): 1000-4000 mass ppm are added to the basic component consisting of iron oxide (in terms of Fe2O3): 51.0-53.0 mol %, zinc oxide (in terms of ZnO): more than 12.0 mol % and 18.0 mol % or less, cobalt oxide (in terms of CoO): 0.04-0.60 mol %, and manganese oxide (in terms of MnO): balance; Phosphorus, boron, sulfur, and chlorine in the unavoidable impurities are reduced as follows, phosphorus: less than 3 mass ppm, boron: less than 3 mass ppm, sulfur: less than 5 mass ppm, and chlorine: less than 10 mass ppm; and a ratio of a measured specific surface of the Mn—Zn—Co ferrite core to an ideal specific surface of the Mn—Zn—Co ferrite core satisfies: Measured specific surface/ideal specific surface <1500.
    Type: Application
    Filed: January 29, 2010
    Publication date: November 17, 2011
    Applicant: JFE CHEMICAL CORPORATION
    Inventors: Hirofumi Yoshida, Yukiko Nakamura, Satoshi Goto
  • Publication number: 20110279217
    Abstract: A Mn—Zn ferrite core includes a basic component, sub-components, and unavoidable impurities, wherein, as the sub-components, silicon oxide (in terms of SiO2): 50 to 400 mass ppm and calcium oxide (in terms of CaO): 50 to 4000 mass ppm are added to the basic component consisting of iron oxide (in terms of Fe2O3): 51.0 to 54.5 moil, zinc oxide (in terms of ZnO): 8.0 to 12.0 moil, and manganese oxide (in terms of MnO): balance; amounts of phosphorus, boron, sulfur, and chlorine in the unavoidable impurities are reduced as follows, phosphorus: less than 3 mass ppm, boron: less than 3 mass ppm, sulfur: less than 5 mass ppm, and chlorine: less than 10 mass ppm; and a ratio of a measured specific surface of the Mn—Zn ferrite core to an ideal specific surface of the Mn—Zn ferrite core satisfies: Measured specific surface/ideal specific surface<1500 - - - (1).
    Type: Application
    Filed: January 29, 2010
    Publication date: November 17, 2011
    Applicant: JFE CHEMICAL CORPORATION
    Inventors: Hirofumi Yoshida, Yukiko Nakamura, Satoshi Goto
  • Patent number: 8038933
    Abstract: A gas sensor is for determining at least one physical quantity of a gas, e.g., an exhaust gas of an internal combustion engine, the gas sensor having a sensor element that is fixed in a housing of the gas sensor by a seal assembly. The seal assembly includes a sealing element, which has a ceramic and/or a metallic material. After the heat treatment, the sealing element has a maximum decrease in volume of 5 percent, or an increase in volume, based on the volume of the sealing element prior to the heat treatment.
    Type: Grant
    Filed: July 26, 2007
    Date of Patent: October 18, 2011
    Assignee: Robert Bosch GmbH
    Inventors: Helmut Weyl, Claudio De La Prieta, Andreas Hachtel, Thomas Schulte, Thomas Egner, Juergen Wilde, Markus Siebert, Michael Kupzig, Uwe Glanz, Rainer Mueller, Leonore Schwegler, Petra Kuschel, Andreas Pesch
  • Patent number: 8017070
    Abstract: A method of sintering a 17-4PH alloy powder and a sintered 17-4PH sintered part are disclosed. The part is formed by selective laser sintering a 17-4PH alloy powder and binder mixture to form a green part that is sintered to form a part having a substantially pure martensitic structure. The metal powder includes boron. The sintered part may be further processed by shot peening to improve crack resistance.
    Type: Grant
    Filed: May 17, 2007
    Date of Patent: September 13, 2011
    Assignee: The Boeing Company
    Inventors: Steven C. Low, Jerry G. Clark, Neal W Muylaert, Richard J. Nord, Blair E. Thompson, Bryan E. Ake, Reid W. Williams