Abstract: A compression molding which is high in both dimensional accuracy and mechanical strength is difficult to manufacture by a powder molding process. Especially, a molding including a soft magnetic material with high soft magnetic properties is difficult to manufacture. A composite metal molding according to the present invention includes metal particles and the carbide of a resin intervening among the particles. It is manufactured by coating metal particles with a resin, molding the prepared molding material under pressure into a predetermined shape, and heating the prepared pressurized preform to calcine the resin and weld mutually the particles. The carbide of the resin has a weight ratio of 0.001 to 2% to the metal particles when the particles have their proportion expressed as 100. The particles have a weld ratio of 10 to 80%. The particles preferably contain a soft magnetic material and the resin is preferably a furan resin.

Abstract: The present invention provides metal powder compositions for pressed powder metallurgy and methods of forming metal parts using the metal powder compositions. In each embodiment of the invention, the outer surface of primary metal particles in the metal powder composition is chemically cleaned to remove oxides in situ, which provides ideal conditions for achieving near full density metal parts when the metal powder compositions are sintered.

Abstract: A composition for coating sliding or rolling or fretting or impacting members is formed by preparing a composite powder of TiB2 and BN, with a TiB2 to BN ratio ranging from 1:7 to 20:1, and a metallic matrix selected from the group consisting of nickel, chromium, iron, cobalt, aluminum, tungsten, carbon and alloys thereof.

Abstract: A nanocomposite magnet containing an Fe particle in the grain boundary of an Nd2Fe14B compound particle is produced by mixing a dispersion of the Nd2Fe14B compound particle in a solvent containing a surface-active agent and a dispersion of the Fe particle in a solvent containing a surface-active agent, and then supporting the Fe particle on the surface of the Nd2Fe14B compound particle by stirring the mixture of the dispersions while adding an amphiphilic solvent, and then performing the drying and the drying and the sintering.

Abstract: A method of making a powder metal compact is disclosed. The method includes forming a coated metallic powder comprising a plurality of coated metallic powder particles having particle cores with nanoscale metallic coating layers disposed thereon, wherein the metallic coating layers have a chemical composition and the particle cores have a chemical composition that is different than the chemical composition of the metallic coating layers. The method also includes applying a predetermined temperature and a predetermined pressure to the coated powder particles sufficient to form a powder metal compact by solid-phase sintering of the nanoscale metallic coating layers of the plurality of coated powder particles to form a substantially-continuous, cellular nanomatrix of a nanomatrix material, a plurality of dispersed particles dispersed within the cellular nanomatrix and a solid-state bond layer extending throughout the cellular nanomatrix.

Abstract: The present invention demonstrates a superior, more economical, and scalable process to increase the fluidity of metal powders by surface modification with alkylsilane reagents. This invention discloses that the most efficient process results from treatment with methyltrichlorosilane in hexane. In particular, the fluidity of aluminum powders having mean diameters smaller than 10 micrometers was considerably improved by the process of the present invention. It is emphasized that this abstract is provided to comply with the rules requiring an abstract that will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope of the claims.

Abstract: A sliding material has a sintered layer formed atop a backing plate. The sintered layer contains 5-15 mass % of Bi nonuniformly distributed in a Cu—Sn alloy matrix consisting essentially of 8-12 mass % of Sn and a remainder of Cu. The sliding material can be manufactured by nonuniformly mixing Cu—Sn alloy powder and Bi powder, dispersing the mixed powder on a backing plate, and sintering the mixed powder to form a sintered layer on the backing plate. The sliding material does not undergo seizing and does not have separation of the sintered layer from the backing plate even when used in severe conditions such as in hydraulic equipment or construction equipment.

Abstract: A method for manufacturing bodies formed from insulated soft magnetic metal powder by forming an insulating film of an inorganic substance on the surface of particles of a soft magnetic metal powder, compacting and molding the powder, then carrying out a heat treatment to provide a body formed from insulated soft magnetic metal powder the method comprising: compacting and molding the powder; then magnetically annealing the powder at a high temperature above the Curie temperature for the soft magnetic metal powder and below the threshold temperature at which the insulating film is destroyed in a non-oxidizing atmosphere, such as a vacuum, inert gas, or the like; and then carrying out a further heat treatment at a temperature of from 400° C. to 700° C. in an oxidizing atmosphere, such as air, or the like.

Abstract: Flowability-improving particles containing 50 to 100% by mass of carbon black are adhered to surfaces of iron powder through a binder to provide an iron-based powder for powder metallurgy which has excellent flowability and which is capable of uniformly filling a thin-walled cavity, compaction with high ejection force, and maintaining sufficient strength of a sintered body in subsequent sintering.

Abstract: The invention relates to a metal matrix material made of a hydrogen-permeable metal 1 and a chemically stable metal 2 that is also hydrogen permeable, said matrix material having a structure comprised of a plurality of centers made of the metal 2 surrounded by the metal 1. The invention further relates to a method for the production of said matrix material, having the following steps: a. optionally pretreating the metal 1 and/or 2 b. coating metal 1 with a metal 2 to form a composite metal powder c. pressing the composite metal powder into the metal matrix material according to the invention in the form of a pressed body d. optionally deforming the pressed body thus obtained to form a molded body. The metal matrix material has a greater mechanical stability as compared to a conventionally coated metal film by virtue of a more homogeneous stress distribution during the change in volume of the metal phases as a result of hydrogen absorption and thermal expansion.

Abstract: A thermoelectric converter made of a thermoelectric conversion material is provided in which metal or alloy particles having an average particle size of 1 to 100 nm are dispersed, wherein at least a part of the metal or alloy particles are dispersed at a distance not more than the mean free path of the phonon of the thermoelectric conversion material.

Abstract: A magnet core (1) made of a composite of platelet-shaped particles of a thickness D and a binder has a particularly linear relative permeability curve over a pre-magnetised constant field. For this purpose, the platelet-shaped particles (5) are provided with an amorphous volume matrix (8), wherein areas (9) with a crystalline structure having a thickness d of 0.04*D?d?0.25*D and covering a proportion x of x?0.1 of the surface (6, 7) of the particle (5) are embedded on the surface (6, 7) of the particle (5).

Abstract: A method for manufacturing valve metal anodes of electrolytic capacitors by deoxidizing the anodes using Mg vapor in a deoxidizing furnace, removing the anodes from deoxidizing furnace, placing them in sintering furnace, sintering at temperature lower than the temperature conventionally used for sintering in vacuum, and leaching of Mg oxide off the anode surface. The process limits free oxygen and improves morphology of valve metal anodes, which results in improved performance of electrolytic capacitors with these anodes. The process does not require any special equipment or maintenance operations and, thereby, is highly productive due to performing deoxidizing and sintering separately in traditional deoxidizing and sintering furnaces.

Abstract: A soft magnetic material includes a plurality of composite magnetic particles (40) each including a metal magnetic particle (10) and an insulation coating (20) covering the surface of the metal magnetic particle (10), wherein the insulation coating (20) contains Si (silicon), and 80% or more of Si contained in the insulation coating constitutes a silsesquioxane skeleton. Therefore, it is possible to effectively decrease a hysteresis loss while suppressing an increase in eddy-current loss.

Abstract: A method of forming a sputtering target and other metal articles having controlled oxygen and nitrogen content levels and the articles so formed are described. The method includes surface-nitriding a deoxidized metal powder and further includes consolidating the powder by a powder metallurgy technique. Preferred metal powders include, but are not limited to, valve metals, including tantalum, niobium, and alloys thereof.

Abstract: A drill bit that includes a bit body having a plurality of blades extending radially therefrom, the bit body comprising a first matrix region and a second matrix region, wherein the first matrix region is formed from a moldable matrix material; and at least one cutting element for engaging a formation disposed on at least one of the plurality of blades is disclosed.

Abstract: The present invention discloses a process for sintering particles using a sintering aid. The sintering aid can be brought into contact with a plurality of particles to be sintered such that a mixture of the particles and the sintering aid is provided. The mixture of particles and the sintering aid is heated and at least part of the sintering aid is vaporized. Sintering of the particles to form a sintered component followed by cooling of the sintered component can complete the process, or in the alternative, a subsequent heating step or steps can be included whereby additional vaporization of the sintering aid can occur.

Abstract: The invention provides a dense bulk thermoelectric composition containing a plurality of nanometer-sized particles of a thermoelectric material. The bulk composition provides thermoelectric power up to 550 ?V/° C. In some embodiments, the surface of each particle is coated by another thermoelectric material. The size of the particles ranges from about 5 nm to about 500 nm. The density of thermoelectric composition ranges from about 80% to about 100% of theoretical density.

Abstract: A component is produced by powder metallurgy from hard metal. The alloy includes at least one grain growth-inhibiting additive from the group consisting of V, Cr, Ti, Ta and Nb with, at least locally, a graduated concentration profile. As a result, the mechanical properties also have a graduated profile. In the fabrication process, a dispersion or solution which contains the grain growth-inhibiting additive in finely distributed or dissolved form is applied to the surface of a green compact. Penetration of this dispersion or solution along open pores leads to a graduated distribution of the grain growth-inhibiting additive in the green compact. There is also described a process in which the grain growth-inhibiting additive in the form of a solution is distributed uniformly in the green compact and is then gradually broken down from edge regions by a heat treatment or a solvent.

Abstract: Provided is a hydrogen separation membrane prepared by compression-molding metal microparticles having hydrogen adsorbing properties, wherein the microparticles are composed of 0.5 to 50% by weight of a first metal powder and 50 to 99.5% by weight of a second metal powder having a relatively larger average particle diameter than the first metal powder.

Abstract: A particle (10) of ferromagnetic powder for use in preparation of soft magnetic core components has a core-shell structure. The particle includes a central core (12) and a shell (14) coated on the central core. The central core is made of magnetic material and is used for providing the necessary magnetic property for the magnetic core components made from the ferromagnetic powder. The shell has a higher electrical resistance than the central core so as to reduce an eddy current loss of the magnetic core component. The shell also functions to provide an excellent bonding strength between particles of the powder.

Abstract: A precursor particle having a particle size of 10 nm or more and 1 ?m or less, and comprising a first compound selected from an alkoxide, a hydroxide, a sulfate, a nitrate, a carbonate, or a carboxylate of magnetic metal containing at least one metal of Fe and Co, and a second compound selected from an alkoxide or a hydroxide, a sulfate, a nitrate, a carbonate, or a carboxylate of a metal element for forming an oxide, is prepared. Then the precursor particle is heated in a reducing atmosphere to form an insulating particle made of an oxide of the metal element by decomposing the second compound, and to precipitate a particle of the magnetic metal in the insulating particle at a particle size of 1 nm or more and 100 nm or less, thereby manufacturing a high frequency magnetic material.

Abstract: The object of the present invention is to provide a powder core and method for making the same that is equipped with insulative coating having superior heat resistance, with the coating making it possible to adequately restrict the flow of eddy currents between particles. The powder core is equipped with a plurality of compound magnetic particles bonded to each other. Each of said plurality of composite magnetic particles includes: a metal magnetic particle 10; an insulative lower layer coating 20 surrounding a surface 10a of said metal magnetic particle 10; an upper layer coating 30 surrounding said lower layer coating 20 and containing silicon; and dispersed particles 50 containing a metal oxide compound and disposed in said lower layer coating 20 and/or said upper layer coating 30. A mean particle diameter R of the dispersed particles 50 meets the condition 10 nm<R?2 T, where the average thickness of the coating combining the lower layer coating 20 and the upper layer coating 30 is T.

Abstract: Novel powders or particles are formed by associating them with relatively small proportions of hydrolysable liquid material. The resulting particle/liquid mass is placed in a mold and sintered under conditions of heat and pressure that enables at least some of the hydrolysable liquid to react within the sintered mass. The sintered mass displays a controllable range of properties such as increased density, increased tensile strength, and improved natural polish finish. The hydrolysable liquid may partially hydrolyze and/or react with the powders and particles, but the liquid is not completely (not 100%) reduced to an inorganic oxide prior to introduction to the mold and performance of the sintering process.

Abstract: The invention concerns a powder metal composition comprising an iron based powder and a lubricant and/or binder comprising at least one secondary amide of the general formula: R1—NH—CO—R2, wherein R1 and R2 are the same or different, straight or branched, saturated or unsaturated aliphatic hydrocarbon groups. The invention further concerns a method of making green bodies of the powder metal composition according to the invention, a method of producing a bonded iron-based powder composition, as well as the use of the at least one secondary amide as a lubricating and/or binding agent for iron based powders and the use as a die wall lubricant.

Abstract: A method and apparatus for producing products from a powered base material, by means of so-called free form fabrication, wherein the powder granules are bound together into a solid product.

Abstract: An object of the present invention is to provide a composite soft magnetic sintered material that has high density, high mechanical strength and high relative magnetic permeability at high frequencies and, in order to achieve this object, the present invention provides a method of producing the composite soft magnetic sintered material, which comprises mixing a composite soft magnetic powder, that consists of iron powder, Fe—Si based soft magnetic iron alloy powder, Fe—Al based soft magnetic iron alloy powder, Fe—Si—Al based soft magnetic iron alloy powder, Fe—Cr based soft magnetic iron alloy powder or nickel-based soft magnetic alloy powder (hereinafter these powders are referred to as soft magnetic metal powder) of which particles arc coated with a ferrite layer which has a spinel structure, with 0.05 to 1.

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.

Abstract: Polycrystalline diamond (PCD) carbide composites of this invention have a microstructure comprising a plurality of granules formed from PCD, polycrystalline cubic boron nitride, or mixture thereof, that are distributed within a substantially continuous second matrix region that substantially surrounds the granules and that is formed from a cermet material. In an example embodiment, the granules are polycrystalline diamond and the cermet material is cemented tungsten carbide. PCD carbide composites of this invention display improved properties of fracture toughness and chipping resistance, without substantially compromising wear resistance, when compared to conventional pure PCD materials.

Abstract: In W—Cu alloy having a homogeneous micro-structure and a fabrication method thereof, the method includes forming mixed powders by mixing tungsten powders with W—Cu composite powders; forming a compact by pressurizing-forming the mixed powders; forming a skeleton by sintering the compact; and contacting copper to the skeleton and performing infiltration. W—Cu alloy having a homogeneous structure fabricated by the present invention shows better performance by being used as a material for high voltage electric contact of a contact braker, a material for heat sink of an IC semiconductor and a shaped charge liner.

Abstract: A 3D Printing Rapid Prototyping process using Al/Mg particles coated with a metal (i.e. copper, nickel, zinc, or tin) that (1) prevents oxidation of the Al/Mg particles, and (2) either alone, or when alloyed with the aluminum or magnesium core metal, melts below the liquidus temperature of the core.

Abstract: Methodology for constructing composite particles from ingredients comprising two or more particulate components. The resultant particles are usefully incorporated into powder coating compositions. The approach also finds utility in other applications, including but not limited to the food, drug, and cosmetics industry. Fluidized particles are subjected to an intense, but relatively brief heating event. This causes associated particles to fusingly assemble into fused composite clusters.

Abstract: The present invention concerns a method of improving the properties of powder metallurgically produced SMC compacted body consisting of a soft magnetic material of insulated powder particles and a lubricant, to a stress relieving heat treatment in a furnace until the component has reached a temperature of at least 400° C. in an oxygen containing atmosphere having a CO content is less than 0.25% by volume.

Abstract: An electrochemical cell capable of operating in pressure differentials exceeding about 2,000 psi, using a porous electrode. The porous electrode comprises a catalyst adsorbed on or in a porous support that is disposed in intimate contact and fluid communication with the electrolyte membrane.

Abstract: The method of the present invention incorporates an amorphous metal powder coated with a ductile crystalline metal or alloy. The coated powder is consolidated to form a dense compact of isolated or continuous amorphous metal particles within a continuous ductile metal network. This provides a material in bulk product form exhibiting improved fracture properties including ductility and fracture toughness.

Abstract: This invention pertains to product and process. The product is a transparent product of a density in excess 99.5% comprising spinel and having uniform mechanical properties. The process pertains to fabrication of a transparent spinel product comprising the steps of dissolving a sintering aid in water to form a neutral sintering aid solution, adding a suitable additive to the sintering aid solution, applying the sintering aid solution to spinel particles to form a spinel dispersion, sub-dividing or atomizing the spinel dispersion to form droplets comprising one or more spinel particles coated with the final spinel solution, drying the droplets to form dried coated particles comprising one or more spinel particles coated with a dried layer of the sintering aid, and densifying the dried coated particles to form a transparent spinel product having uniform optical and mechanical properties in absence of grains of exaggerated size.

Abstract: A method of firing magnetic cores includes the steps of attaching a powder to the surface of a plurality of flattened-ring compact bodies made of a magnetic material, arranging the plurality of flattened-ring compact bodies adjacently so that the axes of flattened through-holes of the flattened-ring compact bodies are vertically oriented, and firing the flattened-ring compact bodies while the powder is interposed between the adjacent flattened-ring compact bodies. Alternatively, a method of firing magnetic cores includes the steps of attaching a powder to the surface of a plurality of thin compact bodies made of a magnetic material, vertically arranging the plurality of thin compact bodies adjacently, and firing the thin compact bodies while the powder is interposed between the adjacent thin compact bodies.

Abstract: Novel powders or particles are formed by associating them with relatively small proportions of hydrolysable liquid material. The resulting particle/liquid mass is placed in a mold and sintered under conditions of heat and pressure that enables at least some of the hydrolysable liquid to react within the sintered mass. The sintered mass displays a controllable range of properties such as increased density, increased tensile strength, and improved natural polish finish. The hydrolysable liquid may partially hydrolyze and/or react with the powders and particles, but the liquid is not completely (not 100%) reduced to an inorganic oxide prior to introduction to the mold and performance of the sintering process.

Abstract: There are disclosed a method for producing a composite material composed of a dispersing agent and a matrix, and a composite material produced by the method. The matrix is formed by the steps of coating a metal-coated dispersing agent to form a metal-coated layer on the surface of the dispersing agent, filling the metal-coated dispersing agent in a jig prepared in a fixed shape, and then causing the reaction of the metal-coated layer with a molten Al by impregnating the metal-coated dispersing agent with the molten Al filled in the jig.

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.

Abstract: A method of providing a resistance to oxidation of Nickel at high temperatures by combining Ni powder with five percent Pt resinate, and heating the same to a temperature of 500° C. to 1300° C. Electro-conductive components serving as electrodes and the like comprise a Ni/Pt powder subjected to temperatures of between 500° C. and the respective melting points of Ni and Pt.

Abstract: The present invention relates to a method of making a cemented carbide by mixing powder of WC and possibly other powders forming hard constituents and binder phase and pressing agent, drying, pressing and sintering whereby; the mixing is wet mixing with no change in grain size or grain size distribution of the hard constituent powders; the WC grains are coated with binder metal and deagglomerated prior to the mixing. The sintering is made by microwave sintering at 1325-1410° C. with a holding time of 5-15 min. As a result a cemented carbide with improved properties is obtained.

Abstract: A spray powder to be used for forming a coating, which comprises from 80 to 97 wt %, based on the total weight, of a cermet powder and from 3 to 20 wt %, based on the total weight, of a metal powder, wherein the metal powder comprises Cr and Ni in a total amount of at least 90 wt %, based on the total weight of the metal powder, and the content of Cr is from 0 to 55 wt %, based on the total weight of the metal powder.

Abstract: Pressed material such as anodes are described and formed from oxygen reduced oxide powders using additives, such as binders and/or lubricants. Methods to form the pressed material are also described, such as with the use of atomizing, spray drying, fluid bed processing, microencapsulation, and/or coacervation.

Abstract: A method for easily sintering a magnetic core while preventing damage to the magnetic core caused by deformation or other problems, includes preparing a flattened tubular compact by forming the compact to have a flattened tubular shape and a through hole. A supporting plate made from a baked porcelain material or a metal material having a dimension that allows for insertion into the through hole of the flattened tubular compact, as well as a length that is sufficiently longer than that of the flattened tubular compact, is inserted through the through hole. The flattened tubular compact is placed inside of a sintering container having highly pure alumina powder spread therein so that the axial direction of the compact is horizontal. The flattened tubular compact is then sintered in a sintering furnace to produce the magnetic core.

Abstract: A method and apparatus for producing products from a powered base material, by means of so-called free form fabrication, wherein the powder granules are bound together into a solid product.

Abstract: An optical recording medium is provided with a recording layer made of a phase-change recording material including Ag, In, Sb, and Te as the main constituent elements, with the respective atomic percents of a, b, c, and d thereof being in the relationship of 0.1≦a≦5, 5≦b≦13, 62≦c≦73, 22≦d≦26, and a+b+c+d≧97. Alternatively, the recording material includes the constituent elements of Ag, In, Sb, Te, and Ge, with the respective atomic percents of a, b, c, d, and e thereof being in the relationship of 0.1≦a≦5, 5≦b≦13, 62≦c≦73, 22≦d≦26, 0.3≦e≦3, and a +b+c+d+e≧97. A sputtering target for forming the recording layer is also disclosed.

Abstract: The present invention relates to a method of making a cemented carbide comprising WC, 6-12 wt. % Co and 0.1-0.7 wt. % Cr, wherein the WC-grains are coated with Cr prior to mixing and no milling takes place during the mixing step. As a result a cemented carbide with improved properties is obtained.

Abstract: As there is disclosed a cemented carbide body comprising WC with an average grain size of <10 ?m in a binder phase. In the cemented carbide body the WC grains can be classified in at least two groups in which a group of smaller grains has a maximum grain size amax and a group of larger grains has a minimum grain size bmin and each group contains at least 10 % of the total amount of WC grains. According to the invention bmin?amax>0.5 ?m and the difference in grain size within each group is >1 ?m.

Abstract: The present invention relates to a method of making a cemented carbide body with a bimodal grain size distribution by powder metallurgical methods including wet mixing, without milling, of WC-powders with different grain size distributions with binder metal and pressing agent, drying, pressing and sintering. The grains of the WC-powders are classified in at least two groups, a group of smaller grains and a group of larger grains. According to the method of the present invention, the grains of the group of smaller grains are precoated with a growth inhibitor with or without binder metal.