Extruding Patents (Class 419/41)
  • Patent number: 10500674
    Abstract: An additive friction stir fabrication method and system is described which may be used to fabricate and join a rib to a metallic substrate or to repair a defect in a metallic substrate through extrusion. The method may be carried out with or without the addition of preformed ribs. One such method involves feeding a friction-stir tool with a consumable filler material such that interaction of the friction-stir tool with the substrate generates plastic deformation at an interface between the friction-stir tool and a metallic substrate to bond the plasticized filler and substrate together and extrude this material through a forming cavity to form a rib joined to the metallic substrate. Further described is a system for fabricating a rib joined to a metallic substrate through extrusion.
    Type: Grant
    Filed: December 1, 2017
    Date of Patent: December 10, 2019
    Assignee: MELD Manufacturing Corporation
    Inventors: Kumar Kandasamy, Jeffrey Patrick Schultz
  • Patent number: 10471511
    Abstract: A method of manufacturing a multi-material tubular structure includes spinning a can, depositing a powdered material into the can and compacting the powdered material within the can to provide a tubular structure.
    Type: Grant
    Filed: November 5, 2014
    Date of Patent: November 12, 2019
    Assignee: United Technologies Corporation
    Inventors: Mario P. Bochiechio, Darryl Slade Stolz
  • Patent number: 9617896
    Abstract: A catalyst unit may include a carrier, a channel opening portion through which exhaust gas passes, a skin portion that is formed along a circumference and integrally formed with the channel opening portion, and a skin addition portion that is formed with a second thickness on an outside surface of the skin portion. A fabrication device of the catalyst unit may include a container, a masking member, and an elastic member, wherein plugging material flows through opened channels and does not contact the masking member. A manufacturing method of the catalyst unit may include covering the masking member and inserting plugging material into an opened channel. A channel corresponding to a dead zone is plugged and the catalyst coating layer is not formed in the plugged channels, thus reducing the cost of the catalyst.
    Type: Grant
    Filed: May 8, 2015
    Date of Patent: April 11, 2017
    Assignee: HYUNDAI MOTOR COMPANY
    Inventor: Sungmu Choi
  • Publication number: 20150093282
    Abstract: A brazing rod for forming a wear resistant coating on a substrate by a brazing process. The brazing rod includes a composite material having a plurality of round particles bound together by a binding material. Each of the plurality of round particles includes a round outer layer encapsulating a wear resistant element.
    Type: Application
    Filed: October 1, 2014
    Publication date: April 2, 2015
    Inventor: Andrew BELL
  • Patent number: 8961647
    Abstract: The invention is a process for manufacturing a nano aluminum/alumina metal matrix composite and composition produced therefrom. The process is characterized by providing an aluminum powder having a natural oxide formation layer and an aluminum oxide content between about 0.1 and about 4.5 wt. % and a specific surface area of from about 0.3 and about 5 m2/g, hot working the aluminum powder, and forming a superfine grained matrix aluminum alloy. Simultaneously there is formed in situ a substantially uniform distribution of nano particles of alumina. The alloy has a substantially linear property/temperature profile, such that physical properties such as strength are substantially maintained even at temperatures of 250° C. and above.
    Type: Grant
    Filed: December 4, 2012
    Date of Patent: February 24, 2015
    Inventors: Thomas G. Haynes, III, Martin Walcher, Martin Balog
  • Patent number: 8840832
    Abstract: Material processing systems are disclosed. Some systems include methods of eliminating or reducing defects in elongate workpieces that can undergo large deformations during processing. Some systems include apparatus configured to facilitate such large deformations while maintaining internal stresses (e.g., tensile stresses) below a threshold stress. Some disclosed systems pertain to powder extrusion techniques. Continuous and batch processing systems are disclosed.
    Type: Grant
    Filed: March 2, 2011
    Date of Patent: September 23, 2014
    Assignee: Accellent Inc.
    Inventors: Mark W. Broadley, James Alan Sago, John Eckert, Jeffrey M. Farina
  • 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: 8591804
    Abstract: A method of metal injection molding on an injection molding machine having a heated barrel with an increasing temperature gradient is disclosed. A first step includes providing a metal alloy feedstock including a first component having a first melting point and a second component having a second melting point that is higher than the first melting point, the first melting point and the second melting point selected to match the temperature gradient of the heated barrel of the injection molding machine. A second step includes feeding the metal alloy feedstock into the injection molding machine. A third step includes melting the metal alloy feedstock within the heated barrel of the injection molding machine. A fourth step includes maintaining the percentage of solids to liquids in the metal alloy feedstock of the first component and second component within a processable range of about 5% to about 30%.
    Type: Grant
    Filed: May 31, 2011
    Date of Patent: November 26, 2013
    Assignee: Cool Polymers, Inc.
    Inventors: Kevin A. McCullough, James D. Miller
  • Publication number: 20110286873
    Abstract: The composition includes the iron as the main particulate metallic material; at least one particulate alloy element, with the function of hardening the ferrous structural matrix; and a precursor non-metallic particulate compound, generally a carbide or a carbonate, which is capable of generating, upon its dissociation during the sintering, graphite nodules, whose formation is facilitated: by the precursor compound itself when it includes a chemical element which stabilizes the iron alpha phase of the ferrous structural matrix; or by an additional alloy element included in the composition and which is defined by a chemical element that stabilizes the iron alpha phase during the sintering. The composition can be conformed by compaction or by powder injection molding. The process of the invention leads to obtaining products in self-lubricating sintered steel from said composition.
    Type: Application
    Filed: December 9, 2009
    Publication date: November 24, 2011
    Inventors: Roberto Binder, Aloisio Nelmo Klein, Cristiano Binder, Waldyr Ristow Junior
  • Patent number: 8033314
    Abstract: A method for producing a sintered magnet comprising steps of; wet-pulverizing a magnetic powder under the presence of a surface active agent, drying said wet-pulverized magnetic powder 20 for obtaining magnetic powder to which said surface active agent is adhered, heating and kneading said dried magnetic powder 20 with binder resin to form pellet, melting said pellet and injecting said pellet in a mold to which magnetic field is applied, to form a preform body, and firing said preform body.
    Type: Grant
    Filed: March 27, 2009
    Date of Patent: October 11, 2011
    Assignee: TDK Corporation
    Inventors: Masashi Gotoh, Yoshihiko Minachi, Yoshihiro Enda, Shunichi Kudo, Tomohiko Aida
  • 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
  • Publication number: 20110176951
    Abstract: The invention relates to a filler device (1) comprising an exterior tube (2) having an extrusion die (3) located therein and a filler piece (4) that is filled with a metal powder mixture in the intermediate space (8) formed between the filler piece (4) and the extrusion die (3), whereupon the intermediate space is closed. In order to compact the metal powder, the filler device (1) is placed in a hydrostatic pressing system and the metal powder mixture is pressed into a green preform. The pressed tubes are subsequently sintered in one or more passes through a furnace, for which purpose the pressed tubes are subjected to a preselected time/temperature progression so as to ensure that a melt of tungsten (W) forms and contracts evenly in all directions so that a geometrically desired solid body results after sintering.
    Type: Application
    Filed: July 16, 2008
    Publication date: July 21, 2011
    Applicant: RHEINMETALL WAFFE MUNITION GMBH
    Inventors: Klaus-Dieter Beister, René Oudelhoven, Michael Vagedes
  • Patent number: 7842231
    Abstract: An article made of constituent elements is prepared by furnishing at least one nonmetallic precursor compound, wherein all of the nonmetallic precursor compounds collectively contain the constituent elements. The constituent elements include a titanium-base metallic composition, boron present at a level greater than its room-temperature solid solubility limit, and, optionally, a stable-oxide-forming additive element present at a level greater than its room-temperature solid solubility limit. The precursor compounds are chemically reduced to produce a material comprising a titanium-base metallic composition having titanium boride particles therein, without melting the titanium-base metallic composition. The titanium-base metallic composition having the titanium boride particles therein is consolidated without melting.
    Type: Grant
    Filed: April 18, 2008
    Date of Patent: November 30, 2010
    Assignee: General Electric Company
    Inventors: Andrew Philip Woodfield, Eric Allen Ott, Clifford Earl Shamblen, Michael Francis Gigliotti, David Alan Utah, Alan Glen Turner
  • 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
  • Publication number: 20100215978
    Abstract: There is provided a method for fabricating a dual alloy structure that may in turn be machined to fabricate a rotary component for use in a gas turbine engine. The method provides a powder metal (PM) nickel based superalloy and a nickel aluminide intermetallic based alloy. The powder metal (PM) nickel based superalloy displays characteristics, such as improved strength, low cycle fatigue resistance, fracture toughness, and crack growth resistance. The nickel aluminide intermetallic based alloy displays characteristics, such as high temperature creep and oxidation resistance, suitable for use in the outer radial area of an impeller. A bore sub-element is fabricated from the powder metal (PM) nickel based superalloy. A body sub-element is fabricated from the nickel aluminide intermetallic based alloy. The bore sub-element and body sub-element are joined by inertia welding or diffusion bonding at a common mating surface.
    Type: Application
    Filed: February 24, 2009
    Publication date: August 26, 2010
    Applicant: HONEYWELL INTERNATIONAL INC.
    Inventor: Derek Anthony Rice
  • Patent number: 7641955
    Abstract: A honeycomb structured body comprising a pillar-shaped honeycomb block including a honeycomb unit in which a number of cells are longitudinally placed in parallel with a cell wall therebetween. The honeycomb unit comprising inorganic particles, as well as inorganic fibers and/or whiskers, and the inorganic fibers and/or whiskers increase a specific surface area of the honeycomb unit. A sealing material provided on a peripheral portion of the honeycomb block. Irregularities are formed on the peripheral face of the honeycomb structured body and the pillar-shaped honeycomb block. A least square curve is obtained by a least square method on the basis of points comprising the contour of a cross-section perpendicular to the longitudinal direction of the honeycomb structured body and the honeycomb block.
    Type: Grant
    Filed: December 8, 2005
    Date of Patent: January 5, 2010
    Assignee: Ibiden Co., Ltd.
    Inventors: Kazushige Ohno, Masafumi Kunieda, Kazutake Ogyu
  • Publication number: 20090263268
    Abstract: A raw magnesium alloy powder material having a relatively small crystal grain diameter is obtained by subjecting a starting material powder having a relatively large crystal grain diameter to a plastic working in which the powder is passed through a pair of rolls to undergo compressive deformation or shear deformation. The starting material powder is a magnesium alloy powder having a fine intermetallic compound (21) precipitated and dispersed in a base (22) by a heat treatment. A work strain (22) is formed around the precipitated intermetallic compound (21) in the magnesium alloy powder after processed by the plastic working. The magnesium alloy powder after processed by the plastic working has a maximum size of 10 mm or less and a minimum size of 0.1 mm or more, and the magnesium particle constituting the base (20) has a maximum crystal grain diameter of 20 ?m or less.
    Type: Application
    Filed: June 14, 2006
    Publication date: October 22, 2009
    Applicants: GOHSYU CO., LTD., KURIMOTO, LTD.
    Inventors: Katsuyoshi Kondoh, Mitsuhiro Goto, Hideaki Fukui, Kantaro Kaneko, Shuji Shiozaki, Katsuhito Itakura
  • Patent number: 7537725
    Abstract: A compositionally graded gas turbine disk is made by placing a cylindrically symmetric slip case concentrically into an interior of a cylindrically symmetric outer container. A first nickel-base superalloy powder is loaded into a radially inner first portion of the interior and a second nickel-base superalloy powder is loaded into a radially outer second portion of the interior. The slip case is removed so that the first nickel-base superalloy powder and the second nickel-base superalloy powder contact in the transition region and form a non-compacted powder mass. The non-compacted powder mass is processed into a gas turbine disk, typically by compacting the non-compacted powder mass to form a compacted powder mass, and thereafter heat treating the compacted powder mass.
    Type: Grant
    Filed: September 19, 2005
    Date of Patent: May 26, 2009
    Assignee: General Electric Company
    Inventors: Jon Raymond Groh, Eric Allen Ott, Robert Edward Schafrik, Daniel Donald Krueger
  • Publication number: 20090092517
    Abstract: A copper alloy extruded material is provided by extruding a copper alloy powder solidified billet and old grain boundaries remain in it.
    Type: Application
    Filed: July 25, 2006
    Publication date: April 9, 2009
    Inventors: Yoshiharu Kosaka, Masanori Okuyama, Akimichi Kojima, Katsuyoshi Kondoh
  • Patent number: 7488443
    Abstract: An electrically conducting cermet comprises at least one transition metal element dispersed in a matrix of at least one refractory oxide selected from the group consisting of yttria, alumina, garnet, magnesium aluminum oxide, and combinations; wherein an amount of the at least one transition metal element is less than 15 volume percent of the total volume of the cermet. A device comprises the aforementioned electrically conducting cermet.
    Type: Grant
    Filed: January 10, 2008
    Date of Patent: February 10, 2009
    Assignee: General Electric Company
    Inventors: Bernard Patrick Bewley, Bruce Alan Knudsen, James Anthony Brewer, James Scott Vartuli, Dennis Joseph Dalpe, Mohamed Rahmane
  • Patent number: 7419528
    Abstract: A metallic article made of metallic constituent elements is fabricated from a mixture of nonmetallic precursor compounds of the metallic constituent elements. The mixture of nonmetallic precursor compounds contains more of a base-metal element, such as nickel, cobalt, iron, iron-nickel, and iron-nickel-cobalt than any other metallic element. The mixture of nonmetallic precursor compounds is chemically reduced to produce a metallic superalloy material, without melting the metallic superalloy material. The metallic superalloy material is consolidated to produce a consolidated metallic article, without melting the metallic superalloy material and without melting the consolidated metallic article.
    Type: Grant
    Filed: February 19, 2003
    Date of Patent: September 2, 2008
    Assignee: General Electric Company
    Inventors: Clifford Earl Shamblen, Andrew Philip Woodfield, Eric Allen Ott, Michael Francis Xavier Gigliotti
  • Patent number: 7410610
    Abstract: An article made of constituent elements is prepared by furnishing at least one nonmetallic precursor compound, wherein all of the nonmetallic precursor compounds collectively contain the constituent elements. The constituent elements include a titanium-base metallic composition, boron present at a level greater than its room-temperature solid solubility limit, and, optionally, a stable-oxide-forming additive element present at a level greater than its room-temperature solid solubility limit. The precursor compounds are chemically reduced to produce a material comprising a titanium-base metallic composition having titanium boride particles therein, without melting the titanium-base metallic composition. The titanium-base metallic composition having the titanium boride particles therein is consolidated without melting.
    Type: Grant
    Filed: November 12, 2004
    Date of Patent: August 12, 2008
    Assignee: General Electric Company
    Inventors: Andrew Philip Woodfield, Eric Allen Ott, Clifford Earl Shamblen, Michael Francis Xavier Gigliotti, David Alan Utah, Alan Glen Turner
  • Publication number: 20080181805
    Abstract: A nanocomposite comprising a plurality of nanoparticles dispersed in a molybdenum-based matrix, and an x-ray tube component formed from such a nanocomposite. The nanocomposite contains volume fraction of nanoparticle dispersoids in a range from about 2 volume percent to about 20 volume percent. A method of making such molybdenum-based nanocomposites is also disclosed.
    Type: Application
    Filed: June 28, 2007
    Publication date: July 31, 2008
    Applicant: GENERAL ELECTRIC COMPANY
    Inventors: Pazhayannur Ramanathan Subramanian, Judson Sloan Marte, Paul Leonard Dupree
  • Patent number: 7371344
    Abstract: A blank for a rotary tool for chip removing machining, such as a helix drill or an end mill is formed by advancing a mixture of hard metal powder and carrier through an extrusion passage. The mixture is fed past a core having pins secured thereto for forming respective internal holes through the mixture. Then the mixture is advanced through a rotary part that is rotating about a center axis of the extrusion passage, wherein the rotary part and the internal holes become twisted to a predetermined pitch. The mixture is also advanced past a plurality of shaping parts which project transversely into the extrusion passage for shaping exterior chip flutes in the mixture, e.g., by embossing or cutting. The mixture is allowed to harden into a green body, and the green body is then sintered to form a blank.
    Type: Grant
    Filed: June 1, 2004
    Date of Patent: May 13, 2008
    Assignee: Seco Tools AB
    Inventors: Mikael Grönquist, Johnny Bruhn, Mattias Svensson
  • Publication number: 20080075622
    Abstract: A composition for forming a green body is provided. The composition for forming the green body contains powder constituted of a metallic material and a binder containing a first resin which is decomposable by ozone and a second resin which is also decomposable by ozone but decomposed later than the first resin. The green body formed of the composition is used in producing a brown body, wherein the brown body is produced by first exposing the green body to a high ozone content atmosphere to decompose the first resin and remove the decomposed first resin and then decompose the second resin and remove the decomposed second resin, and then at least once exposing the thus obtained green body to a low ozone content atmosphere whose ozone concentration is lower than an ozone concentration of the high ozone content atmosphere.
    Type: Application
    Filed: September 21, 2007
    Publication date: March 27, 2008
    Inventors: Masaaki Sakata, Junichi Hayashi
  • Patent number: 7348049
    Abstract: A honeycomb structural body comprising: a pillar-shaped ceramic block and a sealing material provided on an outer peripheral portion of said ceramic block, each of them having irregularities formed on an outer peripheral face wherein: when a least square curve is determined by a least square method on the basis of points constituting the contour of a cross-section, a center-of-gravity is defined as c1, a distance between a minimum concentric circumscribed curve having c1 and the center-of-gravity c1 is defined as D1, a distance between a maximum concentric inscribed curve having c1 and the center-of-gravity c1 is defined as D2, and the following inequality is satisfied: about 0.
    Type: Grant
    Filed: April 5, 2005
    Date of Patent: March 25, 2008
    Assignee: Ibiden Co., Ltd.
    Inventor: Yutaka Yoshida
  • Patent number: 7056470
    Abstract: A capacitor-grade wire made from powder metallurgy containing at least niobium and silicon, wherein the niobium is the highest weight percent metal present in the niobium wire. The wire having a controlled tensile strength at finish diameter exceeds the strength of capacitor-grade wire formed by ingot metallurgy. Also, the powder metallurgy wire hardness exceeds capacitor-grade wire formed from ingot metallurgy with electrical leakage meeting the specifications normally applied to capacitor grade tantalum, niobium or niobium-zirconium lead wire at sinter temperatures of about 1150° C. and above.
    Type: Grant
    Filed: January 21, 2003
    Date of Patent: June 6, 2006
    Assignee: H. C. Starck Inc.
    Inventors: Richard Malen, Prabhat Kumar
  • Patent number: 7001570
    Abstract: A metal-made seamless pipe is provided, containing at least one metal selected from the group consisting of metals each having a melting point of 1,600° C. or more, and has a porosity of 0.3 to 25%. The porosity is defined as a ratio of the open pores present at the outer surface of the pipe to the total surface area of the outer surface of the pipe. The open pores do not include through-pores perforating to the inner surface of the pipe. A process for producing such a metal-made seamless pipe is also provided. The metal-made seamless pipe is low in processability but can be produced having a small thickness and a small inner diameter, having superior mechanical strength and gastightness, and can be suitably used as a sealing member of a translucent vessel of a high-pressure discharge lamp.
    Type: Grant
    Filed: April 25, 2003
    Date of Patent: February 21, 2006
    Assignee: NGK Insulators, Ltd.
    Inventor: Norikazu Niimi
  • Patent number: 6921510
    Abstract: An article has a metallic matrix made of its constituent elements with a dispersoid distributed therein. The article is prepared by furnishing at least one nonmetallic matrix precursor compound. All of the nonmetallic matrix precursor compounds collectively include the constituent elements of the metallic matrix in their respective constituent-element proportions. A mixture of an initial metallic material and the dispersoid is produced. The matrix precursor compounds are chemically reduced to produce the initial metallic material, without melting the initial metallic material, and the dispersoid is distributed in the initial metallic material. The mixture of the initial metallic material and the dispersoid is consolidated to produce a consolidated article having the dispersoid distributed in the metallic matrix comprising the initial metallic material. The initial metallic material, the dispersoid, and the consolidated article are not melted during the consolidation.
    Type: Grant
    Filed: January 22, 2003
    Date of Patent: July 26, 2005
    Assignee: General Electric Company
    Inventors: Eric Allen Ott, Andrew Philip Woodfield, Clifford Earl Shamblen, Michael Francis Xavier Gigliotti
  • Patent number: 6908588
    Abstract: The invention relates to a process for manufacturing an evaporation source for physical vapor deposition. The evaporation source is formed of the actual sputtering target with an aluminum component and one or more further components as well as of a backing plate made from a material having better thermal conductivity than the target. The backing plate made of a powdery starting material is pressed, together with the powdery components of the sputtering target, into sandwiched powder fractions and then formed.
    Type: Grant
    Filed: June 12, 2002
    Date of Patent: June 21, 2005
    Assignee: Plansee Aktiengesellschaft
    Inventors: Peter Wilhartitz, Stefan Schönauer, Peter Polcik
  • Patent number: 6902699
    Abstract: High strength aluminum alloy powders, extrusions, and forgings are provided in which the aluminum alloys exhibit high strength at atmospheric temperatures and maintain high strength and ductility at extremely low temperatures. The alloy is produced by blending about 89 atomic % to 99 atomic % aluminum, 1 atomic % to 11 atomic % of a secondary metal selected from the group consisting of magnesium, lithium, silicon, titanium, zirconium, and combinations thereof, and up to about 10 atomic % of a tertiary metal selected from the group consisting of Be, Ca, Sr, Ba, Ra, Sc, V, Cr, Mn, Fe, Co, Ni, Cu, Zn, Y, Nb, Mo, Tc, Ru, Rh, Pd, Ag, Cd, W, and combinations thereof. The alloy is produced by nanostructure material synthesis, such as cryomilling, in the absence of refractory dispersoids. The synthesized alloy is then canned, degassed, consolidated, extruded, and optionally forged into a solid metallic component. Grain size within the alloy is less than 0.5 ?m, and alloys with grain size less than 0.
    Type: Grant
    Filed: October 2, 2002
    Date of Patent: June 7, 2005
    Assignee: The Boeing Company
    Inventors: Leslie G. Fritzemeier, Daniel E. Matejczyk, Thomas J. Van Daam
  • Patent number: 6852272
    Abstract: The present invention relates to the fabrication of low cost, in situ, porous metallic, ceramic and cermet foam structures having improved mechanical properties such as energy absorption and specific stiffness. Methods of fabricating the structures from compositions including ceramic and/or metallic powders are provided. The flowable compositions also include an immiscible phase that results in pores within the final structure. Furthermore, the structures may be shaped to have external porosity, such as with mesh-like structures.
    Type: Grant
    Filed: January 27, 2003
    Date of Patent: February 8, 2005
    Assignee: Advanced Ceramics Research, Inc.
    Inventors: Gregory Artz, K. Ranji Vaidyanathan, Michael L. Fulcher, Mark J. Rigali, John L. Lombardi, Joseph Walish, Ronald A. Cipriani
  • Patent number: 6759004
    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.
    Type: Grant
    Filed: June 6, 2000
    Date of Patent: July 6, 2004
    Assignee: Southco, Inc.
    Inventor: Ratnesh K. Dwivedi
  • Patent number: 6743973
    Abstract: Thermoelectric material of (Bi, Sb)(Te, Se) system is produced through a liquid quenching method and an extrusion from a die unit having an inlet portion and an outlet portion crossing each other at 30-150 degrees so that the crystal grains have an average grain size equal to or less than 30 microns and (001) planes mostly oriented in parallel to a direction in which electric current to flow, thereby achieving the figure of merit equal to or greater than 3.0×10−3/K.
    Type: Grant
    Filed: November 29, 2001
    Date of Patent: June 1, 2004
    Assignee: Yamaha Corporation
    Inventors: Takahiro Hayashi, Yuma Horio, Toshiharu Hoshi
  • Patent number: 6699821
    Abstract: A Nb3Al superconducting wire and method for fabricating the same wherein Nb and Al powders in combination, or Nb—Al alloy powders are encapsulated in a metal tube, preferably copper or copper-alloy (e.g., CuNi), and the resultant composite is processed by conventional means to fine wire. Multifilamentary composites are produced by rebundling of the powder-filled wires into metal tubes followed by conventional processing to wire of a desired size. It is required for the use of Nb and Al powders in combination that the Nb and Al powder particle size be less than 100 nm. In the use of Nb—Al alloy powders, it is preferred, but not required, that the powder particle size be similarly of a nanometer scale. The use of nanometer-scale powders is beneficial to wire fabrication, allowing the production of long wire piece-lengths. At final wire size, the wires produced by practice of the present invention are heat treated at temperatures below the melting point of copper (1083° C.
    Type: Grant
    Filed: April 9, 2002
    Date of Patent: March 2, 2004
    Assignee: Composite Materials Technology, Inc.
    Inventors: Mark K. Rudziak, Leszek R. Motowidlo, Terence Wong
  • Patent number: 6699430
    Abstract: A method of producing a substantially regular cylindrical body that consists of a deformable material, especially a sintered metal blank. The blank is provided with an interior helical recess. The blank is first produced with a substantially linear course of the interior recess, for example by extrusion. The body is cut to a defined length and is subjected to a rolling movement by a friction surface while being supported across its entire length on a support. The speed of the rolling movement changes in a linear and continuous manner across the length of the body, thereby regularly twisting the body.
    Type: Grant
    Filed: March 11, 2002
    Date of Patent: March 2, 2004
    Inventor: Arno Friedrichs
  • Patent number: 6669899
    Abstract: A ductile particle-reinforced amorphous matrix composite characterized in that ductile powder is dispersed into amorphous matrix and the mixture is plastically worked to be consolidated and a method for manufacturing the same are provided. The amorphous powder includes any alloy, which can be produced in the form of amorphous structure and which is selected from the group consisting of Ni-, Ti-, Zr-, Al-, Fe-, La-, Cu- and Mg-based alloys. The method for manufacturing a ductile particle-reinforced amorphous matrix composite, the method comprising steps of preparing a mixture consisting of amorphous powder and ductile powder, obtaining a billet by compacting the mixture in a hermetically sealing condition, and plastic working the mixture by processing the billet at the temperature in the super-cooled liquid region of the amorphous alloy.
    Type: Grant
    Filed: January 25, 2002
    Date of Patent: December 30, 2003
    Assignee: Yonsei University
    Inventors: Dong Hyun Bae, Min Ha Lee, Jin Kyu Lee, Do Hyang Kim, Won Tae Kim, Daniel J. Sordelet
  • Patent number: 6630100
    Abstract: A rectangular pipe is molded by mixing aluminum powder with powder of a neutron absorbing material, molding a premolded body by means of cold isostatic pressing (CIP), canning the premolded body, sintering the premolded body by means of hot isostatic pressing (HIP), performing outer cutting and end face cutting on the can after the sintering, taking a billet out of the can, and extruding this billet.
    Type: Grant
    Filed: April 9, 2001
    Date of Patent: October 7, 2003
    Assignee: Mitsubishi Heavy Industries, Ltd.
    Inventors: Kazuo Murakami, Yasuhiro Sakaguchi, Toshiro Kobayashi, Toyoaki Yasui
  • Patent number: 6617504
    Abstract: A method of fabricating a thermoelectric element of enhanced thermoelectric performance is provided by improving the preparation of thermoelectric material and employing hot plastic working in combination. The method comprises the step (a) of mixing and heat-melting a raw material of a predetermined composition; the step (b) of turning the heat-melted material 106 into microglobules by either of scattering and spraying, and then quenching the microglobules, thereby providing a globular powdery thermoelectric material; and the step (c) of plastically deforming the thermoelectric material in a hot condition, thereby to bring crystal grains of the thermoelectric material into a crystal orientation affording an excellent figure of merit.
    Type: Grant
    Filed: May 9, 2001
    Date of Patent: September 9, 2003
    Assignee: Komatsu Ltd.
    Inventors: Takeshi Kajihara, Akio Konishi, Yong Hoon Lee, Kiyoharu Sasaki, Kenichi Tomita, Takeji Kajiura
  • Patent number: 6592808
    Abstract: A method of making a ceramic discharge chamber comprising forming a plurality of preform chambers by assembling at least two ceramic components. The preform chambers are axially aligned within a tube, comprised of an alumina cermet. The tube containing the preform chambers is then fired at a temperature of at least 900° C.
    Type: Grant
    Filed: December 30, 1999
    Date of Patent: July 15, 2003
    Assignee: General Electric Company
    Inventors: Frederick W. Dynys, Curtis Edward Scott
  • Patent number: 6582651
    Abstract: A process for forming a shaped metallic article, including the steps of combining the starting materials, forming the starting materials into a shape to produce a nonmetallic metal precuror article of a certain geometry, and converting the nonmetallic article to a metallic article by reduction or decomposition, while substantially retaining the geometry of the nonmetallic article. The forming step in which the starting materials are fabricated into a shape can include extrusion, dry pressing, or slurry casting. Further, another embodiment is a metallic article produced by converting a nonmetallic article with a certain geometry, including a plurality of open-ended channels, substantially to the same geometry as the nonmetallic article from which it was converted.
    Type: Grant
    Filed: June 9, 2000
    Date of Patent: June 24, 2003
    Assignee: Geogia Tech Research Corporation
    Inventors: Joe Kennedy Cochran, Jr., Kon Juin Lee, Thomas H. Sanders, Jr.
  • Patent number: 6555051
    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.
    Type: Grant
    Filed: June 12, 2000
    Date of Patent: April 29, 2003
    Assignee: Injex Corporation
    Inventors: Masaaki Sakata, Kenichi Shimodaira
  • Patent number: 6524522
    Abstract: The present invention relates to the extrusion freeform fabrication of low cost, in situ, metallic foam components having oriented microstructures and improved mechanical properties such as energy absorption and specific stiffness. The present invention relates to the freeform fabrication of metallic foams to form parts having complex geometry that demonstrate superior mechanical properties and energy absorbing capacity.
    Type: Grant
    Filed: March 7, 2002
    Date of Patent: February 25, 2003
    Assignee: Advanced Ceramics Research, Inc.
    Inventors: K. Ranji Vaidyanathan, John L. Lombardi, Joseph Walish, Ronald A. Cipriani
  • Patent number: 6482352
    Abstract: A method of the present invention manufactures a watch-bracelet component through step (1A) of producing a green body containing a raw material powder by extrusion molding, step (2A) of cutting the green body, step (3A) of debinding the cut green body, and step (4A) of sintering the debound body to yield a sintered body. Subsequently, the method can easily manufacture even a product having a complicated shape, and the invention can provide a method of manufacturing a watch-bracelet component with a wide range of materials to choose from.
    Type: Grant
    Filed: October 12, 2001
    Date of Patent: November 19, 2002
    Assignee: Injex Corporation
    Inventors: Masaaki Sakata, Junichi Hayashi
  • Patent number: 6454991
    Abstract: A method of forging a raw material for sintering and forging. The method comprises the steps of: (a) compacting metallic powder containing iron as a main component and graphite to obtain a compact having a predetermined density; (b) sintering the compact at a temperature ranging from 700 to 1000° C. to form a sintered compact having a texture in which graphite is retained at grain boundary of metal powder; (c) compressing the sintered compact from two directions to obtain a compressed sintered compact; and (d) extruding the compressed sintered compact upon pressing the compressed sintered compact from the two directions in a manner that a pressure in one of the two directions is reduced relative to a pressure in the other of the two directions to accomplish extrusion forging.
    Type: Grant
    Filed: October 29, 2001
    Date of Patent: September 24, 2002
    Assignee: Unisa Jecs Corporation
    Inventors: Takashi Yoshimura, Mitsumasa Iijima, Shin Koizumi, Yasuo Hatai
  • Patent number: 6413472
    Abstract: A method of manufacturing screws which can form screws each having a desired hollow axial bore easily and having excellent machinability is provided. The method comprises the steps of (A) producing a green body containing metal powder by means of extrusion molding; (B) debinding the green body to obtain a brown body; and (C) sintering the brown body to obtain a sintered compact, wherein at least one machine working including a thread cutting process is carried out at anytime after the completion of the step (A). The step (C) of this method may include a pre-sintering step for obtaining a pre-sintered compact and a secondary sintering process, and the machining process including a thread cutting process is carried out onto the pre-sintered compact after the completion of the pre-sintering step.
    Type: Grant
    Filed: August 14, 2000
    Date of Patent: July 2, 2002
    Assignee: Injex Corporation
    Inventors: Masaaki Sakata, Junichi Hayashi
  • Publication number: 20020060520
    Abstract: A metal-made seamless pipe contains, as a main component, at least one kind of metal selected from the group consisting of metals each having a melting point of 1,600° C. or more. The metal-made seamless pipe has a porosity of 0.3 to 25% when the porosity is defined as a proportion of the open pores not perforating in the thickness direction of the pipe, present at the outer surface of the pipe, to the total area (100%) of the outer surface of the pipe; and a process for producing such a metal-made seamless pipe. The metal-made seamless pipe is low in processability but can be produced in a small thickness and a small inner diameter, is superior in mechanical strengths and gastightness, and can be suitably used as a sealing member of a translucent vessel of a high-pressure discharge lamp.
    Type: Application
    Filed: September 20, 2001
    Publication date: May 23, 2002
    Inventor: Norikazu Niimi
  • Patent number: 6336950
    Abstract: An aspect of this invention is an electrode rod for spark alloying, comprising a compact of a first powder of a first component which comprises a metal selected from a group of Fe, Co, Ni, metals of 4a, 5a and 6a of the periodic table and Si, and a second powder of a second component which is capable of self-propagating high temperature synthesis to form with said first component carbide, nitride, boride, silicide or intermetallic compound, said first and second powders being mixed intimately with each other and formed into an axial rod.
    Type: Grant
    Filed: May 5, 2000
    Date of Patent: January 8, 2002
    Assignees: The Ishizuka Research Institute Ltd., Moscow Steel and Alloys Institute, SHS-Center
    Inventors: Mitsue Koizumi, Manshi Ohyanagi, Satoru Hosomi, Evgeny Alexandrovich Levashov, Alexander Gennadievich Nikolaev, Alexander Evgenievich Kudryashov
  • Patent number: 6207101
    Abstract: A fired body and method of making involves compounding powder, binder, aqueous solvent for the binder, surfactant, and non-solvent with respect to at least the binder, the solvent, and the powder, with the addition of an organosilicon compound. The non-solvent is lower in viscosity than the binder combined with the solvent, and the amount of solvent is less than the amount that would be used absent the non-solvent. The components are mixed and plasticized and then shaped into a green body, which is then fired to produce the product body. The organosilicon compound enhances the stiffness in the green body afforded by other non-solvents, and results in increased strength and reduced cracking in the fired body, among other advantages.
    Type: Grant
    Filed: September 30, 1999
    Date of Patent: March 27, 2001
    Assignee: Corning Incorporated
    Inventors: Douglas M. Beall, Devi Chalasani, Gregory Albert Merkel, Y. Lisa Peng
  • Patent number: 6086819
    Abstract: A process is disclosed for manufacturing thin-walled pipes made of a heat- and wear-resistant aluminium-based material. A billet or tube blank made of a hypereutectic AlSi material is produced, optionally overaged by an annealing process, then extruded into a thick-walled pipe or round bar. The thus obtained preform is severed and extruded into a thin-walled pipe. This process is particularly suitable to manufacture light metal cylinder liners for internal combustion engines, since the thus manufactured cylinder liners have the required properties regarding wear-resistance, heat-resistance and lowered pollutant emissions.
    Type: Grant
    Filed: February 27, 1998
    Date of Patent: July 11, 2000
    Assignee: Erbsloh Aktiengesellschaft
    Inventors: Bernhard Commandeur, Rolf Schattevoy, Klaus Hummert, Dirk Ringhand