Abstract: A process for dewaxing injection molded metal pieces consisting of a metal/binder mixture, wherein a metal oxide is added to the metal/binder mixture.

Abstract: Rare-earth alloy anisotropic powders consist of, in atomic percent, over 12 percent and not more than 20 percent of R (R is at least one on neodymium and praseodymium or at least one of them and or more rare-earth elements), not less than 4 percent and not more than 10 percent of boron, not less than 0.05 percent and not more than 5 percent of copper and the rest that consists of iron and unavoidable impurities. Up to 20 percent of the iron contained is replaceable with cobalt. The alloy powders are made up of flat crystal grains having mean thickness h (the shortest measure), d not smaller than 0.01 .mu.m and not larger than 0.5 .mu.m and ratio d/h not smaller than 2, where d is the means measure of the grains taken at right angles to the widthwide direction thereof, and the alloy powders are magnetically anisotropic.

Abstract: A method for producing metal carbide grade powders suitable for isostatic compaction which comprises combining a binder metal powder with an esterified wax and heating the wax to a temperature above the melting point of the wax to melt the wax and maintain it in the molten state to form a first mixture, with the amount of wax being sufficient to result in a level of wax in the subsequently produced second mixture of no greater than about 1/2% by weight, combining a metal carbide powder component with the first mixture while maintaining the wax in the molten state, forming a slurry of the second mixture and water, attritor milling the slurry at a temperature below the melting point of the wax, and removing water from the resulting attritor milled mixture to form the metal carbide grade powder.

Abstract: A starting material for injection molding of a metal powder including from 38 to 46% by volume of an organic binder and the balance of spherical iron powder with an average particle size from 2 to 6 .mu.m, which provides a sintered part having a density ratio of higher than 94%, by conducting injection molding, debinding and sintering in a non-oxidizing atmosphere at a temperature lower than the A.sub.3 transformation point of carbon steel.

Abstract: A method of manufacturing a soft magnetic Fe-Si alloy sintered product comprising a step of injection molding a composition comprising an Fe-Si powder mixture blended so as to contain from 1 to 10% by weight of Si and the substantial balance of Fe and a binder a step of applying binder-removal under heating to the resultant green body and applying a degassing and Si-diffusing; and a step of subsequently applying sintering. The sintered product is, preferably, applied with further heating for obtaining better soft magnetic property. Soft magnetic property of the sintered products is as comparable with or superior to products by conventional powder metallurgy.

Abstract: A composite comprised of a sintered matrix of spinel ferrite and a non-exposed continuous phase of elemental silver or Ag-Pd alloy ranging to 25 atomic % Pd is produced by co-firing a laminated structure of ferrite powder-containing tapes containing non-exposed metallization-forming material. The composite can be formed into a composite product which contains a continuous silver or Ag-Pd alloy phase with two end portions wherein only the end portions are exposed.

Abstract: A sintered body is produced by a process comprising the steps of mixing one or more metal powder particles with an organic binder, injection-molding the mixture to form a green body of a predetermined shape, removing the binder from the green body to form a porous body substantially made of the metal powder, and heating the porous body to a sintering temperature and holding it at that temperature to produce a sintered body, in which process the binder is removed through the sequence of the following steps: preheating the green body in an inert gas atmosphere in a temperature range that creates open pores in it; placing the green body, in which open pores have started to form, in a hydrogen gas atmosphere optionally mixed with an inert gas; holding the green body in a temperature range where the metal powder is not carburized and where the open pores will be maintained, so that the greater part of the binder is removed to form a porous body that is substantially made of the metal powder alone; and further hold

Abstract: A process is provided for igniting a mixed powder material compact containing sufficient fuel to support an exothermic reaction between ingredients contained in the compact. The ignition is achieved in an inert atmosphere with an electric arc produced by an electrode without contacting the compact and thereby initiating the reaction.

Abstract: Sintering metal powder in inert and/or reducing atmosphere has been found to result in a hard porous metal structure without the use of sintering aids. The oxidation resistance of the structure can be enhanced by the firing process comprised of the following steps: oxidation, reduction, and then inert gas sintering.

Abstract: The present invention is directed to porous sintered aluminide structures of aluminum, nickel, titanium, and/or rare earth metal. A process is disclosed for forming and sintering aluminides. Other components are optionally added to the aluminide compositions to vary the physical properties of the resultant structure.

Abstract: A copper-tungsten mixture net-shaped product produced using powder metallurgical techniques with injection molding and liquid phase sintering. The product has a very low leak rate in helium gas, a high thermal conductivity and a rate of thermal expansion which is substantially the same as some glass and ceramic materials.

Abstract: A tungsten carbide powder and cemented tungsten carbide article made from the powder are disclosed. The powder has a particle size of greater than 20 micrometers in diameter and no particles less than one-half the average particle size or greater than two and one-half times the average particle size.

Abstract: A seal elements of hard material for use, for instance, as a pair of small plates which form the parts to control the fluid flow through a faucet. The seal is constructed of a hard material--a metal, a metallic oxide, a metallic carbide, a metallic nitride, a ceramic or glassy material--which is sintered from a semi-finished product obtained by mixing a powder of fine particle size of the aforementioned hard materials with an organic binder--a plastic material, a wax, or a combination of these substances. This mixture is formed under compression in a mold and, eventually, at least some of the binder is eliminated.

Abstract: A single step is relied on in the canning process for hot isostatic pressing metallurgy composites. The composites are made from arc-sprayed and plasma sprayed monotape. The HIP can is of compatible refractory metal and is sealed at high vacuum and temperature. This eliminates out-gassing during hot isostatic pressing.

Abstract: A method of removing a binder from a green body capable of accomplishing the binder removal at a substantially reduced temperature and in a significantly reduced period of time. The binder mainly consists of a polymer material of ultraviolet degradation properties such as, for example, a polymer material having a main chain containing a tertiary carbon atom. The green body is irradiated with ultraviolet rays at a temperature within the range of 150.degree. C. to 300.degree. C. under an atmospheric pressure to rapidly carry out the photo degradation of the polymer material by ultraviolet rays, so that the binder may be readily removed from the green body.

Abstract: The present invention relates to an infiltrated ferrous powder metal part containing certain additives, yielding a part having improved dimensional control during infiltration and uniform and predictable distribution of dynamic properties within a given group of commonly manufactured parts.

Abstract: A sintering metal powder consisting of metal particles having a particle diameter distribution including a plurality of peaks. The larger of the two particle diameters at every adjoining two, respectively, of the peaks has a ratio of between 5 and 10 to the smaller. The height of one of every adjoining two of the peaks has a ratio of between 1 and 5 to that of the other that is not higher than the one peak. The particle diameter at one of every adjoining two of the peaks which is not higher than the other is smaller than that at the other peak. The particle diameter at the highest peak is between 30 and 80 microns. A process for making a sintered product from such a powder is also disclosed.

Abstract: A mixture of two powdered alloys of the M, Cr, Al type, M being Co and/or Ni, is disclosed, in one form, for use in providing an abradable surface of an article and is characterized by the substantial absence of B. The first alloy has substantially no Si and has a higher melting range than that of the second alloy. The second alloy has substantially no Y and consists essentially of, by weight, 8-12% Si, 1.5-4% Al, 10-30%Cr, with the balance M and incidental impurities. The total mixture composition consists essentially of, by weight, 10-35% Cr, 4-10% Al, from a small but effective amount up to about 0.09% Y, 2-6% Si, with the balance M and incidental impurities.

Abstract: In a process for producing a sintered body using a gas-impermeable membrane formed by softening of a powder layer provided on the surface of a porous body, a metal polymer selected from polysilanes, polycarbosilanes, polysilazanes and hydrolyzates of metal alkoxides is added as a binder to the powder layer. According to the process of the invention, the gas-impermeable membrane is formed with high reliability, and high density sintered bodies can be obtained in a simple process.

Abstract: The mould of this invention is intended for the manufacture of small dimensioned parts, in particular those dimensioned on the order of 0.1 mm or less. It comprises one or several mould shells each of which is obtained by:machining a matrix (100) from a hard material of which at least a portion (104) will have the form of a negative of the desired shell, such portion having dimensions slightly greater than those of the shell to be finally obtained;positioning the matrix within a cavity (106) and obtaining a blank of the shell (116) by injecting a mixture composed of a metallic powder and a binding agent into the cavity;eliminating the binding agent by heating the blank and thereafter subjecting said blank to a sintering operation.

Abstract: Cobalt-bound tungsten carbide metal matrix composites having a unique microstructure are produced by consolidating partially sintered greenware under high pressures, e.g., 120,000 psi, at temperatures less than those used for conventional liquid phase sintering in a relatively short time, e.g., from less than one minute to less than about one hour. The composites have a binder phase which contains less than about 80 weight percent of the tungsten found in a composite prepared from the same or similar compositions via liquid phase sintering. These composites provide cutting tools with both toughness and wear resistance which exceed that of cutting tools made from the same or similar compositions via liquid phase sintering.

Abstract: The present invention relates to porous powder metal (P/M) parts having improved dynamic properties such as impact and fatigue strength. These properties are achieved by the use of finer metal powders.

Abstract: A rotary drill bit and process of fabrication in which internal fluid passages and watercourses of the bit are lined with a hard metal matrix material which renders the fluid passages more resistant to the erosive forces of the drilling fluid is provided. Also, elements such as lands for cutter element mountings, sockets, ridges, shoulders and the like on the exterior surface of the bit can be fabricated of a hard abrasion and erosion resistant material and incorporated into the bit body during fabrication. The process includes the steps of providing a hollow mold for molding at least a portion of the drill bit and positioning one or more flexible or moldable tubular elements which correspond to the internal watercourses in the mold. The elements are fabricated of a hard metal powdered material dispersed in a polymeric binder. A bit blank is then positioned at least partially within the mold and the mold packed with a metal matrix material which forms the body of the bit.

Abstract: The present invention provides a dewaxing process for metal powder compact which comprises the steps of embeding in alumina powder an injection-molded metal powder compact consisting of metal powder and an organic binder including low melting point substances; heating the embeded compact to a temperature of 200.degree. C. in a chemically inert atmosphere in a dewaxing furnace, thereby removing the low melting point substances from the compact without deformation of the compact; placing the compact in a closed sintering vessel so as to keep the surrounding temperature constant and disposing the vessel in a vacuum furnace; evacuating the vacuum furnace; and removing the organic binder by heating to a temperature of 550.degree. to 650.degree. C. at a heating rate of 300.degree. to 600.degree. C./hr while supplying an inert gas into the vacuum furnace.

Abstract: Greenbodies are produced by a RIM injection molding process wherein a homogeneous mixture of finely divided ceramic or metallic material and a polymerizable monomeric binder is injected into a mold and held at an elevated temperature for a sufficient time to polymerize the binder and form the greenbody. A preferred monomeric binder includes di- and tri-acrylate or -methacrylate esters of polyols. The low viscosity of the monomeric binder allows a loading of ceramic material of greater than 50 vol. % without adversely affecting the ability to injection mold the mixture.

Abstract: A single step is relied on in the canning process for hot isostatic pressing powder metallurgy composites. The binders are totally removed while the HIP can of compatible refractory metal is sealed at high vacuum and temperature. This eliminates out-gassing during hot isostatic pressing.

Abstract: A method is disclosed for producing metal carbide grade powders, which comprises forming a wax mixture consisting essentially of in percent by weight about 10 to 60 of an organic compound additive which is a solid at room temperature and contains a C.dbd.

Abstract: A method is disclosed for producing metal carbide grade powders, which comprises dry milling metal carbide powder which can be tungsten carbide, titanium carbide, tantalum carbide, niobium carbide, vanadium carbide, chromium carbide, and combinations thereof to increase the surface area of the powder particles to result in essetially all of the powders being converted to single crystals, forming a mixture of the resulting dry milled carbide powder, a binder metal which can be cobalt, nickel, and combinations thereof, and a wax, while heating the carbide powder, the binder metal and the wax to a temperature above the melting point of the wax and maintaining the temperature to result in a uniform distribution of the wax on the carbide and binder metal particles, forming a slurry of the mixture and water, attritor milling the slurry at a temperature below the melting point of the wax, and removing the water from the resulting attritor milled mixture and aggiomerating the mixture to produce the metal carbide grad

Abstract: A rotary drill bit is provided for boring earth formations which includes a bit blank and a metal matrix secured to the blank. The metal matrix includes a filler material dispersed therein. Cutting elements are mounted on the exterior face of the bit, and substantially all of the exposed internal and external surfaces of the bit are coated with an erosion and abrasion resistant hardfacing material bonded to the metal matrix.

Abstract: An improved method for encasing objects in metal is disclosed as are the novel encased objects so prepared. An object is wrapped with a sheet comprising sinterable particulate or powdered metal and an organic binder, and is the fired to volatilize the binder and to sinter the particulate metal into a unitary metal structure. In the preferred embodiment of this invention, the object to be encased is a green sinterable particulate object which undergoes sintering simultaneously with the particulate metal casing during the firing step.

Abstract: A starting material for injection molding of a metal powder including from 38 to 46% by volume of an organic binder and the balance of spherical iron powder with an average particle size from 2 to 6.5 .mu.m and having high density sinterability at low sintering temperature, and a method of producing a sintered parts by conducting injection molding, debinding and sintering using the above-mentioned starting material in a non-oxidizing atmosphere at a temperature lower than the A.sub.3 transformation point.

Abstract: A process for producing flat products from gas atomised particulate material comprises the steps of forming a relatively smooth castable slurry comprising a suspension of such particulate material in a solution of film-forming binder material, depositing a coating of the slurry onto a substrate or support surface and drying the coating to form a flexible flat product. The dried flat product may be bonded onto the substrate or support surface by the drying process or, alternatively, may be removed therefrom and roll-bonded to a suitable substrate for subsequent compaction and sintering.

Abstract: In a method of sintering an injection-molded article of raw material powder and organic binder, the injection-molded article already debinderized is initially heated up to a certain reaction temperature at which residual binder is removed from it. In subsequent decarburizing step, the residual binder is removed from the molded article under atmospheric or reduced pressure, while being supplied with H.sub.2 gas. Thereafter, in a reducing and sintering step, the molded article is heated up to a sintering temperature and is held at this temperature under reduced pressure for a predetermined period, with H.sub.2 gas being supplied. H.sub.2 content of the atmosphere in the decarburizing step is kept higher than that in the reducing and sintering step.

Abstract: A process is described in which hollow spheres or hollow-sphere composites (moldings) having high-strength walls are produced. Additional layers are applied to metallized spherical lightweight particles having a core of foamed polymer. In order to increase the strength of the wall of the spherical particle and the strength of the molding, metallized lightweight spherical particles having a metal wall thickness of 5 to 20 microns are treated (coated) with a dispersion of particulate metal or metal oxide or particulate ceramic or refractory material, the lightweight spherical particles coated in a thickness from 15 to 500 microns are dried, the dried particles are heated to a temperature of about 400.degree. C. to effect a pyrolysis of the polymer core, and the particles are subsequently sintered at a temperature from 900.degree. to 1400.degree. C.

Abstract: A process for producing flat products from particulate material comprises the steps of forming relatively smooth, castable slurry comprising a suspension of particulate material in an aqueous solution, a film-forming binder material and a dispersion of a particulate synthetic resin in an aqueous solution, depositing a coating of this slurry onto a support surface and, heating the deposited coating to a temperature at which a component of the synthetic resin volatilises. The coating may be removed from the support surface as a flat product either before or after heating to volatilize a component of the synthetic resin.

Abstract: A method of producing metal-coated abrasive grain granules suitable for the manufacture of metal bonded diamond tools, by the steps of initially preparing a slurry of metal powder with a solution of an agglomerating binder dissolved in an organic solvent, agitating the slurry to homogenously suspend the metal powder therein, and spraying the slurry using an atomizing nozzle into a fluidized suspension of abrasive grains within a fluid bed granulator to progressively build and dry a uniform spherical coating of the slurry on each individual abrasive grain.

Abstract: Provided is a method of manufacturing sintered parts from particulate material, e.g metal or ceramic parts. The method comprises mixing together predetermined amounts of powdered particulate material and a binder, which mixture is then molded under heat and pressure. The binder comprises at least a lower melting point component and a higher melting point component, with the lower melting point component remaining in a liquid state, becoming semi-solid or relatively soft upon cooling to ambient temperatures. Prior to sintering, the lower melting point component of the binder is selectively dissolved in a liquid solvent, and the higher melting point component is removed upon heating at temperatures below the sintering temperature. The result is a process which eliminates or prevents the formation of oxides, substantially reduces the time required for debinding and sintering, and essentially eliminates cracking in the finished part.

Abstract: This invention is concerned with the production of hard, porous, sintered bodies consisting essentially of Al and Fe with, optionally, Sn and/or Cu and/or Cr. The mechanism of the invention relies upon the presence of a small amount of Mg and/or Ca to act as a getter for oxygen. In the preferred embodiment, particles of the metals can be extruded into honeycomb structures which can then be fired in the presence of Mg and/or Ca to yield sound high cell density structures of controlled porosity.

Abstract: The present invention is concerned with a method of molding metallic powders, in which a binder fluid having a specific freezing point, typically water, is added to the metallic powder to be molded to form a mixture, after which a die having the desired cavity is filled with said mixture. The mixture is then pressure molded and rapidly cooled, freezing the binder fluid to produce a frozen molded shape, which is then dried to remove the binder fluid and sintered.The amount of the binder fluid of specific freezing point to be added to the said metallic powder is the minimum amount that will satisfy the dual demands of flowability during molding and shape retention after the removal of the binder fluid, with from 25 to 50 vol% generally being appropriate. Molding is achieved by injection molding, compression molding or other technique in which pressure is applied to the material in the mold.

Abstract: A process for preparing a porous metal plate is disclosed which is adapted to use short metal fiber to prepare the plate. The process is capable of providing a porous metal plate which has increased bending strength and porosity, of which the porosity and thickness are controlled as desired and which has a wide and lengthy shape. The so-formed porous metal plate is capable of being extensively utilized, for example, not only as a filter and a sound absorption material but for a fuel cell, a catalyst and the like. It is formed by applying adhesive onto a surface of a substrate, and embedding short metal fibers in the adhesive. The composite thus formed is then pressed, to push over the short metal fibers, and the composite is then sintered. The substrate is a material which is capable of being burned out, or is a metal net, or is a release paper, so that the final plate will be porous throughout.

Abstract: To increase service life and suppress interferences in high voltage electrodes for the ignition distributing system of internal combustion engines, the electrodes consist of molded and sintered mixture of 50-90% by weight iron powder and 50-10% by weight calcium silicide. Preferably, the electrode has tipstretched contact area of nonalloyed iron.

Abstract: (1) A process comprising spray drying a powder-containing slurry, the slurry containing a powder constituent susceptible of oxidizing under the temperature conditions of the spray drying, while reducing the tendency for oxidation of the constituent by including as a liquid constituent of the slurry an organic liquid; (2) a process comprising spray drying a powder-containing slurry, the powder having been pretreated to reduce content of a powder constituent susceptible of oxidizing under the temperature conditions of the spray drying, the pretreating comprising heating the powder to react the constituent; and (3) a process comprising reacting ceramic powder, grinding the reacted powder, slurrying the ground powder, spray drying the slurried powder, and blending the dried powder with metal powder.

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

Abstract: A sintered, metal infiltrated article and a method for preparing same is disclosed. The method permits mass production by injection molding, of metal infiltrated sintered articles of complex shape without excessive machining of the final product. The articles so produced have desirable physical properties such as abrasion resistance, high hardness, and high resistance to erosion at extreme temperatures encountered in use.

Abstract: Mill scale, iron ore, or taconite is utilized in a powder metallurgy process to form steel articles having approximately the same density as that of conventional rolled steel. Particulate iron is mixed with manganese, carbon, additional alloying ingredients, and a binder to form a particulate admixture. The particulate admixture is then compressed, preferably under extreme pressure until the density of the compressed particulate admixture is from about 0.2408 lbs/in.sup.3 (6.67 g/cm.sup.3) to about 0.2833 lbs/in.sup.3 (7.83 g/cm.sup.3), which corresponds to a density of from about 85% to about 100% of the density of conventional rolled steel. The resultant coherent mass is subjected to sintering and below fusion heating to form an alloyed article which can be swaged, rolled, drawn, or worked at elevated temperature to decrease the grain size of the alloyed article. The resultant end-product will preferably have a density of from about 0.2408 lbs/in.sup.3 (6.67 g/cm.sup.3) to about 0.2833 lbs/in.sup.3 (7.

Abstract: A method for fixing an alloy powder molding at sintering composition by placing an alloy powder molding formed by rolling a mixture of an alloy powder and a synthetic resin-based pressure-sensitive adhesive composition on a metal base material by interposing a composition between the molding and the base material until the molding is sintered, in the case that the alloy powder molding is placed on the metal base material and sintered after keeping at 150.degree. to 400.degree. C. for at least 5 minutes under a non-oxidizing atmosphere, the composition comprising as a main component an acrylic copolymer which comprises about 80 to 99.5% by weight of alkyl (meth)acrylate having an average carbon atom number of 2 to 12 in the alkyl moiety and about 20 to 0.5% by weight of a polymerizable monomer having a functional group in the molecule or a mixture of 100 parts by weight of the copolymer and about 0.

Abstract: Coatings of a powdered protective metallic material or refractory material and mixtures thereof are formed on a ferrous metal strip as a wet film dispersion in a resin binder composition of a synthetic organic resin and a volatile organic solvent compatible with said resin, and the coated strip is heated to effect curing said resin binder and forming a flexible non-tacky dry film. The metal strip having the cured dry film containing powdered protective metallic material can be subjected to varying heat treatments to provide a wide range of protective coatings having improved surface properties, including iron-protective metal diffusion alloy coatings, such as iron-aluminum diffusion alloy coatings having a surface concentration of aluminum between about 8 and 10 wt. percent aluminum, which have improved high temperature oxidation resistance after being severely strained during fabrication at room temperature.

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

Abstract: Sintering of metal particles at their normal sintering temperature is inhibited by coating the metal particles with an organic material such as polyvinyl butyral, polyvinyl formvar, polyvinyl alcohol, polyacrylonitrile epoxies, urethanes and cross-linked polyvinyl butyral. The organic coating serves as a barrier preventing physical contact between metal particles during the initial phase of the sintering cycle and degrades into a carbonaceous coating followed by volatilization during the intermediate phase of the cycle permitting coalescence of the metal particles into a dense mass along with the coalescence of the glass-ceramic particles. Co-sintering of the metal particles and the glass-ceramic particles with the aid of the organic coating results in a hermetic multi-layer glass ceramic substrate free of dimensional stability problems without deleteriously affecting the electrical conductivity of the metal conductor pattern.

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