Abstract: A conductive metal-filled substrate is formed by intermingling copper or nickel particles into the substrate, contacting the metal particles with a specified developing agent, and heating the metal particles and the developing agent. The filled substrates are electrically conductive and are useful for a variety of uses such as EMI shielding.

Abstract: 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.

Abstract: A magnetically anisotropic R-T-B magnet having crystal grains having aspect ratios of 2 or more and showing a substantially uniform maximum energy product distribution is produced by (a) rapidly quenching an alloy melt; (b) finely pulverizing the rapidly quenched alloy to provide magnetic powder; (c) mixing the magnetic powder with a carbon-containing additive; (d) coating the resulting mixture with a protective layer of a first lubricant such as BN substantially unreactive with the alloy components; (e) compressing it; (f) further coating the resulting compressed body with a second lubricant such as graphite or graphite+glass; and (g) further compressing it.

Abstract: This invention relates to a process for producing a rare earth-containing material capable of being formed into a permanent magnet comprising crushing a rare earth-containing alloy and treating the alloy with a passivating gas at a temperature below the phase transformation temperature of the alloy. This invention further 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. This invention also relates to a process for producing a rare earth-containing powder comprising crushing a rare earth-containing alloy in water, drying the crushed alloy material at a temperature below the phase transformation temperature of the material, and treating the crushed alloy material with a passivating gas at a temperature from the ambient temperature to a temperature below the phase transformation temperature of the material.

Abstract: The present invention relates to a method of fabricating various types of bearing materials and the bearing materials produced thereby. The processes of the invention may be used to produce porous self-lubricating bearings, laminated composite bearings (babbitt bearings) and bearings for high temperature application. The processes of the invention involve the use of micro-pyretic synthesis to achieve bearing materials with improved bearing properties, including higher bearing capacity and toughness.

Abstract: A process for forming articles from inorganic sinterable particulates includes providing a well-dispersed, low pressure injectable slurry, freeze-forming the slurry into a desired geometry, and drying the piece so formed by a predominantly sublimative process, to produce a green article that can be conventionally sintered. The vehicle has a volume change on freezing of not more than .+-.10% by volume; to further control the volume change on freezing, an emulsion derived from different vehicles can be tailored. The slurries preferably have a solids content of at least about 35 v/o, a viscosity of preferably not more than about 1000 cP at 100 s.sup.-1, and are preferably injectable at not more than about 1000 psi, usually at less than 100 psi.

Abstract: This invention relates generally to materials and processes for making materials and, more particularly, to high performance boride dispersion strengthened materials, including alloy-modified, boride dispersion strengthened materials and techniques for making such materials.

Abstract: A conductive metal-filled substrate is formed by intermingling copper or nickel particles into the substrate, contacting the metal particles with a specified developing agent, and heating the metal particles and the developing agent. The filled substrates are electrically conductive and are useful for a variety of uses such as EMI shielding.

Abstract: A magnesium-based composite material having improved mechanical strength, and in particular an improved modulus of elasticity, and a relatively low density. The material is provided by pressing and sintering a mixture of magnesium or magnesium-based alloy particles or a particulate combination of magnesium particles and particles of one or more additional metals, with a reinforcement additive of boron, or boron-coated B.sub.4 C, Si.sub.3 N.sub.4, SiC, Al.sub.2 O.sub.3 or MgO particles.

Abstract: A high melting metal silicide sputtering target which comprises a fine texture whose stoichiometric composition grains of MSi.sub.2, where M represents a high melting metal, have a maximum grain size of 20 .mu.m, whose free silicon grains have a maximum grain size of 50 .mu.m and whose oxygen content is not more than 200 ppm and has a density ratio to the theoretical density of 99% or more has good film characteristics including the reduction in the number of grains formed on the sputtered film and is useful as an electrode material or a wiring material in semi-conductor devices.

Abstract: A process for controlling fractionation in selenium alloys comprising providing pellets of an alloy comprising amorphous selenium and an alloying component selected from the group consisting of tellurium, arsenic, and mixtures thereof, the particles having an average particle size between about 300 micrometers and about 3,000 micrometers, exposing the pellets to an ambient temperature of between about 114.degree. C. and about 190.degree. C. until an exotherm occurs in the pellets resulting in substantially complete crystallization between about 104.degree. C. and about 180.degree. C., grinding the pellets into fresh powder having an average particle size of less than about 200 micrometers, and compressing the fresh powder into fresh pellets having an average weight between about 50 mg and about 1000 mg. The resulting fresh pellets may be heated in a vacuum chamber to vacuum deposit the alloy onto a substrate.

Abstract: A composition of matter comprised of copper and particles which are dispersed throughout the copper, where the particles are comprised of copper oxide and copper having a coating of copper oxide, and a method for making this composition of matter.

Abstract: Contact materials based on AgSnO.sub.2 and having Bi.sub.2 O.sub.3 and CuO as further metal oxide additives were previously disclosed. In these materials the total content of all metal oxides was supposed to be between 10 and 25% by volume with the SnO.sub.2 share equal to or greater than 70% by volume of the total amount of oxide.According to this invention the quantity of SnO.sub.2 is kept smaller than 70% by volume; specifically at about 65%, but in any case equal to or greater than 50%. The SnO.sub.2 weight content is to be in the 4% to 8% range and the weight percentage ratio of SnO.sub.2 to CuO is to be between 8:1 and 12:1.In the associated production process, either Bi.sub.2 O.sub.3 powder is purposely admixed to an internally oxidized alloy powder (IOAP) in an additional operation, a grain restructuring with locally different Bi.sub.2 O.sub.3 concentrations occurring in the structure after sintering and compacting.

Abstract: A silver base electrical contact material is described which contains a dispersion of particles consisting of cadmium oxide and nickel. The nickel particles are surrounded by a continuous adherent coating of nickel oxide which eliminates the detrimental reaction which would otherwise occur between nickel and cadmium oxide. The invention contact materials have improved lives and are fabricated by any one of several different powder metallurgy techniques.

Abstract: A method of producing a material having a layer of ceramic as a first component, a layer of a metal as a second component and an intermediate layer lying between said layers and including said first and second components in continuous gradient ratios so that the properties of the material may change continuous, including a step of forming said intermediate layer by igniting a powder mixture of metallic and nonmetallic constitutive elements of said ceramic component and said metal component so as to cause a synthetic reaction in the powder mixture.

Abstract: A rare earth-iron-boron alloy powder which consists essentially of:12.5 to 20 at % R wherein R.sub.1 is 0.05 to 5 at %, 4 to 20 at % B, and 60 to 83.5 at % Fe,wherein R.sub.1 is at least one heavy rare earth element selected from the group consisting of Gd, Tb, Dy, Ho, Er, Tm and Yb, 80 to 100 at % of R.sub.2 consists of Nd and/or Pr, the balance in the R.sub.2 being at least one element selected from the group consisting of rare earth elements including Y and except for R.sub.1, and R=R.sub.1 =R.sub.2 by atomic %, wherein a major phase of at least 80 vol % of the entire alloy coinsists of a tetragonal structure, and wherein oxygen does not exceed 10,000 ppm, carbon does not exceed 1000 ppm and calcium does not exceed 2000 ppm. The alloy powder is produced by directly reducing a mixture comprising rare earth oxide, iron and other ingredients or oxide thereof with a reducing agent Ca and CaCl.sub.2, putting the reduced product into water, then treating with water. Up to 35 at % Co may be substituted for Fe.

Abstract: A process is disclosed for producing tungsten heavy alloy sheet. The process comprises crystallizing from solution the compounds of the component metals of the alloy, and drying the compounds, introducing the compounds into a container so that the compounds are loosely and uniformly packed in the container, the container being made of molybdenum coated with a ceramic, and having the same shape as the sheet which is to be made. The compounds are then reduced to their respective metals and the resulting metal powder is sintered to a density equal to or greater than about 90% of the theoretical density of the alloy to form the sheet.

Abstract: A process is disclosed for producing a sheet of tungsten heavy alloy which comprises forming a solution of chemical compounds containing the metal values of the alloy in the correct proportion as in the alloy, forming from the solution a precipitate of the compounds containing the metal values, removing the precipitate from the resulting liquor an forming a planar cake of the precipitate, drying the cake, and reducing the compounds in the cake to their respective metals wherein each of the resulting reduced particles is an admixture of the alloy components and sintering the cake to a density equal to or greater than about 90% of the theoretical density of the alloy to form the sheet.

Abstract: Reactive sintering process for producing a shaped body containing the nickel aluminide compound Ni.sub.3 Al, which comprises sintering a compacted shaped mass containing an intimate mixture of substances, e.g. including elemental nickel powder and elemental aluminum powder in a stoichiometric atomic ratio generally corresponding to the compound Ni.sub.3 Al, by heating the mass, e.g. in a vacuum, to an elevated sintering temperature, e.g. 500-750.degree. C., sufficiently to initiate an exothermic reaction, and at a heating rate sufficiently for consequent progressive generation of a transient liquid below the melting point of the aluminum powder and at the corresponding eutectic temperature, and upon initiation of the exothermic reaction continuing the sintering sufficiently to form a densified shaped body containing the nickel aluminide compound Ni.sub.

Abstract: What is disclosed is an improvement in a method for treating the reaction residue from the preparation of organochlorosilanes or chlorosilanes from the reaction of metallic silicon with a chlorinated hydrocarbon or hydrogen chloride, said method comprising combining the reaction residue with water and granulating the mixture of the reaction residue and water, the improvement comprising (A) coating the resulting granules from the granulating of the mixture of the reaction residue and water with an inert inorganic powder.

Abstract: Metal or alloy articles having complicated shapes can be produced with high precision by injection molding a kneaded mixture of a metal or alloy powder and an organic binder comprising a special methylcellulose, a plasticizer, a lubricant and water, followed by removal of the organic binder and sintering.

Abstract: A chemical pretreatment method is used to produce boron carbide-, boron-, and boride-reactive metal composites by an infiltration process. The boron carbide or other starting constituents, in powder form, are immersed in various alcohols, or other chemical agents, to change the surface chemistry of the starting constituents. The chemically treated starting constituents are consolidated into a porous ceramic precursor which is then infiltrated by molten aluminum or other metal by heating to wetting conditions. Chemical treatment of the starting constituents allows infiltration to full density. The infiltrated precursor is further heat treated to produce a tailorable microstructure. The process at low cost produces composites with improved characteristics, including increased toughness, strength.

Abstract: Nitride dispersion strengthening of stainless steel or nickel-based alloys is achieved by mechanically alloying the constituents of the alloy together with a nitride former, such as titanium, and a nitrogen donor, such as chromium nitride, and heating the mechanically alloyed powder to dissociate the donor and combine the resulting nitride with the nitride former. The heating step may be carried out in the course of hot consolidating the powder, e.g. by extrusion.

Abstract: A process is disclosed for producing composite powder particles consisting essentially of a matrix phase and a reinforcement phase. The process involves entraining agglomerated particles in a carrier gas, the agglomerated particles consisting essentially of titanium diboride and particles of a metal selected from the group consisting of aluminum and aluminum based alloys. The agglomerated particles are fed through a high temperature zone having a temperature sufficient to allow the metal particles to melt, coalesce together, and encapsulate the titanium diboride particles. The metal is then resolidified, resulting in the formation of the composite powder particles wherein the matrix phase consists essentially of the metal and the reinforcement phase consists essentially of the titanium diboride particles.

Abstract: A reduction process for the production of a product metal which includes the step of reacting at least one reducible metal compound and a reducing metal in a sealed reaction zone by heating the reactants without any substantial agitation from a temperature below the melting point of the reducing metal to a temperature which is both above the melting point of the reducing metal and below the temperature at which the reduction reaction between the metal compound(s) and the reducing metal will proceed spontaneously; initiating a reduction reaction between the reducible metal compound(s) and a molten reducing metal by causing the surface of the molten reducing metal to be suddenly disrupted, thereupon releasing the reaction mixture from said first reaction zone into a product collection zone while permitting the reduction reaction to continue to thereby produce a reduced metal or alloy in zero valent state; and apparatus for conducting the above process.

Abstract: A tetrafluoroethylene-type fluoroplastic powder is added and mixed with a metal powder and the mixture is shaped. The compact is heated in a nonoxidizing atmosphere and the oxides on the surface of the metal particles are converted and removed as gaseous fluorides. Alternatively, after the oxides are converted to solid or liquid fluorides, the fluorides are reduced by hydrogen and then they are removed as gaseous reaction products. Thereafter, the compact is sintered.

Abstract: A ZrB.sub.2 -containing sintered cermet comprising zirconium diboride partially substituted by at least one member selected from the group consisting of chromium boride, molybdenum boride and tungsten boride, and a binding component containing at least one member selected from the group consisting of metals of Group VIII of the periodic table.

Abstract: A powder of a film-forming metal, such as tantalum, is combined with a binder of polyethylene oxide and ammonium carbonate. The powder-binder combination is pressed to form an anode body and then heated to about 300.degree. C. for about 4 hours to remove the binder. The polyethylene oxide is a superior binding agent producing anodes of high porosity and strength. The ammonium carbonate reacts with liquid polyethylene oxide to release large quantities of gas which sweeps the polyethylene oxide out of the anode pores, resulting in an unusually small amount of binder residue and yielding capacitors with low d.c. leakage.

Abstract: A method for producing high technology ceramics with minimal porosity comsing the steps of filling a can with a constituent powder of a ceramic, creating a vacuum in the can and maintaining the vacuum throughout the entire process; outgassing the powder in the can by placing a furnace around the area of the can that encloses the powder and heating the furnace to at least 100.degree. C.; removing the furnace after a minimum of five minutes of heating; cold rolling the can in a rolling system; igniting the powder so a localized propagation reaction front is created; and hot rolling the can in the rolling system so the propagation reaction front is maintained between the rolls of the rolling system.

Abstract: The invention relates to a process for the treatment of a metal oxide powder, particularly a UO.sub.2 or PuO.sub.2 powder, with a view to its fritting.This process consists of oxidizing the powder, so as to form on its surface a hydrated oxide layer of the same metal. When the oxide is UO.sub.2 or PuO.sub.2 and mixtures thereof, as well as those prepared with ThO.sub.2, the treated powder can be used for producing nuclear fuel pellets by cold compression, followed by fritting.

Abstract: A process for producing readily sinterable aluminum nitride powder, which comprises mixing(i) alumina powder and/or powder of a compound capable of forming alumina by heat treatment,(ii) carbon powder and/or powder of a compound capable of forming carbon by heat treatment, and(iii) powder of at least one compound selected from the group consisting of alkaline earth metal oxides, compounds capable of forming said alkaline earth metal oxides by heat treatment, rare earth element oxides and compounds capable of forming said rare earth element oxides by heat treatment,and calcining the resulting mixture in a nitrogen-containing non-oxidative atmosphere, provides an aluminum nitride powder which is readily sinterable without further mixing with a sintering aid.

Abstract: A process is disclosed for the preparation of metallic products from metal salts admixed with solvent wherein at least one of the metal salt and the solvent is easily reducible. The admixture is heated under hypercritical conditions of temperature and pressure to produce metallic products and a hypercritical fluid. The hypercritical fluid is subsequently removed from the reaction zone and the metallic product is collected. The metallic product includes pure metals selected from the group of silver, gold, platinum, palladium, ruthenium, rhodium, mercury, arsenic, rhenium, tellurium, iridium, osmium, and copper, and alloys and mixtures thereof. The metallic product ordinarily exists as finely divided powders which may be highly porous.

Abstract: A process is provided for the preparation and fabrication of sintered titanium horseshoes whereby titanium powder is processed so that its characteristics are such that it is ideally suited for horseshoes.The sintered powder titanium horseshoes have many advantages over the present state of the art some of their advantages being that they are light weight, have high strength, are flexible, have excellent wearing characteristics, are abrasion resistant and are easily formed and shaped into the desired configuration.

Abstract: Hard, tough, lightweight boron-carbide-reactive metal composites, particularly boron-carbide-aluminum composites, are produced. These composites have compositions with a plurality of phases. A method is provided, including the steps of wetting and reacting the starting materials, by which the microstructures in the resulting composites can be controllably selected. Starting compositions, reaction temperatures, reaction times, and reaction atmospheres are parameters for controlling the process and resulting compositions. The ceramic phases are homogeneously distributed in the metal phases and adhesive forces at ceramic-metal interfaces are maximized. An initial consolidation step is used to achieve fully dense composites. Microstructures of boron-carbide-aluminum cermets have been produced with modulus of rupture exceeding 110 ksi and fracture toughness exceeding 12 ksi.sqroot.in. These composites and methods can be used to form a variety of structural elements.

Abstract: In a process for sintering a metal member bonded to a substrate during which the metal member undergoes densification at a temperature which is different from the curing temperature of the substrate, an improvement is provided which comprises causing the densification temperature of the metal member to be closer to or identical with the curing temperature of the substrate by adding to said metal member prior to sintering an amount of organometallic compound which undergoes decomposition before the densification temperature of the metal member has been reached to provide under the sintering conditions employed a densification temperature-modifying amount of a metal or metal oxide which can be the same as or different from the metal of the aforesaid metal member.The improved sintering process of the present invention is particularly adapted for use in the fabrication of multilayer ceramic substrates which serve as circuit modules for seminconductor chips.

Abstract: A method of manufacturing a scandate dispenser cathode having a matrix at least the top layer of which at the surface consists substantially of tungsten (W) and scandium oxide (Sc.sub.2 O.sub.3) and with emitter material in or below said matrix. If said method comprises the following steps:(a) compressing a porous plug of tungsten powder(b) heating said plug in a non-reactive atmosphere and in contact with scandium to above the melting temperature of scandium,(c) cooling the plug in a hydrogen (H.sub.2) atmosphere(d) pulverizing the plug to fragments(e) heating said fragments to approximately 800.degree. C. and firing them at this temperature for a few to a few tens of minutes in a hydrogen atmosphere and slowly cooling in said hydrogen atmosphere(f) grinding the fragments to scandium hydride-tungsten powder (ScH.sub.2 /W)(g) compressing a matrix or a top layer on a matrix of pure tungsten from said ScH.sub.

Abstract: A cermet is produced by providing a bulk reaction mixture of particulate reactants which react to produce a self-sustaining ceramic body, and carrying out the reaction with the bulk reaction mixture in contact with molten metal which moderates the reaction and infiltrates the resulting ceramic body. The method is particularly applicable for boride-based ceramics infiltrated with aluminum, suitable as components of electroytic cells for the production of aluminum by molten salt electrolysis.

Abstract: Amorphous metal alloy compositions are synthesized by solid state incorporation/reduction reactions wherein a high-surface area support is brought in contact with a precursor metal-bearing compound in such a manner that the compound is incorporated into the support or caused to deposit metal onto the surface of the support. The composition obtained is an amorphous alloy composition or can be made so by heat treating at a temperature below the crystallization temperature of the amorphous metal alloy desired to be formed.

Abstract: An improved inert electrode composition is suitable for use as an inert electrode in the production of metals such as aluminum by the electrolytic reduction of metal oxide or metal salt dissolved in a molten salt bath. The composition comprises one or more metals or metal alloys and metal compounds which may include oxides of the metals comprising the alloy. The alloy and metal compounds are interwoven in a network which provides improved electrical conductivity and mechanical strength while preserving the level of chemical inertness necessary for such an electrode to function satisfactorily.

Abstract: To increase the creep strength of a titanium-containing alloy which also contains chromium, the alloy powder is heated in the presence of ammonia at a temperature of the order of 700.degree. C. so as to form a layer of chromium nitride(s) on the particles and is then heated further in an inert atmosphere at a temperature between 1000.degree. C. and 1150.degree. C. to dissociate the chromium nitride(s) thereby effecting nitriding of the titanium to titanium nitride which affords dispersion-strengthening of the alloy.

Abstract: A porous metal body, e.g. an electrode for an electric cell, is prepared using the following steps:preparing a foam by adding a surface active agent and a gelling agent to water and then foaming the mixture by stirring and/or blowing air through it;incorporating metal powder in the foam in order to obtain a suspension of the metal therein;shaping the foam with its suspension of metal, and adding a stabilizing agent thereto, said stabilizing agent being one which polymerizes on contact with water, thereby causing the shaped foam to set in shape; andheating the set foam to pyrolize the organic material therein and to sinter the metal.This method produces a more even and a more reliable pore size than has previously been possible.

Abstract: A process for the production of valve metal powder, which is doped with boron or boron compounds, for electrolytic capacitors having a low relative leakage current and a high specific charge. The doping with boron or boron compounds in amounts of up to 0.5 percent by weight, relative to the metal content, can take place either during the production of the metal powder or the green valve metal anodes.

Abstract: A process for forming a mat (14) of metal fibers (2) which can be used to hold ceramic material onto the surface of equipment to be protected from heat and corrosion, including the steps of mixing a plurality of metal fibers (2) with polybutene (8) and a finely-divided brazing material (10). This mixture is spread onto a support member (4) having an insulating coating (6) thereon to prevent the fibers from becoming brazed to the support member. The support member containing the fibers thereon is then subjected to a brazing temperature (12), brazing the fibers together to form a loose mat. The mat is then removed from the support member, and reduced (16) in thickness into a more dense mat of fibers. The dense mat (14) is then again subjected to a brazing temperature (18), to form a final product having unusual strength qualities.

Abstract: Tantalum powder for electrolytic capacitors is treated with a non-aqueous solution of ammonium thiocyanate in N,N'-dimethylformamide or N-methylpyrrolidinone after the powder has been subjected to a thermal treatment in the absence of oxygen step and before the powder is exposed to an oxygen-containing fluid to prevent oxygen uptake by the powder. The thermal treatment step is carried out at 700.degree. C. and above.

Abstract: A method and material for the manufacture of improved bearing elements such as annular inner and outer bearing ring blanks for ball, roller and needle bearing assemblies comprising the steps of mixing a powder consisting substantially of iron with ferro-alloy powders of substantially smaller size, each ferro-alloy containing at least 80% iron and the balance being an alloying element, together with graphite powder and a lubricant, compacting the resulting mixture to form a preform, pre-sintering the preform, and then coating the sintered preform with a stop-off and lubricant. The preform is subjected to a plastic deformation of at least 50% in a cold (room temperature) forging operation to produce an article which is at least 98% dense and has approximately the shape of the finished article. This cold forged shape is resintered and annealed, after which the annealed and resintered shape is roll formed into substantially final dimensions.

Abstract: The invention relates to a process for the treatment of a metal oxide powder, particularly a UO.sub.2 or PuO.sub.2 powder, with a view to its fritting.This process consists of oxidizing the powder, so as to form on its surface a hydrated oxide layer of the same metal. When the oxide is UO.sub.2 or PuO.sub.2 and mixtures thereof, as well as those prepared with ThO.sub.2, the treated powder can be used for producing nuclear fuel pellets by cold compression, followed by fritting.