Heat And Pressure Simultaneously To Effect Sintering Patents (Class 419/48)
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Patent number: 11103926Abstract: An inventive method is provided for synthesizing an intermetallic compound. According to exemplary inventive practice, two metallic elements are weighed out in quantities corresponding to their molecular weights in an intermetallic compound of interest. The two metallic elements are mixed together to produce a metallic mixture in powder form. According to many inventive embodiments, a ball-mill device is implemented to thoroughly or intimately mix the two metallic elements into a fine powder. The powdered metallic mixture is exothermically reacted to produce an at least substantially pure intermetallic compound in powder form. According to many inventive embodiments, the exothermic reaction is brought about in a vacuous or inert-gaseous (e.g., helium) environment through electrification of a tungsten wire filament that is completely embedded in the powdered metallic mixture.Type: GrantFiled: March 7, 2018Date of Patent: August 31, 2021Assignee: The United States of America, as represented by the Secretary of the NavyInventors: William A. Ferrando, Mark M. Opeka, James A. Zaykoski
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Patent number: 10926334Abstract: A powder metal composition for high wear and temperature applications is made by atomizing a melted iron based alloy including 3.0 to 7.0 wt. % carbon; 10.0 to 25.0 wt. % chromium; 1.0 to 5.0 wt. % tungsten; 3.5 to 7.0 wt. % vanadium; 1.0 to 5.0 wt. % molybdenum; not greater than 0.5 wt. % oxygen; and at least 40.0 wt. % iron. The high carbon content reduces the solubility of oxygen in the melt and thus lowers the oxygen content to a level below which would cause the carbide-forming elements to oxidize during atomization. The powder metal composition includes metal carbides in an amount of at least 15 vol. %. The microhardness of the powder metal composition increases with increasing amounts of carbon and is typically about 800 to 1,500 Hv50.Type: GrantFiled: January 27, 2020Date of Patent: February 23, 2021Assignee: Tenneco Inc.Inventors: Philippe Beaulieu, Denis B. Christopherson, Jr., Leslie John Farthing, Todd Schoenwetter, Gilles L'Espérance
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Patent number: 10569362Abstract: A method of making a component includes depositing a metallic powder on a workplane; directing a beam from a directed energy source to fuse the powder in a pattern corresponding to a cross-sectional layer of the component; repeating in a cycle the steps of depositing and fusing to build up the component in a layer-by layer fashion; and during the cycle of depositing and melting, using an external heat control apparatus separate from the directed energy source to maintain a predetermined temperature profile of the component, such that the resulting component has a directionally-solidified or single-crystal microstructure.Type: GrantFiled: November 12, 2014Date of Patent: February 25, 2020Assignee: General Electric CompanyInventors: Todd Jay Rockstroh, Michael Francis Xavier Gigliotti, William Thomas Carter, David Henry Abbott, Rajendra Machukar Kelkar
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Patent number: 10202820Abstract: A lightweight, selectively degradable composite material includes a compacted powder mixture of a first powder and a second powder. The first powder comprises first metal particles comprising Mg, Al, Mn, or Zn, having a first particle oxidation potential. The second powder comprises low-density ceramic, glass, cermet, intermetallic, metal, polymer, or inorganic compound second particles. At least one of the first particles and the second particles includes a metal coating layer of a coating material disposed on an outer surface having a coating oxidation potential that is different than the first particle oxidation potential. The compacted powder mixture has a microstructure comprising: a matrix comprising the first metal particles; the second particles dispersed within the matrix; and a network comprising interconnected adjoining metal coating layers that extends throughout the matrix, the lightweight, selectively degradable composite material having a density of about 3.5 g/cm3 or less.Type: GrantFiled: December 17, 2014Date of Patent: February 12, 2019Assignee: BAKER HUGHES, A GE COMPANY, LLCInventors: Zhiyue Xu, Bobby J. Salinas, Zhihui Zhang
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Patent number: 10183331Abstract: A method manufactures a metal alloy part by spark plasma sintering. The method includes the simultaneous application, inside a die, of a uniaxial pressure and of an electric current to a powder component material that has the following composition: 42 to 49% aluminum, 0.05 to 1.5% boron, at least 0.2% of at least one element selected from tungsten, rhenium and zirconium, optionally 0 to 5% of one or more elements selected from chromium, niobium, molybdenum, silicon and carbon, the balance being titanium and the total of the elements without aluminum and titanium being between 0.25 and 12%.Type: GrantFiled: June 11, 2014Date of Patent: January 22, 2019Assignees: CENTRE NATIONAL DE LA RECHERCHE SCIENTIFIQUE—CNRS—, ONERA (OFFICE NATIONAL D'ETUDES ET DE RECHERCHES AÉROSPATIALES)Inventors: Alain Couret, Jean-Philippe Monchoux, Marc Thomas, Thomas Voisin
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Patent number: 10173930Abstract: In one aspect, sintered ceramic bodies are described herein which, in some embodiments, demonstrate improved resistance to wear and enhanced cutting lifetimes. For example, a sintered ceramic body comprises tungsten carbide (WC) in an amount of 40-95 weight percent, alumina in an amount of 5-30 weight percent and ditungsten carbide (W2C) in an amount of at least 1 weight percent.Type: GrantFiled: July 5, 2017Date of Patent: January 8, 2019Assignee: KENNAMETAL INC.Inventors: Jason Goldsmith, Sheng Chao
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Patent number: 10138913Abstract: A cartridge assembly having a chamber for containing hydraulic fluid, an intensifier element capable of reciprocating in the chamber and displacing the hydraulic fluid responsive to a drive system acting on the intensifier element, and a piston capable of reciprocating in the chamber and being displaceable responsive to a change in the pressure of the hydraulic fluid. The cartridge assembly is configured so that when the pressure in the fluid increases responsive to a first force being applied by the drive system on the intensifier, the hydraulic fluid will exert a second force on the piston, the second force being greater than the first force; the mass of the hydraulic fluid being substantially conserved within the cartridge assembly.Type: GrantFiled: March 22, 2013Date of Patent: November 27, 2018Assignee: Element Six LimitedInventors: Maximilian Voggenreiter, Thomas Heinrich Voggenreiter, Michael Martin Petri
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Patent number: 9903212Abstract: A method of manufacturing an assembly (10), including: positioning a first component (12) and a second component (14) in a desired positional relationship with each other; and building-up a locking component (16) by depositing layer after layer of material onto a surface (24, 26) of the assembly until a completed locking component is formed in-situ that holds the first component and the second component in the desired positional relationship.Type: GrantFiled: July 30, 2013Date of Patent: February 27, 2018Assignee: SIEMENS AKTIENGESELLSCHAFTInventor: Allister William James
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Patent number: 9709058Abstract: A compressor includes a closed container, a compression element disposed in the closed container, and a motor disposed in the closed container to drive the compression element via a shaft. The compression element includes a first and second bearings supporting the shaft. At least one cylinder having at least one cylinder chamber is disposed between the first and second bearings, with at least one roller fitted to the shaft disposed in the at least one cylinder chamber. The first bearing is disposed closer to the motor than the second bearing. The first and second bearings have first and second annular grooves formed in first and second opposing surfaces opposed to end faces of the at least one roller. The first and second annular grooves are opened to the at least one cylinder chamber. A width of the second annular groove is larger than a width of the first annular groove.Type: GrantFiled: August 29, 2012Date of Patent: July 18, 2017Assignee: Daikin Industries, Ltd.Inventors: Takehiro Kanayama, Naoto Tomioka, Yuuichirou Watanabe
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Patent number: 9707607Abstract: Disclosed is an impact extrusion can making system that uses induction heating to preheat an extruder punch and an extruder forming die, to increase yield during a cold start. In addition, a highly precise laser measuring device is used to measure dome thickness, so that stroke length and/or position of an extruder and/or extrusion die can be automatically adjusted in a predictive control system. High quality products with high yield are produced using these techniques.Type: GrantFiled: October 24, 2014Date of Patent: July 18, 2017Assignee: Integrated Packaging Solutions, LLCInventors: Michael W. Calahan, Kevin M. Gillest
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Patent number: 9701587Abstract: Provided is a method for producing an inorganic fiber-bonded ceramic material, which can produce, at a high yield, an inorganic fiber-bonded ceramic material with fewer defects, and with an end part and a central part equivalent to each other in microstructure and mechanical properties, and also makes it possible to increase the ceramic material in size. The method for producing an inorganic fiber-bonded ceramic material is characterized in that it includes: a first pressing step of setting, in a carbon die, a laminate to be surrounded by a ceramic powder, the laminate obtained by stacking a coated inorganic fiber shaped product including an inorganic fiber part of inorganic fibers that have a pyrolysis initiation temperature of 1900° C. or lower, and a surface layer of an inorganic substance for bonding the inorganic fibers to each other, and pressing the laminate at a temperature of 1000 to 1800° C.Type: GrantFiled: March 21, 2013Date of Patent: July 11, 2017Assignee: Ube Industries, Ltd.Inventors: Kenji Matsunaga, Shinji Kajii, Shohei Suizu, Tsutomu Kodama
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Patent number: 9199308Abstract: One embodiment of the invention may include a method of producing a composite article comprising a container, filling the container with a powdered metal, and compacting the powdered metal in the container such that an interfacial bond is created between the compacted powdered metal and the container.Type: GrantFiled: September 20, 2011Date of Patent: December 1, 2015Assignee: GM Global Technology Operations LLCInventors: Chongmin Kim, Anil K. Sachdev
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Patent number: 9079246Abstract: A method of making a powder metal compact is disclosed. The method includes forming a coated metallic powder comprising a plurality of coated metallic powder particles having particle cores with nanoscale metallic coating layers disposed thereon, wherein the metallic coating layers have a chemical composition and the particle cores have a chemical composition that is different than the chemical composition of the metallic coating layers. The method also includes applying a predetermined temperature and a predetermined pressure to the coated powder particles sufficient to form a powder metal compact by solid-phase sintering of the nanoscale metallic coating layers of the plurality of coated powder particles to form a substantially-continuous, cellular nanomatrix of a nanomatrix material, a plurality of dispersed particles dispersed within the cellular nanomatrix and a solid-state bond layer extending throughout the cellular nanomatrix.Type: GrantFiled: December 8, 2009Date of Patent: July 14, 2015Assignee: Baker Hughes IncorporatedInventors: Zhiyue Xu, Gaurav Agrawal, Bobby Salinas
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Patent number: 9011763Abstract: The present invention is generally directed to nanocomposite thermoelectric materials that exhibit enhanced thermoelectric properties. The nanocomposite materials include two or more components, with at least one of the components forming nano-sized structures within the composite material. The components are chosen such that thermal conductivity of the composite is decreased without substantially diminishing the composite's electrical conductivity. Suitable component materials exhibit similar electronic band structures. For example, a band-edge gap between at least one of a conduction band or a valence band of one component material and a corresponding band of the other component material at interfaces between the components can be less than about 5kBT, wherein kB is the Boltzman constant and T is an average temperature of said nanocomposite composition.Type: GrantFiled: September 20, 2012Date of Patent: April 21, 2015Assignees: Massachusetts Institute of Technology, Trustees of Boston CollegeInventors: Gang Chen, Mildred Dresselhaus, Zhifeng Ren
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Patent number: 8961647Abstract: The invention is a process for manufacturing a nano aluminum/alumina metal matrix composite and composition produced therefrom. The process is characterized by providing an aluminum powder having a natural oxide formation layer and an aluminum oxide content between about 0.1 and about 4.5 wt. % and a specific surface area of from about 0.3 and about 5 m2/g, hot working the aluminum powder, and forming a superfine grained matrix aluminum alloy. Simultaneously there is formed in situ a substantially uniform distribution of nano particles of alumina. The alloy has a substantially linear property/temperature profile, such that physical properties such as strength are substantially maintained even at temperatures of 250° C. and above.Type: GrantFiled: December 4, 2012Date of Patent: February 24, 2015Inventors: Thomas G. Haynes, III, Martin Walcher, Martin Balog
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Patent number: 8961719Abstract: A method for making a treated super-hard structure, the method including providing a super-hard structure comprising super-hard material selected from polycrystalline cubic boron nitride (PCBN) material or thermally stable polycrystalline diamond (PCD) material; subjecting the super-hard structure to heat treatment at a treatment temperature of greater than 700 degrees centigrade at a treatment pressure at which the super-hard material is not thermodynamically stable, for a treatment period of at least about 5 minutes to produce the treated super-hard structure.Type: GrantFiled: May 25, 2012Date of Patent: February 24, 2015Assignee: Element Six LimitedInventors: Stig Åke Andersin, Bernd Heinrich Ries, Frank Friedrich Lachmann, Lars-Ivar Nilsson
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Patent number: 8951465Abstract: A method for preparing an implant having a porous metal component. A loose powder mixture including a biocompatible metal powder and a spacing agent is prepared and compressed onto a metal base. After being compressed, the spacing agent is removed, thereby forming a compact including a porous metal structure pressed on the metal base. The compact is sintered, forming a subassembly, which is aligned with a metal substrate portion of an implant. A metallurgical bonding process, such as diffusion bonding, is performed at the interface of the subassembly and the metal substrate to form an implant having a porous metal component.Type: GrantFiled: February 25, 2013Date of Patent: February 10, 2015Assignee: Biomet Manufacturing, LLCInventor: Gautam Gupta
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Publication number: 20150034483Abstract: Provided is a Fe—Co-based alloy sputtering target material having a composition represented as an atomic ratio by the compositional formula: (Fea—Co100-a)100-b-c-d—Tab—Nbc-Md, wherein 0<a?80, 0?b?10, 0?c?15, 5?b+c?15, 2?d?20, 15?b+c+d?25, and M represents one or more elements selected from the group consisting of Mo, Cr and W, with the balance consisting of unavoidable impurities, wherein the sputtering target material has a bending fracture strain ?fB at 300° C. of 0.4% or more.Type: ApplicationFiled: May 30, 2013Publication date: February 5, 2015Inventors: Jun Fukuoka, Kazuya Saito, Kouichi Sakamaki, Tomoyuki Hata
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Publication number: 20140377120Abstract: A method of manufacturing a thermoelectric material comprising: ball-milling a compound comprising a plurality of components, the first component M comprising at least one of a rare earth metal, an actinide, an alkaline-earth metal, and an alkali metal, the second component T comprising a metal of subgroup VIII, and the third component X comprises a pnictogen atom. The compound may be ball-milled for up to 5 hours, and then thermo-mechanically processed by, for example, hot pressing the compound for less than two hours. Subsequent to the thermo-mechanical processing, the compound comprises a single filled skutterudite phase with a dimensionless figure of merit (ZT) above 1.0 and the compound has a composition following a formula of MT4X12.Type: ApplicationFiled: June 19, 2014Publication date: December 25, 2014Inventors: Qing Jie, Zhifeng Ren
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Publication number: 20140356218Abstract: A method for producing a high speed steel that with reference to its chemical composition consists of the following elements: 1-3 wt-% carbon (C), 3-6 wt-% chromium (Cr), 0-7 wt-% molybdenum (Mo), 0-15 wt-% tungsten (W), 3-14 wt-% vanadium (V), 0-10 wt-% cobalt (Co), 0-3 wt-% niobium (Nb), 0-0.5 wt-% nitrogen (N), 0.2-1 wt-% yttrium (Y), and remainder iron (Fe) and unavoidable impurities, and wherein Mo+0.5W=2-10 weight %, characterized in that the method comprises the steps of: providing a powder comprising the elements of the high speed steel, forming a body of the powder, and subjecting the body to elevated heat and pressure such that a consolidation of the powder thereof is achieved.Type: ApplicationFiled: September 19, 2012Publication date: December 4, 2014Applicant: SANDVIK INTELLECTUAL PROPERTY ABInventor: Tomas Berglund
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Publication number: 20140346038Abstract: Provided are a crystalline alloy having significantly better thermal stability than an amorphous alloy as well as glass-forming ability, and a method of manufacturing the crystalline alloy. The present invention also provides an alloy sputtering target that is manufactured by using the crystalline alloy, and a method of manufacturing the alloy target. According to an aspect of the present invention, provided is a crystalline alloy having glass-forming ability which is formed of three or more elements having glass-forming ability, wherein the average grain size of the alloy is in a range of 0.1 ?m to 5 ?m and the alloy includes 5 at % to 20 at % of aluminum (Al), 15 at % to 40 at % of any one or more selected from copper (Cu) and nickel (Ni), and the remainder being zirconium (Zr).Type: ApplicationFiled: December 4, 2012Publication date: November 27, 2014Inventors: Seung-Yong Shin, Kyoung-Il Moon, Ju-Hyun Sun, Chang-Hun Lee
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Publication number: 20140334964Abstract: Titanium alloy containing iron, that is, iron-containing titanium alloy having high strength and hardness in which iron in a composition which cannot be realized in a conventional method, is contained with no segregation, and is provided in lower cost. The ?+? titanium alloy or ? titanium alloy is produced by a forming process such as hot extrusion of titanium alloy powder containing 3 to 15 mass % of iron powder. The method for production of the ?+? titanium alloy or ? titanium alloy includes a step of mixing 3 to 15 mass % of iron powder and titanium alloy powder as the remainder, and a step of performing a forming process of hot extrusion on this powder mixture.Type: ApplicationFiled: December 16, 2011Publication date: November 13, 2014Inventors: Osamu Kanou, Satoshi Sugawara, Hideo Takatori
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Patent number: 8883047Abstract: Compositions related to skutterudite-based thermoelectric materials are disclosed. Such compositions can result in materials that have enhanced ZT values relative to one or more bulk materials from which the compositions are derived. Thermoelectric materials such as n-type and p-type skutterudites with high thermoelectric figures-of-merit can include materials with filler atoms and/or materials formed by compacting particles (e.g., nanoparticles) into a material with a plurality of grains each having a portion having a skutterudite-based structure. Methods of forming thermoelectric skutterudites, which can include the use of hot press processes to consolidate particles, are also disclosed. The particles to be consolidated can be derived from (e.g., grinded from), skutterudite-based bulk materials, elemental materials, other non-Skutterudite-based materials, or combinations of such materials.Type: GrantFiled: April 30, 2009Date of Patent: November 11, 2014Assignees: Massachusetts Institute of Technology, Trustees of Boston CollegeInventors: Zhifeng Ren, Jian Yang, Xiao Yan, Qinyu He, Gang Chen, Qing Hao
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Patent number: 8845956Abstract: The disclosure relates to a method for production of a component, such as a contact piece, for a switchgear assembly. To introduce a slot and apply a contact outer contour directly during the powder-metallurgical production process of the contact material, contouring in the form of a slot or slots is introduced into the powder-metal material, which is located in a mold, essentially in a direction parallel to a normal to a surface of the component, to form the component with a slot.Type: GrantFiled: November 30, 2009Date of Patent: September 30, 2014Assignee: ABB Technology AGInventors: Dietmar Gentsch, Guenter Pilsinger
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Patent number: 8834785Abstract: A method for producing a metal article according to one embodiment may involve the steps of: Providing a composite metal powder including a substantially homogeneous dispersion of molybdenum and molybdenum disulfide sub-particles that are fused together to form individual particles of the composite metal powder; and compressing the molybdenum/molybdenum disulfide composite metal powder under sufficient pressure to cause the mixture to behave as a nearly solid mass.Type: GrantFiled: July 11, 2011Date of Patent: September 16, 2014Assignee: Climax Engineered Materials, LLCInventors: Matthew C. Shaw, Carl V. Cox, Yakov Epshteyn
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Patent number: 8795489Abstract: [Problems] To provide a sputtering target that is capable of forming a Cu—Ga film to which Na is favorably added by a sputtering method, and a method for producing the same. [Means for Solving the Problems] The sputtering target is provided wherein 20 to 40 at % of Ga and 0.05 to 1 at % of Na are contained as metal components except fluorine (F) of the sputtering target, a remaining portion has a component composition consisting of Cu and unavoidable impurities, and Na is contained in the state of a NaF compound. Also, a method for producing the sputtering target includes the steps of forming a molded article consisting of a mixed powder of NaF powder and Cu—Ga powder or a mixed powder of NaF powder, Cu—Ga powder, and Cu powder; and sintering the molded article in a vacuum atmosphere, an inert gas atmosphere, or a reducing atmosphere.Type: GrantFiled: November 4, 2010Date of Patent: August 5, 2014Assignee: Mitsubishi Materials CorporationInventors: Shoubin Zhang, Yoshinori Shirai
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Patent number: 8795585Abstract: There is provided cryogenic milled nanophase copper alloys and methods of making the alloys. The alloys are fine grained having grains in the size range from about 2 to about 100 nanometers, and greater. The nanophase alloys possess desirable physical properties stemming from the fine grain size, such as potentially high strength. Some embodiments of the cryogenic milled copper alloys may also be tailored for ductility, toughness, fracture resistance, corrosion resistance, fatigue resistance and other physical properties by balancing the alloy composition. In addition, embodiments of the alloys generally do not require extensive or expensive post-cryogenic milling processing.Type: GrantFiled: December 21, 2006Date of Patent: August 5, 2014Assignee: The Boeing CompanyInventors: Barun Majumdar, James D. Cotton, Clifford C. Bampton
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Patent number: 8790438Abstract: A colored metal composite including a metal matrix; and colored particles distributed throughout the metal matrix AND/OR a method including providing metal powder as a first phase of a composite; providing colored particles to form a second phase of the composite; mixing the metal powder and colored particles; and sintering the metal powder around the colored particles to form a metal matrix that has colored particles distributed throughout.Type: GrantFiled: December 29, 2009Date of Patent: July 29, 2014Assignee: Nokia CorporationInventors: Caroline Elizabeth Millar, Stuart Paul Godfrey
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Patent number: 8784728Abstract: There is provided cryogenic milled copper alloys and methods of making the alloys. The alloys are fine grained and possess desirable physical properties stemming from the fine grain size. Embodiments include desirable physical properties, such as potentially high strength. Some embodiments of the cryogenic milled copper alloys may also be tailored for ductility, toughness, fracture resistance, corrosion resistance, fatigue resistance and other physical properties by balancing the alloy composition. In addition, embodiments of the alloys generally do not require extensive or expensive post-cryogenic milling processing.Type: GrantFiled: December 5, 2006Date of Patent: July 22, 2014Assignee: The Boeing CompanyInventors: Clifford C. Bampton, James D. Cotton, Barun Majumdar
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Patent number: 8753755Abstract: A body, such as a pick tool for cutting coal, includes a steel substrate and a hard face structure fused to the steel substrate. The hard face structure includes at least 1 weight percent Si, at least 5 weight percent Cr and at least 40 weight percent W. Substantially the balance of the hard face structure includes carbon and an iron group metal M selected from Fe, Co, Ni and alloy combinations of these elements. The hard face structure includes a plurality of elongate or platelike micro-structures having a mean length of at least 1 micron, a plurality of nano-particles having a mean size of less than 200 nanometers, and a binder material.Type: GrantFiled: July 6, 2011Date of Patent: June 17, 2014Assignee: Element Six GmbHInventors: Igor Yuri Konyashin, Bernd Heinrich Ries, Frank Friedrich Lachmann, Kersten Heinrich Schafer
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Patent number: 8728389Abstract: A method for producing high strength aluminum alloy tanks and other vessels containing L12 dispersoids from an aluminum alloy powder containing the L12 dispersoids. The powder is consolidated into a billet having a density of about 100 percent. Tanks are formed by rolling consolidated billets into sheets, cutting preforms from said sheets, roll forming the performs into cylindrical shapes and friction stir welding the seams to form cylinders. L12 alloy domes are spin formed from the rolled sheet and friction stir welded to the cylinder. Circular bases are cut from the rolled sheet and friction stir welded to the domed cylinder to form bottoms of the tank.Type: GrantFiled: September 1, 2009Date of Patent: May 20, 2014Assignee: United Technologies CorporationInventor: Awadh B. Pandey
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Patent number: 8708682Abstract: A method for repairing gas turbine components, in particular gas turbine blades, including at least the following steps: a) preparing a gas turbine component to be repaired; b) removing a damaged portion from the gas turbine component to be repaired, thereby forming a plane separation surface; c) placing the gas turbine component at least partly in a process chamber in such a way that the plane separation surface extends approximately horizontally within the process chamber; d) filling the process chamber with a metal powder that is bonding-compatible with the material of the gas turbine component to be repaired, namely up to the level of the separation surface; e) building up the removed portion on the separation surface by depositing metal powder in layers onto the separation surface and by fusing the metal powder, which has been deposited in layers onto the separation surface, to the separation surface.Type: GrantFiled: November 5, 2009Date of Patent: April 29, 2014Assignee: MTU Aero Engines GmbHInventors: Roland Huttner, Karl-Heinz Dusel, Erwin Bayer, Albin Platz
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Publication number: 20140072470Abstract: The present invention employs Equal Channel Angular Extrusion (ECAE) to consolidate Fe16N2, Fe4N, Sm2Fe17Nx, either alone or in combination with other magnetic powders made from Nd2Fe14B, SmCo5, Sm2Co17, Sm2Fe17Nx and MnBi to prepare dense bodies at temperatures as low as room temperature or as high as 800° C., depending on the composition. When a soft magnetic material such as ?-Fe powder or Fe4N powder is mixed with a hard magnetic material such as Nd2Fe14B, SmCo5, Sm2Co17 or Sm2Fe17Nx or MnBi or FeCr alloys or a semi-hard material such as Fe16N2, exchange-coupled magnets are obtained. This is due to the fact that the current theory on exchange-coupling phenomena indicates that a nanocrystalline size of the soft magnetic material is a necessary condition for the promotion of exchange-coupling.Type: ApplicationFiled: September 10, 2013Publication date: March 13, 2014Inventors: Suryanarayan G. Sankar, Laszlo John Kecskes
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Patent number: 8663359Abstract: Methods of forming larger sintered compacts of PCD and other sintered ultrahard materials are disclosed. Improved solvent metal compositions and layering of the un-sintered construct allow for sintering of thicker and larger high quality sintered compacts. Jewelry may also be made from sintered ultrahard materials including diamond, carbides, and boron nitrides. Increased biocompatibility is achieved through use of a sintering metal containing tin. Methods of sintering perform shapes are provided.Type: GrantFiled: June 25, 2010Date of Patent: March 4, 2014Assignee: Dimicron, Inc.Inventors: David P. Harding, Mark E. Richards, Richard H. Dixon, Victoriano Carvajal, Bao-Khang Ngoc Nguyen, German A. Loesener, A. Ben Curnow, Troy J. Medford, Trenton T. Walker, Jeffery K. Taylor, Bill J. Pope
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Publication number: 20140044584Abstract: A titanium alloy containing copper, which cannot be realized by a conventional method, is provided, having a composition in which copper is contained in titanium with no segregation, and having improved strength and hardness. In addition a method is also provided, in which the titanium alloy is produced at lower cost than in a conventional method. The ?+? or ? titanium alloy contains copper at 1 to 10 mass %, has a crystal phase of ? and ? phase or of ? phase, is formed of crystal particles not more than 100 ?m, and has a copper concentration per an arbitrary specified 1 mm3 portion of the crystal phase at within ±40% compared to another arbitrary specified portion. The ?+? or ? titanium alloy is produced by mixing 1 to 10 mass % of copper powder and the remainder of titanium alloy powder and then pressing and forming while being heated.Type: ApplicationFiled: April 27, 2012Publication date: February 13, 2014Applicants: TOHO TITANIUM CO., LTD., SANYO SPECIAL STEEL CO., LTD.Inventors: Osamu Kanou, Satoshi Sugawara, Hideo Takatori
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Patent number: 8535604Abstract: A method of producing composites of micro-engineered, coated particulates embedded in a matrix of metal, ceramic powders, or combinations thereof, capable of being tailored to exhibit application-specific desired thermal, physical and mechanical properties to form substitute materials for nickel, titanium, rhenium, magnesium, aluminum, graphite epoxy, and beryllium. The particulates are solid and/or hollow and may be coated with one or more layers of deposited materials before being combined within a substrate of powder metal, ceramic or some combination thereof which also may be coated. The combined micro-engineered nano design powder is consolidated using novel solid-state processes that prevent melting of the matrix and which involve the application of varying pressures to control the formation of the microstructure and resultant mechanical properties.Type: GrantFiled: April 21, 2009Date of Patent: September 17, 2013Inventors: Dean M. Baker, Henry S. Meeks
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Patent number: 8510942Abstract: An automotive engine component and method of producing the same. The method uses dynamic magnetic compaction to form components, such as camshaft lobes, with non-axisymmetric and related irregular shapes. A die is used that has an interior profile that is substantially similar to the non-axisymmetric exterior of the component to be formed such that first and second materials can be placed into the die prior to compaction. The first material is in powder form and can be placed in the die to make up a first portion of the component being formed, while a second material can be placed in the die to make up a second portion of the component. The second material, which may possess different tribological properties from those of the first material, can be arranged in the die so that upon formation, at least a portion of the component's non-axisymmetric exterior profile is shaped by or includes the second material.Type: GrantFiled: October 8, 2008Date of Patent: August 20, 2013Assignee: GM Global Technology Operations LLCInventors: Shekhar G. Wakade, Frederick J. Rozario, Glenn E. Clever, Joseph E. Robbins, Stephen R. Kornblum
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Patent number: 8501048Abstract: The present invention provides a metal-graphite composite material favorable to two-dimensional diffusion of heat and having a high thermal conductivity in two axial directions, and a production method therefor. The metal-graphite composite material of the present invention includes: 20 to 80% by volume of a scaly graphite powder; and a matrix selected from the group consisting of copper, aluminum and alloys thereof, wherein the scaly graphite powder in which a normal vector to a scaly surface thereof is tilted at 20° or higher with respect to a normal vector to a readily heat-conducting surface of the metal-graphite composite material is 15% or less relative to a whole amount of the scaly graphite powder, and the metal-graphite composite material has a relative density of 95% or higher.Type: GrantFiled: October 14, 2008Date of Patent: August 6, 2013Assignee: Shimane Prefectural GovernmentInventors: Toshiyuki Ueno, Takashi Yoshioka
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Patent number: 8460602Abstract: A sintering method with uniaxial pressing includes: a powder filling step of disposing a spent target in an inner space of a frame jig having the inner space piercing in a uniaxial direction, and filling the inner space with a raw material powder for a target to cover an erosion part side of the spent target with the raw material powder for a target, a cushioning-material disposition step of disposing a deformable cushioning material so that the raw material powder for a target with which the inner space has been filled in the powder filling step is sandwiched between the spent target and the deformable cushioning material; and a sintering step of pressing the raw material powder for a target with which the inner space has been filled and the spent target in the uniaxial direction through the cushioning material and sintering them.Type: GrantFiled: December 17, 2009Date of Patent: June 11, 2013Assignee: Tanaka Holdings Co., LtdInventors: Toshiya Yamamoto, Takanobu Miyashita, Osamu Itoh
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Publication number: 20130140174Abstract: A preparing method of a glass substrate film sputtering target is disclosed, which comprises the following steps of: weighing an alloy material for forming the glass substrate film sputtering target; adding the alloy material weighed into a plasma pressure compaction sintering cavity and sintering the alloy material to obtain a sintered target, wherein the sintering temperature is 500° C.˜1600° C. and the sintering time is 5˜20 minutes; and post-processing the sintered target. A glass substrate film sputtering target prepared by the preparing method is further disclosed. Because the plasma pressure compaction for quick sintering is adopted for the glass substrate film sputtering target and the preparing method thereof of the present disclosure, quality of the target can be improved and the time necessary for preparing the target can be shortened.Type: ApplicationFiled: December 12, 2011Publication date: June 6, 2013Applicant: Shenzhen China Star Optoelectronics Technology Co., LTD.Inventor: Hao Kou
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Patent number: 8454933Abstract: The invention provides a polycrystal magnesium oxide (MgO) sintered body which is capable of having a sintered density close to a theoretical density thereof. The MgO sintered body exhibits excellent mechanical properties and heat conductivity, while reducing contamination of an atmosphere due to gas generation. The invention also provides a production method for the sintered body. The polycrystal MgO sintered body has a unique crystalline anisotropy in which (111) faces are oriented along a surface applied with a uniaxial pressure at a high rate. The polycrystalline MgO sintered body is obtained by a method which includes the steps of: sintering an MgO raw material powder, having a particle size of 1 ?m or less, under a uniaxial pressure and then subjecting the sintered powder to a heat treatment under an atmosphere containing 0.05 volume % or more of oxygen, at a temperature of 1273 K or more for 1 minute or more.Type: GrantFiled: January 27, 2009Date of Patent: June 4, 2013Assignees: Nippon Tungsten Co., Ltd., Ube Material Industries, Ltd.Inventors: Mitsuyoshi Nagano, Masanobu Takasu, Yo Arita, Satoru Sano
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Patent number: 8435429Abstract: A process for forming a thermoelectric component having optimum properties is provided. The process includes providing a plurality of core-shell nanoparticles, the nanoparticles having a core made from silica, metals, semiconductors, insulators, ceramics, carbon, polymers, combinations thereof, and the like, and a shell containing bismuth telluride. After the core-shell nanoparticles have been provided, the nanoparticles are subjected to a sintering process. The result of the sintering provides a bismuth telluride thermoelectric component having a combined electrical conductivity and Seebeck coefficient squared of greater than 30,000 ?V2S/mK2 at 150° C.Type: GrantFiled: July 22, 2010Date of Patent: May 7, 2013Assignee: Toyota Motor Engineering & Manufacturing North America, Inc.Inventor: Michael Paul Rowe
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Publication number: 20130101455Abstract: A method of forming a sintered nickel-titanium-rare earth (Ni—Ti-RE) alloy includes adding one or more powders comprising Ni, Ti, and a rare earth constituent to a powder consolidation unit comprising an electrically conductive die and punch connectable to a power supply. The one or more powders are heated at a ramp rate of about 35° C./min or less to a sintering temperature, and pressure is applied to the powders at the sintering temperature, thereby forming a sintered Ni—Ti-RE alloy.Type: ApplicationFiled: October 19, 2012Publication date: April 25, 2013Applicant: University of LimerickInventor: University of Limerick
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Patent number: 8409498Abstract: A sputter target material which is of a sintered material, wherein the sputter target material consists of 0.5 to 50 atomic % in total of at least one metal element (M) selected from the group of Ti, Zr, V, Nb and Cr, and the balance of Mo and unavoidable impurities, and has a microstructure seen at a perpendicular cross section to a sputtering surface, in which microstructure oxide particles exist near a boundary of each island of the metal element (M), and wherein the maximum area of the island, which is defined by connecting the oxide particles with linear lines so as to form a closed zone, is not more than 1.0 mm2.Type: GrantFiled: June 5, 2009Date of Patent: April 2, 2013Assignee: Hitachi Metals, Ltd.Inventors: Keisuke Inoue, Tsuyoshi Fukui, Shigeru Taniguchi, Norio Uemura, Katsunori Iwasaki, Kazuya Saitoh
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Patent number: 8409497Abstract: A method and apparatus for producing high strength aluminum alloys from a powder containing Ll2 intermetallic dispersoids. The powder is degassed, sealed under vacuum in a container, consolidated by vacuum hot pressing, extruded into a rolling preform and rolled into a usable part.Type: GrantFiled: October 16, 2009Date of Patent: April 2, 2013Assignee: United Technologies CorporationInventor: Awadh B. Pandey
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Patent number: 8390122Abstract: Methods are generally provided for forming a conductive oxide layer on a substrate. In one particular embodiment, the method can include sputtering a transparent conductive oxide layer (e.g., including cadmium stannate) on a substrate from a target in a sputtering atmosphere comprising cadmium. The transparent conductive oxide layer can be sputtered at a sputtering temperature greater of about 100° C. to about 600° C. Methods are also generally provided for manufacturing a cadmium telluride based thin film photovoltaic device.Type: GrantFiled: September 19, 2011Date of Patent: March 5, 2013Assignee: Primestar Solar, Inc.Inventor: Scott Daniel Feldman-Peabody
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Patent number: 8372334Abstract: Diamond-bonded constructions include a diamond-bonded body having a thermally stable region extending a distance below a diamond-bonded body surface. The thermally stable region comprises a matrix phase of bonded-together diamond crystals, and interstitial regions comprising a reaction product. The reaction product is formed by reaction between the diamond crystals and a reactive material. The reactant is a carbide former and the reaction product is a carbide. The diamond-bonded body includes a further diamond region extending from the thermally stable region that comprises the matrix phase and a Group VIII metal disposed within interstitial regions of the matrix phase. The thermally stable region is substantially free of a catalyst material used to initially form the diamond-bonded body. The diamond-bonded body may include a material layer formed from the reaction product that is disposed on a surface of the diamond-bonded body thermally stable region.Type: GrantFiled: July 15, 2011Date of Patent: February 12, 2013Assignee: Smith International, Inc.Inventors: Georgiy Voronin, J. Daniel Belnap
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Patent number: 8366994Abstract: A method for manufacturing a cobalt (Co) alloy-based ceramic composite sputtering target is provided. A cobalt ingot and a chromium (Cr) ingot are melted in vacuum and then nebulized to form a cobalt-chromium (CoCr) alloy powder. Additionally, a ceramic powder and a platinum powder are wetly mixed to form a platinum-ceramic (Pt-ceramic) slurry, in which the ceramic powder is applied onto the platinum powder's surface uniformly. Next, the CoCr alloy powder and the Pt-ceramic slurry are wetly mixed to form a CoCrPt-ceramic slurry. Thereafter, the CoCrPt-ceramic slurry is dried, molded and compressed to form the cobalt alloy-based ceramic composite sputtering target. The resulted cobalt alloy-based ceramic composite sputtering target, which has a fine and dense structure, uniform composition and lower magnetic permeability, is beneficial to a magnetron sputter deposition process, as well as a film sputtering process used in the magnetic recording industry.Type: GrantFiled: November 4, 2010Date of Patent: February 5, 2013Assignee: China Steel CorporationInventors: Rong-Zhi Chen, Chun-Hao Chiu, Jui-Tung Chang, Deng-Far Hsu, Chih-Huang Lai
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Publication number: 20130028781Abstract: A method of making a selectively corrodible article is disclosed. The method includes forming a powder comprising a plurality of metallic powder particles, each metallic powder particle comprising a nanoscale metallic coating layer disposed on a particle core. The method also includes forming a powder compact of the powder particles, wherein the powder particles are substantially elongated in a predetermined direction to form substantially elongated powder particles. In one embodiment, forming the powder compact includes compacting the powder particles into a billet, and forming the billet to provide the powder compact of the powder particles, wherein the powder particles are substantially elongated in a predetermined direction to form substantially elongated powder particles.Type: ApplicationFiled: July 29, 2011Publication date: January 31, 2013Inventor: Zhiyue Xu
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Patent number: 8329093Abstract: A method for preparing metal-matrix composites including cold-process isostatic compaction of previously mixed powders and hot-process uniaxial pressing of the resulting compact is disclosed. The method enables metal-matrix composites with improved properties to be obtained. A device for implementing isostatic compaction comprising a latex sheath into which the mixture of powders is poured, a perforated cylindrical container in which the latex sheath is arranged, and means for sealed insulation of the mixture of powders contained in the sheath is also disclosed.Type: GrantFiled: March 14, 2006Date of Patent: December 11, 2012Assignee: Forges de BologneInventor: Jacques Tschofen