Abstract: The present invention discloses a method for densifying previously sintered parts constructed of powdered metals, ceramics or the like to nearly 100% theoretical density. The method of the present invention comprises heating the parts above their liquid phase temperature and then applying a pressure in the range of 50-2,000 psi to the parts for a predetermined period of time and simultaneously maintaining the parts at or above their liquid phase temperature. The method of the present invention achieves complete closure of even large voids and the elimination of substantially all porosity within the part.

Abstract: A high density shot made of a cold-compacted mixture of at least two metal powders, a first one of such powders more dense than lead and a second one of such being flowable under compaction to serve as a binder. The shot has an extended range as compared to conventional lead shot.

Abstract: A quantity of material (10), which is at less than a predetermined density, is disposed within a sealed container (12) which is, in turn, encapsulated in a pressure-transmitting (18) medium which is, in turn, placed within a pot die (20) of a press where it is restrained as a ram (24) enters the pot die (20) and applies a force to the pressure-transmitting medium (18) to densify the material within the container into a compact (10') of predetermined density. The pressure-transmitting medium (18) is characterized by a rigid interconnected ceramic skeleton structure (26) which is collapsible in response to a predetermined force and fluidizing glass (28) capable of fluidity and supported by and retained within the skeleton structure (26). The glass (28) becomes fluidic and capable of plastic flow at temperatures utilized for compaction whereas the ceramic skeleton (26) retains its configuration and acts as a carrier for the fluidic glass (28).

Abstract: Shape-memory alloys comprised of Cu/Al or Cu/Al/Ni are produced by a powder metallurgical process wherein a coarse-grained powder of pre-alloyed and/or pre-mixed powder alloys having a grain size of 0.05 to 0.8 mm is introduced into a metal container which is then evacuated, sealed, and hot isostatically pressed. The resulting billet is then hot worked. In another embodiment, the powder is first placed in a rubber tube and cold isostatically pressed. The billet is then placed in a cylinder having deformable walls, such as a copper cylinder, the cylinder is sealed, and the powder therein is then hot isostatically pressed, and the billet so prepared is subjected to a homogenization heat treatment and hot working.

Abstract: New nickel rich metal alloys containing copper along with specific amounts of boron are disclosed. The alloys are subjected to rapid solidification processing (RSP) techniques which produce cooling rates between .about.10.sup.5 .degree. to 10.sup.7 .degree. C./sec. The as-quenched ribbon, powder, etc. consists primarily of a metastable crystalline solid solution phase. The metastable crystalline phases are subjected to suitable heat treatments so as to produce a transformation to a stable multiphase microstructure which includes borides. This heat treated alloy exhibits superior mechanical properties with good corrosion and/or oxidation resistance for numerous engineering applications.

Abstract: The present invention is directed to a process for preparing a body of polycrystalline silicon doped with aluminum comprising melting a mixture of silicon powder and aluminum powder, rapidly quenching the melt, grinding the solidified silicon-aluminum alloy and hot pressing to form a compact.

Abstract: Novel very hard compositions of matter are prepared by using in all embodiments only a minor amount of a particular carbide (or materials which can form the carbide in situ when subjected to heat and pressure); and no strategic cobalt is needed. Under a particular range of conditions, densified compositions of matter of the invention are prepared having hardnesses on the Rockwell A test substantially equal to the hardness of pure tungsten carbide and to two of the hardest commercial cobalt-bonded tungsten carbides. Alternately, other compositions of the invention which have slightly lower hardnesses than those described above in one embodiment also possess the advantage of requiring no tungsten and in another embodiment possess the advantage of having a good fracture toughness value.

Abstract: New copper-rich metal alloys containing nickel along with certain specific amounts of boron are disclosed. The alloys are subjected to a rapid solidification processing (RSP) technique which produces cooling rates between .about.10.sup.5.degree. to 10.sup.7 .degree. C./sec. The asquenched ribbon, powder, etc. consists primarily of a metastable crystalline solid solution phase. The metastable crystalline phases are subjected to suitable heat treatments so as to produce a transformation to a stable multiphase microstructure, which includes borides. This heat treated alloy exhibits superior mechanical properties with good corrosion and/or oxidation resistance for numerous engineering applications.

Abstract: A method for manufacturing elongated dense bodies of metals or metal alloys by extrusion of a powder charge enclosed in a metal capsule. A closed, powder-filled capsule is heated to a temperature necessary for bonding the charge under pressure, and the capsule is then inserted in a pressure chamber and surrounded by a layer of a solid, readily deformable material, such as talcum powder or pyrophyllite. A piston is inserted into the pressure chamber and subjects the capsule and the surrounding material to a pressure such that the capsule and the surrounding material are pressed out together through an opening in a die. Tubes can also be extruded, with the deformable packing material filling the tube bore.

Abstract: Aluminum alloy atomized powder containing 4 to 12% iron and 1 to 7% cerium or other rare earth metal, when properly compacted and shaped into a useful article, exhibits very high strength at relatively high temperatures. The iron content exceeds the cerium or rare earth metal content, and the powder may contain refractory elements such as W, Mo and others. The powder is produced by atomizing alloyed molten aluminum, preferably in a nonoxidizing atmosphere, and is compacted to a density approaching 100% under controlled conditions including controlled temperature conditions. The alloy may be subsequently shaped by conventional forging, extruding or rolling processes.

Abstract: A method is provided for producing a fully dense high temperature powdered metal component. This process comprises the steps of filling a centrally located mold cavity with a high temperature powder, heating the filled mold to a temperature greater than half the melting temperature of the powder in degrees centigrade and less than the melting temperature of the powder, while the cavity is maintained in a vacuum level of at least twenty microns of mercury, axially compressing the heated mold while maintaining the vacuum at a pressure of at least 345 megapascals, while restricting the mold about its lateral periphery holding the mold in a compressed state for at least 20 seconds after attaining maximum pressure, and separating the mold materials from the component. The mold is composed of a material having substantially the same flow stress throughout, and the material is able to maintain its dimensional stability in a viscoelastic state at a temperature of between approximately 950.degree. to 1300.degree. C.

Abstract: A .[.container.]. .Iadd.method .Iaddend.for hot consolidating powder of metallic and non-metallic composition and combinations thereof by the application of heat and pressure .[.wherein the.]. .Iadd.to a thick-walled and regularly shaped .Iaddend.container .[.includes.]. .Iadd.having .Iaddend.a mass of container material which is substantially fully dense and incompressible and is capable of plastic flow at .[.pressing.]. .Iadd.conventinal compaction .Iaddend.temperatures, a cavity of .[.a predetermined.]. .Iadd.an irregular .Iaddend.shape formed within the mass for receiving a quantity of powder, the mass including walls around the cavity of sufficient thickness so that the exterior surface thereof does not closely follow the contour of the cavity whereby, upon the application of heat and pressure to the container, the mass acts like a fluid to apply hydrostatic pressure to the powder contained in the cavity.