Sintering Which Includes A Chemical Reaction Patents (Class 419/45)
  • Patent number: 9907183
    Abstract: This invention relates generally to uses of novel nanomaterial composition and the systems in which they are used, and more particularly to nanomaterial compositions generally comprising carbon and a metal, which composition can be exposed to pulsed emissions to react, activate, combine, or sinter the nanomaterial composition. The nanomaterial compositions can alternatively be utilized at ambient temperature or under other means to cause such reaction, activation, combination, or sintering to occur.
    Type: Grant
    Filed: October 5, 2016
    Date of Patent: February 27, 2018
    Assignee: NCC NANO, PLLC
    Inventors: Kurt A. Schroder, Steve McCool, Denny Hamill, Dennis Wilson, Wayne Furlan, Kevin Walter, Darrin Willauer, Karl Martin
  • Patent number: 9870862
    Abstract: A number of variations may include a method including providing a first powder comprising iron; compacting the first powder into a compacted powder product having a non-planar surface, wherein the compacting includes dynamic magnetic compaction or combustion driven compaction; and increasing the magnetic coercivity of at least one of the first powder or compact powder product.
    Type: Grant
    Filed: April 23, 2013
    Date of Patent: January 16, 2018
    Assignee: GM Global Technology Operations LLC
    Inventors: Shekhar G. Wakade, Yucong Wang, Edward P. Becker
  • Patent number: 8974719
    Abstract: A method of forming nano-structure composite materials that have a binder material and a nanostructure fiber material is described. A precursor material may be formed using a mixture of at least one metal powder and anchored nanostructure materials. The metal powder mixture may be (a) Ni powder and (b) NiAl powder. The anchored nanostructure materials may comprise (i) NiAl powder as a support material and (ii) carbon nanotubes attached to nanoparticles adjacent to a surface of the support material. The process of forming nano-structure composite materials typically involves sintering the mixture under vacuum in a die. When Ni and NiAl are used in the metal powder mixture Ni3Al may form as the binder material after sintering. The mixture is sintered until it consolidates to form the nano-structure composite material.
    Type: Grant
    Filed: February 12, 2010
    Date of Patent: March 10, 2015
    Assignee: Consolidated Nuclear Security, LLC
    Inventors: Roland D. Seals, Paul A. Menchhofer, Jane Y. Howe, Wei Wang
  • Patent number: 8955220
    Abstract: Methods of forming scroll compressor components are provided. The methods include forming at least one component of a scroll member from a powder metallurgy technique and joining the component with another distinct component via a sinter-brazing process. For example, a baseplate having a spiral scroll involute is joined to a hub via a joint interface having brazing material to form a braze joint with superior quality. At least one component is formed from a powder metal material including carbon and at least one species that reacts with or binds carbon to prevent migration during brazing of the sinter-brazing heat process. Optionally, during the powder metallurgy process, an alloy with a lower concentration of carbon is selected, which may be incorporated into a crystal structure with the species that prevents carbon migration.
    Type: Grant
    Filed: March 10, 2010
    Date of Patent: February 17, 2015
    Assignee: Emerson Climate Technologies, Inc.
    Inventors: Marc J. Scancarello, Roxana E. L. Ruxanda
  • Publication number: 20150037197
    Abstract: An oxygen source-containing composite nanometal paste including at least composite nanometal particles, in which an organic coating layer is formed around a submicron or smaller silver core, and an oxygen source, which feeds oxygen contributing to pyrolysis at a pyrolysis temperature range in which the organic coating layer is pyrolyzed. The oxygen source comprises an oxygen-containing metal compound, and the oxygen content of the oxygen source is within a range of 0.01 mass % to 2 mass % per 100 mass % of the composite nanometal particles.
    Type: Application
    Filed: February 20, 2013
    Publication date: February 5, 2015
    Inventor: Teruo Komatsu
  • Publication number: 20150030494
    Abstract: Methods and apparatus for producing an object, the method comprising: performing an Additive Manufacturing process to produce an intermediate object from provided metal or alloy, whereby the intermediate object comprises regions having a contaminant concentration level above a threshold level; based upon one or more parameters, determining a temperature and a duration; and performing, on the intermediate object, a contaminant dispersion process by, for a duration that is greater than or equal to the determined duration, heating the intermediate object to a temperature that is greater than or equal to the determined temperature and less than the melting point of the metal or alloy, the contaminant dispersion process being performed so as to disperse, within the intermediate object, a contaminant from regions of high contaminant concentration to regions of low contaminant concentration until the intermediate object comprises no regions having a contaminant concentration level above the threshold level.
    Type: Application
    Filed: February 20, 2013
    Publication date: January 29, 2015
    Inventor: Charles Malcolm WARD-CLOSE
  • Publication number: 20140370323
    Abstract: A method for increasing the resolution when forming a three-dimensional article through successive fusion of parts of a powder bed, said method comprising providing a vacuum chamber, providing an electron gun, providing a first powder layer on a work table inside said vacuum chamber, directing an electron beam from said electron gun over said work table causing the powder layer to fuse in selected locations to form a first cross section of said three-dimensional article, providing a second powder layer on said work table, directing the electron beam over said work table causing said second powder layer to fuse in selected locations to form a second cross section of said three-dimensional article, reducing the pressure in the vacuum chamber from a first pressure level to a second pressure level between the providing of said first powder layer and said second powder layer.
    Type: Application
    Filed: December 4, 2012
    Publication date: December 18, 2014
    Applicant: ARCAM AB
    Inventor: Ulf Ackelid
  • Patent number: 8802004
    Abstract: The invention relates to components which are produced or processed by powder metallurgy, and to processes for producing components of this type. The components produced by powder metallurgy are intended both to have porous regions and to provide fluid-tight properties, and it should also be possible to produce them at correspondingly low cost and suitably flexibly. For this purpose, a component of this type has at least one porous region, which is formed from an intermetallic phase or solid solutions. However, it may also have a corresponding surface coating. Moreover, in a component of this type there is at least one areal fluid-tight region which is formed from a meta or metal alloy of the corresponding intermetallic phase or solid solution.
    Type: Grant
    Filed: December 5, 2007
    Date of Patent: August 12, 2014
    Assignees: Alantum Corporation, Fraunhofer Gesellschaft zur Forderung der Angewandten Forschung E.V.
    Inventors: Dirk Naumann, Thomas Weissgarber, Alexander Bohm
  • Patent number: 8636947
    Abstract: The present invention provides an improved metal separator for a fuel cell and a method for preparing same. More particularly, the invention provides a metal separator for a fuel cell, whereby the separator has a surface structure that imparts reduced contact resistance, improved corrosion resistance, and stable electrical conductivity. The invention further provides a surface treatment method for making the metal separator of the invention. The inventive method comprises sintering Fe—Cr—B—V-based powder on the surface of a metal foam to form an alloy layer; and forming a nitride layer of a (Cr—V—B)N-based material while supplying nitrogen gas on the surface of the alloy layer.
    Type: Grant
    Filed: November 22, 2010
    Date of Patent: January 28, 2014
    Assignee: Hyundai Motor Company
    Inventors: Young Min Nam, Yoo Chang Yang, Suk Min Baeck, Seung Gyun Ahn
  • Patent number: 8568117
    Abstract: Scrolls made from one or more near-net shaped powder metal processes either wholly or fabricated together from sections. Both “conventional” press and sinter methods and metal injection molding methods will be described.
    Type: Grant
    Filed: November 5, 2010
    Date of Patent: October 29, 2013
    Assignee: Emerson Climate Technologies, Inc.
    Inventor: Marc J. Scancarello
  • Patent number: 8361381
    Abstract: A process for making a diffusion hardened medical implant having a porous surface is disclosed. The medical implant is made by a hot isostatic pressing process which simultaneously forms that porous surface and the diffusion hardened surface.
    Type: Grant
    Filed: July 21, 2009
    Date of Patent: January 29, 2013
    Assignee: Smith & Nephew, Inc.
    Inventors: Daniel A. Heuer, Vivek Pawar, Marcus Lee Scott, Shilesh C. Jani
  • 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
  • Publication number: 20120258008
    Abstract: The present invention relates to a method for controlling the carbon and/or oxygen content in a material by forming a feedstock composition comprising at least one powder, at least one platinum group metal and at least one binder; and forming the material by powder injection molding; wherein at least a proportion of the carbon and/or oxygen is catalytically removed by the at least one platinum group metal.
    Type: Application
    Filed: October 13, 2010
    Publication date: October 11, 2012
    Applicant: JOHNSON MATTHEY PUBLIC LIMITED COMPANY
    Inventor: Hugh Gavin Charles Hamilton
  • Patent number: 8273291
    Abstract: A controlled combustion synthesis apparatus comprises an ignition system, a pressure sensor for detecting internal pressure, a nitrogen supply, a gas pressure control valve for feeding nitrogen and exhausting reaction gas, means for detecting the internal temperature of the reaction container, a water cooled jacket, and a cooling plate. A temperature control system controls the temperature of the reaction container by controlling the flow of cooling water supplied to the jacket and the cooling plate in response to the detected temperature. By combustion synthesizing, while controlling the internal pressure and temperature, the apparatus can synthesize a silicon alloy including 30-70 wt. % silicon, 10-45 wt. % nitrogen, 1-40 wt. % aluminum, and 1-40 wt % oxygen.
    Type: Grant
    Filed: March 19, 2009
    Date of Patent: September 25, 2012
    Assignee: Sumikin Bussan Corporation
    Inventors: Toshiyuki Watanabe, Masafumi Matsushita, Toshitaka Sakurai, Kazuya Sato, Yoko Matsushita
  • Publication number: 20110318216
    Abstract: Disclosed herein is a method and gas atmosphere for a metal component in a continuous furnace. In one embodiment, the method and gas atmosphere comprises the use of an effective amount, or about 1 to about 10 percent volume of endo-gas, into an atmosphere comprising nitrogen and hydrogen. In another embodiment, there is provided a method sintering metal components in a furnace at a one or more operating temperatures comprising: providing a furnace comprising a belt comprising a wire mesh material wherein the metal components are supported thereupon; and sintering the components in the furnace in an atmosphere comprising nitrogen, hydrogen, and effective amount of endothermic gas at the one or more operating temperatures ranging from about 1800° F. to about 2200° F. wherein the amount of endothermic gas in the atmosphere is such that it is oxidizing to the wire mesh material and reducing to the metal components.
    Type: Application
    Filed: December 13, 2010
    Publication date: December 29, 2011
    Applicant: AIR PRODUCTS AND CHEMICALS, INC.
    Inventors: Donald James Bowe, Anna K. Wehr-Aukland, John Lewis Green
  • Publication number: 20110176952
    Abstract: The aim of the invention is to devise a binder that is an alternative to prior art binders for producing sintered molded articles. Said aim is achieved by a binder comprising a first substance that has a first melting point and a first vapor pressure at 80° C. and a second substance that has a second melting point and a second vapor pressure at 80° C., the maximum melting point of the first and second substance amounting to about 150° C., and the minimum vapor pressure of the first and second substance amounting to about 5 torr (667 Pa) at 80° C.
    Type: Application
    Filed: February 14, 2011
    Publication date: July 21, 2011
    Applicant: GKN SINTER METALS HOLDING GMBH
    Inventors: Vladislav Kruzhanov, Lars Wimbert, Nicola De Cristofaro
  • Publication number: 20110020164
    Abstract: The process for producing, processing, sintering, pressing or extruding thermoelectric materials with heat treatment under inert gas or under reduced pressure at temperatures in the range from 100 to 900° C. comprises producing, processing, sintering, pressing or extruding in the presence of oxygen scavengers which form thermodynamically stable oxides in the presence of free oxygen under the production, processing, sintering, pressing or extrusion conditions and hence keep free oxygen away from the thermoelectric material.
    Type: Application
    Filed: July 26, 2010
    Publication date: January 27, 2011
    Applicant: BASF SE
    Inventors: Madalina Andreea STEFAN, Frank Haass
  • Patent number: 7845918
    Abstract: Scrolls made from one or more near-net shaped powder metal processes either wholly or fabricated together from sections. Both “conventional” press and sinter methods and metal injection molding methods will be described.
    Type: Grant
    Filed: February 28, 2006
    Date of Patent: December 7, 2010
    Assignee: Emerson Climate Technologies, Inc.
    Inventor: Marc J Scancarello
  • Patent number: 7820097
    Abstract: This invention relates generally to uses of novel nanomaterial composition and the systems in which they are used, and more particularly to nanomaterial compositions generally comprising carbon and a metal, which composition can be exposed to pulsed emissions to react, activate, combine, or sinter the nanomaterial composition. The nanomaterial compositions can alternatively be utilized at ambient temperature or under other means to cause such reaction, activation, combination, or sintering to occur.
    Type: Grant
    Filed: November 23, 2005
    Date of Patent: October 26, 2010
    Assignee: NCC Nano, LLC
    Inventors: Kurt A. Schroder, Steve McCool, Denny Hamill, Dennis Wilson, Wayne Furlan, Kevin Walter, Darrin Willauer, Karl Martin
  • Patent number: 7718116
    Abstract: A method for obtaining a selectively non-carburized powdered metal part. The steps include compacting, sintering, removing, forging and cooling. A metal powder is compacted to form a preform having at least one first surface in which a forged part is required to have a case depth and at least one second surface in which a carburized portion is required to be removed prior to forging. The preform is then sintered and carburized. After carburizing the at least one second surface of the preform is removed and subsequently forged and cooled. The forged part has at least one second surface having improved post forging properties and at least one first surface having improved performance features. A part made from the present method is also provided.
    Type: Grant
    Filed: March 24, 2006
    Date of Patent: May 18, 2010
    Assignee: GKN Sinter Metals, Inc.
    Inventor: Timothy E. Geiman
  • 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: 7615185
    Abstract: After an alloy powder including W, Cr, at least one of Ti, Zr, and Hf, and at least one of V, Nb, and Ta is produced, the alloy powder, a powdery carbon material, and a catalyst are heat-treated in the presence of a nitrogen gas. The alloy powder is carbonitrided into a multicomponent ceramics powder, and sintered into a sintered body. Alternatively, a powder of a first substance including at least two of Ti, Al, V, Nb, Zr, Hf, Mo, Ta, Cr, and W is molded into a molded body. Then, the surface of the molded body is surrounded by a second substance including a metal element which is not contained in the powder of the first substance, and the molded body is heat-treated in an atmosphere in which N is present. A porous sintered body thus produced is crushed into a multicomponent ceramics powder.
    Type: Grant
    Filed: December 12, 2007
    Date of Patent: November 10, 2009
    Assignee: Honda Giken Kogyo Kabushiki Kaisha
    Inventor: Mitsuo Kuwabara
  • Patent number: 7601403
    Abstract: A method for preparing highly dense functional oxides with crystallite size in the range of 10-20 nm. Using a high pressure modification of a the Spark Plasma Sintering (SPS) technique, rapid thermal cycles (<10 min) coupled with very rapid pressure increase up to 1 GPa can be obtained allowing high degree of compaction and very limited grain growth. This combination of techniques was employed to produce the finest-grained ceramics ever prepared in bulk form in the case of fully stabilized zirconia and Sm-doped Ceria.
    Type: Grant
    Filed: April 15, 2005
    Date of Patent: October 13, 2009
    Assignee: The Regents of the University of California
    Inventors: Umberto Anselmi-Tamburini, Zuhair A. Munir, Javier E. Garay
  • Patent number: 7524475
    Abstract: A cerium oxide powder for one-component CMP slurry, which has a specific surface area of 5 m2/g or more, and a ratio of volume fraction of pores with a diameter of 3 nm or more to that of pores with a diameter less than 3 nm of 8:2˜2:8, is disclosed. A method for preparing the same, a one-component CMP slurry comprising the same as an abrasive material, and a method of shallow trench isolation using the one-component CMP slurry are also disclosed. The CMP slurry causes no precipitation of the cerium oxide powder even if it is provided as a one-component CMP slurry, because the CMP slurry uses, as an abrasive material, cerium oxide powder that is obtained via a low-temperature calcination step, optionally a pulverization step, and a high-temperature calcination step and has a high pore fraction and low strength.
    Type: Grant
    Filed: September 1, 2006
    Date of Patent: April 28, 2009
    Assignee: LG Chem, Ltd.
    Inventors: Seung Beom Cho, Jun Seok Nho, Dong Mok Shin, Jong Pil Kim, Myoung Hwan Oh, Jang Yul Kim, Eun Mi Choi, Min Jin Ko
  • Patent number: 7470393
    Abstract: Methods of fabricating cermet materials and methods of utilizing the same such as in filtering particulate and gaseous pollutants from internal combustion engines having intermetallic and ceramic phases. The cermet material may be made from a transition metal aluminide phase and an alumina phase. The mixture may be pressed to form a green compact body and then heated in a nitrogen-containing atmosphere so as to melt aluminum particles and form the cermet. Filler materials may be added to increase the porosity or tailor the catalytic properties of the cermet material. Additionally, the cermet material may be reinforced with fibers or screens. The cermet material may also be formed so as to pass an electrical current therethrough to heat the material during use.
    Type: Grant
    Filed: February 25, 2005
    Date of Patent: December 30, 2008
    Assignee: Battelle Energy Alliance, LLC
    Inventor: Peter C. Kong
  • Publication number: 20080170656
    Abstract: A method includes fabricating an energy detector using a sol-gel process.
    Type: Application
    Filed: January 16, 2007
    Publication date: July 17, 2008
    Inventor: Haochuan Jiang
  • Patent number: 7378053
    Abstract: The invention proposes a copper-based material with low thermal expansion and high thermal conductivity having good machinability and adaptability to nickel plating and also proposes a method for producing the same. The copper-based material is prepared through the steps of: adding 5 to 60% of iron-based alloy power having a certain value in thermal expansion coefficient into a matrix powder of pure copper phase powder and/or a precipitation hardening copper alloy powder; mixing the powders together; compacting the obtained powder mixture into a green compact and sintering it at temperatures of 400 to 600° C.
    Type: Grant
    Filed: April 27, 2004
    Date of Patent: May 27, 2008
    Assignee: Hitachi Powered Metals Co., Ltd.
    Inventor: Zenzo Ishijima
  • Patent number: 7374717
    Abstract: The present invention provides a method for efficiently producing an intermetallic compound porous material. Specifically, the invention provides a porous material production method comprising molding a mixed powder of at least two inorganic powders and performing a combustion synthesis reaction of the resulting molded mixed powder; wherein (1) the porous material contains an intermetallic compound, (2) the intermetallic compound has a three-dimensional network skeletal structure, and (3) the porous material has a relative density of not more than about 80%.
    Type: Grant
    Filed: March 21, 2005
    Date of Patent: May 20, 2008
    Assignees: Osu Corporation
    Inventor: Osamu Yamada
  • Publication number: 20080075620
    Abstract: A method for producing a sintered body is provided. The method for producing the sintered body comprising: forming a green body by molding a composition for forming a green body into a specified shape to obtain the green body, the composition comprising powder constituted of a metallic material and a binder containing a first resin which is decomposable by ozone; first debinding the green body by exposing the green body to a high ozone content atmosphere to decompose the first resin and remove the decomposed first resin form the green body to obtain a brown body; exposing the thus obtained brown body at least once to a low ozone content atmosphere whose ozone concentration is lower than an ozone concentration of the high ozone content atmosphere to obtain an intermediate brown body; and sintering the intermediate brown body which has been exposed to the low ozone content atmosphere to obtain the sintered body.
    Type: Application
    Filed: September 21, 2007
    Publication date: March 27, 2008
    Inventors: Masaaki Sakata, Junichi Hayashi
  • Publication number: 20080075622
    Abstract: A composition for forming a green body is provided. The composition for forming the green body contains powder constituted of a metallic material and a binder containing a first resin which is decomposable by ozone and a second resin which is also decomposable by ozone but decomposed later than the first resin. The green body formed of the composition is used in producing a brown body, wherein the brown body is produced by first exposing the green body to a high ozone content atmosphere to decompose the first resin and remove the decomposed first resin and then decompose the second resin and remove the decomposed second resin, and then at least once exposing the thus obtained green body to a low ozone content atmosphere whose ozone concentration is lower than an ozone concentration of the high ozone content atmosphere.
    Type: Application
    Filed: September 21, 2007
    Publication date: March 27, 2008
    Inventors: Masaaki Sakata, Junichi Hayashi
  • Patent number: 7273581
    Abstract: The present invention relates to an improved process for in-situ preparation of alumina-(Ti,Zr) borides composite. The present invention particularly relates to fast and in-situ process for synthesis and consolidation of Al2O3—Zr/Ti B2 composites of approximate-95% density with controlled grain-growth in the range of less than or the order of 5 micrometer or less grain size using a dynamic Self propagating high temperature synthesis (SHS) process.
    Type: Grant
    Filed: September 7, 2004
    Date of Patent: September 25, 2007
    Assignee: Council of Scientific and Industrial Research
    Inventors: Suman Kumari Mishra, Vladimir Andreevich Shcherbakov
  • Patent number: 7112302
    Abstract: The manufacturing methods according to the present teachings provide shape memory alloy products having both a uniform composition and a precise shape memory recovery temperature. In this manufacturing method, raw material powders (e.g., Ti and Ni powders) may be precisely mixed. Next, a compound may be synthesized from the raw material powder mixture using a combustion synthesis method. The combustion synthesized compound may be melted and cast into a desired shape (e.g., a shape of the final product or a shape close to that of the final product).
    Type: Grant
    Filed: May 20, 2004
    Date of Patent: September 26, 2006
    Assignees: Yoshimi Inc., MIE TLO Co., Ltd.
    Inventors: Yoshiharu Yoshimi, Yasushi Okumura, Masataka Tokuda
  • Patent number: 7086151
    Abstract: Scrolls made from one or more near-net shaped powder metal processes either wholly or fabricated together from sections. Both “conventional” press and sinter methods and metal injection molding methods will be described.
    Type: Grant
    Filed: January 20, 2004
    Date of Patent: August 8, 2006
    Assignee: Copeland Corporation
    Inventor: Marc J Scancarello
  • 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: 7048808
    Abstract: The present invention provides a rare-earth sintered magnet exhibiting desirable magnetic properties in which the amount of Nd and/or Pr forming a non-magnetic phase in a grain boundary phase is reduced. Specifically, the present invention provides a rare-earth sintered magnet having a composition of (R1x+R2y)T100-x-y-zQz where R1 is at least one element selected from the group consisting of all rare-earth elements excluding La (lanthanum), Y (yttrium) and Sc (scandium); R2 is at least one element selected from the group consisting of La, Y and Sc; T is at least one element selected from the group consisting of all transition elements; Q is at least one element selected from the group consisting of B and C, and including, as a main phase, a crystal grain of an Nd2Fe14B crystalline structure, wherein: molar fractions x, y and z satisfy 8?x?18 at %, 0.1?y?3.
    Type: Grant
    Filed: October 1, 2001
    Date of Patent: May 23, 2006
    Assignee: Neomax Co., Ltd.
    Inventors: Yuji Kaneko, Katsuya Taniguchi, Takao Sekino
  • Patent number: 6926969
    Abstract: The invention relates to a process for the production of sintered porous bodies, to porous bodies produced correspondingly using the process, and to their use. With the solution according to the invention, sintered bodies which achieve improved properties, such as an increased surface area, deformability of the structures at room temperature or modification of the initial pore volume, are to be produced. To this end, at least one sintering-active powder which forms at least one intermetallic phase or mixed crystals is applied to the surface of a porous basic body. Heat treatment is to be carried out subsequently, in which intermetallic phases or mixed crystals which increase the specific surface area can be formed.
    Type: Grant
    Filed: October 4, 2002
    Date of Patent: August 9, 2005
    Assignees: Inco Limited, Fraunhofer-Gesellschaft zur Forderung der angewandten Forschung e. V.
    Inventors: Alexander Bohm, Hartmut Gohler, Dirk Naumann
  • 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
  • Patent number: 6916355
    Abstract: A composite material 5 in which a dispersing material 7 is dispersed in a matrix 6 is provided. The composite material 5 is producible by steps of filling said mixed material in a space forming region to be defined by at least two container elements when said at least two container elements are integrated into one body, and then infiltrating said aluminum (Al) being molten due to heat generated by said self-combustion reaction into pores inside said mixed material through at least one hole formed in an upper part of a reaction container formed by combining said at least two container elements in which said mixed material is filled in said space forming region in a state being fixed to a predetermined shape, thereby an aluminide intermetallic compound is formed by self-combustion reaction between said metal powder and said aluminum (Al), and a dispersing material is dispersed into said matrix.
    Type: Grant
    Filed: November 19, 2002
    Date of Patent: July 12, 2005
    Assignee: NGK Insulators, Ltd.
    Inventors: Masahiro Kida, Takahiro Ishikawa, Masayuki Shinkai, Takatoshi Ikematsu
  • Patent number: 6899845
    Abstract: A formed body prepared by compacting tungsten powders is embedded in a powder mixture capable of performing combustion synthesis, a part of the powder mixture is powerfully heated to ignite the part and perform combustion synthesis, by the heat of formation released, a temperature of a formed body is instantaneously elevated to induce a sintering reaction, and a high temperature state is retained to convert a whole of the formed body into sintered tungsten.
    Type: Grant
    Filed: March 12, 2003
    Date of Patent: May 31, 2005
    Assignee: National Institute for Materials Science
    Inventor: Yoshinari Kaieda
  • Patent number: 6896846
    Abstract: A method for synthesis of biomedical alloys has been developed based on combustion phenomena. This low pressure combustion synthesis (LPCS) technique may be used for production of Co-based and other metal-based alloys, which cover the entire range of orthopaedic implants, including total hip and knee replacements, as well as hone screws, plates, and wires. A unique aspect of the method is that combustion synthesis under low ambient gas pressure allows one to produce pore-free (>99% theoretical density) alloys with high purity and precise chemical and phase compositions.
    Type: Grant
    Filed: October 31, 2002
    Date of Patent: May 24, 2005
    Assignee: University of Notre Dame
    Inventors: Arvind Varma, Alexander Mukasyan, Bing-Yun Li
  • Patent number: 6896845
    Abstract: W powders and C powders are mixed at a ratio of 1:1, the raw material mixed powder is compacted to prepare a formed body, the formed body is embedded into a powder mixture capable of performing combustion synthesis, a part of the powder mixture is powerfully heated to ignite the part and perform combustion synthesis, and according to heat of formation released, a reaction represented by W+C?WC is induced and the reaction is subjected to combustion synthesis to convert a whole of the formed body into sintered WC.
    Type: Grant
    Filed: March 12, 2003
    Date of Patent: May 24, 2005
    Assignee: National Institute for Materials Science
    Inventor: Yoshinari Kaieda
  • Patent number: 6858176
    Abstract: The invention relates to a method for sintering ferroalloy materials in a continuously operated band sintering process, in which method the pellets to be sintered are arranged on the sintering underlay as an essentially even pellet bed, which pellet bed is conveyed on the sintering underlay through the various steps of the sintering process, and in connection with the sintering process, gas is conducted through the pellet bed. According to the invention, at least the major part of the carbon-bearing material needed for heating the pellet bed up to the sintering temperature is fed onto the surface of ready-made pellets prior to bringing the pellets to the sintering step.
    Type: Grant
    Filed: December 1, 2000
    Date of Patent: February 22, 2005
    Assignee: Outokumpu Oyj
    Inventors: Helge Krogerus, Päivi Oikarinen, Timo Lintumaa, Esko Lamula
  • Patent number: 6805971
    Abstract: A method for forming a metallic coating on a substrate comprising an intermetallic compound, and the coatings made by this method are disclosed. The method broadly comprises forming an alloyed agglomerate from a precursor comprising at least two metals suitable for forming an intermetallic compound and depositing a coating of the partially converted agglomerate onto a roughened surface of a substrate.
    Type: Grant
    Filed: May 2, 2002
    Date of Patent: October 19, 2004
    Inventors: George E. Talia, Fred J. Callahan
  • Patent number: 6767505
    Abstract: A gas operated part forming die apparatus has compact high tonnage presses which are operated by high pressure gas generated within chambers and controlled to operate high pressure pistons and dies for compressing particulate material into dense formed parts. Combustion chambers are filled with pressurized mixtures of combustible gases and diluents. Elongated chambers have insulating walls and spaced electrodes. Some contain liquid or particulate ablatable materials or ablatable liners. Others extend fuzes between the electrodes and are filled with pressurized gases. Gas is removed from the particulate material. Die cavities may be precompressed during filing of chambers with pressurized gas. Igniting the combustible gases or creating arcs between the electrodes produces rapidly expanding high pressure resultant gases for driving pistons and movable dies and rapidly compressing die cavities. Pressures in the chambers are contained, or pistons are restrained until releasing and driving the pistons.
    Type: Grant
    Filed: July 12, 2001
    Date of Patent: July 27, 2004
    Assignee: Utron Inc.
    Inventors: F. Douglas Witherspoon, Dennis W. Massey, T. Arul Mozhi, David L. Kruczynski, John M. Ryan
  • Patent number: 6723280
    Abstract: A method of providing a resistance to oxidation of Nickel at high temperatures by combining Ni powder with five percent Pt resinate, and heating the same to a temperature of 500° C. to 1300° C. Electro-conductive components serving as electrodes and the like comprise a Ni/Pt powder subjected to temperatures of between 500° C. and the respective melting points of Ni and Pt.
    Type: Grant
    Filed: January 15, 2002
    Date of Patent: April 20, 2004
    Assignee: Vishay Vitramon Incorporated
    Inventor: Vito A. Coppola
  • Publication number: 20040052673
    Abstract: A method for producing fine or ultra fine powder particles comprising mixing a metal alkoxide with a non-metallic hydride in an organic solvent, agitating the mixed solution, and then burning the mixed solution. The burning process comprises igniting the solution directly or burning the solution in situ. A self-sustaining flame will result. When the precursor solution burns, the metallic compound will be co-fired with the organic solvent. As a result, fine or ultra fine particles of mixed metal will burst from the flame, or thrust through the flame and be synthesized.
    Type: Application
    Filed: July 17, 2003
    Publication date: March 18, 2004
    Inventor: Fukuo Huang
  • Patent number: 6682780
    Abstract: A method for protecting low-carbon steel and stainless steel from coking and corrosion at elevated temperatures in corrosive environments, such as during ethylene production by pyrolysis of hydrocarbons or the reduction of oxide ores, by coating the stainless steel with a coating of MCrAlXSiT in which M is nickel, cobalt, iron or a mixture thereof, X is yttrium, hafnium, zirconium, lanthanum, scandium or combination thereof, and T is tantalum, titanium, platinum, palladium, rhenium, molybdenum, tungsten, niobium, boron or combination thereof. A blended powder composition to produce a desired MCrAlXSiT surface alloy may be applied to the substrate. The overlay coating and stainless steel substrate preferably are heat-treated at about 1000 to 1200° C. for about 10 minutes or longer effective to metallurgically bond the overlay coating to the substrate and to form a multiphased microstructure.
    Type: Grant
    Filed: May 22, 2002
    Date of Patent: January 27, 2004
    Assignee: Bodycote Metallurgical Coatings Limited
    Inventors: Konstantin K. Tzatzov, Alexander S. Gorodetsky, Andrew Wysiekierski, Gary Anthony Fisher
  • Patent number: 6620375
    Abstract: Disclosed is a method of making a composite diamond having a cutting edge comprising a diamond compact bonded to a cemented carbide substrate, the diamond compact having a working surface, an edge of which provides the cutting edge, wherein the diamond compact comprises a first phase containing a polycrystalline mass of diamond particles and a second phase containing a diamond catalyst/solvent and ruthenium, which method includes the steps of providing a cemented carbide substrate, providing a layer of diamond particles on a surface of the substrate, providing a source of diamond catalyst/solvent and ruthenium, wherein the source of the diamond catalyst/solvent and ruthenium is the cemented carbide substrate.
    Type: Grant
    Filed: December 5, 2000
    Date of Patent: September 16, 2003
    Inventors: Klaus Tank, Noel John Pipkin, Johan Myburgh
  • Patent number: 6613276
    Abstract: Alloys of transition metal suicides that contain one or more alloying elements are fabricated by a two-stage process involving mechanical activation as the first stage and densification and field-activated reaction as the second stage. Mechanical activation, preferably performed by high-energy planetary milling, results in the incorporation of atoms of the alloying element(s) into the crystal lattice of the transition metal, while the densification and field-activated reaction, preferably performed by spark plasma sintering, result in the formation of the alloyed transition metal silicide. Among the many advantages of the process are its ability to accommodate materials that are incompatible in other alloying methods.
    Type: Grant
    Filed: April 16, 2002
    Date of Patent: September 2, 2003
    Assignee: The Regents of the University of California
    Inventors: Zuhair A. Munir, Joseph N. Woolman, John J. Petrovic
  • Patent number: 6582651
    Abstract: A process for forming a shaped metallic article, including the steps of combining the starting materials, forming the starting materials into a shape to produce a nonmetallic metal precuror article of a certain geometry, and converting the nonmetallic article to a metallic article by reduction or decomposition, while substantially retaining the geometry of the nonmetallic article. The forming step in which the starting materials are fabricated into a shape can include extrusion, dry pressing, or slurry casting. Further, another embodiment is a metallic article produced by converting a nonmetallic article with a certain geometry, including a plurality of open-ended channels, substantially to the same geometry as the nonmetallic article from which it was converted.
    Type: Grant
    Filed: June 9, 2000
    Date of Patent: June 24, 2003
    Assignee: Geogia Tech Research Corporation
    Inventors: Joe Kennedy Cochran, Jr., Kon Juin Lee, Thomas H. Sanders, Jr.