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.

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.

Abstract: The invention relates to a method for manufacturing thin-walled pipes, which are made of a heat-resistant and wear-resistant aluminum-based material. The method comprises the providing of a billet or a tube blank made of a hypereutectic aluminum-silicon AlSi material, possibly a subsequent averaging annealing, the extruding of the billet or of the tube blank to a thick-walled pipe, and the hot deformation of this pipe to a thin-walled pipe. Such a method is in particular suited for the production of cylinder liners of internal combustion engines, since the produced liners exhibit the required properties in regard to wear resistance, heat resistance and reduction of pollutant emission.

Abstract: A method for making thermocouple wire from powdered alloys and metals. The metal or alloy is atomized from its liquid state into a powdered state as it leaves a melting vat. The powder is then compacted and cold worked to form thermocouple wire. Different lots of a powdered alloy or a powdered metal may be blended to reduce the calibration error of the resultant thermocouple wire.

Abstract: A process for production of a moulded ceramic and/or metallic body from a ductile material comprising one or more ceramic and/or metallic components, which material is fed into the pre-heated mould cavity (1) of a moulding tool. The moulded tool includes at least two mould parts (4, 5) of which at least one wholly or partly consists of a microporous material with communicating micropores. At least one mould cavity (1) comprising at least one mould surface (2, 3) exhibiting closed micropores is arranged in the microporous mould part (4, 5) or in a microporous section (6) thereof. The microporous mould part (4, 5) or the microporous section (6) thereof is pre-heated by supply of warm fluid, such as a heated gas. Said part (4, 5) or section (6) is after terminated moulding cooled by supply of cold fluid, such as a condensed gas. the invention includes in a further aspect a moulded body produced according to the process.

Abstract: Sintered silver-iron material for electrical contacts, with properties comparable with those of silver-nickel materials, is obtained by using iron powder having more than 0.25% carbon by weight and microhardness higher than 200 HV 0.025 and sintering in a hydrogen-free protective gas.

Abstract: An improved metal matrix composite utilizes boron carbide as a ceramic additive to a base material metal. The base material metal is aluminum, magnesium, or titanium, or an alloy thereof, provided in powder form with the balance of the material comprising various trace metals such as chromium, copper, iron, magnesium, silicon, titanium, and zinc. The boron carbide powder comprises 10 to 30% by weight of the metal matrix composition. There is at least one other metal additive. The compositions are useful in a variety of applications where lightweight, strength, stiffness, hardness, and low density are desirable. The compositions are extrudable and weldable.

Abstract: The invention relates generally to aluminum containing iron-base alloys useful as electrical resistance heating elements. The aluminum containing iron-base alloys have 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 alloy has an entirely ferritic microstructure which is free of austenite and includes, in weight %, over 4% Al, .ltoreq.1% Cr and either .gtoreq.0.05% Zr or ZrO.sub.2 stringers extending perpendicular to an exposed surface of the heating element or .gtoreq.0.1% oxide dispersoid particles. The alloy can contain 14-32% Al, .ltoreq.2% Ti, .ltoreq.2% Mo, .ltoreq.1% Zr, .ltoreq.1% C, .ltoreq.0.1% B, .ltoreq.30% oxide dispersoid and/or electrically insulating or electrically conductive covalent ceramic particles, .ltoreq.1% rare earth metal, .ltoreq.1% oxygen, .ltoreq.3% Cu, balance Fe.

Abstract: A method of making a shaped article involves forming an aqueous mixture comprising inorganic powder material, supercritical fluid, organic binder component a portion of which is essentially insoluble in water, and aqueous vehicle, and extruding the mixture into a shaped article.

Abstract: An improvement in a method of extruding a plasticized inorganic powder mixture having a plasticizing organic binder carried in an aqueous vehicle, by passing the mixture through an extruder and then through a die to produce an extrudate. The improvement involves homogeneously blending in the extruder as part of the mixture, carbon dioxide in the supercritical and/or liquid form, to lower the viscosity of the mixture and produce an extrudate that is stiffer in a shorter time than it would be, absent the carbon dioxide, without increasing the extrusion pressure.

Abstract: A method for making multi-channel structures suitable for use as 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. The inner core comprises a powdered carbon channel-forming filler material such as graphite or amorphous carbon, and a powdered binder. The composite rod may be deformed, as by extrusion, to reduce its diameter. A bundle of composite rods is assembled and deformed, as by extrusion, to reduce the diameter of the bundle and of its component composite rods. Further bundles of the reduced diameter bundles of composite rods may be likewise deformed by extrusion to reduce further the diameter of the component composite rods of the successive bundles, thereby also increasing the number of such rods per given cross section area of the bundle.

Abstract: A low-cost thermal decomposition degreasing method capable of drastically reducing the time required for a degreasing process which involves heating, vaporization and thermal decomposition, while assuring the shape retention property of an injection molded product during degreasing. The degreasing process comprises: (i) a first step wherein a molded product placed under a reduced pressure less than or equal to atmospheric pressure is heated at a temperature lower than the melting point of a thermoplastic binder so that the thermoplastic binder partially evaporates by 5 wt % or more, and then the molded product is further heated at a temperature lower than higher one of the melting points of a more volatile organic compound and a thermoplastic resin whereby the thermoplastic binder further evaporates by 10 wt % or more, and wherein the final temperature is set to 200.degree. C.

Abstract: The invention relates to an inorganic support obtained by sintering and intended to constitute a support for a filter membrane, the support comprising: an inorganic feedstock having a grain size greater than 20 .mu.m and constituted by a metal compound containing only one metal selected from the following metals: aluminum, silicon, and titanium; and an inorganic binder that reacts with the feedstock under the heat treatment conditions of the support in the range 1200.degree. C. to 1500.degree. C., so as to obtain a support having porosity greater than 25% and mechanical strength defined by ultimate bending stress for plane supports greater than 15 MPa, and by ultimate tensile stress for tubular supports greater than 5 MPa, without including a compound liable to create microcracks in the support.

Abstract: Contact material based on silver, use of such a contact material in a switching device in power engineering, and process for preparing the contact material.For contact pieces in low-voltage switches, in particular, substitute materials based on silver-iron oxide are proposed for the silver-nickel hitherto often used in practice. According to the invention, such a material contains, as a further effective component, an oxide of a metal of the third sub-group, yttrium oxide (Y.sub.2 O.sub.3) being especially designed for this purpose. For example, a material of the composition Ag/Fe.sub.2 O.sub.3 10/Y.sub.2 O.sub.3 1 meets, with its favourable temperature behaviour, the properties required with respect to the contact property spectrum. In addition, at least one metal oxide which contains elements of the sixth sub-group of the Periodic Table of the Elements, preferably iron tungstate (FeWO.sub.4), can be present. In particular, a material of the composition Ag/Fe.sub.2 O.sub.3 9/Y.sub.2 O.sub.3 1/FeWO.sub.4 0.

Abstract: An improvement in a method of extruding a plasticized powder mixture having a thermally gellable binder carried in an aqueous vehicle, by passing the mixture through an extruder and then through a die to produce an extrudate, the improvement being the additional step of contacting the extrudate directly after it leaves the die with an agent for simultaneously lowering the gel point of the binder and dehydrating the extrudate. The result is a stiffening of the extrudate in a shorter time than it would be, absent the additional step.

Abstract: A process for the production of a shaped part which is produced from a high-melting point metal powder with crystalline sinter-activating additives. The process includes the steps of preparing, compressing and sintering the metal powder. Prior to the sintering step, the final contour of the shaped part is substantially shaped. The process is primarily directed for the production of shields for radiation protection, as melting crucibles or as electrodes.

Abstract: A method for making multi-channel structures suitable for use as 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 deformed, as by extrusion, to reduce its diameter. In any event, a bundle of composite rods is assembled and deformed, as by extrusion, to reduce the diameter of the bundle and of its component composite rods.

Abstract: A method for forming nickel base superalloy articles of manufacture by a combination of hot die forging, isothermal forging and heat treatment below and above the solvus.

Abstract: A method of extruding a boron carbide-aluminum alloy metal matrix composite includes heating the ingots of the composite to temperatures of about 570.degree. C., holding the ingots at about 570.degree. C. to soften the ingots, placing the ingots in a heated extrusion chamber, and extruding the softened ingots at pressures about 15% to 20% higher than typical pressures used to extrude aluminum alloys. A method of casting a boron carbide-aluminum alloy metal matrix composite includes heating ingots of the composite to about 700.degree. C. to melt the ingots, gently stirring the melt, removing dross from the melt, vigorously stirring the melt with an impeller without creating a vortex, degassing the melt with an argon diffuser wand, and continuously removing froth formed during degassing until the rate of froth formation is reduced and the melt gently bubbles.

Abstract: The manufacturing method of plastically formed products prevents the generation of cracks at the time of plastic working, thereby increasing the productivity. It is also prevented that the metallic particles constituting the product become large and rough in structure. In the manufacturing method, only the compact treatment and the vacuum deaeration treatment are carried out prior to the extrusion treatment, without the pressure-heat treatment performed. Therefore, processing steps prior to the extrusion treatment are simplified, so that the productivity of the plastically formed products is improved and the metallic particles are prevented from being large and rough. The diffusion treatment between the extrusion treatment and the forging treatment enhances the adhesion at the inner part of the extruded material in the radial direction, whereby the generation of cracks at the time of plastic working is avoided.

Abstract: Methods for making, methods for using and articles comprising cermets, preferably cemented carbides and more preferably tungsten carbide, having at least two regions exhibiting at least one property that differs are discussed. Preferably, the cermets further exhibit uniform or controlled wear to impart a self-sharpening character to an article. The multiple-region cermets are particularly useful in wear applications. The cermets are manufactured by juxtaposing and densifying at least two powder blends having different properties (e.g., differential carbide grain size or differential carbide chemistry or differential binder content or differential binder chemistry or any combination of the preceding).

Abstract: A plastically deformable aqueous mixture capable of being shaped into a body, the mixture being composed of any one or combination of ceramic, glass-ceramic, glass, molecular sieve, carbon, or metal powders, cellulose ether organic binder, water insoluble hydrophobic polymer co-binder having an average molecular weight of at least about 8,000, plasticizer, and water. A method of making a body which involves mixing the above components in a high shear mixer at a temperature of about 30.degree. C. to 70.degree. C. to form a homogeneous mixture, extruding the mixture at a temperature of about 30.degree. C. to 70.degree. C. into a green body, followed by drying and firing to produce the product body.

Abstract: A method of high retained strain forging is described for Ni-base superalloys, particularly those which comprise a mixture of .gamma. and .gamma.' phases, and most particularly those which contain at least about 30 percent by volume of .gamma.'. The method utilizes an extended subsolvus anneal to recrystallize essentially all of the superalloy and form a uniform, free grain size. Such alloys may also be given a supersolvus anneal to coarsen the grain size and redistribute the .gamma.'. The method permits the manufacture of forged articles having a fine grain size in the range of about ASTM 5-12 (5-60 .mu.m).

Abstract: The preferred sintered parts made of oxygen-sensitive, non-reducible powders and their production by injection-molding are distinguished by the powders used being freed of their oxide layer by attritor milling in a water-free organic solvent, in the presence or absence of an additional reductant, the oxide particles being removed if necessary by filtration or screening in the presence of the organic solvent, the oxide-free powder being mixed as suspension with a polyacetal as binder under a protective gas, the organic solvent being distilled off, the mixture of powder and polyacetal being heated above the melting point of the polyacetal and being compounded to give a homogeneous composition, the granular material thus obtained being processed in an injection-molding machine made inert with argon to give shaped bodies, the shaped bodies being freed of binder under the action of oxalic acid in a closed ceramic container which nevertheless allows pressure equilibration under protective gas at atmospheric pressur

Abstract: An improved method is disclosed for encasing an object in a shell or layer of outer material. The encased object and the outer material are formed from sinterable metal or ceramic particulate material. Both the object to be encased and the shell or encasement are formed by extrusion. Novel methods are disclosed by which the object and the outer material can be simultaneously formed by co-extruding the sinterable particulate materials, or by extruding the outer layer onto a formed object using the die assembly of the invention.

Abstract: A method of making a homogeneous formable mixture involves simultaneously mixing organic binder which can be cellulose ethers, cellulose ether derivatives, and combinations of these, powder material capable of being formed into a body when combined with the organic binder, water-insoluble wax, and vehicle of which at least about 90 wt % is water, at a temperature which is at least as high the temperature at which the wax begins to deform under shear. A method of making a shaped body involves shaping the above-described mixture into a green body, followed by drying and heating the green body at a temperature and for a time sufficient to form the product body. Preferably the mixture is extruded at a temperature between room temperature and the melting point of the wax, into a honeycomb. The honeycomb has no voids and a smooth skin. A formable mixture made up of organic binder, powder, and wax as described above, wherein the wax which makes up at least 3 wt.

Abstract: A method for producing a ribbed electrode for a fuel cell including the steps of depositing a suspension of a powdered electrode metal onto the face of a substantially flat porous electrode metal substrate, forming a plurality of raised structures on the face of the electrode, and sintering the electrode.

Abstract: The present invention provides a method of increasing debinding rates in Powder Injection Molding of metal and ceramic parts by use of a catalytic binding system.

Abstract: The invention relates to a method of forming honeycomb structures having cross-directional flow channels, such as cross-flow cellular bodies using a novel movable die which is adapted to move while extrudate is passing through the die, thus causing the cells or channels to alternate between straight-through flow, Z-flow, L-flow, U-flow or other similar cross-directional flow patterns. This novel die arrangement may be comprised of either a single movable die body, or a plurality of die parts or sections all of which are independently movable relative to the other.

Abstract: Electrical heating elements and related articles having oxidation resistance at high temperatures, produced by a method involving micropyretic synthesis. A composition subjected to micropyretic synthesis comprises a filler material, a reactive system capable of undergoing micropyretic synthesis, and (optionally) a plasticizer or extrusion agent. The method of preparation of articles includes slurry techniques, plastic extrusion, slip casting, or coating.

Abstract: A method is provided for manufacturing interlocking parts, in which at least one part is manufactured by powder injection molding. To compensate for the amount of contraction of one of the parts manufactured by powder injection molding and, if desired, to produce an additional clearance, a separation layer of plastic material is applied between the interlocking parts. After the injection process to form the separation layer, the separation layer and the binder are removed by a binder-removing and sintering process step. The method is also applicable to powdered metal extrusion for manufacture of double-layered metal parts.

Abstract: A heat-resistant metallic monolith manufactured by forming metal powders into a honeycomb structure and by sintering the structure, a heat-resistant metal oxide coated on the surface of the cell walls and that of the pores thereof. Such a heat-resistant metallic monolith is manufactured by mixing metal powders, an organic binder and water to prepare a mixture, by forming the mixture into a shape of a desired honeycomb configuration, by sintering the shape in a non-oxidizing atmosphere at a temperature between 1000.degree. and 145.degree. C. and then by coating a heat-resistant metal oxide on a surface of the cell walls and that of the pores of the obtained sintered body.

Abstract: A method is presented for uniformly heating plastically deformable material, which comprises particles of electrically conducting matter. This method comprises inducing an electric current, or causing hysteresis loss within such material, by using electromagnetic radiation with frequency between about 50 Hertz and about 10 MegaHertz, to cause heating of the material.

Abstract: A process for fabricating Thallium-based superconducting tapes comprising the steps of: (1) preparing a powder mixture having a nominal composition of (Tl.sub.1-x-y Bi.sub.y Pb.sub.z)(Ba.sub.2-z Sr.sub.z)Ca.sub.2 Cu.sub.3 O.sub.9 ; (2) placing the powder mixture into a silver tube and drawing and/or swaging the silver tube containing the powder mixture into a wire having a pre-determined diameter, wherein x and y are real numbers between 0.2 and 0.4, and z is a real number between 0 and 2; (3) rolling the wire into a tape having a pre-determined thickness; and (4) subjecting the tape to a two-stage single-sintering process at two respective sintering temperatures. The two-stage single-sintering process of the present invention allows Thallium-based superconducting tapes to be fabricated which exhibit substantially increased critical current density, without causing a substantially increased cost and complexity, as do other prior art processes, such as the double-sintering process.

Abstract: A magnet is formed as a ring magnet and magnetized by radial application of a magnetic field while the intensity of the magnetic field is changed periodically along the circumference of the ring magnet to give a circumferentially sinusoidal waveform distribution of magnetic flux density to the ring magnet in the magnetized state of the magnet.

Abstract: A process for the production of foamable elements, in which a metal powder is mixed with a foaming agent powder, the powder mixture is brought to an elevated temperature in a receiver and is extruded through a die, so that the extruded part can be subsequently foamed by decomposition of the foaming agent powder by heating of the extruded part and then cooled to yield a finished foam element. The powder mixture is continuously introduced into a channel, leading to the die, which has a moving wall component by which the powder mixture is transported in the channel by friction with precompacting and is extruded through the die. The speed of the wall component is selected so that the heating necessary for the precompacting comes from heat generated in the transport operation.

Abstract: A semifinished product for electric contact made from a composite material based on silver-tin oxide is described as well as a powder-metallurgical process of making said product. The structure of the semifinished products contains regions which contain no metal oxide or very little metal oxide in alternation with regions which contain the entire metal oxide component or a greatly predominating/share thereof in a fine division.

Abstract: An article and method of manufacture of (Bi,Pb)-Sr-Ca-Cu-O superconductor. The superconductor is manufactured by preparing a first powdered mixture of bismuth oxide, lead oxide, strontium carbonate, calcium carbonate and copper oxide. A second powdered mixture is then prepared of strontium carbonate, calcium carbonate and copper oxide. The mixtures are calcined separately with the two mixtures then combined. The resulting combined mixture is then subjected to a powder in tube deformation and thermal processing to produce a substantially phase pure (Bi,Pb)-Sr-Ca-Cu-O superconductor.

Abstract: Billets are produced from powdery alloys by a process which comprises densely packing in a can a powdery metal or alloy easy of plastic working and a powdery alloy difficult of plastic working in that order, sealing hermetically the can and thereafter degassing the same; or a process which comprises densely packing a powdery alloy difficult of plastic working in a can and, then, densely packing a powdery metal or powdery alloy easy of plastic working in the can to make the powdery metal or alloy into a lid of the can, wherein the powdery alloy easy of plastic working is coarse powder, while the powdery alloy difficult of plastic working is fine powder, and the powdery alloy is a rapidly solidified powdery alloy comprising an Al-base, Mg-base, Ni-base, Ti-base or Fe-base alloy.

Abstract: A method for making metal injection molded medical devices is disclosed. The method comprises melt blending, inject ion molding, and sintering a granulated hardenable metal feedstock.

Abstract: A method of forming or reforming a composite material comprises relatively rotating a pair of members (2,3) while urging them together under pressure so as to mix or remix together the materials (1) making up the composite. The urging direction is substantially parallel with the axis of relative rotation. The composite is then extruded (7).

Abstract: A process for production of superconductor wire having multiple rings, comprising the steps of: preparing a silver mixture comprising a silver or silver-gold alloy mixed with a bonding agent, and a superconductor mixture comprising a superconductor powder with bonding agent; arranging both the silver mixture and the superconductor mixture in a extrusion die; extruding a wire having at least one ring of the superconductor mixture and one ring of the silver mixture in the radial direction; and heating the wire at the sinter temperature of the oxide superconductor so that the bonding agent is removed and the oxide superconductor powder and the silver powder are sintered. A superconductor wire comprising an inner core and an outer ring covering the core, wherein one of the ring on the core comprises a sintered silver powder and the other of the ring on the core comprises a sintered oxide superconductor powder.

Abstract: A cylindrical, iron-based sintered slug comprising an iron-based sintered alloy having a surface hardness represented by an HRB of 40-90 is formed such that its interior porosity is 5% or less but greater than 0%, the porosities of both its surface layer regions lying at most 1 mm below its outer and inner surfaces are fixed at at least 3% or less but greater than 0% and the distribution of pores in each of the surface layers is decreased gradually toward the surface.

Abstract: A magnesium based metal matrix composite is made from rapidly solidified magnesium alloy powder and SiC particulate using liquid suspension coprocessing or mechanical alloying. The composite is suitable for consolidation into bulk shapes having, in combination, high strength, high stiffness, low density, low coefficient of thermal expansion, and high hardness. The composite is suited for uses in such applications as space and missile guidance and navigation and control system precision components where low density, very high specific stiffness and long term dimensional and environmental stability are principal performance criteria.

Abstract: A polyacetal binder is removed from an extruded or injection molded ceramic green body in less than 25 hours by a variable heating rate schedule in which the heating rate is reduced when the temperature of the green body reaches the point at which isothermal degradation of the polyacetal binder can take place and wherein at least 80 wt. % of the binder can be removed. In air, the isothermal removal of the binder can take place within the range of 160.degree.-220.degree. C. while in nitrogen the range is from about 300.degree.-360.degree. C.

Abstract: A method of sintering a sinterable metal powder honeycomb monolith structure comprises sintering the honeycomb monolith structure in a reducing atmosphere containing hydrogen. The honeycomb monolith structure is encased in a sintering jig and thereby disposed close to or in contact with the sintering jig.

Abstract: A method for producing a compacted fully dense permanent magnet by providing a particle charge of a permanent magnet alloy composition from which the article is to be made and placing the charge in a cylindrical container having a generally axially positioned core with the charge surrounding the core within the container. The container and charge are heated to an elevated temperature and extruded to compact the charge to a substantially fully dense permanent magnet article.

Abstract: A method for the production of a metallic powder molding material is disclosed which comprises a step of imparting mechanical energy due to at least one of such physical actions as vibration, pulverization, attrition, rolling, shocks, agitation, and mixing a metallic particles in a vessel whose interior is held under vacuumized atmosphere or an atmosphere of inert gas thereby enabling the metallic particles to contact each other and acquire improvement in surface quality and a step of hot molding the metallic particles thereby producing a molding material.

Abstract: A process of making anisotropic permanent magnets by extruding a rare earth magnetic alloy below the melting temperature of the alloy at an extrusion ratio of from 10:1 to 26:1.

Abstract: Magnesium lithium based alloys prepared by mechanical alloying are disclosed.