Additional Material Is Solid Patents (Class 419/37)
  • Patent number: 10030209
    Abstract: A particulate composite lubricant for powder metallurgy comprises: first discrete particles comprising at least about 90 wt % of a fatty primary monoamide wax, being substantially free of fatty bisamide wax, and being at least partially coated with metal oxide nanoparticles and second metal-stearate free discrete particles comprising a fatty bisamide wax. A particulate composite lubricant for powder metallurgy can comprise: a Montan acid ester wax and at least one fatty amide wax comprising at least one of a fatty monoamide wax and a fatty bisamide wax.
    Type: Grant
    Filed: September 12, 2014
    Date of Patent: July 24, 2018
    Assignee: NATIONAL RESEARCH COUNCIL OF CANADA
    Inventors: Yannig Thomas, Vincent Paris, Sylvain St-Laurent
  • Patent number: 9388479
    Abstract: A method of forming an article includes forming a layer of a mixture of at least two distinct metal powders selected such that when combined they are chemically in the proportions of a superalloy containing a gamma prime phase, and fusing the powders locally without diffusion to define the shape of a part of the article such that the materials of the distinct metal powders remain substantially chemically segregated forming regions of different chemical composition. The method further includes repeating the forming and fusing until the derived article is formed, and heat treating the finished article such that at least one of the distinct separate materials diffuses to form a gamma prime phase containing superalloy with the other.
    Type: Grant
    Filed: January 20, 2015
    Date of Patent: July 12, 2016
    Assignee: Materials Solutions
    Inventor: Gordon Green
  • Patent number: 9320622
    Abstract: A nickel-free stainless steel stent using a stainless steel which does not substantially contain Ni in the stainless steel, has a metal allergy onset-preventing effect, and is excellent in terms of precision workability, strength, and ductility, is provided. The nickel-free stainless steel stent is characterized by using a stainless steel containing, as a chemical composition, from 15 to 30% by mass of Cr, from 0.97 to 2% by mass of Mo, and from 0.5 to 1% by mass of N, with the remainder being Fe, and optionally containing inevitable impurities.
    Type: Grant
    Filed: November 25, 2011
    Date of Patent: April 26, 2016
    Assignee: NATIONAL INSTITUTE FOR MATERIALS SCIENCE
    Inventors: Tetsushi Taguchi, Yasuyuki Katada, Ryozo Nagai, Ichiro Manabe, Katsuhito Fujiu
  • Publication number: 20150078952
    Abstract: A first die is filled with a mixed powder including a lubricant. A first pressure is applied to the mixed powder to form a mixed powder intermediate compressed body having a density ratio of 85 to 96%, provided that the maximum density of the mixed powder intermediate compressed body that can be molded by applying the first pressure is 100%. The mixed powder intermediate compressed body is heated to the melting point of the lubricant powder. The mixed powder intermediate compressed body is placed in a second die that is pre-heated to the melting point. A second pressure is applied to the mixed powder intermediate compressed body in the second die to form a high-density mixed powder final compressed body.
    Type: Application
    Filed: April 22, 2013
    Publication date: March 19, 2015
    Applicant: AIDA ENGINEERING, LTD.
    Inventors: Kazuhiro Hasegawa, Yoshiki Hirai
  • Patent number: 8951465
    Abstract: A method for preparing an implant having a porous metal component. A loose powder mixture including a biocompatible metal powder and a spacing agent is prepared and compressed onto a metal base. After being compressed, the spacing agent is removed, thereby forming a compact including a porous metal structure pressed on the metal base. The compact is sintered, forming a subassembly, which is aligned with a metal substrate portion of an implant. A metallurgical bonding process, such as diffusion bonding, is performed at the interface of the subassembly and the metal substrate to form an implant having a porous metal component.
    Type: Grant
    Filed: February 25, 2013
    Date of Patent: February 10, 2015
    Assignee: Biomet Manufacturing, LLC
    Inventor: Gautam Gupta
  • Patent number: 8932516
    Abstract: It is an objective of the present invention to provide an aluminum porous body which is formed of a pure aluminum and/or aluminum alloy base material and has excellent sinterability and high dimensional accuracy without employing metal stamping. There is provided an aluminum porous body having a relative density of from 5 to 80% with respect to the theoretical density of pure aluminum, in which the aluminum porous body contains 50 mass % or more of aluminum (Al) and from 0.001 to 5 mass % of at least one selected from chlorine (Cl), sodium (Na), potassium (K), fluorine (F), and barium (Ba). It is preferred that the aluminum porous body further contains from 0.1 to 20 mass % of at least one selected from carbon (C), silicon carbide (SiC), iron (II) oxide (FeO), iron (III) oxide (Fe2O3), and iron (II,III) oxide (Fe3O4).
    Type: Grant
    Filed: April 1, 2011
    Date of Patent: January 13, 2015
    Assignee: Hitachi, Ltd.
    Inventors: Masami Taguchi, Kazutaka Okamoto, Akio Hamaoka, Kouji Sasaki
  • Patent number: 8911663
    Abstract: The present invention relates to ferromagnetic powders with an electrically insulating layer on iron particles intended for the manufacture of components having improved soft magnetic properties at low and medium frequencies. The invention comprises an iron powder coated with a dielectric insulating layer comprising boron bearing compounds to form an insulated ferromagnetic powder. The present invention also relates to a method of making these insulated ferromagnetic powders. The present invention further relates to a method of synthesizing a product made from insulated ferromagnetic powders via a post-heat treatment at a moderate temperature (300° C. to 700° C.), to form a glass-like coating which acts as an electrical insulator. A preferred embodiment of the present invention is obtained when small amounts of alkali bearing compounds are added to the precursors to modify the coating chemistry and significantly increase the electrical resistivity after heat treatment.
    Type: Grant
    Filed: March 5, 2009
    Date of Patent: December 16, 2014
    Assignee: Quebec Metal Powders, Ltd.
    Inventors: Guillem Vachon, Claude Gelinas
  • Patent number: 8871142
    Abstract: Provided are methods for processing a green body that includes compacted metal powder, comprising impacting the green body with a particulate material for a time and under conditions effective to displace a portion of the metal powder from the green body. The present methods can be used to prepare green bodies that have “roughened” surfaces and that can be used to make orthopedic implants displaying low movement relative to bone when installed in situ, which corresponds to higher stability upon implantation and decreases the time required for biological fixation of the implant. Also provided are implants comprising a metallic matrix, and methods comprising surgically installing an implant prepared from a “surface roughened” green body in accordance with the present invention.
    Type: Grant
    Filed: May 21, 2009
    Date of Patent: October 28, 2014
    Assignee: DePuy Synthes Products, LLC
    Inventors: Bryan Smith, Jeffrey A. Rybolt, Derek Hengda Liu, Andrew James Martin
  • Patent number: 8852498
    Abstract: A process for fabricating hollow metal shells such as Be or Al filled with a selected gas such as D or T. An organic preform is coated with a slurry of organic binder and metal powder of Be or Al. The coated preform is heated to remove the preform and any organics to form a hollow shell which is then fired at an elevated temperature in a gas so as to seal the shell and capture the gas inside the sealed shell.
    Type: Grant
    Filed: April 20, 2012
    Date of Patent: October 7, 2014
    Assignee: Imaging Systems Technology, Inc.
    Inventor: Carol Ann Wedding
  • Patent number: 8795586
    Abstract: A sinter of stable quality is produced by molding a powder for powder metallurgy. This process includes successively conducting the following steps: charging a powder and a solid lubricant into a mold compact formation in which the powder charged into the mold is compacted; releasing the compact from the mold; and the powder for powder metallurgy is charged again into the mold after the release step. The temperature of the mold is set at a value in the range of from the boiling point of water to the melting point of the solid lubricant. The compact can be continuously formed without causing, e.g., a failure in the feeding of the powder for powder metallurgy. The sinter obtained by sintering the compact is almost even in strength and density.
    Type: Grant
    Filed: November 14, 2005
    Date of Patent: August 5, 2014
    Assignee: Diamet Corporation
    Inventors: Kinya Kawase, Takashi Nakai
  • Patent number: 8758675
    Abstract: The invention relates to a method for fabricating an open-porous metal foam body with a nickel base alloy, to a metal foam body fabricated this way as well as advantageous applications for the separation of specific components and pollutants from fluid flows. On the occasion, according to the set object open-porous metal foam bodies which have improved mechanical properties, and in addition an enlarged specific surface and/or increased surface roughness are to be provided. During fabricating it is proceeded such that an open-porous base foam body made of nickel or a nickel base alloy is coated with a liquid binding agent. Subsequent to this, a mixture of a powdery nickel base alloy and an organic component the temperature of phase transformation of which is at least 30 degrees centigrade from its solid phase to the liquid phase is deposited. The temperature should then be below the respective temperature of phase transformation.
    Type: Grant
    Filed: February 24, 2006
    Date of Patent: June 24, 2014
    Assignees: Alantum Corporation, Fraunhofer Gesellschaft zur Forderung der Angewandten Forschung E.V.
    Inventors: Alexander Böhm, Dirk Naumann, Tilo Büttner, Gunnar Walther, Shadi Saberi, Lloyd Timberg
  • Patent number: 8734715
    Abstract: A method for preparing a porous metal article using a powder metallurgy forming process is provided which eliminates the conventional steps associated with removing residual carbon. The method uses a feedstock that includes a ferrous metal powder and a polycarbonate binder. The polycarbonate binder can be removed by thermal decomposition after the metal article is formed without leaving a carbon residue.
    Type: Grant
    Filed: January 13, 2011
    Date of Patent: May 27, 2014
    Assignee: UT-Battelle, LLC
    Inventor: Curtis Jack Miller
  • Patent number: 8361380
    Abstract: A method for providing a porous metal implant. A mixture of biocompatible metal, a spacing agent, and a binder is provided. The mixture is formed into a shape and the spacing agent is removed to form a plurality of pores in the implant. A shaped porous metal is also provided.
    Type: Grant
    Filed: February 7, 2011
    Date of Patent: January 29, 2013
    Assignee: Biomet Manufacturing Corp.
    Inventors: Ned M. Hamman, James B. Fleming, Isaac Janson, Mukesh Kumar, Jason D. Meridew, Elizabeth A. Schlueter
  • Patent number: 8359743
    Abstract: A valve sealant fitting includes a spring coupling unit having an internal screw thread for coupling unit assembly below the ball installation groove of the sealant body, the internal screw thread having a hexagonal groove for preventing a downward separation of the coil spring, allowing a fluid to flow and facilitating fastening and releasing of the screw, and having an external screw thread at an outer circumference of the spring coupling unit, and outer sealing O-rings disposed in O-ring installation grooves formed on respective upper and lower positions of the valve coupling taper screw part formed on the outer lower side of the sealant body.
    Type: Grant
    Filed: February 27, 2009
    Date of Patent: January 29, 2013
    Inventors: Do A Kim, Seong Cheol Han
  • Patent number: 8062583
    Abstract: A method for producing a soft magnetic powdered core includes preparing a mixture of a soft magnetic powder and a resin powder, compacting the mixture into a predetermined shape so as to obtain a compact, and heating the compact. The resin powder has a median size of not more than 30 ?m, a maximum particle size of not more than 100 ?m, and a specific surface area of not less than 1.0 m2/cm3, and the additive amount thereof is 0.005 to 2 vol %.
    Type: Grant
    Filed: March 17, 2008
    Date of Patent: November 22, 2011
    Assignees: Hitachi Powdered Metals Co., Ltd., Denso Corporation
    Inventors: Chio Ishihara, Kazuo Asaka, Kohei Muramatsu, Tsuyoshi Akao, Hirotake Hamamatsu
  • Publication number: 20110212339
    Abstract: The metallurgical composition includes a main particulate metallic material, for example iron or nickel, and at least one alloy element for hardening the main metallic material, which form a structural matrix; a particulate solid lubricant, such as graphite, hexagonal boron nitride or mixture thereof; and a particulate alloy element which is capable of forming, during the sintering of the composition conformed by compaction or by injection molding, a liquid phase, agglomerating the solid lubricant in discrete particles. The composition may include an alloy component to stabilize the alpha-iron matrix phase, during the sintering, in order to prevent the graphite solid lubricant from being solubilized in the iron. The invention further refers to a self-lubricating sintered product, obtained from the composition, and to the process for obtaining said product.
    Type: Application
    Filed: September 9, 2009
    Publication date: September 1, 2011
    Inventors: Roberto Binder, Aloisio Nelmo Klein, Cristiano Binder, Gisele Hammes, Moises Luiz Parucker, Waldyr Ristow Junior
  • Patent number: 7993576
    Abstract: A method for producing a sintered body includes: a) molding a composition containing a powder primarily made of an inorganic material and a binder including an aliphatic carbonic acid ester based resin in a predetermined shape so as to obtain a compact; b) exposing the compact to a first atmosphere containing an alkaline gas and thus decomposing and removing the aliphatic carbonic acid ester based resin from the compact so as to obtain a degreased body; and c) sintering the degreased body so as to obtain a sintered body.
    Type: Grant
    Filed: March 14, 2008
    Date of Patent: August 9, 2011
    Assignee: Seiko Epson Corporation
    Inventors: Masaaki Sakata, Nobuyuki Hamakura
  • Patent number: 7959706
    Abstract: A sintering compound containing a sinterable powder and a binder removable in a debinding step is injected into a metal mold set provided with a sintering compound injecting mold, in a sintering compound molding step (S104). An add-on forming compound which becomes removable or separable from the sintering compound injection molded body in the debinding step or the sintering step is injected into the metal mold set provided with an add-on mold in an add-on forming step (S102). The sintering compound injection molded body and the add-on are formed integrally with each other in the metal mold set. The integral formation of the add-on and the sintering compound injection molded body enables to prevent damage during release from the mold and make easy to handle the injection molded body.
    Type: Grant
    Filed: December 29, 2009
    Date of Patent: June 14, 2011
    Assignee: Taisei Kogyo, Ltd.
    Inventor: Shigeo Tanaka
  • Publication number: 20110104476
    Abstract: A soft magnetic material includes a composite magnetic particle and an organic substance. The composite magnetic particle has a metallic magnetic particle and a coating layer coating the metallic magnetic particle and containing an oxide therein. The organic substance is formed by adding at least one of a thermoplastic resin and a higher fatty acid having an effect of increasing resistivity of the material, to a non-thermoplastic resin having an effect of improving durability such as material fatigue limit. The organic substance is contained in the soft magnetic material by not less than 0.001% by mass and not more than 0.2% by mass. The present invention provides a soft magnetic material having high magnetic property and mechanical strength and also having fatigue property and resistivity satisfying durability enough for use as a motor core or the like, and a method for manufacturing the same. Further, the invention provides a motor core and a transformer core made of the soft magnetic material.
    Type: Application
    Filed: May 28, 2004
    Publication date: May 5, 2011
    Inventors: Haruhisa Toyoda, Daichi Kawaguchi, Shohzoh Tanaka, Kazuhiko Ueda
  • Patent number: 7931855
    Abstract: A method of reducing the oxygen content of a powder is provided. A canister is prepared with a getter, filled with the powder to be densified, sealed and evacuated. The canister is subjected to a hydrogen atmosphere at an elevated temperature whereby hydrogen diffuses into the canister through the walls thereof. The hydrogen forms moisture when reacted with the oxygen of the powder and the moisture in the reacted with the getter in order to remove oxygen from the powder to the getter. The atmosphere outside the canister is then altered to an inert atmosphere or vacuum, whereby hydrogen diffuses out of the canister. A dense body having a controlled amount of oxygen can thereafter be produced by conventional powder metallurgy techniques.
    Type: Grant
    Filed: October 6, 2005
    Date of Patent: April 26, 2011
    Inventors: Roger Berglund, Hans Eriksson, Johan Sundstrom, Per Arvidsson
  • Patent number: 7892314
    Abstract: The present invention provides powder metal compositions and methods of making and using the same. Powder metal compositions according to the invention include base metal particles, a lubricant that transforms from a solid phase material to a viscous, liquid phase material during pressing, and a micronized deformable solid material. The micronized deformable solid material fills at least a portion of the void space between the base metal particles during pressing, which allows at least a portion of the lubricant to migrate as a viscous liquid phase material to the interface between the surface of the green compact and the wall of the mold cavity to provide lubrication that reduces the ejection force necessary to remove the green compact from the mold cavity.
    Type: Grant
    Filed: August 26, 2005
    Date of Patent: February 22, 2011
    Assignee: Apex Advanced Technologies, LLC
    Inventor: Dennis L Hammond
  • Patent number: 7883661
    Abstract: A method for providing a porous metal implant. A mixture of a biocompatible metal, a spacing agent, and a binder is provided. The mixture is formed into a shaped the spacing agent is removed to form a plurality of pores in the implant. A shaped porous metal implant is also provided.
    Type: Grant
    Filed: September 11, 2009
    Date of Patent: February 8, 2011
    Assignee: Biomet Manufacturing Corp.
    Inventors: Ned M. Hamman, James B. Fleming, Isaac Janson, Mukesh Kumar, Jason D. Meridew, Elizabeth A. Schlueter
  • Patent number: 7816307
    Abstract: The invention relates to a novel self-lubricating solid material; to a method of preparing such a material from a powder mixture; to said powder mixture; and to mechanical parts made of said novel material. Said powder mixture comprises a powder of a metal alloy that is a precursor for the matrix of said material, particles of a first solid lubricant such as CeF3 that are for insertion in said matrix without reacting with said metal alloy, and particles of a second solid lubricant such as WS2 or MoS2 for reacting with a component of said metal alloy during sintering of the powder to form a lubricating phase. Said material can be used for fabricating a bushing that is to receive a root of a variable-pitch vane of an airplane turbojet compressor.
    Type: Grant
    Filed: January 11, 2006
    Date of Patent: October 19, 2010
    Assignees: SNECMA, SNECMA Services
    Inventors: Frederic Braillard, Christelle Foucher, Philippe Perruchaut
  • Patent number: 7811512
    Abstract: A method for producing a sintered body is provided. The method for producing the sintered body comprising: forming a green body by molding a composition for forming a green body into a specified shape to obtain the green body, the composition comprising powder constituted of a metallic material and a binder containing a first resin which is decomposable by ozone; first debinding the green body by exposing the green body to a high ozone content atmosphere to decompose the first resin and remove the decomposed first resin form the green body to obtain a brown body; exposing the thus obtained brown body at least once to a low ozone content atmosphere whose ozone concentration is lower than an ozone concentration of the high ozone content atmosphere to obtain an intermediate brown body; and sintering the intermediate brown body which has been exposed to the low ozone content atmosphere to obtain the sintered body.
    Type: Grant
    Filed: September 21, 2007
    Date of Patent: October 12, 2010
    Assignee: Seiko Epson Corporation
    Inventors: Masaaki Sakata, Junichi Hayashi
  • Patent number: 7776255
    Abstract: Hollow metal and/or metal alloy articles are fabricated by the reduction of metal containing compounds, particularly non-metallic metal compounds.
    Type: Grant
    Filed: April 15, 2008
    Date of Patent: August 17, 2010
    Assignee: Imaging Systems Technology
    Inventors: Carol Ann Wedding, Thomas J. Pavliscak, Oliver M. Strbik, III, Joe K. Cochran, Jr.
  • Publication number: 20100183471
    Abstract: A method for forming an article by metal injection moudling of aluminium or an aluminium alloy. The method comprises the steps of forming a mixture containing an aluminium powder or an aluminum alloy powder or both and optionally ceramic particles, a binder, and a sintering aid comprising a low melting point metal. The mixture is injection moulded and the binder is removed to form a green body. The green body is sintered. The sintering is conducted in an atmosphere containing nitrogen and in the presence of an oxygen getter.
    Type: Application
    Filed: August 7, 2007
    Publication date: July 22, 2010
    Applicant: THE UNIVERSITY OF QUEENSLAND
    Inventors: Zhenyun Liu, Timothy Barry Sercombe, Graham Barry Schaffer
  • Patent number: 7713466
    Abstract: The invention provides a valve-acting metal sintered body for anode of a solid electrolytic capacitor, having a high capacitance, well impregnated with cathode material, and exhibiting excellent properties particularly when having a large volume, a capacitor having a low ESR, an excellent tan ? value and good long-term reliability such as moisture resistance and heat resistance by using the sintered body, and a production method therefor comprising the following steps: coating/printing/shaping a granulated product of a mixed dispersion containing a pore-forming agent, an organic binder and a primary powder or secondary aggregated powder of at least one member selected from valve-acting metal, a valve-acting metal compound and a valve-acting metal alloy or a granulated powder thereof, and a solvent, or compressing and shaping the granulated product of a mixture obtained by removing the solvent from the dispersion; sintering the shaped article containing a pore-forming agent; and removing the pore-forming agent
    Type: Grant
    Filed: April 27, 2004
    Date of Patent: May 11, 2010
    Assignee: Showa Denko K.K.
    Inventors: Kazuhiro Omori, Yoshinori Shibuya
  • Patent number: 7691172
    Abstract: Provided is iron-based metal powder for powder metallurgy including a metallic soap containing at least one or more types selected from a group of Ag, Au, Bi, Co, Cu, Mo, Ni, Pd, Pt, Sn, Te and W having a higher standard oxidization potential than iron, and an iron sintered body having a rust prevention function, wherein at least one or more types of metallic soap selected from a group of Ag, Au, Bi, Co, Cu, Mo, Ni, Pd, Pt, Sn, Te and W having a higher standard oxidization potential than iron is added to iron-based metal powder for powder metallurgy, and sintering is performed thereto. As a result, obtained is mixed powder for powder metallurgy capable of improving the rust prevention effect easily without having to hardly change the conventional processes.
    Type: Grant
    Filed: August 5, 2005
    Date of Patent: April 6, 2010
    Assignee: Nippon Mining & Metals Co., Ltd.
    Inventors: Toru Imori, Atsushi Nakamura, Yasushi Narusawa, Masataka Yahagi
  • Patent number: 7682558
    Abstract: A metallurgical composition is provided for making compacted parts, comprising: (a) at least about 80 percent by weight of an iron or iron-based powder; (b) up to about 20 percent by weight of at least one alloying powder; (c) from about 0.05 to about 2 percent by weight of a binding agent comprising a C14-C30 fatty alcohol; and (d) from about 0.001 to about 0.2 percent by weight of a flow agent.
    Type: Grant
    Filed: December 20, 2006
    Date of Patent: March 23, 2010
    Assignee: Höganäs AB (PUBL)
    Inventors: Per Knutsson, Per-Olof Larsson, Hilmar Vidarsson
  • Patent number: 7666348
    Abstract: A production method includes: preparing a metal powder composed of one of Mo and W, and a binder composed of a thermoplastic resin and a wax; mixing the metal powder and 40 to 60 volume % of the binder with respect to the metal powder into a mixed powder; and heating and kneading the mixed powder into a raw material. The production method further includes: supplying a predetermined of the raw material in a hole of a die; and compacting the raw material into a cup-shaped green compact by pressing the raw material by a punch, the cup-shaped green compact having a cylindrical portion, a bottom formed at one end portion thereof, and an opening formed at another end portion thereof. The production method further includes: ejecting the cup-shaped green compact from the hole of the die; removing the binder from the ejected cup-shaped green compact by heating; and sintering the cup-shaped green compact by heating the green compact and diffusion-bonding particles of the green compact.
    Type: Grant
    Filed: May 8, 2006
    Date of Patent: February 23, 2010
    Assignee: Hitachi Powdered Metals Co., Ltd.
    Inventors: Zenzo Ishijima, Masahiro Okahara, Narutoshi Murasugi
  • Patent number: 7662338
    Abstract: A sintering compound containing a sinterable powder and a binder removable in a debinding step is injected into a metal mold set provided with a sintering compound injecting mold, in a sintering compound molding step (S104). An add-on forming compound which becomes removable or separable from the sintering compound injection molded body in the debinding step or the sintering step is injected into the metal mold set provided with an add-on mold in an add-on forming step (S102). The sintering compound injection molded body and the add-on are formed integrally with each other in the metal mold set. The integral formation of the add-on and the sintering compound injection molded body enables to prevent damage during release from the mold and make easy to handle the injection molded body.
    Type: Grant
    Filed: November 2, 2004
    Date of Patent: February 16, 2010
    Assignee: Taisei Kogyo Co., Ltd.
    Inventor: Shigeo Tanaka
  • Publication number: 20090308662
    Abstract: Methods of forming cutter assemblies for use on earth-boring tools include sintering a cone structure to fuse one or more cutting elements thereto and having a hardened land area. In some embodiments, one or more green, brown, or fully sintered cutting elements may be positioned on a green or brown cone structure prior to sintering the cone structure to a final density. Cutter assemblies may be formed by such methods, and such cutter assemblies may be used in earth-boring tools such as, for example, earth-boring rotary drill bits and hole openers.
    Type: Application
    Filed: June 11, 2008
    Publication date: December 17, 2009
    Inventor: Nicholas J. Lyons
  • Publication number: 20090252638
    Abstract: The invention relates to the cost-effective manufacture of near-net shape titanium articles from sintered powders containing titanium and all required alloying elements. The cost-effective initial powder composition for subsequent room temperature consolidation and sintering contains: (a) 10-50 wt. % of underseparated titanium powder with ?500 ?m in particle size manufactured from underseparated titanium sponge comprising up to 2 wt. % of chlorine and up to 2 wt. % of magnesium. The underseparated titanium powder costs significantly less than that for fully separated powder of completely reduced sponge; (b) 10-90 wt. % of hydrogenated titanium powder, whereby this powder is a mixture of two hydrogenated powders A and B containing different amount of hydrogen: powder A contains amount of hydrogen in the range of 0.2-1 wt. % and powder B contains amount of hydrogen in the range of 2-3.9 wt. %.
    Type: Application
    Filed: June 11, 2007
    Publication date: October 8, 2009
    Inventors: Volodymyr A. Duz, Orest M. Ivasishin, Vladimir S. Moxson, Dmitro G. Savvakin, Vladislav V. Telin
  • Patent number: 7582255
    Abstract: A hydroxy fatty acid salt having an average particle diameter of from 5 ?m to 100 ?m with a composition of from 0.3 wt % to 2 wt %, and more preferably, from 0.5 wt % to 2 wt % is added to a raw material powder in powder metallurgy, and worm molding is performed. In addition, a hydroxy fatty acid salt having an average particle diameter of 50 ?m or less is attached on a mold in advance, and after that, the warm molding is performed. As a hydroxy fatty acid salt, 12-hydroxy lithium stearate is suitably used.
    Type: Grant
    Filed: November 24, 2004
    Date of Patent: September 1, 2009
    Assignee: Mitsubishi Materials PMG Corporation
    Inventors: Takashi Nakai, Kinya Kawase
  • Patent number: 7431981
    Abstract: A prepreg material infused with a bulk resin, where the bulk resin has shape memory alloy (SMA) particles intermixed in the resin to toughen the material when the material is used in an application and is cured. The SMA particles may be of various shapes and sizes. The material may form a prepreg fabric having interwoven fibers or a prepreg unidirectional tape having fibers oriented unidirectionally. Opposing surfaces of the material may be infused with quantities of bulk resin having different concentrations of SMA particles. The SMA particles may be mixed in the bulk resin while in their austenitic or martensitic states to suit the needs of specific applications.
    Type: Grant
    Filed: November 17, 2004
    Date of Patent: October 7, 2008
    Assignee: The Boeing Company
    Inventor: Terry L Schneider
  • Patent number: 7416578
    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.
    Type: Grant
    Filed: September 19, 2005
    Date of Patent: August 26, 2008
    Assignee: Höganäs AB
    Inventors: Åsa Ahlin, Maria Ramstedt
  • Patent number: 7351371
    Abstract: A porous near-net-shape metallic parts with an open porosity of at least 10% by volume is made by first forming an injectable mass of a metallic powder of stainless steel, Ti, NiTi, or a titanium alloy, at least one thermoplastic binder, and at least one place holder. The mass then injection molded into the shape of the part to be produced, cooled, set in a capillary-active material, and subjected to a first-stage binder removal to produce an open porosity. The place holder is then removed at least partially from the part with a fluid, and the part is subjected to a thermal binder-removing process. Finally the part is sintered.
    Type: Grant
    Filed: September 19, 2003
    Date of Patent: April 1, 2008
    Assignee: Forschungszentrum Julich GmbH
    Inventors: Heinz Nelles, Martin Bram, Hans Peter Buchkremer, Detlev Stöver
  • Patent number: 7329302
    Abstract: Particulate lubricants are disclosed which comprise discrete particles of a fatty monoamide, especially oleamide and discrete particles of at least one other powder metallurgy lubricant, which provide a synergistic free-flowing composition; there are also provided novel compositions of matter for forming sintered metal components comprising a mixture of sinterable powdered metal and the particulate lubricants.
    Type: Grant
    Filed: November 5, 2004
    Date of Patent: February 12, 2008
    Assignee: H. L. Blachford Ltd./Ltee
    Inventor: James M. McCall
  • 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: 7264646
    Abstract: The present invention provides a lubricant system in the pressing of powders to form a part. The lubricant system is a solid at ambient conditions. However, upon application of pressure during the pressing of the metal parts, the lubricant system forms a liquid phase along the walls of cavity in which the powder is being pressed. The lubricant system may also be used in connection with a polar powder thereby providing certain beneficial results.
    Type: Grant
    Filed: January 26, 2004
    Date of Patent: September 4, 2007
    Assignee: Apex Advanced Technologies, LLC
    Inventor: Dennis L. Hammond
  • Patent number: 7186369
    Abstract: The present invention relates to a method of forming a part made of a molybdenum-copper composite material. The composite material is formed by forming a mixture of molybdenum, phenolic, and wax, laser sintering the mixture to form a green form, placing the green form and oxygen free copper into a furnace, and subjecting the green form and oxygen free copper to a furnace heating cycle.
    Type: Grant
    Filed: March 4, 2005
    Date of Patent: March 6, 2007
    Assignee: The United States of America as represented by the Secretary of the Navy
    Inventors: Peter J. Hardro, Brent Stucker
  • Patent number: 7147819
    Abstract: The invention relates to a method for producing highly porous, metallic molded bodies. The inventive method consists of the following steps: a metallic powder used as a starting material is mixed with a dummy; a green body is pressed out of the mixture; the green body is subjected to conventional mechanical machining, the dummy advantageously increasing the stability of the green body; the dummy material is thermally separated from the green body by means of air, a vacuum or an inert gas; and the green body is sintered to form the molded body and is then advantageously finished. Suitable materials for the dummy are, for example, ammonium bicarbonate or carbamide. The mechanical machining carried out before the sintering advantageously enables a simple production close to the desired final contours, even for complicated geometries of the molded body to be produced, without impairing the porosity, and without high wear of the tools.
    Type: Grant
    Filed: May 9, 2003
    Date of Patent: December 12, 2006
    Assignee: Forschungszentrum Julich GmbH
    Inventors: Martin Bram, Alexander Laptev, Detlev Stöver, Hans Peter Buchkremer
  • Patent number: 7108828
    Abstract: The porous material of the present invention is produced by heating a dry powder mixture, containing mainly an organic solid binder and inorganic particles. The mixture is foamed while the organic binder is melted. Foaming comes from a foaming agent in the powder mixture. The solid foamed structure comprising inorganic particles embedded in an organic binder is then heated to eliminate the organic binder and finally to sinter the remaining inorganic tri-dimensional network into a rigid structure having interconnected porosity.
    Type: Grant
    Filed: June 23, 2003
    Date of Patent: September 19, 2006
    Assignee: National Research Council of Canada
    Inventors: Louis-Philippe Lefebvre, Yannig Thomas, Maxime Gauthier
  • Patent number: 6989062
    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.
    Type: Grant
    Filed: February 14, 2003
    Date of Patent: January 24, 2006
    Assignee: Höganäs AB
    Inventors: Ye Zhou, Per-Olof Larsson, Henrik Andersson, Lars Hultman
  • Patent number: 6893702
    Abstract: The present invention relates to a substrate for a magnetic recording medium that ensures a floating height on a magnetic head. This substrate is made of a sintered body provided with pores having a diameter in the range of 0.05 ?m to 2.0 ?m extending across 5% to 50% of the surface area of the substrate.
    Type: Grant
    Filed: January 20, 2004
    Date of Patent: May 17, 2005
    Assignee: Fujitsu Limited
    Inventor: Shinichi Takahashi
  • Patent number: 6861028
    Abstract: A manufacturing method for high-density iron-based powder compacts is disclosed. The temperature of the die is adjusted at ordinary temperature or at a predetermined temperature by preheating. A lubricant for die lubrication prepared by mixing at least two different lubricants having melting points higher than a predetermined temperature of the compaction pressure is sprayed at the upper part of the die and is introduced into the die and adhered by electrification to the surface of the die. The resulting die is filled with an iron-based mixed powder including a lubricant and molding is performed at ordinary temperature or at a temperature raised by heating.
    Type: Grant
    Filed: March 27, 2001
    Date of Patent: March 1, 2005
    Assignee: Kawasaki Steel Corporation
    Inventors: Yukiko Ozaki, Satoshi Uenosono, Shigeru Unami
  • Patent number: 6849230
    Abstract: A mixture of two particulate phases used in the production of a green compact that can be sintered at higher temperatures. The first phase contains particles that consist of a metal and/or a metal allow and/or a metal compound. The second phase contains particles from the group of the inorganic compounds that do not release any decomposition products at temperatures of more than 400° C., that are interstitially soluble in the sintering metal phase, and/or that react with the second phase to stable compounds. The mixture, by providing the second phase, is effective in supporting the fine structure of the first phase against the forces of surface tensions during the sintering process. During sintering, the second phase remains thermally stable and substantially chemically inert with respect to the first phase.
    Type: Grant
    Filed: September 14, 1999
    Date of Patent: February 1, 2005
    Assignee: Stratec Medical AG
    Inventor: Heinrich Feichtinger
  • Patent number: 6814926
    Abstract: A powder blend for use in laser sintering and a method for forming tough, strong, wear-resistant, corrosion-resistant infiltrated metal products are provided. The powder blend comprises a steel alloy, a polymeric binder and a high melting temperature fine particulate which are blended together, then applied layer by layer to a working surface in a laser sintering system, exposed a layer at a time to fuse together the powder until a green part of high strength is formed, and then the green part is infiltrated with a metal infiltrant in a non-reducing gas atmosphere at an effective temperature for an effective period of time. The preferred steel is a mild steel alloy.
    Type: Grant
    Filed: March 19, 2003
    Date of Patent: November 9, 2004
    Assignee: 3D Systems Inc.
    Inventors: Brad Geving, Kris Alan Schmidt, Kenneth J. Newell
  • Publication number: 20040175286
    Abstract: The present invention provides a lubricant system in the pressing of powders to form a part. The lubricant system is a solid at ambient conditions. However, upon application of pressure during the pressing of the metal parts, the lubricant system forms a liquid phase along the walls of cavity in which the powder is being pressed. The lubricant system may also be used in connection with a polar powder thereby providing certain beneficial results.
    Type: Application
    Filed: January 26, 2004
    Publication date: September 9, 2004
    Applicant: Apex Advanced Technologies, LLC
    Inventor: Dennis L. Hammond
  • Patent number: 6788866
    Abstract: Structures include a substrate with a release layer on the surface of the substrate and a uniform material over the release layer. The release layer generally includes powders or partly sintered powders. In some embodiments the uniform material is an optical material, which can be a glass. The optical material can be mechanically decoupled fro the substrate such that the optical material is stress free. The release layer can function as a transfer layer for transferring the uniform material to another substrate of separating the uniform material to create a freestanding structure. The release layer can be formed by the deposition of a material with a higher sintering temperature than powders used to form the uniform material. In other embodiments, a heating step is performed to preserve the release layer while consolidating powders on top into the uniform material.
    Type: Grant
    Filed: August 17, 2001
    Date of Patent: September 7, 2004
    Assignee: NanoGram Corporation
    Inventor: Michael A. Bryan