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.

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.

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.

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.

Abstract: The invention relates to a method for producing component parts with a high degree of dimensional precision, made of NiTi-shape memory alloys. The invention makes it possible to apply a known metal injection moulding method to NiTi-shape memory alloys by adapting the binding system, temperature control and reducing the time necessary for debinding.

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 &mgr;m to 2.0 &mgr;m extending across 5% to 50% of the surface area of the substrate.

Abstract: A powder compaction method in which a powder p is filled by air tapping or other suitable method into a mold 1, then while the mold 1 being filled with the powder, the powder particles are bound with each other without application of force from outside the mold to form a compact C, and then the compact C is taken out from the mold 1. This method produces a variety of shapes of the compact far greater than in conventional methods, and net shape manufacturing of products with complex shapes is made possible by this method. Because this method uses far less binder compared to MIM and PIM that are expected as methods for producing products with complicated shapes, the time needed for elimination of the binder is much shorter than in MIM and PIM.

Abstract: Although MIM (metal injection molding) has received widespread application, aluminum has not been widely used for MIM in the prior art because of the tough oxide layer that grows on aluminum particles, thus preventing metal—metal bonding between the particles. The present invention solves this problem by adding a small amount of material that forms a eutectic mixture with aluminum oxide, and therefore aids sintering, to reduce the oxide, thereby allowing intimate contact between aluminum surfaces. The process includes the ability to mold and then sinter the feedstock into the form of compacted items of intricate shapes, small sizes (if needed), and densities of about 95% of bulk.

Abstract: A metal injection-molding feedstock is heated and plasticized. Supercritical carbon dioxide is injected into the feedstock to form micropores when the pressure is reduced and a parts mold is filled. The micropores are retained when the green parts are debindered and sintered.

Abstract: A manufacturing process for articles that are formed from powders containing tungsten and at least one binder. The manufacturing process includes compacting the mixture of powders under a first pressure to yield a desired intermediate structure, then reshaping the structure under a second pressure that is lower than the first pressure to yield the desired article. The binder utilized in the manufacturing process may include a metallic binder or a non-metallic binder, or both. The process is particularly suited for the manufacture of lead substitutes, including firearms projectiles, such as a bullet or shot. Such projectiles may be ferromagnetic or non-ferromagnetic, frangible or infrangible, and jacketed or unjacketed.

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 &mgr;m to 2.0 &mgr;m extending across 5% to 50% of the surface area of the substrate.

Abstract: A method for selectively and rapidly extracting/removing a plasticizer from a compact such as a green laminate that is produced at a certain point in the process of manufacturing a multilayer ceramic capacitor. Carbon dioxide is introduced into a pressure chamber in which the green laminate has been placed, and the temperature and the pressure of the pressure chamber are set to 40° C. and 10 MPa, respectively, so that the pressure chamber is filled with a supercritical carbon dioxide. The plasticizer is extracted/removed from the green laminate by using the supercritical carbon dioxide. Then, a de-binder step and a baking step are performed in an ordinary manner. By performing the de-plasticizer process of selectively extracting/removing the plasticizer before the de-binder step, it is possible to suppress the formation of a graphite-like substance even if the temperature is increased rapidly in the subsequent de-binder step and the baking step.

Abstract: The invention relates to an nickel-poor austenitic steel containing iron and the following components: manganese: less than 9.0% by weight; chrome: less than 16 and a maximum of 22% by weight; nitrogen: more than 0.30 and a maximum of 0.70% by weight; carbon: more than 0.08 and a maximum of 0.30% by weight and silicon: less than 2.0% by weight. The invention also relates to the production and utilization of said steel.

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.

Abstract: A method and an apparatus for sintering a compact of particulate material for a ceramic or of particles of a metal, or a ceramic precursor film, wherein the sintering is performed by heating and burning the compact or the ceramic precursor film while applying centrifugal force to the compact or the ceramic precursor film.

Abstract: Hard sintered moldings having a nickel- and cobalt-free, nitrogen-containing steel as a binder of the hard phase, processes for the powder metallurgical production of these hard sintered moldings, in particular by powder injection molding, and powder injection molding materials for the production of these hard sintered moldings by powder injection molding.

Abstract: This invention provides a process for forming sintered, molded articles having improved dimensional stability. More particularly, this invention pertains to process for forming heat sinks. This process includes forming a substantially uniform copper composition comprising a polysaccharide binder, water, and copper particles; molding the copper composition under conditions sufficient to form a solid molded intermediate; and sintering the solid molded intermediate at a sufficient temperature and for a sufficient time to form a heat sink.

Abstract: This invention relates to a lubricant for metallurgical powder compositions. According to the invention, the lubricant contains a polyolefine-based polymer, which has a weight-average molecular weight Mw of 500-10000. The invention further concerns a metal-powder composition containing the lubricant, method for making sintered products by using the lubricant, and use of the same in cold and warm compaction.

Abstract: A process for the removal of binder material from powder injected molded parts that employs a low pressure plasma reactor to generate reactive species which react with the binder material in the injected molded part is presented. The reactive species cause the binder material to break down into smaller molecules and thereby be removed from the injected molded part.

Abstract: The invention concerns a metal powder composition for warm compaction comprising an iron-based powder and lubricant powder consisting of a polycarboxylic acid amide wax having a melting point peak in the range of 180° to 210° C.

Abstract: Boron powders are sintered and densified utilizing a microwave environment for so doing.

Abstract: In a method for manufacturing a sintered body of the present invention, a feed stock including metal powder, a binder, and an organic material having a melting point lower than that of the binder is extrusion molding by using an extruder 1, so that an extruded body having a desired shape (cross-sectional shape) and dimensions is manufactured. In this method, a temperature of an extrusion side die 52 of an extrusion die 5 is lower than the melting point of the binder and higher than that of the organic material. Next, a debinding treatment (treatment for removing binder) of the obtained extruded body is performed. The debinding treatment is separately performed by a first process in a low temperature region and a second process in a temperature region higher than that in the first process. Subsequently, an obtained debounded body is sintered by baking in a sintering furnace, whereby the sintered body (metal product) is manufactured.

Abstract: A method by which the distribution of the particulates of a plurality of metal powders, the metals of each powder being of different densities, may be uniformly disbursed within a dry mixture of the powders and by which this uniform dispersion of the different density powders can be sustained through subsequent handling and/or storage of the mixture. In accordance with one aspect of the present invention, a quantity of each of a plurality of metal powders is admixed with a dry stabilizing non-metal powder. One particularly useful non-metal powder is a micronized polymer, preferably micronized polyethylene.

Abstract: A suspension application apparatus for applying a suspension containing powder particles of an oxide dispersed in a liquid to a plate for magnet sintering, the oxide having a specific gravity greater than the liquid. The apparatus includes: a container for storing the suspension; a stirrer for stirring the suspension stored in the container; a transport path through which the suspension is transported from the container to the plate; and a homogenizer for homogenizing the suspension by applying a mechanical force to at least part of the suspension flowing through the transport path.

Abstract: A method for manufacturing complex shape memory alloy materials is described. The method comprises generating a particulate form of a shape memory alloy, combining the particulate with a binder, molding, heating (which may include the steps of debinding and sintering), and thermo-mechanical processing. The method allows for the formation of complex shape memory alloy materials that exhibit the desirable properties of shape memory alloys, namely shape memory and superelasticity.

Abstract: A method is provided for manufacturing a form tool used for forming threaded fasteners. The method utilizes powdered metal technology and processes to produce densified parts having at least the near net shape of the desired threaded fastener form tool.

Abstract: A method of directly fabricating metal parts with surface features only requires first preparing a mold of the desired metal part. A powder blend is poured into the mold, which includes a base metal, a lower melting temperature alloy of the base metal, and a polymer binder. The mold containing the powder blend is heated until the polymer binder melts and adheres the metal particles to form a green part. The green part is removed from the mold and placed in a crucible, and loose ceramic powder is packed around the part to support it. The supported green part is then heated as needed to vaporize the binder and consolidate the part via liquid phase sintering. Once cool, the consolidated part can be machined to meet precise dimensional tolerances, if necessary.

Abstract: A cutting element for a drill bit used in drilling subterranean formations is formed with an internal chamber or passage for the flow of drilling fluid therethrough. A substrate having at least one internal passage, and prior to attaching the table thereto, the at least one passage is filled with a removable substantially incompressible filler material. Attachment or bonding of the table to the substrate under high temperature and high pressure is accomplished without significant distortion of the shape and size of the passage. The filler material may be a crystalline salt such as sodium chloride or halite, which are removable by dissolution in water, or may be boron nitride or a volcanic material such as Pyrofolyte material which are mechanically removable.

Abstract: Parts made from powder use a material that originates from a salt to bind powder particles together. The salt may be provided dissolved in a solution, as molten salt, or as a dry powder. The figure is an electron micrograph of a cross section of a silver nitrate bound product with a skeleton of steel powder.

Abstract: A method of thermally removing binder from porous compacts pressed from metallic or ceramic materials using atmospheric pressure and binder-free compacts produced therefrom.

Abstract: To provide a method for forming undercuts of a metal injection molded product by simple processes and metal injection molded products having undercuts formed by the forming method thereof, steps are included of injection-molding a feed stock containing metal powder and binding resin, forming undercuts to an injection green body obtained by the injection-molding, and sintering after debinding the injection green body formed with undercuts. It is preferable that undercuts are formed by deforming at least one part of an injection green body; it is more preferable that they are deformed by pressing with a pressing member.

Abstract: The present invention concern a method using powder metallurgy for producing molded parts intended to be assembled by self-brazing to metal parts capable of receiving them and said receiving parts. The method comprises forming a homogenous mixture of a basic metal powder, brazing powder and a liquid binding agent which is injection molded to form a self-brazing part.

Abstract: The slide member 5 slidably guided on the outer peripheral surface of a shaft is formed by adding 10-50% by volume of thermosetting resin to a metal powder consisting mainly of copper powder, iron powder or a mixture thereof and sintering the same at temperatures not less than the sintering temperature of the metal powder.

Abstract: This invention concerns a lubricant for warm compaction of iron-based metallurgical powder compositions. 50 to 100% by weight of the lubricant is a polyester, aromatic or partly aromatic, which has a number-average molecular weight Mn of 5,000-50,000. This invention further concerns a metal powder composition containing the lubricant, a method for making sintered products by using the lubricant, and use of the same in warm compaction of metallurgical powders.

Abstract: The present invention concerns a process of preparing high density, warm compacted bodies of a stainless steel powder comprising the steps of providing a mixture of a low carbon, low oxygen stainless steel powder including 10-30% by weight of Cr, optional alloying elements and graphite and inevitable impurities, mixing the powder with a high temperature lubricant and compacting the mixture at an elevated temperature. The invention also concerns a composition of the stainless steel powder, optional additional alloying elements and a high temperature lubricant.

Abstract: A method is disclosed to accurately determine the volumetric composition of thermoplastic compounds made from sinterable materials mixed with an organic binder so that parts produced from such compounds will have a precisely controlled shrinkage upon sintering. The invention allows the use of a single molding tool to fabricate parts to very tight manufacturing tolerances in a range of different sizes and from different materials such as stainless steels, carbides, advanced ceramics, metal and ceramic matrix composites, etc. The invention also allows the miniaturization of metal and ceramic injection molded components.

Abstract: A method is disclosed to form micromolds and micromold components from mixtures of micrometer or nanometer-sized particulates dispersed in an organic binder. Following extraction of the organic binder the green micromolds or micromold components are sintered to full density, upon which they shrink by accurately predetermined amounts. The method allows to achieve complex-shaped micrometer and nanometer-sized precision parts such as MEMS devices and MEMS packages.

Abstract: A method for making small punches by employing multi-layer ceramic (MLC) technology includes the steps of preparing a sublaminate matrix of a high or low sintering temperature material, drilling holes in the sublaminate using a mask as a guide, filling the holes with punch material paste by a solupor process, laminating the sublaminate to a base plate or as a freestanding substrate, firing a laminate at an appropriate sintering temperature and removing the matrix material by a chemical or mechanical method. In accordance with the present invention, a large number of small punches are made in parallel to precise dimensions of two to ten mils in diameter and approximately 100 mils in length. This method allows that a punch plate array can also be used to simultaneously punch an array of vias in a greensheet and eliminates the additional step of loading individual punches into a punch plate, offering cost and time savings.

Abstract: Organic acid-based binders are efficiently removed from powder metallurgy compacts, such as tantalum capacitor anode bodies, by immersion in a heated aqueous alkanolamine solution followed by rinsing in warm water. This method results in lower residual carbon and oxygen levels than are found with thermal binder removal methods.

Abstract: A method is provided for fabricating metallic microstructures, i.e., microcomponents of micron or submicron dimensions. A molding composition is prepared containing an optional binder and nanometer size (1 to 1000 nm in diameter) metallic particles. A mold, such as a lithographically patterned mold, preferably a LIGA or a negative photoresist mold, is filled with the molding composition and compressed. The resulting microstructures are then removed from the mold and the resulting metallic micro structures so provided are then sintered.

Abstract: A method for manufacturing the roller carrier of a vibration balance device, the roller carrier is installed with at least one round track around a rotary axis thereof for carrying a plurality of rollers; characterized in that: the roller carrier is made of alloy powder and made by a process of metal powder metallurgy. The material of the powder is SUS-316L or other proper alloy powder. The manufacturing process of the metal powder metallurgy includes the steps of: feeding material, compacting, sintering, and sizing, or other manufacturing process of the metal powder metallurgy (MIM) can be used, which includes the steps of feeding material, pelletizing, injection molding, debinding, sintering, and sizing. The roller carrier from aforementioned processes uses less materials, can be mass-produced, has a precise dimension, is light weighted, has a smooth surface and has a high surface hardness.

Abstract: A hydrogen storage material is disclosed with no collapse due to pulverization of hydrogen storage alloy particles by repeated hydrogen absorption and desorption thereby permitting repeated use while manifesting excellent electric and thermal conductivities. Pressure molding of hydrogen storage alloy particles, each being covered with a plated metal film having microgranules of a thermoplastic resin, at a temperature higher than a glass transition temperature or a melting point of and below a thermal decomposition temperature of the thermoplastic resin can produce a porous hydrogen storage material of hydrogen storage alloy particles being bonded to each other via the thermoplastic resin. The hydrogen storage material can become firm and strong because the plated metal films covering the hydrogen storage alloy particles are clasped with each other complexly.

Abstract: A method of manufacturing a sliding part includes: an injection molding step of injection-molding a compacted member of a molding compound which is a mixture of powder material equivalent to SUS440C, graphite carbon corresponding to an oxygen content of the material, and a binder; a degreasing step of heating the compacted member thus obtained by the injection molding step under a neutral atmospheric condition to remove substantially all of the binder from the compacted member; and a baking step of heating the compacted member which is degreased under a vacuum condition of 0.1333 Pa or less from a room temperature up to 1000° C. to reduce an oxygen content of the compacted member to 0.02% or less by the reaction of C+O→CO, and then heating the compacted member under an argon atmospheric condition of 133.3 to 3999 Pa for two hours after the temperature is increased up to 1250° C.

Abstract: Disclosed is a method of shaping powdered metal parts comprising: (a) providing powdered metal from a source; (b) applying a heated fugitive coating to the powdered metal; (c) passing the powdered metal through a heated tube from a supply thereof to the die for the molding of the part; (d) monitoring the temperature of the heated tube during the passage of the powdered metal there through; (e) heating the die and monitoring the temperature thereof; (f) heating a punch die and monitoring the temperature thereof; (g) after filling the die with coated powdered metal, compacting the powdered metal by applying pressure from the punch die to the filled die thereby compacting the metal to a desired shape.

Abstract: A powder metallurgical process of preparing iron aluminide useful as electrical resistance heating elements having improved room temperature ductility, electrical resistivity, cyclic fatigue resistance, high temperature oxidation resistance, low and high temperature strength, and/or resistance to high temperature sagging. The iron aluminide has an entirely ferritic microstructure which is free of austenite and can include, in weight %, 20 to 32% Al, and optional additions such as ≦1% Cr, ≧0.05% Zr or ZrO2 stringers extending perpendicular to an exposed surface of the heating element, ≦2% Ti, ≦2% Mo, ≦1% Zr, ≦1% C, ≦0.1% B, ≦30% oxide dispersoid and/or electrically insulating or electrically conductive covalent ceramic particles, ≦1% rare earth metal, ≦1% oxygen, and/or ≦3% Cu.

Abstract: Improved methods for coating particulate materials at low shear conditions and preferably below the melting point of the coating material are provided. In one aspect, metallurgical compositions are provided that contain a metal-based powder bound to an alloying powder or powders by way of a low melting polymer or wax binding agent, which is preferably polyethylene. The binding agent is blended with the metal-based and alloying powders at elevated temperatures preferably below the melting point of the binding agent. The bonded metallurgical composition can be used in compaction processes to manufacture compacted parts that can be sintered to impart strength.

Abstract: A method for making foam structures suitable for use as mechanical energy absorbers, structural members, filters, catalyst carriers or the like. A composite rod comprising an outer shell and an inner core is formed of respective mixtures of powders. The mixture for the outer shell comprises a sinterable powdered structural material such as ceramics, metals, intermetallics, and a powdered binder such as paraffin, wax or polymer. The inner core comprises a powdered channel-forming filler material such as melamine or polymers, or soluble inorganic compounds or a metal that can differentially be removed from the structural material of the shell. The composite rod may be formed by extrusion. The composite rod is sectioned into a plurality of composite rod segments of predetermined length and a plurality of these segments is assembled in randomly oriented relationship to one another. The assemblage of rod segments is then consolidated, and the binder and filler are then removed, as by heating.

Abstract: A pressable powder is formed by a method comprising [I] mixing, in essentially deoxygenated water, [A] a first powder selected from the group consisting of a transition metal carbide and transition metal with [B] an additional component selected from the group consisting of (i) a second powder comprised of a transition metal carbide, transition metal or mixture thereof; (ii) an organic binder and (iii) combination thereof and [II] drying the mixed mixture to form the pressable powder, wherein the second powder is chemically different than the first powder. The pressable powder may then be formed into a shaped part and subsequently densified into a densified part, such as a cemented tungsten carbide.

Abstract: A gelcasting composition has improved drying behavior, machinability and shelf life in the dried and unfired state. The composition includes an inorganic powder, solvent, monomer system soluble in the solvent, an initiator system for polymerizing the monomer system, and a plasticizer soluble in the solvent. Dispersants and other processing aides to control slurry properties can be added. The plasticizer imparts an ability to dry thick section parts, to store samples in the dried state without cracking under conditions of varying relative humidity, and to machine dry gelcast parts without cracking or chipping. A method of making gelcast parts is also disclosed.

Abstract: The invention relates to a process for producing sinterable metallic shaped parts from a metal powder, which is mixed with an auxiliary compacting agent containing at least in part components from the polyalkylene glycol family, is filled into a compacting mold and, following the compacting under pressure, is ejected from the mold as compacted shaped part.