Pretreatment Of Consolidated Powders Patents (Class 419/44)
  • Patent number: 9771642
    Abstract: The embodiments described herein relate to BMG articles with high bulk having all dimensions greater than the critical dimension. Exemplary BMG article can include at least one bulk component and/or one or more fixation elements configured on surface of the bulk component or inserted into the bulk component. Other embodiments relate to methods of making the BMG articles by thermo-plastic-formation of BMG alloy materials.
    Type: Grant
    Filed: July 4, 2012
    Date of Patent: September 26, 2017
    Assignee: Apple Inc.
    Inventors: Joseph C. Poole, Christopher D. Prest, Matthew S. Scott, Dermot J. Stratton, Stephen P. Zadesky
  • Patent number: 9111745
    Abstract: A method of producing rectangular seeds for use in semiconductor or solar material manufacturing includes connecting an adhesive layer to a top surface of a template, the template including a plurality of parallel slots, and drawing alignment lines on the adhesive layer, the alignment lines aligned with at least some of the parallel slots. The method also includes connecting quarter sections to the alignment layer such that an interface between a rectangular seed portion and a curved wing portion of each quarter section is aligned with at least one of the alignment lines drawn on the adhesive layer, and slicing each of the quarter sections to separate the rectangular seed portions from the curved wing portions.
    Type: Grant
    Filed: December 31, 2012
    Date of Patent: August 18, 2015
    Assignee: MEMC Singapore Pte., Ltd. (UEN200614794D)
    Inventors: Jihong John Chen, Susan S. Dwyer, Shawn Wesley Hayes, Thomas E. Doane, Dale A. Witte, Linda K. Swiney, Travis L. Hambach
  • Patent number: 9039920
    Abstract: There are provided a permanent magnet and a manufacturing method thereof enabling carbon content contained in magnet particles to be reduced in advance before sintering even when wet milling is employed. Coarsely-milled magnet powder is further milled by a bead mill in a solvent together with an organometallic compound expressed with a structural formula of M-(OR)X (M represents V, Mo, Zr, Ta Ti W or Nb, R represents a substituent group consisting of a straight-chain or branched-chain hydrocarbon, X represents an arbitrary integer) so as to uniformly adhere the organometallic compound to particle surfaces of the magnet powder. Thereafter, a compact body of compacted magnet powder is held for several hours in hydrogen atmosphere at 200 through 900 degrees Celsius to perform hydrogen calcination process. Thereafter, through sintering process, a permanent magnet 1 is formed.
    Type: Grant
    Filed: March 28, 2011
    Date of Patent: May 26, 2015
    Assignee: NITTO DENKO CORPORATION
    Inventors: Izumi Ozeki, Katsuya Kume, Keisuke Hirano, Tomohiro Omure, Keisuke Taihaku, Takashi Ozaki
  • Publication number: 20150104345
    Abstract: A green metal body includes metal particles and a binder in the shape of an orthodontic bracket and/or base plate. The green metal body is fabricated by being laser-cut with a laser to shape the green metal body into the shape of an orthodontic bracket and/or to carve recesses and/or undercuts into the bonding surface of the bracket. The green metal body is sintered to shrink its volume into a denser and less porous sintered metal body configured to be an orthodontic bracket. The resultant sintered orthodontic bracket includes recesses and/or undercuts in the bonding surface to provide a mechanical aspect when bonded to a tooth.
    Type: Application
    Filed: December 17, 2014
    Publication date: April 16, 2015
    Inventors: Norbert Abels, Claus H. Backes
  • Patent number: 9005374
    Abstract: There are provided a permanent magnet and a manufacturing method thereof capable of decreasing an activity level of a calcined body activated by a calcination process. To fine powder of milled neodymium magnet is added an organometallic compound solution containing an organometallic compound expressed with a structural formula of M-(OR)x (M represents V, Mo, Zr, Ta, Ti, W or Nb, R represents a substituent group consisting of a straight-chain or branched-chain hydrocarbon, x represents an arbitrary integer) so as to uniformly adhere the organometallic compound to particle surfaces of the neodymium magnet powder. Thereafter, desiccated magnet powder is held for several hours in hydrogen atmosphere at 200 through 900 degrees Celsius. Thereafter, the powdery calcined body calcined through the calcination process in hydrogen is held for several hours in vacuum atmosphere at 200 through 600 degrees Celsius for a dehydrogenation process.
    Type: Grant
    Filed: March 28, 2011
    Date of Patent: April 14, 2015
    Assignee: Nitto Denko Corporation
    Inventors: Izumi Ozeki, Katsuya Kume, Keisuke Hirano, Tomohiro Omure, Keisuke Taihaku, Takashi Ozaki
  • Patent number: 8845957
    Abstract: A method for producing a magnetizable metal shaped body comprising a ferromagnetic starting material that is present in powder and in particulate form, using the following steps: (a) first compaction of the starting material (S3) such that adjoining particles become bonded to each other by means of positive adhesion and/or integral bonding in sections along the peripheral surfaces thereof and while forming hollow spaces, (b) creating an electrically isolating surface coating on the peripheral surfaces of the particles in regions outside the joining sections (S4), and (c) second compaction of the particles (S5) provided with the surface coating, such that the hollow spaces are reduced in size or eliminated.
    Type: Grant
    Filed: April 27, 2009
    Date of Patent: September 30, 2014
    Assignees: ETO Magnetic GmbH, Kennametal Europe GmbH
    Inventors: Paul Guempel, Stefan Glaeser, Beat Hofer
  • Patent number: 8703044
    Abstract: A method of fabricating a machine component is provided. The method includes preparing at least a portion of a surface of a machine component for receiving a sintered preform. The method also includes forming a pre-sintered preform hybrid hardface mixture that includes combining a predetermined portion of at least one hardfacing material with a predetermined portion of at least one brazing material. The method further includes forming a pre-sintered preform. The pre-sintered preform has predetermined dimensions. The method also includes forming the sintered preform and positioning the sintered preform on the machine component. The method further includes fixedly coupling the sintered preform to at least a portion of the machine component via brazing.
    Type: Grant
    Filed: January 3, 2006
    Date of Patent: April 22, 2014
    Assignee: General Electric Company
    Inventors: Sujith Sathian, Anjilivelil K. Kuruvilla, Daniel Nowak
  • Patent number: 8585853
    Abstract: A layered manufacturing method for forming a desired three-dimensional object by using a powder as a raw material. The method forms a desired solid body, which is employed in a layered manufacturing device, including a stage member having stage surface; a transparent member having an optical window to cover the stage surface to form an enclosed region together with the stage surface; and an exhaust system for exhausting gasses in the enclosed region. The optical window is positioned at a vertical upper direction when the enclosed region is formed.
    Type: Grant
    Filed: May 17, 2011
    Date of Patent: November 19, 2013
    Inventors: Keijirou Yamamoto, Tsuyoshi Tokunaga
  • Patent number: 8309839
    Abstract: A method of improving the thermoelectric figure of merit (ZT) of a high-efficiency thermoelectric material is disclosed. The method includes the addition of fullerene (C60) clusters between the crystal grains of the material. It has been found that the lattice thermal conductivity (?L) of a thermoelectric material decreases with increasing fullerene concentration, due to enhanced phonon-large defect scattering. The resulting power factor (S2/?) decrease of the material is offset by the lattice thermal conductivity reduction, leading to enhanced ZT values at temperatures of between 350 degrees K and 700 degrees K.
    Type: Grant
    Filed: April 30, 2004
    Date of Patent: November 13, 2012
    Assignees: GM Global Technology Operations LLC, Shanghai Institute of Ceramics, Chinese Academy of Sciences
    Inventors: Lidong Chen, Xun Shi, Jihui Yang, Gregory P. Meisner
  • Patent number: 8043555
    Abstract: An earth-boring bit has a steel body and bearing pin for rotatably supporting a cone. The cone has an exterior surface containing rows of cutting elements. The cone and cutting elements are formed of cemented tungsten carbide. The cone may be manufactured by applying pressure to a mixture of hard particles and metal alloy powder to form a billet, then machining the billet to a desired over-sized conical shaped product. Then the conical-shaped product is liquid-phase sintered to a desired density, which causes shrinking to the desired final shape.
    Type: Grant
    Filed: December 7, 2009
    Date of Patent: October 25, 2011
    Assignee: Baker Hughes Incorporated
    Inventors: Redd H. Smith, Trevor Burgess, Jimmy W. Eason
  • Patent number: 7993577
    Abstract: The invention relates to manufacture of titanium articles from sintered powders. The cost-effective initial powder: 10-50 wt % of titanium powder having ?500 microns in particle size manufactured from underseparated titanium sponge comprising ?2 wt % of chlorine and ?2 wt % of magnesium; 10-90 wt % of a mixture of two hydrogenated powders A and B containing different amount of hydrogen; 0-90 wt % of standard grade refined titanium powder, and/or 5-50 wt % of alloying metal powders. The method includes: mixing powders, compacting the blend to density at least 60% of the theoretical density, crushing titanium hydride powders into fine fragments at pressure of 400-960 MPa, chemical cleaning and refining titanium powders by heating to 300-900° C. and holding for ?30 minutes, heating in vacuum at 1000-1350° C., holding for ?30 minutes, and cooling.
    Type: Grant
    Filed: June 11, 2007
    Date of Patent: August 9, 2011
    Assignee: Advance Materials Products, Inc.
    Inventors: Volodymyr A. Duz, Orest M. Ivasishin, Vladimir S. Moxson, Dmitro G. Savvakin, Vladislav V. Telin
  • Publication number: 20100262149
    Abstract: An orthopedic tool being made from an alloy in the group comprising stainless steel alloys, cobalt-chrome alloys, titanium alloys and alumina and zirconia ceramic alloys, and having a density less than 98% of a theoretical possible density for the alloy, the orthopedic tool being made by a metal injection moulding process.
    Type: Application
    Filed: November 13, 2009
    Publication date: October 14, 2010
    Inventors: Dupuy Charles, Boisclair Mathieu, Julien Benoit, Lawson Mark
  • Patent number: 7713467
    Abstract: A process for the production of a ball screw, which has at least one element produced powder metallurgically, is suggested, with which the at least one element is produced from a plurality of parts, wherein at least one first precursor body with a first joining area and one second precursor body with a second joining area are produced and the first precursor body and the second precursor body have been or are brought into contact via the first joining area and the second joining area prior to the sintering and/or during the sintering.
    Type: Grant
    Filed: December 19, 2005
    Date of Patent: May 11, 2010
    Assignee: Danaher Linear GmbH
    Inventors: Wolfgang Becker, Ralf Branz, Winfried Schroeppel
  • Patent number: 7708936
    Abstract: A cemented carbide tool comprising hard constituents in a binder phase of Co and/or Ni and at least one surface portion and an interior portion in which surface portion the grain size is smaller than in the interior portion is disclosed. The surface portion with the fine grain size has a lower binder phase content than the interior portion. A method to form the cemented carbide cutting tool is also disclosed.
    Type: Grant
    Filed: October 23, 2008
    Date of Patent: May 4, 2010
    Assignee: Sandvik Intellectual Property Aktiebolag
    Inventors: Marianne Collin, Susanne Norgren, Håkan Engström
  • Patent number: 7635078
    Abstract: This invention relates to a method of brazing while the thickness of the opening between materials being brazed can not be maintained constant or can not be adjusted in the appropriate range. In order to solve this issue the porous material of metals or metal alloys consisting of Ni, Cu, Ti, Al, Ag or W should be utilized. The metallic porous material is inserted into the brazing opening mentioned above by using the softness of it, and is made to hold the brazing solder and to reinforce the bonding part after brazing.
    Type: Grant
    Filed: February 6, 2006
    Date of Patent: December 22, 2009
    Assignee: Kanto Yakin Kogyo Kabushiki Kaisha
    Inventors: Tadashi Ariga, Kiichi Kanda
  • Patent number: 7326892
    Abstract: A process for heating a powder material by microwave radiation so that heating of the powder material is selective and sufficient to cause complete melting of the particles. The process entails providing a mass of powder comprising a quantity of filler particles of a metallic composition, and subjecting the mass to microwave radiation so that the filler particles within the mass couple with the microwave radiation and are completely melted. According to one aspect, the mass further contains at least one constituent that is more highly susceptible to microwave radiation than the filler particles, and the filler particles are melted as a result of heating by microwave radiation and thermal contact with the at least one constituent. According to another aspect, the powder mass is thermally pretreated to induce an irreversible increase in its dielectric loss factor prior to melting by microwave irradiation.
    Type: Grant
    Filed: September 21, 2006
    Date of Patent: February 5, 2008
    Assignee: General Electric Company
    Inventors: Laurent Cretegny, David Edwin Budinger, Vasile Bogdan Neculaes, Holly Sue Shulman, Morgana Lynn Fall, Shawn Michael Allan
  • Patent number: 7135288
    Abstract: A combinatorial library includes a gelcast substrate defining a plurality of cavities in at least one surface thereof; and a plurality of gelcast test materials in the cavities, at least two of the test materials differing from the substrate in at least one compositional characteristic, the two test materials differing from each other in at least one compositional characteristic.
    Type: Grant
    Filed: September 27, 2002
    Date of Patent: November 14, 2006
    Assignee: UT-Battelle, LLC
    Inventors: Robert J. Lauf, Claudia A. Walls, Lynn A. Boatner
  • Patent number: 7052526
    Abstract: A magnesium base composite material is provided such that compound particles generated by a solid-phase reaction with magnesium are uniformly dispersed in a magnesium alloy body. The compound particles dispersed in the body comprise magnesium silicide (Mg2Si) and magnesium oxide (MgO) so that the magnesium base composite material may have excellent strength, hardness and abrasion resistance and tempered opponent aggression.
    Type: Grant
    Filed: February 14, 2003
    Date of Patent: May 30, 2006
    Assignee: Toudai TLO, Ltd.
    Inventor: Katsuyoshi Kondoh
  • Patent number: 7045093
    Abstract: A method for manufacturing a sintered magnet includes the steps of producing a green compact of powder for the sintered magnet, machining the green compact with a wire-saw, and sintering the green compact.
    Type: Grant
    Filed: July 26, 2002
    Date of Patent: May 16, 2006
    Assignee: Neomax Co., Ltd.
    Inventors: Atsuo Tanaka, Shoichi Matsugami, Tadahiro Iwasaki, Atsushi Ogawa, Hitoshi Morimoto
  • Patent number: 7025930
    Abstract: In a process for handling green compacts made from a rare earth metal-based magnetic alloy powder by a press machine to slide, on a sintering support plate, the green compacts, the support plate used has a surface roughness degree Ra in a range of 0.6 to 47 ?m. At a first step, the green compacts are disposed in a first position near a final transport position, and at a second step, the said green compacts disposed in the first position are slid on the sintering support plate and disposed in the final transport position. Thus, by using the support plate having a surface roughness degree in a particular range, the green compacts made from the rare earth metal-based magnetic alloy powder can be sintered without occurrence of the deposition of the green compacts to the support plate, the chipping of the green compacts and the like. In addition, the efficiency of operation of the press machine can be increased.
    Type: Grant
    Filed: February 4, 2003
    Date of Patent: April 11, 2006
    Assignee: Neomax Co. Ltd.
    Inventors: Shuhei Okumura, Hiroshi Hashikawa
  • Patent number: 6926777
    Abstract: The invention relates to a method for producing rod-shaped permanent magnets according to which pressed parts (2) are produced that are then assembled to a rod-shaped green product. Said green product is subsequently sintered, whereby a rod-shaped single-piece permanent magnet (1) is produced.
    Type: Grant
    Filed: December 19, 2000
    Date of Patent: August 9, 2005
    Assignee: Vacuumschmelze GmbH & Co. KG
    Inventors: Georg Werner Reppel, Volker Zellmann
  • Publication number: 20040086413
    Abstract: A relatively economical process allows producing sintered shaped parts, such as sliding sleeves in motor vehicle transmissions. Open-pored undercut surfaces are formed at an internal toothing by hypocycloid milling of the part prior to its final hardening.
    Type: Application
    Filed: October 21, 2003
    Publication date: May 6, 2004
    Inventors: Gunter Rau, Lorenz Sigl
  • Patent number: 6649106
    Abstract: A method for debindering of powder molded body, including dipping, in an extracting solution an aqueous surfactant solution, a ceramic powder or metal powder molded body containing a binder with at least two kinds of binder components, to selectively extract and remove at least one kind of binder component from the molded body, and then removing the binder components remaining in the molded body after extraction. This debindering method permits rapid debindering while preventing the generation of defects such as cracks and the like, is highly safe to human health and environment, and requires a low facility cost.
    Type: Grant
    Filed: March 7, 2002
    Date of Patent: November 18, 2003
    Assignee: NGK Insulators, Ltd.
    Inventors: Shinji Sakaguchi, Shigeki Kato, Takayuki Kawae
  • Patent number: 6554609
    Abstract: Nanostructured non-stoichiometric non-equilibrium materials are disclosed. Novel electromagnetic materials and their applications are discussed. More specifically, the specifications teach the use of nanotechnology and nanostructured materials for developing novel electrical devices and products.
    Type: Grant
    Filed: May 17, 2002
    Date of Patent: April 29, 2003
    Assignee: NanoProducts Corporation
    Inventors: Tapesh Yadav, Roger Dirstine, John Alexander
  • Publication number: 20030059334
    Abstract: Device and process for sintering a powder with a laser beam. In the field of design and prototyping, and the in particular in industrial model construction, the development of new types of more rapid production methods are continuously being sought. One category of this type of rapid production methods is referred to as the rapid prototyping process. This category includes selective laser sintering (SLS).
    Type: Application
    Filed: February 20, 2001
    Publication date: March 27, 2003
    Inventors: Jialin Shen, Jurgen Steinberger
  • 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
  • Patent number: 6355209
    Abstract: A method of consolidating metal powder to form an object that includes pressing the powder into a preform, and preheating the preform to elevated temperature; providing flowable pressure transmitting particles and transmitting microwaves into the particles to heat same, and providing a bed of the flowable and heated pressure transmitting particles; positioning the preform in such relation to the bed that the particles substantially encompass the perform; and pressurizing the bed to compress the particles and cause pressure transmission to the preform, thereby to consolidate the preform into a desired object shape, the powder of step a) consisting essentially of at least two of the following: W, Ni, Fe, Co, manganese and titanium, and preferably at least three of same.
    Type: Grant
    Filed: April 18, 2000
    Date of Patent: March 12, 2002
    Assignee: Ceracon, Inc.
    Inventors: Morris F. Dilmore, Henry S. Meeks, III, Marc S. Fleming
  • Patent number: 6232368
    Abstract: An embodiment of the present invention provides a method for improving the tensile strength of foundry cores and molds over what may be conventionally achieved. The use of acidic methylene compounds in binder compositions which include strongly alkaline phenolic resoles results in an ester curable binder that may be used to make foundry cores and molds having significantly greater tensile strengths than are achieved with prior art binders. An embodiment of the present invention provides a composition which includes a phenolic resole having a pH ranging from about 10.5 to about 13.5 and an acidic methylene compound.
    Type: Grant
    Filed: October 12, 1999
    Date of Patent: May 15, 2001
    Assignee: Borden Chemical, Inc.
    Inventor: Kenneth B. White
  • Patent number: 6090178
    Abstract: A frangible metal bullet, a method for making it, and ammunition made therefrom. The frangible metal bullet is formed from a mixture of metal particles and metal or metalloid binder forming material which is compacted into the desired shape, heated to a temperature above that needed to form at least one intermetallic compound but below the temperature of joining of the metal particles by sintering and below the temperature of formation of substantial amounts of a ductile alloy of the metal of the particles and the metal or metalloid binder forming material and then cooled. Such bullets have sufficient strength to maintain their integrity during firing but disintegrate into powder on impact and can be formulated to be lead-free.
    Type: Grant
    Filed: November 5, 1998
    Date of Patent: July 18, 2000
    Assignee: SinterFire, Inc.
    Inventor: Joseph C. Benini
  • Patent number: 6051184
    Abstract: A metal powder injection moldable composition which hardly causes debinding deformation is obtained. This composition consists of a metal powder and an organic binder. The components which constitute the organic binder are:a. polyoxymethylene having a Vicat softening temperature A.gtoreq.150.degree. C.,b. polypropylene having a Vicat softening temperature B.gtoreq.130.degree. C.,c. an organic compound whose viscosity at said Vicat softening temperature A (.degree. C.) is not more than 200 mPa.multidot.s, andd. a thermoplastic resin whose Vicat softening temperature is not higher than said B (.degree. C.).
    Type: Grant
    Filed: October 15, 1998
    Date of Patent: April 18, 2000
    Assignee: Mold Research Co., Ltd.
    Inventor: Yoshimitsu Kankawa
  • Patent number: 6033788
    Abstract: In a process for producing powder metallurgy objects containing two or more individually formed pieces, the individual formed pieces or powder compacts which are comprised of powder and a binder are joined together. A polymer compatible with the binder is sandwiched between two such powder compacts. A lamination joint is formed. The polymer is then softened, and a resultant aggregate body is thermally processed to remove the binder and polymer. The resulting object has no residual interface between the original individually formed pieces. There is no discernable boundary at the lamination joint. The final part is homogeneous and uniform with no foreign material or structural imperfections at the joint.
    Type: Grant
    Filed: November 14, 1997
    Date of Patent: March 7, 2000
    Assignee: Case Western Reserve University
    Inventors: James D. Cawley, William H. Glime, Brian D. Kernan
  • Patent number: 5997605
    Abstract: The present invention concerns a method of producing powder-metallurgical compacted components, which during subsequent processing are split into individual parts mating in pairs, sintered and optionally heat-treated and remated. According to the process, an iron-based powder is compacted, the obtained green body is fracture-split into at least two parts, which are subsequently sintered and optionally heat-treated. The obtained sintered parts are then remated.
    Type: Grant
    Filed: March 31, 1999
    Date of Patent: December 7, 1999
    Assignee: Hoganas AB
    Inventors: Nils Carlbaum, Bjorn Johansson
  • Patent number: 5993729
    Abstract: Post-compaction treatments of iron compacts to improve the mechanical strength of the compacts are provided. Powder is compacted into the desired part. The part is then subjected to a strengthening operation. This operation involves a heat treatment at a moderate temperature combined with an optional resin impregnation. The heat treatment is done at a temperature sufficient to increase the mechanical properties of the compact while maintaining the magnetic losses low for the required application. Impregnation with an insulating binder can be effected to increase the mechanical strength of the part without creating electric contacts between the powder particles.
    Type: Grant
    Filed: February 6, 1997
    Date of Patent: November 30, 1999
    Assignee: National Research Council of Canada
    Inventors: Louis-Philippe Lefebvre, Sylvain Pelletier, Claude Gelinas
  • Patent number: 5932055
    Abstract: Direct Metal Fabrication of metal parts is accomplished with a continuous thermal process in which partial reduction of the "green form" part leaves a thin carbon film that maintains the part's structural integrity. The remaining carbon catalyzes a eutectic reducing element to diffuse throughout the part forming organo-metallic bonds that bind the homogenized metal alloy. Supersolidus liquid phase sintering (SLPS) densities the alloy to provide a final part of parent material quality. The DMF process can be used in magnetographic printing to imprint an image.
    Type: Grant
    Filed: November 11, 1997
    Date of Patent: August 3, 1999
    Assignee: Rockwell Science Center LLC
    Inventors: Kenneth J. Newell, Ira B. Goldberg
  • Patent number: 5912429
    Abstract: Thermoelectric material for high temperature use made of a sintered body of a relative density of at least 75% consisting mainly of cobalt antimony compounds having an elemental ratio Sb/(Co+additives)=x of 2.7<x<3 is produced by a method of firing a shaped body of powders consisting mainly of cobalt and antimony in a non-oxidizing atmosphere under an environmental pressure, wherein the shaped body before the firing is constituted from crystal phases composed of a cubic crystal system compound CoSb.sub.3 (A phase), a monoclinic crystal system compound CoSb.sub.2 (B phase) and a hexagonal crystal system compound CoSb (C phase), and constitutional ratio of these crystal phases is (I.sub.B +I.sub.C)/(I.sub.A +I.sub.B +I.sub.C)<0.15 (wherein, I.sub.X (X is A, B or C) is a relative intensity by X-ray diffraction).
    Type: Grant
    Filed: March 19, 1997
    Date of Patent: June 15, 1999
    Assignees: NGK Insulators, Ltd., Nissan Motor Co., Ltd.
    Inventors: Yuichiro Imanishi, Makoto Miyoshi, Kazuhiko Shinohara, Masakazu Kobayashi
  • Patent number: 5854379
    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.
    Type: Grant
    Filed: January 2, 1997
    Date of Patent: December 29, 1998
    Assignee: Kabushiki Kaisha Komatsu Seisakusho
    Inventors: Takemori Takayama, Yoshitaka Ohyama, Kazuo Okamura, Masato Miyake, Katsuyoshi Saito, Hiroshi Ono
  • Patent number: 5842108
    Abstract: A method for producing high density and ultrafine W/Cu bulk material by a mechano-chemical process is disclosed. In the method of this invention, metal salts as start materials are spray-dried and prepare W--Cu precursor powder having uniformly-dispersed tungsten and copper components. The W--Cu precursor powder in turn is subjected to a desalting and milling process, thus preparing W--Cu oxide composite powder. Thereafter, the W--Cu oxide composite powder may be formed into a formed green body prior to reducing and sintering under hydrogen atmosphere.
    Type: Grant
    Filed: August 13, 1997
    Date of Patent: November 24, 1998
    Assignee: Korea Institute of Machinery & Materials
    Inventors: Byoung-Kee Kim, Gil-Geun Lee, Gook-Hyun Ha, Dong-Won Lee
  • Patent number: 5815789
    Abstract: A method for producing self lubricating powder metal cylinder bore liners for an internal combustion engine includes the steps of loading a powder metal mixture into a die cavity, compacting the powder metal mixture in the die cavity and forming the powder metal cylinder bore liner having a porous structure, sintering the powder metal cylinder bore liner, and impregnating the porous structure of the cylinder bore liner with lubricant.
    Type: Grant
    Filed: July 8, 1996
    Date of Patent: September 29, 1998
    Assignee: Ford Global Technologies, Inc.
    Inventor: Edward Akpan
  • Patent number: 5774780
    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.
    Type: Grant
    Filed: November 22, 1995
    Date of Patent: June 30, 1998
    Assignee: Bayerische Metallwerke GmbH
    Inventor: Oliver Prause
  • Patent number: 5736092
    Abstract: A microwave susceptor bed useful for sintering ceramics, ceramic composites and metal powders is described. The susceptor bed includes granules of a major amount of a microwave susceptor material, and a minor amount of a refractory parting agent, either dispersed in the susceptor material, or as a coating on the susceptor material. Alumina is the preferred susceptor material. Carbon is the most preferred parting agent. Also described is a sintering process using the bed and to novel silicon nitride products produced thereby.
    Type: Grant
    Filed: June 17, 1996
    Date of Patent: April 7, 1998
    Assignee: Microwear Corporation
    Inventors: Prasad Shrikrishna Apte, Larry Roy Morris
  • Patent number: 5730925
    Abstract: In an apparatus for producing a three-dimensional object by laser sintering the object is produced by successive solidification of layers of a powder material at points corresponding to a cross-section of said object using radiation for solidifying said powder material. The apparatus includes a support having a substantially plane upper side for supporting the object, a material applying device for applying a layer of the material onto the upper side or onto another layer formed on the upper side, and a solidification device for solidifying a layer of the material by irradiation. The material applying device has a coating device and a drive for displacing the coating device in a direction parallel to the upper side of the support.
    Type: Grant
    Filed: April 18, 1996
    Date of Patent: March 24, 1998
    Assignee: EOS GmbH Electro Optical Systems
    Inventors: Thomas Mattes, Andreas Lohner, Christian Wilkening
  • Patent number: 5711866
    Abstract: 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: Grant
    Filed: May 9, 1995
    Date of Patent: January 27, 1998
    Assignee: The United States of America as represented by the Secretary of Commerce
    Inventors: David S. Lashmore, Moshe P. Dariel, Christian E. Johnson, Menahem B. Ratzker, Anthony A. Giuseppetti, Frederick C. Eichmiller, Glenn L. Beane, David R. Kelley
  • Patent number: 5701576
    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.
    Type: Grant
    Filed: January 22, 1996
    Date of Patent: December 23, 1997
    Assignee: Mazda Motor Corporation
    Inventors: Makoto Fujita, Yukio Yamamoto, Nobuo Sakate, Shoji Hirabara
  • Patent number: 5662863
    Abstract: A powder preform of aluminum alloy powder is subjected to a heating treatment and then to a compacting and hardening process under a pressure to produce a structural member of aluminum alloy. The aluminum alloy powder used is one having a non-equilibrium phase which shows a calorific value C in a range of C.gtoreq.10 J/g at a temperature-increasing rate of 20 K./min in a differential scanning calorimetry. In the heating treatment, the average temperature-rising rate R.sub.2 from a heat-generation starting temperature Tx (K.) of the aluminum alloy powder to Tx+A (wherein A.gtoreq.30 K.) is R.sub.2 .ltoreq.60 K./min. Thus, the change of the non-equilibrium phase in the powder preform is uniformly performed. In addition, the average temperature-increasing rate R.sub.4 from a processing temperature Tw (K.-B) in the compacting and hardening process to Tw (wherein B.gtoreq.30 K., and Tw-B>Tx+A) is R.sub.4 .gtoreq.60 K./min. Thus, the oxidation of the powder preform is reliably prevented.
    Type: Grant
    Filed: August 18, 1995
    Date of Patent: September 2, 1997
    Assignee: Honda Giken Kogyo Kabushiki Kaisha
    Inventors: Kenji Okamoto, Hiroyuki Horimura, Masahiko Minemi
  • Patent number: 5611978
    Abstract: Sintered moldings are produced by molding a mixture of a sinterable ceramic or metallic powder and polyoxymethylene or a copolymer containing a majority of oxymethylene units as binder to give a compact, removing the binder by treatment with a gaseous acid, and sintering the product, which comprises removing the binder using an acid which is solid at room temperature and sublimes or melts and evaporates at elevated temperatures.
    Type: Grant
    Filed: August 10, 1995
    Date of Patent: March 18, 1997
    Assignee: BASF Aktiengesellschaft
    Inventor: Peter Truebenbach
  • Patent number: 5590386
    Abstract: In a method of making alloy of tungsten and lanthana, lanthanum hydroxide is blended with tungsten metal powder, the mixture is pressed to form a pressed ingot, optionally presintered, and sintered to form the alloy. The use of lanthanum hydroxide as the source of the lanthana dopant allows the pressed or presintered ingots to be stored in air prior to sintering for prolonged periods without becoming degraded from exposure to atmospheric moisture.
    Type: Grant
    Filed: July 26, 1995
    Date of Patent: December 31, 1996
    Assignee: Osram Sylvania Inc.
    Inventors: Thomas J. Patrician, Harry D. Martin, III
  • Patent number: 5574954
    Abstract: A composite, a sintered product of the composite, and a process for producing products from this composite. The composite has a very high volummetric proportion of TiC, and its remainder of a matrix. The TiC constitutes at least 70% by volume and as much as 95% by volume of the ultimate product. The process includes making a green body which can be handled and is thereafter pre-sintered to form a pre-form. The pre-form is oversized relative to the ultimate product. It is sintered and machined, again oversize. Then it is again sintered and subjected to hot isostatic compression, to assume at least a close approximation to the pre-determined dimension of the product. It is characterized by its light weight, resistance to erosion, and resistance to chemical attack.
    Type: Grant
    Filed: June 4, 1992
    Date of Patent: November 12, 1996
    Assignee: Alloy Technology International, Inc.
    Inventor: Jayanti M. Panchal
  • Patent number: 5561834
    Abstract: A process for pneumatically isostatically compacting a sintered compact to densify the compact wherein the surface of the compact is oxidized to form a gas impervious oxide barrier on said surface before the compact is subjected to the pneumatic isostatic compaction process. Oxidation of the compact surface is preferably accomplished by steaming the compact before or after sintering.
    Type: Grant
    Filed: May 2, 1995
    Date of Patent: October 1, 1996
    Assignee: General Motors Corporation
    Inventor: David A. Score
  • Patent number: 5531958
    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.
    Type: Grant
    Filed: October 17, 1995
    Date of Patent: July 2, 1996
    Assignee: BASF Corporation
    Inventor: David C. Krueger
  • Patent number: 5523049
    Abstract: A heat sink composed of thermally conductive particles dispersed in a monolithic structure having a continuous microstructure; and the method of forming a heat sink by molding the heat sink from a thermoplastic or epoxy material which has been filled with thermally conductive particles, debinding the molded heat sink and densifying the debound heat sink into a monolithic structure.
    Type: Grant
    Filed: November 1, 1994
    Date of Patent: June 4, 1996
    Assignee: Iowa State University Research Foundation, Inc.
    Inventors: Robert L. Terpstra, Barbara K. Lograsso, Iver E. Anderson, Jeffrey A. Moore