Comminuting Patents (Class 419/33)
  • Publication number: 20080069716
    Abstract: An improved sintered material and product. A nanometer size reinforcement powder is mixed with a micron size titanium or titanium alloy powder. After the reinforcement powder is generally uniformly dispersed, the powder mixture is compacted and sintered, causing the nano reinforcement to react with the titanium or titanium alloy, producing a composite material containing nano and micron size precipitates that are uniformly distributed throughout the material.
    Type: Application
    Filed: September 14, 2006
    Publication date: March 20, 2008
    Applicants: THE TIMKEN COMPANY, IAP RESEARCH, INC.
    Inventors: Bhanumathi Chelluri, Edward Arlen Knoth, Edward John Schumaker, Ryan D. Evans, James. L. Maloney
  • Patent number: 7329382
    Abstract: Methods for producing medium-density articles from recovered high-density tungsten alloy (WHA) material, and especially from recovered WHA scrap. In one embodiment of the invention, the method includes forming a medium-density alloy from WHA material and one or more medium- to low-density metals or metal alloys. In another embodiment, medium-density grinding media, such as formed from the above method, is used to mill WHA scrap and one or more matrix metals into particulate that may be pressed and, in some embodiments, sintered to form medium-density articles therefrom.
    Type: Grant
    Filed: April 25, 2005
    Date of Patent: February 12, 2008
    Inventor: Darryl D. Amick
  • Patent number: 7311873
    Abstract: The invention relates to manufacturing of fully dense strips, plates, sheets, and foils from titanium alloys, titanium metal matrix composites, titanium aluminides, and flat multilayer composites of said materials by direct powder rolling of blended powders followed by sintering. The resulting titanium alloy flat products have properties that meet or exceed the conventional ingot metallurgy alloys and are suitable for aerospace, automotive, sporting goods, and other applications. The process includes: (a) providing C.P.
    Type: Grant
    Filed: December 30, 2004
    Date of Patent: December 25, 2007
    Assignee: ADMA Products, Inc.
    Inventors: Vladimir S. Moxson, Volodymyr A. Duz
  • Patent number: 7309373
    Abstract: A method of making tungsten carbide and a method of making a densified tungsten carbide-containing ceramic body with a transverse rupture strength greater than 300,000 psi are disclosed.
    Type: Grant
    Filed: August 3, 2005
    Date of Patent: December 18, 2007
    Assignee: Cerbide Corporation
    Inventor: Linwood Anderson
  • Patent number: 7288224
    Abstract: 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: Grant
    Filed: September 25, 2003
    Date of Patent: October 30, 2007
    Assignee: Ricoh Company, Ltd.
    Inventors: Yukio Ide, Hiroko Iwasaki, Yoshiyuki Kageyama, Yujiro Kaneko, Katsuyuki Yamada, Michiaki Shinotsuka, Makoto Harigaya, Hiroshi Deguchi
  • Patent number: 7273584
    Abstract: An oxide dispersion strengthened martensitic steel excellent in high-temperature strength having residual ?-grains can be manufactured by a method comprising mixing either element powders or alloy powders and a Y2O3 powder; subjecting the resulting mixed powder to mechanical alloying treatment; solidifying the resulting alloyed powder by hot extrusion; and subjecting the resulting extruded solidified material to final heat treatment involving normalizing and tempering heat treatment to thereby manufacture an oxide dispersion strengthened martensitic steel in which Y2O3 particles are dispersed in the steel, wherein ?to ?transformation is not allowed to occur during the described hot extrusion and the proportion of residual ?-grains in which oxide particles are finely dispersed in high density is increased by controlling the mixture ratio of the powders for the mechanical alloying treatment.
    Type: Grant
    Filed: August 30, 2004
    Date of Patent: September 25, 2007
    Assignee: Japan Nuclear Cycle Development Institute
    Inventors: Satoshi Ohtsuka, Shigeharu Ukai, Takeji Kaito, Takeshi Narita, Masayuki Fujiwara
  • Patent number: 7255933
    Abstract: A multi-layer sliding part is prepared by a process including mixing 1–50 parts by volume of a Cu-plated solid lubricant powder with 100 parts by volume of a Cu-based alloy powder comprising 5–20 mass % of Sn and a remainder of Cu to form a mixed powder, sintering the mixed powder in a reducing atmosphere to form a sintered mass, pulverizing the sintered mass to form a powder, dispersing the powder formed by pulverizing on a metal backing plate, and sintering the dispersed powder to bond grains of the dispersed powder to each other and to the backing plate. After sintering of the pulverized powder to form bearing metal layer, the bearing metal layer is pressed and densified. After densification, the bearing metal layer is annealed, again pressed, and then coated with a resin having good sliding properties.
    Type: Grant
    Filed: August 17, 2004
    Date of Patent: August 14, 2007
    Assignee: Senju Metal Industry Co., Ltd.
    Inventors: Issaku Sato, Kenzo Tadokoro, Hideaki Tanibata
  • Patent number: 7246439
    Abstract: A relatively economical process allows producing sintered shaped parts, such as sliding sleeves in motor vehicle transmissions. Open-pored undercut surfaces are formed at an internal toothing by hypocycloid milling of the part prior to its final hardening.
    Type: Grant
    Filed: October 21, 2003
    Date of Patent: July 24, 2007
    Assignee: PMG Fuessen GmbH
    Inventors: Günter Rau, Lorenz Sigl
  • Patent number: 7214343
    Abstract: The method for producing a granulated powder of the present invention includes the steps of: preparing an R—Fe—B alloy powder; and granulating the alloy powder using at least one kind of granulating agent selected from normal paraffins, isoparaffins and depolymerized oligomers, to prepare a granulated powder. The produced R—Fe—B alloy granulated powder is excellent in flowability and compactibility as well as in binder removability.
    Type: Grant
    Filed: March 27, 2002
    Date of Patent: May 8, 2007
    Assignee: Neomax Co., Ltd.
    Inventors: Futoshi Kuniyoshi, Yuji Kaneko, Akihito Tsujimoto, Kazunari Shimauchi, Kazuo Tanaka, Shizuo Mori, Kiyofumi Suzuki
  • Patent number: 7195825
    Abstract: A multi-layer sliding part is prepared by a process including mixing 1–50 parts by volume of a Cu-plated solid lubricant powder with 100 parts by volume of a Cu-based alloy powder comprising 5–20 mass % of Sn and a remainder of Cu to form a mixed powder, sintering the mixed powder in a reducing atmosphere to form a sintered mass, pulverizing the sintered mass to form a powder, dispersing the powder formed by pulverizing on a steel backing plate, and sintering the dispersed powder to bond grains of the dispersed powder to each other and to the backing plate.
    Type: Grant
    Filed: August 21, 2003
    Date of Patent: March 27, 2007
    Assignee: Senju Metal Industry Co., Ltd.
    Inventors: Issaku Sato, Kenzou Tadokoro, Hideaki Tanibata
  • Patent number: 7166171
    Abstract: Disclosed is a longitudinal magnetic field compacting method and device for manufacturing a neodymium (Nd) based rare earth magnet in the shape of a butterfly for use in VCM of HDD or DVD, a disk or coin for use in coreless motors, and a block for use in linear motors, characterized in that a longitudinal compacting process is performed under a pulse magnetic field for orientation of rare earth powders in the direction of an applied magnetic field. Further, a compacted body of the rare earth powders has the same shape as end products, thus no additional processing cost, thereby lowering manufacturing costs. In addition, the rare earth powders can be subjected to an aligning process and a longitudinal compacting process at the same time under the high pulse magnetic field of 50–70 kOe, whereby the resulting rare earth magnet can have excellent magnetic properties of 42–50 MGOe.
    Type: Grant
    Filed: July 16, 2003
    Date of Patent: January 23, 2007
    Assignee: Jahwa Electronics Co., Ltd.
    Inventor: Dong-Hwan Kim
  • Patent number: 7141126
    Abstract: 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: Grant
    Filed: June 22, 2004
    Date of Patent: November 28, 2006
    Assignee: Neomax Co., Ltd.
    Inventors: Futoshi Kuniyoshi, Hitoshi Morimoto
  • Patent number: 7087202
    Abstract: This invention concerns particulate reinforced Al-based composites, and the near net shape forming process of their components. The average size of the reinforced particle in the invented composites is 0.1–3.5 ?m and the volume percentage is 10–40%, and a good interfacial bonding between the reinforced particulate and the matrix is formed with the reinforced particles uniformly distributed. The production method of its billet is to have the reinforced particles and Al-base alloy powder receive variable-speed high-energy ball-milling in the balling drum. Then, with addition of a liquid surfactant, the ball-mill proceeds to carry on ball-milling. After the ball-milling, the produced composite powder undergoes cold isostatic pressing and the subsequent vacuum sintering or vacuum hot-pressing to be shaped into a hot compressed billet, which in turn undergoes semisolid thixotropic forming and may be shaped into complex-shaped components. These components can be used in various fields.
    Type: Grant
    Filed: July 28, 2003
    Date of Patent: August 8, 2006
    Assignees: ASM Assembly Automation Ltd., General Research Institute for Non-Ferrous Metals
    Inventors: Deming Liu, Chou Kee Peter Liu, Jian Zhong Fan, Jun Xu, Tao Zuo, Zhao Zu Gao
  • Patent number: 7056393
    Abstract: 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: Grant
    Filed: May 28, 2002
    Date of Patent: June 6, 2006
    Assignee: Neomax, Co., Ltd.
    Inventors: Koki Tokuhara, Hitoshi Morimoto
  • Patent number: 7052526
    Abstract: A magnesium base composite material is provided such that compound particles generated by a solid-phase reaction with magnesium are uniformly dispersed in a magnesium alloy body. The compound particles dispersed in the body comprise magnesium silicide (Mg2Si) and magnesium oxide (MgO) so that the magnesium base composite material may have excellent strength, hardness and abrasion resistance and tempered opponent aggression.
    Type: Grant
    Filed: February 14, 2003
    Date of Patent: May 30, 2006
    Assignee: Toudai TLO, Ltd.
    Inventor: Katsuyoshi Kondoh
  • Patent number: 7037464
    Abstract: In an oxide dispersion strengthened martensitic steel which comprises, by % by weight, 0.05 to 0.25% C, 8.0 to 12.0% Cr, 0.1 to 4.0% W, 0.1 to 1.0% Ti, 0.1 to 0.5% Y2O3 with the balance being Fe and unavoidable impurities and in which Y2O3 particles are dispersed in the steel, by adjusting the Ti content within the range of 0.1 to 1.0% so that an excess oxygen content Ex.O in steel satisfies [0.22×Ti (% by weight)<Ex.O (% by weight)<0.46×Ti (% by weight)], the oxide particles are finely dispersed and highly densified to thereby obtain an oxide dispersion strengthened martensitic steel excellent in high-temperature strength. It is also possible to reduce the amount of oxygen contamination in steel during the mechanical alloying of raw material powders to provide Ex.O within a predetermined range, by carrying out the mechanical alloying in an Ar atmosphere having a super purity of not less than 99.
    Type: Grant
    Filed: August 7, 2003
    Date of Patent: May 2, 2006
    Assignee: Japan Nuclear Cycle Development Institute
    Inventors: Satoshi Ohtsuka, Shigeharu Ukai, Takeji Kaito, Takeshi Narita, Masayuki Fujiwara
  • Patent number: 7018485
    Abstract: An apparatus for subjecting a rare earth alloy block to a hydrogenation process includes a casing, gas inlet and outlet ports, a member arranged to produce a gaseous flow, and a windbreak plate. The casing defines an inner space for receiving a container. The container includes an upper opening and stores the rare earth alloy block therein. A hydrogen gas and an inert gas are introduced into the inner space through the gas inlet port, and are exhausted from the inner space through the gas outlet port. The gaseous flow is produced by a fan, for example, in the inner space. The windbreak plate is disposed upstream with respect to the gaseous flow that has been produced inside the inner space. Also, the windbreak plate reduces a flow rate of the gaseous flow that has been produced near the upper opening of the container.
    Type: Grant
    Filed: June 25, 2002
    Date of Patent: March 28, 2006
    Assignee: Neomax Co., Ltd.
    Inventors: Akihito Tsujimoto, Katsumi Okayama, Shinji Kidowaki, Tadayoshi Muneto
  • Patent number: 6863862
    Abstract: Methods of producing atomized intermetallic aluminide powders with a controlled oxygen content, and articles made from the powders by powder metallurgical techniques are disclosed. Gas atomized intermetallic aluminide powders can be oxidized to increase their oxygen content. Water atomized intermetallic aluminide powders can be milled to change their size, shape and/or oxygen content. Blends or mixtures of modified gas and water atomized intermetallic aluminide powders can be processed into articles by powder metallurgical techniques.
    Type: Grant
    Filed: September 4, 2002
    Date of Patent: March 8, 2005
    Assignee: Philip Morris USA Inc.
    Inventors: Firooz Rasouli, Clive Scorey, John McKernan, John F. Cunningham
  • Publication number: 20040170552
    Abstract: The present invention relates to a hafnium silicide target for forming a gate oxide film composed of HfSi1.02-2.00. Obtained is a hafnium silicide target superior in workability and embrittlement resistance, and suitable for forming a HfSiO film and HfSiON film that may be used as a high dielectric gate insulation film in substitute for a SiO2 film, and to the manufacturing method thereof.
    Type: Application
    Filed: December 10, 2003
    Publication date: September 2, 2004
    Inventors: Shuichi Irumata, Ryo Suzuki
  • Publication number: 20040149354
    Abstract: The method for producing a granulated powder of the present invention includes the steps of: preparing an R—Fe—B alloy powder; and granulating the alloy powder using at least one kind of granulating agent selected from normal paraffins, isoparaffins and depolymerized oligomers, to prepare a granulated powder. The produced R—Fe—B alloy granulated powder is excellent in flowability and compactibility as well as in binder removability.
    Type: Application
    Filed: March 29, 2004
    Publication date: August 5, 2004
    Inventors: Futoshi Kuniyoshi, Yuji Kaneko, Akihito Tsujimoto, Kazunari Shimauchi, Kazuo Tanaka, Kiyofumi Suzuki
  • Patent number: 6770242
    Abstract: Permanent magnet for voice coil actuator motors used to actuate head-arm assemblies in small form disk drives are produced from a dispersion of prealloyed rare earth magnetic particles in a thermoplastic binder. Upon shaping of green parts the magnetic axis of the particles is aligned with the field lines of a magnetic field. Following extraction of the binder the green parts are sintered to net shape. Improved magnetic properties, smaller dimensions, better than tolerances and 100% material utilization are claimed.
    Type: Grant
    Filed: April 26, 2002
    Date of Patent: August 3, 2004
    Inventors: Romain L. Billiet, Hanh T. Nguyen
  • Patent number: 6746545
    Abstract: An R—Fe—B permanent magnet wherein R is Nd or a combination of Nd with a rare earth element is prepared by casting an R—Fe—B alloy, crushing the alloy in an oxygen-free atmosphere of argon, nitrogen or vacuum, effecting comminution, compaction, sintering, aging, and cutting and/or polishing the magnet to give a finished surface. The magnet is then heat treated in an argon, nitrogen or low-pressure vacuum atmosphere having a limited oxygen partial pressure, obtaining a highly oil resistant sintered permanent magnet having corrosion resistance and hydrogen barrier property even in a high pressure hot environment of refrigerant and/or lubricant as encountered in compressors.
    Type: Grant
    Filed: May 30, 2001
    Date of Patent: June 8, 2004
    Assignee: Shin-Etsu Chemical Co., Ltd.
    Inventors: Kazuo Tamura, Masanobu Shimao, Ryuji Hamada, Takehisa Minowa
  • Patent number: 6740287
    Abstract: A method of fabricating nanostructure bodies by integrating the steps of attriting precursor nanometer-sized particulate materials, desorbing the exposed surfaces of the attrited nanoparticulates, adsorbing a surfactant on at most 50% of the desorbed surfaces and dispersing the surfactant-coated nanoparticulates in an organic matrix to form a homogeneous thermoplastic compound from which green bodies are shaped, dewaxed and sintered.
    Type: Grant
    Filed: February 11, 2002
    Date of Patent: May 25, 2004
    Inventors: Romain Louis Billiet, Hanh T. Nguyen
  • Publication number: 20040086413
    Abstract: A relatively economical process allows producing sintered shaped parts, such as sliding sleeves in motor vehicle transmissions. Open-pored undercut surfaces are formed at an internal toothing by hypocycloid milling of the part prior to its final hardening.
    Type: Application
    Filed: October 21, 2003
    Publication date: May 6, 2004
    Inventors: Gunter Rau, Lorenz Sigl
  • Publication number: 20040067154
    Abstract: A melt of an alloy, represented (Fe1-mTm)100-x-y-zQxRyMz, where T is Co and/or Ni, Q is B and/or C, R is at least one rare-earth element, M is selected from Al, Si, Ti, V, Cr, Mn, Cu, Zn, Ga, Zr, Nb, Mo, Ag, Hf, Ta, W, Pt, Au and Pb; 10 at %≦x≦35 at %; 2 at %≦y≦10 at %; 0 at %≦z≦10 at %; and 0≦m≦0.5, is prepared. Next, the melt is brought into contact with, and rapidly cooled and solidified by, the surface of a rotating chill roller. The melt is teemed onto a guide member, of which the guide surface defines a tilt angle with a horizontal plane, runs down on the guide surface, and then is fed through at least one tubular hole onto a contact area on the surface of the chill roller.
    Type: Application
    Filed: June 27, 2003
    Publication date: April 8, 2004
    Applicant: Sumitomo Special Metals Co., Ltd
    Inventor: Hirokazu Kanekiyo
  • Publication number: 20040050455
    Abstract: A method of making an alloy powder for an R—Fe—B—type rare earth magnet includes the steps of preparing a material alloy that is to be used for forming the R—Fe—B—type rare earth magnet and that has a chilled structure that constitutes about 2 volume percent to about 20 volume percent of the material alloy, coarsely pulverizing the material alloy for the R—Fe—B—type rare earth magnet by utilizing a hydrogen occlusion phenomenon to obtain a coarsely pulverized powder, finely pulverizing the coarsely pulverized powder and removing at least some of fine powder particles having particle sizes of about 1.0 &mgr;m or less from the finely pulverized powder, thereby reducing the volume fraction of the fine powder particles with the particle sizes of about 1.0 &mgr;m or less, and covering the surface of remaining ones of the powder particles with a lubricant after the step of removing has been performed.
    Type: Application
    Filed: August 21, 2003
    Publication date: March 18, 2004
    Applicant: Sumitomo Special Metals Co., Ltd.
    Inventors: Yuji Kaneko, Junichiro Baba, Katsuya Taniguchi
  • Patent number: 6706240
    Abstract: Methods of forming niobium powders and other metal powders are described. The method involves milling the metal powders at elevated temperatures and in the presence of at least one liquid solvent. The methods of the present invention have the ability to reduce DC leakage and/or increase capacitance capabilities of metal powders when formed into capacitor anodes. The present invention further has the ability to significantly reduce the milling time necessary to form high surface area metal powders and leads to reducing the amount of contaminants in the metal powders. Metal powders such as niobium powders having reduced amount of contaminants and/or having DC leakage or capacitance capabilities are also described. A process is further described for forming a flaked metal by wet-milling a metal powder into a flaked metal wherein at least one liquid fluorinated fluid is present during the wet-milling process.
    Type: Grant
    Filed: March 11, 2002
    Date of Patent: March 16, 2004
    Assignee: Cabot Corporation
    Inventors: Kurt A. Habecker, James A. Fife
  • Publication number: 20040042922
    Abstract: Methods of producing atomized intermetallic aluminide powders with a controlled oxygen content, and articles made from the powders by powder metallurgical techniques are disclosed. Gas atomized intermetallic aluminide powders can be oxidized to increase their oxygen content. Water atomized intermetallic aluminide powders can be milled to change their size, shape and/or oxygen content. Blends or mixtures of modified gas and water atomized intermetallic aluminide powders can be processed into articles by powder metallurgical techniques.
    Type: Application
    Filed: September 4, 2002
    Publication date: March 4, 2004
    Inventors: Firooz Rasouli, Clive Scorey, John McKernan, John F. Cunningham
  • Patent number: 6692690
    Abstract: There is now provided a cemented carbide grade for rock excavation purposes with 88-96 weight % WC, preferably 91-95% weight % WC, with a binder phase consisting of only cobalt or cobalt and nickel, with a maximum of 25% of the binder being Ni, possibly with small additions of rare earth metals, such as Ce and Y, up to a maximum of 2% of the total cemented carbide. The WC grains are rounded because of the process of coating the WC with cobalt, and not recrystallized or showing grain growth or very sharp cornered grains like conventionally milled WC, thus giving the bodies surprisingly high thermal conductivity. The average grain size should be from 8-30 &mgr;m, preferably from 12-20 &mgr;m. The maximum grain size does not exceed 2 times the average value and no more than 2% of the grains found in the structure are less than half of the average grain size.
    Type: Grant
    Filed: April 2, 2002
    Date of Patent: February 17, 2004
    Assignee: Sandvik AB
    Inventors: Jan &angst;kerman, Thomas Ericson
  • Patent number: 6663827
    Abstract: Rotors for stepping motors used in analog timepieces are produced from a mixture of prealloyed rare earth magnetic particles and a thermoplastic binder. The mixture is either tape cast in a magnetic field following blanking of green rotors or injection molded in a magnetic field. Following extraction of the binder the green parts are sintered to net shape. Improved magnetic properties, smaller dimensions, better tolerances and 100% material utilization are claimed.
    Type: Grant
    Filed: March 11, 2002
    Date of Patent: December 16, 2003
    Inventors: Romain L. Billiet, Hanh Thi Nguyen
  • Patent number: 6652806
    Abstract: A sputtering target contains a target material including as constituent elements Ag, In, Te and Sb with the respective atomic percents (atom. %) of &agr;, &bgr;, &ggr; and &dgr; thereof being in the relationship of 0.5≦&agr;<8, 5≦&bgr;≦23, 17≦&ggr;≦38, 32≦&dgr;≦73, &agr;≦&bgr;, and &agr;+&bgr;+&ggr;+&dgr;=100, and a method of producing the above sputtering target is provided. An optical recording medium includes a recording layer containing a phase-change recording material which includes as constituent elements Ag, In, Te and Sb with the respective atomic percents of &agr;, &bgr;, &ggr; and &dgr; thereof being in the relationship of 1≦&agr;<6, 7≦&bgr;≦20, 20≦&ggr;≦35, 35≦&dgr;≦70, and &agr;+&bgr;+&ggr;+&dgr;=100, and is capable of recording and erasing information by utilizing the phase change of the recording material in the recording layer.
    Type: Grant
    Filed: September 19, 2001
    Date of Patent: November 25, 2003
    Assignee: Ricoh Company, Ltd.
    Inventors: Yukio Ide, Hiroko Iwasaki, Yoshiyuki Kageyama, Yujiro Kaneko, Katsuyuki Yamada, Michiaki Shinotsuka, Makoto Harigaya, Hiroshi Deguchi
  • Patent number: 6635120
    Abstract: A sintered rare earth magnet is produced by finely pulverizing a coarse rare earth magnet alloy powder to an average particle size of 1-10 &mgr;m in a non-oxidizing atmosphere; introducing the resultant fine rare earth magnet alloy powder into a non-oxidizing liquid comprising at least one oil selected from the group consisting of mineral oils, synthetic oils and vegetable oils, and at least one lubricant selected from the group consisting of esters of aliphatic acids and monovalent alcohols, esters of polybasic acids and monovalent alcohols, esters of aliphatic acids and polyvalent alcohols and their derivatives to prepare a slurry; molding the slurry; degreasing the resultant green body; sintering the degreased green body; and then heat-treating the green body.
    Type: Grant
    Filed: September 14, 2001
    Date of Patent: October 21, 2003
    Assignee: Hitachi Metals, Ltd.
    Inventors: Hisato Tokoro, Kimio Uchida
  • Patent number: 6540810
    Abstract: An object of the present invention is to provide a niobium sintered body free of reduction in the CV value, a niobium powder for use in the manufacture of the niobium sintered body, and a capacitor using the niobium sintered body. A niobium powder of the present invention has niobium and tantalum, where the tantalum is present in an amount at most of about 700 ppm by mass. A sintered body and a capacitor each is manufactured using the niobium powder.
    Type: Grant
    Filed: April 23, 2001
    Date of Patent: April 1, 2003
    Assignee: Showa Denko Kabushiki Kaisha
    Inventors: Kazumi Naito, Kazuhiro Omori
  • Patent number: 6537385
    Abstract: The method for manufacturing alloy powder for R—Fe—B type rare earth magnets of the present invention includes a first pulverization step of coarsely pulverizing a material alloy for rare earth magnets and a second pulverization step of finely pulverizing the material alloy. In the first pulverization step, the material alloy is pulverized by a hydrogen pulverization method. In the second pulverization step, easily oxidized super-fine powder (particle size: 1.0 &mgr;m or less) is removed to adjust the particle quantity of the super-fine powder to 10% or less of the particle quantity of the entire powder.
    Type: Grant
    Filed: July 9, 2002
    Date of Patent: March 25, 2003
    Assignee: Sumitomo Special Metals Co., Ltd.
    Inventors: Katsumi Okayama, Naoyuki Ishigaki, Shuhei Okumura
  • Patent number: 6500385
    Abstract: Process for working up powder coating waste to yield reusable powder coatings by compacting the powder coating waste without complete melting to yield a sintered product, in which process powder coating residues arising during powder coating production are continuously separated, continuously compacted and the compacted product is continuously ground together with fresh material to be ground of the same batch of powder coating without extrusion to yield a powder coating.
    Type: Grant
    Filed: April 19, 2000
    Date of Patent: December 31, 2002
    Assignee: E. I. du Pont de Nemours and Company
    Inventors: Karsten Blatter, David Montgomery, Heléne Bolm
  • Patent number: 6475428
    Abstract: A method of producing high purity, low oxygen content titanium powder utilizes a hydrided titanium powder crushed to desired percentage of particles of not more than a desired size. These hydrided particles are dehydrided by a slow heating process under partial vacuum to draw the hydrogen out of the particles with a minimum of sintering of the particles. The hydrided particles may be initially heated relatively rapidly, over a period of between about two hours and six hours to a temperature of between about 450° C. and 500° C. and then slowly over a period of four to five days to a temperature of between 650° C. and 700° C., all under a partial vacuum, until the hydrogen content of the powder reaches a desired value. The now dehydrided titanium powder is cooled, again crushed if and as necessary to break up any sintered particles, screened, and packaged. The method of the invention minimizes the sintering of the particles during the dehydriding process.
    Type: Grant
    Filed: April 21, 2001
    Date of Patent: November 5, 2002
    Inventors: Joseph T. Fraval, Mitchell T. Godfrey
  • Publication number: 20020150496
    Abstract: A product in which at least a portion of the product has a nanocrystalline microstructure, and a method of forming the product. The method generally entails machining a body in a manner that produces chips consisting entirely of nano-crystals as a result of the machining operation imposing a sufficiently large strain deformation. The body can be formed of a variety of materials, including metal, metal alloy and ceramic materials. Furthermore, the body may have a microstructure that is essentially free of nano-crystals, and may even have a single-crystal microstructure. The chips produced by the machining operation may be in the form of particulates, ribbons, wires, filaments and/or platelets. The chips are then used to form the product. According to one aspect of the invention, the chips are consolidated to form the product, such that the product is a monolithic material that may contain nano-crystals.
    Type: Application
    Filed: October 27, 2001
    Publication date: October 17, 2002
    Inventors: Srinivasan Chandrasekar, Walter D. Compton, Thomas N. Farris, Kevin P. Trumble
  • Patent number: 6461565
    Abstract: A green compact of a rare earth alloy magnetic powder is made by pressing the powder. The powder is pressed within an air environment that has a temperature controlled at 30° C. or less and a relative humidity controlled at 65% or less.
    Type: Grant
    Filed: March 8, 2001
    Date of Patent: October 8, 2002
    Assignee: Sumitomo Special Metals Co., Ltd.
    Inventors: Koki Tokuhara, Shuhei Okumura, Akiyasu Oota
  • Patent number: 6454992
    Abstract: A bond coat composition for use in thermal barrier coatings comprises a NiAl—CoCrAlY matrix containing particles of AlN dispersed therein. The bond coat composition is prepared by croymilling NiAl and CoCrAlY in liquid nitrogen.
    Type: Grant
    Filed: September 29, 2000
    Date of Patent: September 24, 2002
    Assignee: Ohio Aerospace Institute
    Inventor: Mohan G. Hebsur
  • Patent number: 6447715
    Abstract: Methods for producing medium-density articles from recovered high-density tungsten alloy (WHA) material, and especially from recovered WHA scrap. In one embodiment of the invention, the method includes forming a medium-density alloy from WHA material and one or more medium- to low-density metals or metal alloys. In another embodiment, medium-density grinding media, such as formed from the above method, is used to mill WHA scrap and one or more matrix metals into particulate that may be pressed and, in some embodiments, sintered to form medium-density articles therefrom.
    Type: Grant
    Filed: January 14, 2000
    Date of Patent: September 10, 2002
    Inventor: Darryl D. Amick
  • Patent number: 6403875
    Abstract: A process for producing a thermoelectric material comprising mixing at least two of bismuth, tellurium, selenium, and antimony and, if desired, a dopant, melting the mixture, grinding the resulting alloy ingot, forming the powder, and sintering the green body under normal pressure, or hot pressing the powder, wherein the grinding and the normal sintering or hot pressing are carried out in the presence of a solvent represented by CnH2n+1OH or CnH2n+2CO (wherein n is 1, 2 or 3).
    Type: Grant
    Filed: February 23, 2001
    Date of Patent: June 11, 2002
    Assignee: Mitsui Mining & Smelting Company, Ltd.
    Inventors: Shinji Karino, Ryouma Tsukuda, Yuichi Anno, Isamu Yashima, Hitoshi Kajino
  • Patent number: 6403024
    Abstract: A hydrogen pulverizer according to the present invention is an apparatus for subjecting a rare-earth alloy magnetic material to a hydrogen pulverization process. The apparatus includes: a hermetically sealable hydrogen furnace, which includes a furnace body with an opening and a cap for closing the opening; a loading chamber for temporarily enclosing the rare-earth alloy magnetic material when the rare-earth alloy magnetic material, which has been pulverized with hydrogen, is unloaded from the furnace body through the opening; and an inert gas supply for supplying an inert gas into the loading chamber.
    Type: Grant
    Filed: February 15, 2000
    Date of Patent: June 11, 2002
    Assignee: Sumitomo Special Metals Co., Ltd.
    Inventors: Akiyasu Oota, Akihito Tsujimoto, Katsumi Okayama
  • Patent number: 6338907
    Abstract: The invention relates to an abrasive tool comprising a support body and at least one abrasive element connected thereto. Said abrasive element has an abrasive grain which is joined by a sintered metal. The sintered metal used for joining is copper-coated iron and is alloyed with metal borides, metal carbides and/or metal silicides and also with tin.
    Type: Grant
    Filed: April 3, 2000
    Date of Patent: January 15, 2002
    Assignee: Tyrolit Schleifmittelwerke Swarovski K.G.
    Inventor: Wolfgang Strelsky
  • Patent number: 6312643
    Abstract: Nanoscale aluminum alloy powder is synthesized by mechanical alloying/milling techniques without significant oxidation, nitridation, or contamination with foreign materials. These powders are consolidated into a very dense billet form without a high temperature sintering step. The desired microstructure and properties were obtained by post hot isostatic pressing, extrusion, and/or forging of the nanoscale material billet made from the powders.
    Type: Grant
    Filed: October 24, 1997
    Date of Patent: November 6, 2001
    Assignee: The United States of America as represented by the Secretary of the Air Force
    Inventors: Kamleshwar Upadhya, Wesley P. Hoffman
  • Patent number: 6312494
    Abstract: A thin arc segment magnet made of a rare earth sintered magnet substantially comprising 28-33 weight % of R and 0.8-1.5 weight % of B, the balance being substantially Fe, wherein R is at least one rare earth element including Y, and T is Fe or Fe and Co, which has an oxygen content of 0.3 weight % or less, a density of 7.56 g/cm3 or more, a coercivity iHc of 1.1 MA/m (14 kOe) or more at room temperature, and an orientation Br/4&pgr;Imax of 96% or more in an anisotropy-providing direction at room temperature can be produced by using a slurry mixture formed by introducing fine alloy powder of the above composition into a mixture liquid comprising 99.7-99.99 parts by weight of a mineral oil, a synthetic oil or a vegetable oil and 0.01-0.3 parts by weight of a nonionic surfactant and/or an anionic surfactant.
    Type: Grant
    Filed: July 5, 2000
    Date of Patent: November 6, 2001
    Assignee: Hitachi Metals, Ltd.
    Inventors: Hisato Tokoro, Kimio Uchida, Kazuo Oda, Tsukasa Mikamoto
  • Patent number: 6312642
    Abstract: A method for controlling oxygen content in valve metal materials. The method includes deoxidizing a valve metal material, typically tantalum, niobium, or alloys thereof, and leaching the material in an acid leach solution at a temperature lower than room temperature. In one embodiment of the present invention, the acid leach solution is prepared and cooled to a temperature lower than room temperature prior to leaching the deoxidized valve metal material. The method of the present invention has been found to lower both the oxygen and fluoride concentrations in valve metal materials, as the use of reduced acid leach temperatures provide lower oxygen for a given quantity of a leach acid, such as hydrofluoric acid.
    Type: Grant
    Filed: July 2, 1999
    Date of Patent: November 6, 2001
    Assignee: Cabot Corporation
    Inventor: James A. Fife
  • Patent number: 6280684
    Abstract: A sputtering target for fabricating a recording layer of a phase-change type optical recording medium contains a compound or mixture including as constituent elements Ag, In, Te and Sb with the respective atomic percent (atom. %) of &agr;, &bgr;, &ggr; and &dgr; thereof being in the relationship of 2≦&agr;≦30, 3≦&bgr;≦30, 10≦&ggr;≦50, 15≦&dgr;≦83 and &agr;+&bgr;+&ggr;+&dgr;=100, and a method of producing the above sputtering target is provided. A phase-change type optical recording medium includes a recording layer containing as constituent elements Ag, In, Te and Sb with the respective atomic percent of &agr;, &bgr;, &ggr; and &dgr; thereof being in the relationship of 0<&agr;≦30, 0<&bgr;≦30, 10≦&ggr;≦50, 10≦&dgr;≦80, and &agr;+&bgr;+&ggr;+&dgr;=100, and is capable of recording and erasing information by utilizing the phase changes of a recording material in the recording layer.
    Type: Grant
    Filed: January 19, 2000
    Date of Patent: August 28, 2001
    Assignee: Ricoh Company, Ltd.
    Inventors: Katsuyuki Yamada, Hiroko Iwasaki, Yukio Ide, Makoto Harigaya, Yoshiyuki Kageyama, Hiroshi Deguchi, Masaetsu Takahashi, Yoshitaka Hayashi
  • Patent number: 6071323
    Abstract: An alloy target comprises at least one rare earth metal element Tb, Dy, Gd, Sm, Nd, Ho, Tm, and Er with a substantial balance of a transition metal element such as Fe, Co and Ni, and has a substantially homogeneous sintered structure and a permeability of 3 or lower. The alloy target is fabricated by a process comprising steps of melting in a high-frequency furnace or crucible furnace, quenching, pulverization, and firing under pressure. After the alloy target has been used up, it is regenerated by mixing alloy powders (to be regenerated) obtained by the mechanical pulverization of the used-up target with the alloy powders obtained at the pulverization step of the aforesaid process to obtain a mixture, and firing the mixture under pressure.
    Type: Grant
    Filed: March 2, 1998
    Date of Patent: June 6, 2000
    Assignee: TDKCorporation
    Inventor: Yukio Kawaguchi
  • Patent number: 6024914
    Abstract: Conventional anodes for solid electrolytic capacitor have small numbers of spaces and gaps therein and, when made into a capacitor, have shown insufficient (high) tan d and ESR. An anode having enlarged numbers of spaces and gaps and giving a capacitor of improved tan d and ESR can be produced by using, as a material for shaped material (anode before sintering), a mixed powder of a granulated valve metal powder of 50 to 200 .mu.m in particle diameter and a solid organic substance of 20 .mu.m or less in average particle diameter.
    Type: Grant
    Filed: August 31, 1998
    Date of Patent: February 15, 2000
    Assignee: NEC Corporation
    Inventor: Katsuhiro Yoshida
  • Patent number: RE40348
    Abstract: A thin arc segment magnet made of a an R-T-B based, rare earth sintered magnet substantially comprising 28-33 weight % of R and 0.8-1.5 weight % of B, the balance being substantially Fe T, wherein R is at least one rare earth element including Y, and T is Fe or Fe and Co, which has an oxygen content of 0.3 weight % or less, a density of 7.56 g/cm3 or more, a coercivity iHc of 1.1 MA/m (14 kOe) or more at room temperature, and an orientation Br/4?Imax of 96% or more in an anisotropy-providing direction at room temperature can be produced by using a slurry mixture formed by introducing fine alloy powder of the above composition into a mixture liquid comprising 99.7-99.99 parts by weight of a mineral oil, a synthetic oil or a vegetable oil and 0.01-0.3 parts by weight of a nonionic surfactant and/or an anionic surfactant.
    Type: Grant
    Filed: November 5, 2003
    Date of Patent: June 3, 2008
    Assignee: Hitachi Metals, Ltd.
    Inventors: Hisato Tokoro, Kimio Uchida, Kazuo Oda, Tsukasa Mikamoto