Isostatic Or Hydrostatic Patents (Class 419/42)
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Patent number: 6372362Abstract: A method for forming a composite vapor-deposited film one side of which suitable for vapor-deposition on a phosphor surface of a CRT, such as a color television picture tube, has high light reflectivity, and the other side of which has a property to absorb radiant heat, and a composite vapor-deposition material suitable for vacuum deposition are disclosed. The composite vapor-deposition material has a high vapor-pressure metal envelope and a low vapor-pressure metal in the core region of the envelope. Low vapor-pressure metal powder should preferably be dispersed and held by high vapor-pressure metal powder in the core region. Vacuum deposition using this composite vapor-deposition material yields a composite deposited film having a composition comprising almost 100% of the high vapor-pressure metal formed in the initial stage of evaporation, and a composition comprising 100% of the low vapor-pressure metal formed in the final stage of evaporation.Type: GrantFiled: March 24, 2000Date of Patent: April 16, 2002Assignee: Hitachi Metals, Ltd.Inventors: Shinji Furuichi, Shigetoshi Takashima
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Patent number: 6336950Abstract: 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: GrantFiled: May 5, 2000Date of Patent: January 8, 2002Assignees: The Ishizuka Research Institute Ltd., Moscow Steel and Alloys Institute, SHS-CenterInventors: Mitsue Koizumi, Manshi Ohyanagi, Satoru Hosomi, Evgeny Alexandrovich Levashov, Alexander Gennadievich Nikolaev, Alexander Evgenievich Kudryashov
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Patent number: 6332905Abstract: The invention according to the present application provides a high strength solidification body by solidifying a starting metallic powder of iron and the like by means of plastic working using hydrostatic pressing, which is, for instance, a high strength high toughness steel material and the like having a superfine texture comprising a crystalline texture consisting of grains 5 &mgr;m or less in average diameter, or preferably, 3 &mgr;m or less in average diameter. Furthermore, the present invention provides a steel material included in the high strength solidification body, which contains oxide grain 0.2 &mgr;m or less in diameter at a volume ratio of from 0.5 to 60%.Type: GrantFiled: December 4, 2000Date of Patent: December 25, 2001Assignees: Japan as represented by Director General of National Research Institute for Metals, Kawasaki Steel CorporationInventors: Minoru Ootaguchi, Shuji Wanikawa, Yuji Muramatsu, Kaneaki Tsuzaki, Kotobu Nagai, Toru Hayashi
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Patent number: 6332906Abstract: Aluminum-silicon alloys having high stiffness are used in forming computer memory disks and actuator arms. Disks formed with the alloy have low flutter and can be spun at 12,000 RPM or greater with a flutter of 10 Å or less.Type: GrantFiled: March 24, 1998Date of Patent: December 25, 2001Assignee: California Consolidated Technology, Inc.Inventors: Tom Haynes, Kevin Anderson
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Publication number: 20010022945Abstract: The invention relates to a process for the powder metallurgical production of material having improved isotropy of its mechanical properties with a rectangular or flat elliptical cross section, so-called broad-flat material, in particular raw material for producing cutting or piercing tools, in which process a powder of an alloy produced with gas, in particular pulverized with nitrogen, is placed into a capsule, compressed, and the capsule is closed, optionally after an evacuation, whereupon a heating and isostatic pressing (HIPing) of the powder capsules occur and the hot isostatically pressed slug produced in this manner is subjected to a forming by forging.Type: ApplicationFiled: March 2, 2001Publication date: September 20, 2001Applicant: Bohler-Uddeholm Aktiengesellshaft of Wien, AustriaInventor: Siegfried Wilmes
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Patent number: 6214177Abstract: A method of producing a silicon aluminum sputtering target is provided. The target is formed from a powder base of between about 80% to about 95% by weight silicon and about 5% to about 20% by weight aluminum which is placed in a containment unit, heated under vacuum and then sealed. The base is then subjected to a pressure greater than about 3000 psi and heated to a temperature between about 1076° F. and about 1652° F. such that some, but not more than 30%, of the resulting target is formed from liquid phase silicon-aluminum.Type: GrantFiled: December 22, 1999Date of Patent: April 10, 2001Assignee: Ultraclad CorporationInventor: Joseph C. Runkle
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Patent number: 6045631Abstract: A method of making a light metal-rare earth metal alloy includes mixing a light metal powder, such as aluminum powder, with a finely divided rare earth metal-containing compound, such as scandium oxide, creating a billet by subjecting the mixture to cold isostatic compaction. The billet formed from the mixture of aluminum powder and rare earth metal-containing compound is preferably sintered at a temperature of about 600.degree. C. to 800.degree. C. and preferably about 640.degree. C. to 680.degree. C., and subsequently feeding the billet to a molten aluminum bath. This method facilitates conversion of in excess of 95% of the rare earth metal oxide to the aluminum-rare earth metal alloy. The rare earth metal may be scandium.Type: GrantFiled: October 2, 1997Date of Patent: April 4, 2000Assignee: Aluminum Company of AmericaInventors: Gary P. Tarcy, Michael L. Slaugenhaupt
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Patent number: 6030507Abstract: A process for making a crystalline solid-solution powder which involves reacting at least two reactants in a plasma arc of a plasma chamber and blast-cooling the resultant product in a high velocity gas stream to form the powder. The first reactant is a molten metal alloy and the second reactant is a gas. The reaction is carried out in a plasma arc and the products rapidly cooled by a gas stream acting at the outlet opening of the plasma chamber. The crystalline solid-solution powder formed by the process has a low electrical resistivity. If an indium-tin alloy is used as the first reactant and oxygen as the second reactant, there is obtained an indium-tin-oxide (ITO) crystalline solid-solution powder which, when compacted to 40% of its theoretical density, has an electrical resistivity in the range of about 2 .OMEGA.cm. This ITO crystalline solid-solution powder is particularly suitable for preparing an ITO target, with high electrical conductivity and thus high achievable sputtering rates.Type: GrantFiled: May 14, 1998Date of Patent: February 29, 2000Assignee: W.C. Heraeus GmbH & Co. KGInventors: David Francis Lupton, Jorg Schielke, Marek Gorywoda, Bernard Serole, Friedhold Scholz
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Patent number: 5985440Abstract: 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.Type: GrantFiled: February 27, 1997Date of Patent: November 16, 1999Assignee: Degussa AktiengesellschaftInventors: Wolfgang Weise, Willi Malikowski, Roger Wolmer, Peter Braumann, Andreas Koffler
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Patent number: 5968428Abstract: Disclosed is a molding method for powder particles, which is excellent in molding performance, and which makes it possible to obtain a preliminary molded product excellent in strength by enhancing mutual bonding between particles in the preliminary molded product. A molding apparatus for powder particles includes an outer frame die having a mold space with a lower punch and an upper punch to be slidably fitted thereto. Slight clearances exist between the outer frame die and the lower and upper punches. A mixture is prepared by mixing a powdery raw material with a liquid additive to cause an exothermic reaction therewith.Type: GrantFiled: June 26, 1997Date of Patent: October 19, 1999Assignee: Honda Giken Kogyo Kabushiki KaishaInventor: Mitsuo Kuwabara
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Patent number: 5937265Abstract: A rapid method for fabricating a tooling die insert (71) is disclosed. A set of master parts (31, 32) in the shape of the insert is formed using stereolithography or other rapid prototyping techniques (106). The master parts are assembled and a flexible material is molded (109, 56, 57) in them to form a flexible mold (111, 61). The flexible mold is then filled (115) with metal powder and the powder is cold isostatically pressed (117) to solidify it and form a green part. The "green part" is then hot isostatically pressed (118) to form the densifyed tool.Type: GrantFiled: April 24, 1997Date of Patent: August 10, 1999Assignee: Motorola, Inc.Inventors: Steven D. Pratt, Sivakumar Muthuswamy, Robert W. Pennisi
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Patent number: 5935722Abstract: A laminated composite structure of alternating metal powder layers, and layers formed of an inorganic bonding media powder, and a method for manufacturing same are discosed. The method includes the steps of assembling in a cavity alternating layers of a metal powder and an inorganic bonding media of a ceramic, glass, and glass-ceramic. Heat, with or without pressure, is applied to the alternating layers until the particles of the metal powder are sintered together and bonded into the laminated composite structure by the layers of sintered inorganic bonding media to form a strong composite structure. The method finds particular application in the manufacture of high performance magnets wherein the metal powder is a magnetic alloy powder.Type: GrantFiled: September 3, 1997Date of Patent: August 10, 1999Assignee: Lockheed Martin Energy Research CorporationInventors: Arthur J. Moorhead, Hyoun-Ee Kim
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Patent number: 5841044Abstract: Silver-iron materials for electrical switching contacts with properties which come very close to those of silver-nickel materials formed of 0.5 to 4.5% by weight iron and 0.05 to 2% by weight of one or more of the oxides magnesium oxide, calcium oxide, yttrium oxide, lanthanum oxide, titanium oxide, zirconium oxide, hafnium oxide, cerium oxide, niobium oxide, tantalum oxide, chromium oxide, manganese oxide, iron oxide, zinc oxide, aluminum oxide, indium oxide, silicon oxide, and tin oxide, the balance being silver.Type: GrantFiled: November 19, 1996Date of Patent: November 24, 1998Assignee: Degussa AktiengesellschaftInventors: Wolfgang Weise, Willi Malikowski, Roger Wolmer, Peter Braumann, Andreas Koffler
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Patent number: 5808213Abstract: Silver-iron materials for electrical switching contacts with properties which come very close to those of silver-nickel materials formed of 4.6 to 15% by weight iron and 0.05 to 5% by weight of one or more of the oxides magnesium oxide, calcium oxide, yttrium oxide, lanthanum oxide, cerium oxide, chromium oxide, iron oxide, aluminum oxide, indium oxide, silicon oxide, and tin oxide, the balance being silver.Type: GrantFiled: November 19, 1996Date of Patent: September 15, 1998Assignee: Degussa AktiengesellschaftInventors: Wolfgang Weise, Willi Malikowski, Roger Wolmer, Peter Braumann, Andreas Koffler
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Patent number: 5774780Abstract: 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.Type: GrantFiled: November 22, 1995Date of Patent: June 30, 1998Assignee: Bayerische Metallwerke GmbHInventor: Oliver Prause
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Patent number: 5762768Abstract: The targets for cathodic sputtering according to this invention are formed of hot-pressed or hot isostatic-pressed indium oxide/tin oxide powder with a minimum density of 95% of the theoretical density and with a sub-stoichiometric oxygen content are known. In order to provide the improvement of high stability and, simultaneously, high sputtering rate, it is proposed according to the invention that the target have a crystalline phase which is formed as a solid solution of indium oxide and tin oxide with a minimum of 90% by weight, preferably a minimum of 97%, of the solid solution, and which has an average grain size ranging from 2 .mu.m to 20 .mu.m.Type: GrantFiled: August 8, 1996Date of Patent: June 9, 1998Assignee: W.C. Heraeus GmbHInventors: Karl-Heinz Goy, David Francis Lupton, Jorg Schielke, Friedhold Scholz, Bernard Serole, Hans Bohmeier
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Patent number: 5765095Abstract: A method for manufacturing a PCD bit by isostatically or mechanically press forming a green on a metallic blank. A metallic blank is vertically suspended into a flexible vessel. Powder metal is mixed with a binder and introduced into the flexible vessel surrounding the lower end of the suspended metallic blank. The vessel is then isostatically or mechanically pressed causing the powder mixture to stick together and to the blank, forming a green on the blank. The blank and green are removed from the vessel and the exposed end of the metallic blank is chucked onto a milling machine and turned for milling the green into the shape of a PCD bit head. After the milling is completed, the green and blank are sintered, hardening the bit head shaped green and strongly bonding it to the metallic blank, forming a PCD bit wherein the hardened green is the bit head while the metallic blank is the bit pin.Type: GrantFiled: August 19, 1996Date of Patent: June 9, 1998Assignee: Smith International, Inc.Inventors: Richard A. Flak, T. H. (Nick) Nichols, Thomas W. Oldham
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Patent number: 5728194Abstract: Silver-iron materials for electrical switching contacts with properties which come very close to those of silver-nickel materials formed of 0.5 to 20% by weight iron 0.5 to 5% by one or more of the elements rhenium, iridium, and ruthenium, and 0.05 to 2% by weight of one or more of the oxides magnesium oxide, calcium oxide, yttrium oxide, lanthanum oxide, titanium oxide, zirconium oxide, hafnium oxide, cerium oxide, niobium oxide, tantalum oxide, chromium oxide, manganese oxide, iron oxide, zinc oxide, copper oxide, aluminum oxide, indium oxide, silicon oxide, and tin oxide, the balance being silver.Type: GrantFiled: November 19, 1996Date of Patent: March 17, 1998Assignee: Degussa AktiengesellschaftInventors: Wolfgang Weise, Willi Malikowski, Roger Wolmer, Peter Braumann, Andreas Koffler
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Patent number: 5711866Abstract: A metallic composite solid, containing alloys and/or intermetallics, is formed by compacting at moderate pressure a mixture of powder particles, foils or sheets at a temperature close to room temperature, well below the melting temperature of the constituent components and without the addition of low melting metals such as mercury, indium or gallium acting as a sintering agent. This low temperature consolidation of the powder mixture is enhanced by having the surface oxide of the powder particles removed, prior to consolidation, and/or by coating the particles with an oxide-replacing metal such as silver or gold. The coating process may be replacement reactions, autocatalytic reduction or electrolytic reduction. The composite formation is assisted by the addition of a liquid acid such as fluoroboric acid, sulfuric acid, fluoric acid, adipic acid, ascorbic acid, or nitric acid.Type: GrantFiled: May 9, 1995Date of Patent: January 27, 1998Assignee: The United States of America as represented by the Secretary of CommerceInventors: David S. Lashmore, Moshe P. Dariel, Christian E. Johnson, Menahem B. Ratzker, Anthony A. Giuseppetti, Frederick C. Eichmiller, Glenn L. Beane, David R. Kelley
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Patent number: 5697042Abstract: 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).Type: GrantFiled: December 21, 1995Date of Patent: December 9, 1997Assignee: Kennametal Inc.Inventors: Ted R. Massa, John S. Van Kirk, Edward V. Conley
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Patent number: 5678166Abstract: The present invention pertains to an apparatus to hot triaxially compact powder. The apparatus includes a device for hydrostatically stressing the powder. The apparatus also includes a device for applying a shear stress to the powder simultaneously with the hydrostatic stress. Additionally, there is a device for heating the powder while the powder is hydrostatically in shear stress. The presence of the shear stress during the compaction of the powder has three primary effects. It can increase the final density and the densification rate of the compacted powder. It can cause microstructural changes in the compacted powder, and it can disrupt heterogeneities.Type: GrantFiled: July 31, 1995Date of Patent: October 14, 1997Assignee: Henry R. PiehlerInventors: Henry R. Piehler, Daniel M. Watkins
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Patent number: 5669059Abstract: An improved metal matrix composite which, in a preferred embodiment disclosed herein, utilizes boron carbide as the ceramic additive to a base material metal. The metal matrix composite of the present invention begins with the preparation of the boron carbide powder by particle size selection in a jet mill. The resulting powder and metal powder are then mixed by blending of powder of all the various elements such as by means of a conventional blender to uniformly mix powdered substances and avoid stratification and settling. After the particles have been sufficiently mixed, they are degassed and then placed into a die and then into a cylindrical container where the particulates are subjected to extremely high pressures transforming the elements into a solid ingot. It is from these ingots that the extrusion tubes or other articles of manufacture may then be made.Type: GrantFiled: September 29, 1995Date of Patent: September 16, 1997Assignee: Alyn CorporationInventor: Robin A. Carden
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Patent number: 5666635Abstract: This invention, using finely ground powders obtained by either a ingot grinding method, a Ca reduction diffusion method or a strip casting method, proposes a fabrication method for high-performance R--Fe--B permanent magnets with excellent press packing characteristics, a high degree of orientation of the magnetization direction of each crystallite and a total sum of A, (BH)max (MGOe) and B, iHc (kOe), A+B greater than 59.5. Here, cast alloys or ground alloys are coarse ground by mechanical grinding or by a H.sub.2 absorption and decomposition method, and then fine ground by either mechanical grinding or by a jet mill grinding process to yield R--Fe--B fine powders with an average particle size of 1.0 .mu.m.about.10 .mu.m. These powders are then packed into a mold at a packing density of 1.4.about.3.5 g/cm.sup.Type: GrantFiled: September 6, 1995Date of Patent: September 9, 1997Assignee: Sumitomo Special Metals Co., Ltd.Inventors: Yuji Kaneko, Naoyuki Ishigaki
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Patent number: 5662749Abstract: A tantalum-containing nickel base superalloy having a .gamma.' phase has greatly improved maximum tensile strength which is substantially independent of the frequency of the stress is processed by forging above the .gamma.' solvus temperature and annealing above the recrystallization temperature of the alloy.Type: GrantFiled: June 7, 1995Date of Patent: September 2, 1997Assignee: General Electric CompanyInventor: Keh-Minn Chang
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Patent number: 5623726Abstract: The invention relates to the manufacture of paper machine roll shells of stainless steel. According to the invention, powder is made of molten steel by gas-atomizing, a roll shell preform is made of the powder, and the roll shell preform is machined to form a roll shell. The main advantage of the rolls shells according to the invention is their good corrosion fatigue resistance.Type: GrantFiled: July 7, 1995Date of Patent: April 22, 1997Assignee: Rauma Materials Technology OYInventors: Erkki Kiiski, Jari Liimatainen, Hannu Martikainen
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Patent number: 5603073Abstract: A high density, high strength and high compressive strain tungsten heavy alloy consists essentially of tungsten in the amount of approximately 90% by weight, and the rest Mn and Ni in an amount sufficient to cause sintering at between 1100.degree. and 1400.degree. C. The W--Ni--Mn alloy exhibits characteristics of intense shear bands (which could indicate failure by adiabatic shear during high strain-rate dynamic testing) thus making it an attractive material for kinetic energy penetrators. Moreover, the alloy provides an inexpensive high density material which can be produced in furnaces for conventional ferrous powder metal part manufacturing and other conventional non-ferrous powder metal part manufacturing by lowering the sintering temperature by 200.degree. to 300.degree. C.Type: GrantFiled: September 1, 1992Date of Patent: February 11, 1997Assignee: Southwest Research InstituteInventor: Animesh Bose
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Patent number: 5593519Abstract: A method of supersolvus 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 40 percent by volume of .gamma.'. The method permits the manufacture of large grain size forged articles having a grain size in the range of 50-150 .mu.m. The method comprises the selection of a fine-grained forging preform of a Ni-base superalloy. Supersolvus forging in the range of 0.degree.-100.degree. F. above the alloy solvus temperature then performed at slow strain rates in the range of 0.01-0.001 s.sup.-1. Subsequent supersolvus annealing followed by controlled cooling may be employed to control the distribution of the .gamma.', and hence influence the alloy mechanical and physical properties. The method may also be used to produce location specific grain sizes and phase distributions within the forged article.Type: GrantFiled: July 7, 1994Date of Patent: January 14, 1997Assignee: General Electric CompanyInventors: Charles P. Blankenship, Jr., Michael F. Henry
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Patent number: 5590388Abstract: A method of producing a molded ceramic article comprises the first step mixing powdery raw materials and a liquid additive, thereby obtaining a mixed raw material, the second step press-molding the mixed raw material obtained in the first step in a hydrostatically applied condition of pressure, thereby removing an excess of the liquid additive to obtain a preform, and the third step calcining the preform obtained in the second step to obtain a molded ceramic article. The molded ceramic article comprises, as a principal component, copper and, as essential components, Cr and Ni within composition ranges of 0.1.ltoreq.Cr<2 wt. % and 0.1.ltoreq.Ni<10 wt. % and further at least one additive component selected from the group consisting of the following composition ratios: the following composition ratios: 0<Fe<5 wt. %, 0.ltoreq.Co<5 wt. %, 0.ltoreq.Al<10 wt. %, 0.ltoreq.Ti<20 wt. %, 0.ltoreq.Mo<3 wt. %, 0.ltoreq.Si<3 wt. %, 0.ltoreq.V<3 wt. %, 0.ltoreq.Mg<1 wt. %, and 0.ltoreq.Type: GrantFiled: September 1, 1994Date of Patent: December 31, 1996Assignee: Honda Giken Kogyo Kabushiki KaishaInventors: Mitsuo Kuwabara, Kiyoshi Ikegami, Teruaki Yoshida, Koji Takahashi, Tamotsu Harada, Takeshi Komiyama, Fumio Hirai, Masamichi Hayashi
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Patent number: 5584948Abstract: A method is provided for reducing the tendency for thermally induced porosity within a .gamma.' precipitation strengthened nickel-base superalloy which has been processed to obtain a uniform and coarse grain microstructure. This method is particularly useful for forming components such as gas turbine compressor and turbine disk assemblies in which optimal mechanical properties, such as low cycle fatigue and creep resistance, are necessary for operating at elevated temperatures within a gas turbine engine. The method generally entails alloying a .gamma.' precipitation strengthened nickel-base superalloy to have a boron content of not more than about 0.02 weight percent, and then forming a billet by melting an ingot of the superalloy in an argon gas atmosphere and atomizing the molten superalloy using argon gas. The above atomizing technique encompasses both powder metallurgy and spray forming processes.Type: GrantFiled: September 19, 1994Date of Patent: December 17, 1996Assignee: General Electric CompanyInventor: Eric S. Huron
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Patent number: 5538683Abstract: A powder-metallurgy-produced, essentially titanium-free, nickel-containing maraging steel article such as for use in the manufacture of die casting die components and other hot work tooling components. The article preferably contains an intentional addition of niobium. The article may be produced as a hot-isostatically-compacted, solution annealed, fully dense mass of prealloyed particles, or alternately, as a hot-isostatically-compacted, plastically deformed and solution annealed, fully dense mass of prealloyed particles.Type: GrantFiled: December 7, 1993Date of Patent: July 23, 1996Assignee: Crucible Materials CorporationInventors: Kenneth E. Pinnow, Carl J. Dorsch
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Patent number: 5523048Abstract: A process for producing high density refractory metal warhead liners from near net shape blanks. A shaped mold is filled with pure or solid solution molybdenum or tungsten powders. The powders may be isostatically pressed and sintered to form a near net shape blank. A hot isostatic press may be used in combination with these steps or by itself to form the near net shape blank. The hot isostatic press densifies the near net shape blank to at least 90% of theoretical density. Where wrought properties are desired, a final forging step is performed. Alternatively, a process such as vacuum plasma spraying may be used to form the near net shape blank. A hot isostatic press densifies the near net shape blank. A final machining step achieves a finished refractory metal warhead liner.Type: GrantFiled: July 29, 1994Date of Patent: June 4, 1996Assignee: Alliant Techsystems Inc.Inventors: Jonathan S. Stinson, Stanley R. Nelson, Craig L. Wittman
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Patent number: 5496513Abstract: A method of preparing dense sintered bodies of beta alumina suitable for solid electrolytes, which comprises preparing a shaped body from a mixture containing an aluminum powder, a sodium compound, a structure stabilizer and a zirconia powder or from a mixture containing an aluminum powder, an alumina powder, a sodium compound, a structure stabilizer and a zirconia powder, and reaction-sintering the shaped body.Type: GrantFiled: December 2, 1992Date of Patent: March 5, 1996Assignee: Sumitomo Chemical Company, LimitedInventors: Kenji Nakane, Tetsu Umeda, Masahide Mohri
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Patent number: 5482672Abstract: The process for extruding tantalum or niobium includes sealing a cold isostatically pressed charge of tantalum or niobium powder in a first metal cylinder and then sealing the first cylinder in a second metal cylinder with a metal powder of spherical shape in a gap between the cylinders. Thereafter, the second cylinder is cold isostatically pressed to prevent the metal powder in the gap from segregating. This is followed by heating and extrusion of the second container to form, e.g. an extruded bar. The ends of the bar and the skin on the bar can be removed to obtain a rod of tantalum (or niobium) with a yield of from 95% to 96% of the original powder.Type: GrantFiled: February 9, 1995Date of Patent: January 9, 1996Inventors: Ira Friedman, Christer Aslund
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Patent number: 5466414Abstract: A process for fabrication of sintered metal components having improved mechanical, physical and wear-resistent properties.Type: GrantFiled: September 1, 1994Date of Patent: November 14, 1995Assignee: TecSyn, Inc.Inventor: Bjorn O. A. Pettersson
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Patent number: 5462920Abstract: In order to prevent inflation of a metallic coating during heat treatment so that no ununiformity is caused in the critical current density in a method of preparing an oxide superconducting wire which is obtained by heat treating and sintering metal-coated raw material powder for an oxide superconductor, raw material powder (5) for an oxide superconductor is filled up in a metal billet (1), which in turn is degassed and sealed in the degassed state, elongated with application of hydrostatic extrusion, and then heat treated.Type: GrantFiled: August 24, 1994Date of Patent: October 31, 1995Assignee: Sumitomo Electric Industries, Inc.Inventors: Hidehito Mukai, Kenichi Sato, Nobuhiro Shibuta
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Patent number: 5460640Abstract: A fully dense ceramic-metal body including 40-88 v/o of an oxide hard phase of, in v/o of the body, 4-88 v/o M-aluminum binary oxides, where the binary oxide has a C-type rare earth, garnet, .beta.-MAl.sub.11 O.sub.18, or perovskite crystal structure, and M is a lanthanide or indium, and 0-79 v/o .alpha.-alumina; about 10-50 v/o of a hard refractory carbide, nitride, or boride as a reinforcing phase; and about 2-10 v/o of a dispersed metal phase combining Ni and Al mostly segregated at triple points of the microstructure. The preferred metal phase contains a substantial amount of the Ni.sub.3 Al ordered crystal structure. In the preferred body, the reinforcing phase is silicon carbide partially incorporated into the oxide grains, and bridges the grain boundaries. The body including a segregated metal phase is produced by densifying a mixture of the hard phase components and the metal component, with the metal component being present in the starting formulation as Ni powder and Al powder.Type: GrantFiled: August 17, 1992Date of Patent: October 24, 1995Assignee: Valenite Inc.Inventor: Sergej-Tomislav Buljan
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Patent number: 5447800Abstract: A martensitic hot work tool steel die block for use in the manufacture of die casting die components and other hot work tooling components and a method for manufacturing the same. The article has a hardness within the range of 35 to 50 HRC and a minimum transverse Charpy V-notch impact toughness of 5 foot pounds when heat treated to a hardness of 44 to 46 HRC and when tested at both 72.degree. F. and 600.degree. F. The article is a hot worked, heat treated and fully dense consolidated mass of prealloyed particles of the composition, in weight percent, 0.32 to 0.45 carbon, 0.20 to 2.00 manganese, 0.05 to 0.30 sulfur, up to 0.03 phosphorous, 0.80 to 1.20 silicon, 4.75 to 5.70 chromium, 1.10 to 1.75 molybdenum, 0.80 to 1.20 vanadium, and balance iron. The alloy may be any conventional wrought AISI hot work tool steel or wrought maraging or precipitation-hardening steel having 0.05 to 0.30 percent sulfur, and having sulfide particles which exhibit a maximum size of 50 microns in their longest dimension.Type: GrantFiled: September 27, 1993Date of Patent: September 5, 1995Assignee: Crucible Materials CorporationInventors: Carl J. Dorsch, Kenneth E. Pinnow, William Stasko
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Patent number: 5445788Abstract: Complex-shaped parts can be produced from powders, for example metal-matrix composites, by injection molding using a mixture of the powders with a suitable binder. The binder must be removed from the powder mixture before the final thermal treatment of the so-called green part. The present invention proposes to remove the binder by surrounding a cast part with a layer of a particulate material and to subject the cast part to isostatic pressure through the surrounding layer which can thus act as an absorbent. The surrounding layer is removed after the isostatic pressing and the part can be subjected to sintering. The method is suitable for example for aluminum-ceramic powder mixtures.Type: GrantFiled: December 1, 1993Date of Patent: August 29, 1995Assignee: National Research Council of CanadaInventors: Sylvain Turenne, Paul-Emile Mongeon
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Patent number: 5445787Abstract: The process of forming an extruded product of tantalum or niobium requires a cold isostatic pressing of a charge of the powder to a density sufficient to form a green compact which is then placed in a capsule. The capsule is then sealed and heated to a temperature and for a time sufficient to anneal the green compact. Thereafter, the capsule and encapsulated compact are subjected to a cold isostatic pressing to achieve a density of from 70% to 85%. This is followed by subsequent heating and extrusion of the heated capsule and encapsulated compact to form the extruded product. The outer layer on the capsule which has been formed by the capsule material can be removed, as by pickling, in the case of the capsule being a carbon steel.Type: GrantFiled: November 2, 1993Date of Patent: August 29, 1995Inventors: Ira Friedman, Christer Aslund
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Patent number: 5415832Abstract: This invention relates to a method of manufacturing a plurality of molded parts by the steps of (a) providing a plurality of subelements, at least one of said subelements being formed by compression moulding of a sheet so as to define a plurality of recesses therein; (b) welding said subelements together to provide a deformable composite capsule in which said recesses define an inlet channel communicating with a plurality of moulding chambers for forming a plurality of moulded parts; (c) passing powdered material through said inlet channel in said capsule to fill said plurality of moulding chambers therein; (d) evacuating said capsule and essentially sealing said inlet channel; (e) isostatically compacting said capsule to form an essentially dense body therein comprising a plurality of interconnected moulded parts, and (f) separating said moulded parts from one another and cleaning them away from said inlet channel.Type: GrantFiled: October 30, 1992Date of Patent: May 16, 1995Assignee: Asea Brown Boveri ABInventors: Sigurd Friborg, Kurt Lill, Krister Torssell
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Patent number: 5407634Abstract: A method of inhibiting grain growth and restricting grain size during heat-treatment and hot-working of metallic materials. A small volume of inert gas is added to a metallic material so that the inert gas is dispersed throughout the metallic material. The metallic material is then heated sufficiently high so that the inert gas forms micropores within the metallic material; the micropores interact with grain boundaries to inhibit grain growth. If desired, all or part of the residual microporosity may be eliminated from the metallic material during the final step of a deformation processing cycle.Type: GrantFiled: January 11, 1994Date of Patent: April 18, 1995Assignee: McDonnell Douglas CorporationInventors: Ricky L. Martin, Richard J. Lederich
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Patent number: 5374391Abstract: A method of producing a molded ceramic article comprises the first step mixing powdery raw materials and a liquid additive, thereby obtaining a mixed raw material, the second step press-molding the mixed raw material obtained in the first step in a hydrostatically applied condition of pressure, thereby removing an excess of the liquid additive to obtain a preform, and the third step calcining the preform obtained in the second step to obtain a molded ceramic article. The molded ceramic article comprises, as a principal component, copper and, as essential components, Cr and Ni within composition ranges of 0.1.ltoreq. Cr< 2 wt. % and 0.1.ltoreq. Ni< 10 wt. % and further at least one additive component selected from the group consisting of the following composition ratios: the following composition ratios: O<Fe< 5 wt. %, O.ltoreq.Co< 5 wt. %, O.ltoreq.Al< 10 wt. %, O.ltoreq.Ti< 20 wt. %, O.ltoreq.Mo< 3 wt. %, O.ltoreq.Si< 3 wt. %, O.ltoreq.V< 3 wt. %, O.ltoreq.Mg< 1 wt. % and O.Type: GrantFiled: June 9, 1993Date of Patent: December 20, 1994Assignee: Honda Giken Kogyo Kabushiki KaishaInventors: Mitsuo Kuwabara, Kiyoshi Ikegami, Teruaki Yoshida, Koji Takahashi, Tamotsu Harada, Takeshi Komiyama, Fumio Hirai, Masamichi Hayashi
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Patent number: 5369088Abstract: In order to prevent inflation of a metallic coating during heat treatment so that no ununiformity is caused in the critical current density in a method of preparing an oxide superconducting wire which is obtained by heat treating and sintering metal-coated raw material powder for an oxide superconductor, raw material powder (5) for an oxide superconductor is filled up in a metal billet (1), which in turn is degassed and sealed in the degassed state, elongated with application of hydrostatic extrusion, and then heat treated.Type: GrantFiled: March 19, 1992Date of Patent: November 29, 1994Assignee: Sumitomo Electric Industries, Inc.Inventors: Hidehito Mukai, Kenichi Sato, Nobuhiro Shibuta
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Patent number: 5360673Abstract: 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.Type: GrantFiled: September 17, 1990Date of Patent: November 1, 1994Assignee: Doduco GmbH + Co. Dr. Eugen DurrwachterInventors: Ursula Mayer, Roland Michal, Karl E. Saeger
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Patent number: 5318743Abstract: A process for producing a thermoelectric material comprises molding a material powder comprising two or more elements selected from the group consisting of bismuth, tellurium, antimony and selenium and having average diameter in the range from 0.05 to 100 .mu.m and sintering the molded material powder with or without hot isostatic pressing. The material powder may be calcinated before the molding. A process for producing a thermoelectric element comprises cutting out pieces of a pillar-like shape from each of a p-type thermoelectric material and a n-type thermoelectric material, connecting the pieces cut out from the p-type thermoelectric material and the pieces cut out from the n-type thermoelectric material alternately with electrodes at the upper faces or the lower faces of the pieces and attaching insulating base plates to the surfaces of the electrodes. The p-type thermoelectric material and the n-type thermoelectric material are respectively produced by the process described above.Type: GrantFiled: November 27, 1992Date of Patent: June 7, 1994Assignees: Idemitsu Petrochemical Co., Ltd., Director-General, Agency of Industrial Science and Technology, Ministry of International Trade and IndustryInventors: Takeo Tokiai, Takashi Uesugi, Kazuyuki Fukumoto, Toshitaka Ohta, Takenobu Kajikawa
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Patent number: 5283232Abstract: A method for producing an oxide superconducting composite wire is disclosed, which comprises the steps of: (a) molding a powdered oxide superconductor material to form a wire; (b) heat treating the wire in an oxygen atmosphere thereby forming the wire into an oxide superconducting member; (c) forming a non-oxidizing metal intermediate layer on a surface of the oxide superconducting member; (d) bundling a plurality of the oxide superconducting members containing the intermediate layer; (e) inserting the bundled oxide superconducting members into an oxidizing metal support tube; and (f) drawing the product of step (e) to reduce its diameter and heat-treating it.Type: GrantFiled: August 20, 1992Date of Patent: February 1, 1994Assignee: Fujikura Ltd.Inventors: Osamu Kohno, Yoshimitsu Ikeno, Nobuyuki Sadakata, Masaru Sugimoto, Mikio Nakagawa
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Patent number: 5273708Abstract: In making a dual alloy gas turbine rotor, a plurality of superalloy components are formed to include an airfoil having a directionally solidified columnar grain structure or a single crystal grain structure. A boron-bearing melting point depressant material is applied to the inner surface and a side surface of the components. The components are arranged side-by-side in an annular array with the first side surface of one component juxtaposed to the second side surface of an adjacent component and with the inner surfaces defining a spray-receiving surface. The airfoils extend in a radial axis or direction of the array while the spray-receiving surface extends in a circumferential direction of the article. A sealing member is positioned adjacent an axial end of the array of the components to close off that end and form a spray-receiving cavity. Boron-bearing melting point depressant material is provided between the sealing member and the end of the array.Type: GrantFiled: June 23, 1992Date of Patent: December 28, 1993Assignee: Howmet CorporationInventor: William R. Freeman
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Patent number: 5244623Abstract: A method for isostatic pressing of formed powder, porous powder compact, and composite intermediates and the intermediate and final products produced thereby. The method includes the steps of:(A) coating the exposed surface of the formed powder, porous powder compact, or composite intermediate with a flowable film-forming material capable of forming a solid continuous impervious flexible film; then(B) solidifying the coating of step (A) on the surface of the intermediate to form a coated intermediate; and(C) subjecting the coated intermediate of step (B) to a uniformly applied pressure exceeding atmospheric pressure to produce a flexible coating formed directly on the parts to be isopressed, permitting small parts or parts with complex shapes to be coated individually or in bulk.Type: GrantFiled: May 10, 1991Date of Patent: September 14, 1993Assignee: Ferro CorporationInventor: Alan G. King
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Patent number: 5227576Abstract: Method and apparatus whereby complex patterns are pressed into the interior of a part formed of compactible material. A flexible, pre-fabricated pattern form bearing the inverse of a desired pattern is wrapped around a conventional mandrel and this assembly is loaded inside of an isostatic pressing bag with a material charge. After compaction, the mandrel is separated from the pattern form, leaving the pattern form behind in the compact. The pattern form is then peeled, pulled, or otherwise removed from the interior of the compact, leaving behind the desired on the compact interior. Alternatively, a collapsible or melt-away mandrel with the inverse of a desired pattern formed on its exterior is employed to form the desired pattern on the interior of a compacted part.Type: GrantFiled: March 4, 1992Date of Patent: July 13, 1993Assignee: Industrial Materials TechnologyInventor: Timothy D. Howard
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Patent number: 5139720Abstract: In a method of manufacturing a sintered ceramic material using the heat generated in a thermit reaction as a heating source, a pre-heating is applied preceding to the sintering step or a mixture comprising: (A) at least one ceramic powder, (B) at least one non-metallic powder selected from the group consisting of carbon, boron and silicon, and (C) a metal powder and/or a non-metallic powder other than the above-mentioned (B) is used. Homogeneous and dense sintered ceramic material or sintered composite ceramic material can be obtained by this method, and the fine texture thereof, and the phase constitution, the phase distribution and the like of the composite ceramic phase can be controlled sufficiently.Type: GrantFiled: February 12, 1991Date of Patent: August 18, 1992Assignee: Kabushiki Kaisha Komatsu SeisakushoInventors: Shuichi Takeda, Hideki Shishiba