Hot Isostatic Pressing (hip) Patents (Class 419/49)
  • Patent number: 10450896
    Abstract: The manufacture of a casing which has a boss includes providing two canister portions a first defining an outer wall geometry of a casing including a boss and a second defining an inner wall geometry of the casing. The casing is made using known PHIP methods. The second canister portion includes an array of holes or recesses which, when the canister portions are aligned, face a recess on the first canister portion which defines the boss such that in the nett shape COS an array of pedestals is provided aligned with the boss. The dimension from an exposed end of a pedestal to an exposed surface of the boss is sufficient to receive a bolt thread of the minimum length required to secure a component to the boss.
    Type: Grant
    Filed: May 26, 2016
    Date of Patent: October 22, 2019
    Assignee: ROLLS-ROYCE plc
    Inventors: Thomas G Mulcaire, Ian M Garry
  • Patent number: 10107113
    Abstract: A steam turbine vane manufacturing method including: a groove processing step for forming a protective part joint surface on a steam turbine vane material that has been subjected to rough processing; a build-up welding step for forming, by build-up welding, a protective part build-up bead on the protective part joint surface; and a processing step for performing processing, by cutting the first steam turbine vane material that has been subjected to rough processing and the protective part build-up bead, to finish the first steam turbine vane material has been subjected to rough processing so that the first steam turbine vane material becomes a second steam turbine vane material that has been subjected to finishing processing. The first steam turbine vane material that has been subjected to rough processing is larger than the second steam turbine vane material that has been subjected to finishing processing.
    Type: Grant
    Filed: January 24, 2014
    Date of Patent: October 23, 2018
    Assignee: MITSUBISHI HITACHI POWER SYSTEMS, LTD.
    Inventors: Hidetaka Haraguchi, Hiroharu Oyama, Takahiro Ota, Motonari Machida, Kohei Hatano, Takumi Matsumura
  • Patent number: 10000011
    Abstract: To reduce distortion in an additively manufactured part, a shrinking platform is formed from a metal particulate filler in a debindable matrix. Shrinking supports of the same material are formed above the shrinking platform, and a desired part of the same material is formed upon them. A sliding release layer is provided below the shrinking platform of equal or larger surface area than a bottom of the shrinking platform to lateral resistance between the shrinking platform and an underlying surface. The matrix is debound sufficient to form a shape-retaining brown part assembly including the shrinking platform, shrinking supports, and the desired part. The shape-retaining brown part assembly is heated to shrink all of the components together at a same rate via atomic diffusion.
    Type: Grant
    Filed: October 2, 2017
    Date of Patent: June 19, 2018
    Assignee: MARKFORGED, INC.
    Inventor: Gregory Thomas Mark
  • Patent number: 9993872
    Abstract: A method includes introducing metallic powder into a fluidizing chamber of a fluidized bed reactor. A fluidization gas is flowed into the fluidizing chamber. The metallic power becomes entrained in the flow of the fluidization gas. Adsorbed water is removed from the metallic powder by exposing the metallic powder to the fluidization gas for a duration of time and at a treatment temperature to cause the adsorbed water to be removed from the metallic powder.
    Type: Grant
    Filed: April 11, 2014
    Date of Patent: June 12, 2018
    Assignee: United Technologies Corporation
    Inventors: Aaron T. Nardi, Michael A. Klecka, Ying She, Zissis A. Dardas
  • Patent number: 9573324
    Abstract: Systems and methods for producing a dense, well bonded solid material from a powder may include consolidating the powder utilizing any suitable consolidation method, such as explosive shockwave consolidation. The systems and methods may also include a post-processing thermal treatment that exploits a mismatch between the coefficients of thermal expansion between the consolidated material and the container. Due to the mismatch in the coefficients, internal pressure on the consolidated material during the heat treatment may be increased.
    Type: Grant
    Filed: June 3, 2015
    Date of Patent: February 21, 2017
    Assignee: TXL GROUP, INC.
    Inventors: David Charles Nemir, Edward S. Rubio, Jan Bastian Beck
  • Patent number: 9039960
    Abstract: A formed article comprising a nanostructured ferritic alloy is provided. Advantageously, the article is not formed via extrusion, and thus, cost savings are provided. Methods are also provided for forming the article, and the articles so produced, exhibit sufficient continuous cycle fatigue crack growth resistance and hold time fatigue crack growth resistance to be utilized as turbomachinery components, and in particular, large, hot section components of a gas or steam turbine engines. In other embodiments, a turbomachinery component comprising an NFA is provided, and in some such embodiments, the turbomachinery component may be extruded.
    Type: Grant
    Filed: January 18, 2013
    Date of Patent: May 26, 2015
    Assignee: General Electric Company
    Inventors: Richard Didomizio, Matthew Joseph Alinger, Raymond Joseph Stonitsch, Samuel Vinod Thamboo
  • Publication number: 20150078951
    Abstract: The present invention relates to a high speed steel with a chemical composition that comprises, in % by weight: 0.6-2.1 C 3-5 Cr 4-14 Mo max 5 W max 15 Co 0.5-4 V, balance Fe and impurities from the manufacturing of the material, which steel is powder metallurgically manufactured and has a content of Si in the range of 0.7<Si?2.
    Type: Application
    Filed: August 4, 2014
    Publication date: March 19, 2015
    Inventor: Stefan Sundin
  • Publication number: 20150064049
    Abstract: A method and apparatus for removing a canister 12 from a component 18 by forming an opening 30 in the canister wall thickness 14, 16 and introducing a pressurised fluid into the opening 14, 16 causing hydrostatic pressure build up between an internal canister surface 14 and the component 18, leading to the removal of the canister 12. This method and apparatus obviates the need to expend significant machining or chemical processing to remove the canister 12.
    Type: Application
    Filed: September 3, 2014
    Publication date: March 5, 2015
    Inventors: John Harold BOSWELL, Daniel CLARK
  • Patent number: 8916091
    Abstract: Disclosed is a method for producing semi-finished products from a shape memory alloy, particularly an NiTi shape memory alloy, wherein a powder is first produced from a shape memory alloy, and subsequently the powder is divided into a coarse fraction and a fine fraction in a separating cut T. While the fine fraction is required, in particular, for the production of a first semi-finished product, employing the metal injection molding (MIM) method, the coarse fraction can be used for the production of a second semi-finished product, employing the hot isostatic pressing (HIP) method. The advantages of the invention can be summarized as follows. The MIM method for producing semi-finished products from a shape memory alloy is qualitatively improved and more cost-effective to implement if the coarse fraction that is typically obtained during powder production, but not used for the MIM process, can advantageously be supplied to a further process, in this case the HIP process.
    Type: Grant
    Filed: August 27, 2008
    Date of Patent: December 23, 2014
    Assignee: Forschungszentrum Juelich GmbH
    Inventors: Manuel Koehl, Martin Bram, Berthold Coenen, Hans Peter Buchkremer, Detlev Stoever
  • Patent number: 8894913
    Abstract: The invention relates to a method for production of a cylindrical acid proof, seamless pressure vessel having hemispherical top and bottom by powder molding in an HIP (Hot Isostatic Pressing) process. Sheet metal molds are produced constituting an internal shell, lower part of an external shell, upper part of an external shell with filling spout with corresponding top and bottom. Distance pins decide the wall thickness and are mounted outward from the internal shell which is led down into the lower part of external shell whereafter shell part with filling spout closes the volume between the internal and external shells which is then filled with powder through the filling spout. The pressure vessel is placed in an HIP-process container for vacuuming, sealing, supply of high-pressure inert gas such as argon, at high temperature such as 1000° C., for processing together with the distance pins to a compact and homogenous material.
    Type: Grant
    Filed: October 8, 2009
    Date of Patent: November 25, 2014
    Assignee: Tool-Tech AS
    Inventor: Egil Eriksen
  • Patent number: 8864918
    Abstract: A method for producing a component of a titanium-aluminum base alloy comprising hot isostatically pressing the alloy to form a blank, subjecting the blank to a hot forming by a rapid solid-blank deformation, followed by a cooling of the component to form a deformation microstructure with high recrystallization energy potential, thereafter subjecting the component to a heat treatment in the range of the eutectoid temperature (Teu) of the alloy, followed by cooling in air, to form a homogeneous, fine globular microstructure composed of phases GAMMA, BETA0, ALPHA2 and having an ordered atomic structure at room temperature. This abstract is neither intended to define the invention disclosed in this specification nor intended to limit the scope of the invention in any way.
    Type: Grant
    Filed: May 3, 2011
    Date of Patent: October 21, 2014
    Assignees: Boehler Schmiedetechnik GmbH & Co. KG, MTU Aero Engines GmbH
    Inventors: Helmut Clemens, Wilfried Wallgram, Martin Schloffer
  • Publication number: 20140294651
    Abstract: A thermal mechanical treatment method includes consolidating a powder by a severe plastic deformation process and ageing the consolidated powder at low temperature. The method may include cryomilling the powder before consolidating the powder by a severe plastic deformation process; hot isostatic pressing the consolidated powder into a dense powder before aging the consolidated powder; hot extruding the dense powder into a stock shape before aging the consolidated powder; hot-working the stock shape on a gyrating forge at a predetermined temperature before aging the consolidated powder; or heating the consolidated powder to a predetermined temperature, and maintaining the consolidated powder at the predetermined temperature for a predetermined time.
    Type: Application
    Filed: March 31, 2014
    Publication date: October 2, 2014
    Applicant: SCHLUMBERGER TECHNOLOGY CORPORATION
    Inventors: Indranil Roy, Rashmi Bhavsar
  • Patent number: 8845957
    Abstract: A method for producing a magnetizable metal shaped body comprising a ferromagnetic starting material that is present in powder and in particulate form, using the following steps: (a) first compaction of the starting material (S3) such that adjoining particles become bonded to each other by means of positive adhesion and/or integral bonding in sections along the peripheral surfaces thereof and while forming hollow spaces, (b) creating an electrically isolating surface coating on the peripheral surfaces of the particles in regions outside the joining sections (S4), and (c) second compaction of the particles (S5) provided with the surface coating, such that the hollow spaces are reduced in size or eliminated.
    Type: Grant
    Filed: April 27, 2009
    Date of Patent: September 30, 2014
    Assignees: ETO Magnetic GmbH, Kennametal Europe GmbH
    Inventors: Paul Guempel, Stefan Glaeser, Beat Hofer
  • Patent number: 8834785
    Abstract: 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: Grant
    Filed: July 11, 2011
    Date of Patent: September 16, 2014
    Assignee: Climax Engineered Materials, LLC
    Inventors: Matthew C. Shaw, Carl V. Cox, Yakov Epshteyn
  • Publication number: 20140234151
    Abstract: An apparatus for manufacturing an article from powder material includes a canister, a sorter, a plurality of hoppers and at least one valve. The canister has a predetermined internal shape to define the shape of the powder metal article. The sorter sorts the powder material by the size of the powder particles, the shape of the powder particles and/or the flow characteristics of the powder particles. The hoppers contain powder material with different sizes of powder particles, different shapes of powder particles and/or powder particles with different flow characteristics. The hoppers are arranged to supply the sorted powder material to the canister. The at least one valve controls the proportions of the different powder materials supplied from the one or more of the different hoppers into the canister to control the packing density of the powder material in the canister at all positions in the canister.
    Type: Application
    Filed: December 18, 2013
    Publication date: August 21, 2014
    Applicant: ROLLS-ROYCE PLC
    Inventors: Ian Colin Deuchar CARE, Daniel CLARK
  • Patent number: 8795489
    Abstract: [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: Grant
    Filed: November 4, 2010
    Date of Patent: August 5, 2014
    Assignee: Mitsubishi Materials Corporation
    Inventors: Shoubin Zhang, Yoshinori Shirai
  • Patent number: 8795584
    Abstract: A small diameter, elongated steel article, comprising fully consolidated, prealloyed metal powder is disclosed. The consolidated metal powder has a microstructure that has a substantially uniform distribution of fine grains having a grain size of not larger than about 9 when determined in accordance with ASTM Standard Specification E 112. The microstructure of the consolidated metal powder is further characterized by having a plurality of substantially spheroidal carbides uniformly distributed throughout the consolidated metal powder that are not greater than about 6 microns in major dimension and a plurality of sulfides uniformly distributed throughout the consolidated metal powder wherein the sulfides are not greater than about 2 microns in major dimension. A process for making the elongated steel article is also disclosed.
    Type: Grant
    Filed: August 23, 2012
    Date of Patent: August 5, 2014
    Assignee: CRS Holdings, Inc.
    Inventors: Olivier Schiess, Pierre Marechal, Gregory J. Del Corso
  • Patent number: 8778259
    Abstract: A self-renewing cutting tool or cutting element is formed by bonding an overcoat, cladding or layer of highly abrasive, very durable material on a surface of a substrate or load-bearing element. The cutting layer is a composite structure and includes appropriately sized, multi-edged pieces of a superhard material, such as tungsten carbide, dispersed in a softer material which produces high strength bonds between and among the pieces and the substrate or load-bearing element.
    Type: Grant
    Filed: May 25, 2011
    Date of Patent: July 15, 2014
    Inventor: Gerhard B. Beckmann
  • Patent number: 8758676
    Abstract: A component is manufactured from a powdered material such as a titanium alloy, by performing a first hot isostatic pressing HIP operation on the powdered material 14 while the powdered material is in contact with a molding surface 8 of a rigid, usable molding tool 2. The first HIP operation creates a non-porous shaped surface 16 on a partially consolidated component 14, but avoids bonding or reaction between the partially consolidated component 14 and the molding tool 2. After separation of the partially consolidated component 14 from the molding tool 2, the partially consolidated component 14 is subjected to a second HIP operation in which the powdered material is fully consolidated.
    Type: Grant
    Filed: November 12, 2010
    Date of Patent: June 24, 2014
    Assignee: Rolls-Royce PLC
    Inventors: Wayne E. Voice, Junfa Mei
  • Patent number: 8703045
    Abstract: The present invention relates to a method of manufacturing a multiple composition component 10, comprising: arranging first, second and third constituent parts 40, 30, 42 having first, second and third compositions respectively A, B, C so that the first constituent part 40 shares a first boundary with the second constituent part 30 and the second constituent part 30 shares a second boundary with the third constituent part 40. The first, second and third constituent parts 40, 30, 42 are each either a powder or a solid so that the first and second boundaries are each a solid adjacent to a powder. The arrangement is then processed so as to form a single solid component having first, second and third regions 16, 18, 20 having first, second and third compositions A, B, C respectively.
    Type: Grant
    Filed: November 15, 2010
    Date of Patent: April 22, 2014
    Assignee: Rolls-Royce PLC
    Inventors: Robert J. Mitchell, Catherine M. F. Rae, Mark C. Hardy, Shaun R. Holmes
  • Publication number: 20140034626
    Abstract: Methods of additive manufacturing a superalloy component are disclosed. In one method a powder bed of superalloy powder is selectively scanned with a focused laser beam in a line-by-line manner; and the spacing between adjacent scan lines is no more than twice the layer thickness being formed. In another method a compressive stress treatment is applied to the surface of the final component prior to separation of said component from the substrate. In a further method a superalloy component is formed on a substrate and the method includes Hot Isostatic Processing of the component wherein the mass of the substrate is reduced prior to the Hot Isostatic Processing. The methods may be combined in a multi-step process.
    Type: Application
    Filed: August 5, 2013
    Publication date: February 6, 2014
    Applicant: MATERIALS SOLUTIONS
    Inventor: TREVOR ILLSTON
  • Patent number: 8622021
    Abstract: A method of increasing mean time between cleans of a plasma etch chamber and chamber parts lifetimes is provided. Semiconductor substrates are plasma etched in the chamber while using at least one sintered silicon nitride component exposed to ion bombardment and/or ionized halogen gas. The sintered silicon nitride component includes high purity silicon nitride and a sintering aid consisting of silicon dioxide. A plasma processing chamber is provided including the sintered silicon nitride component. A method of reducing metallic contamination on the surface of a silicon substrate during plasma processing is provided with a plasma processing apparatus including one or more sintered silicon nitride components. A method of manufacturing a component exposed to ion bombardment and/or plasma erosion in a plasma etch chamber, comprising shaping a powder composition consisting of high purity silicon nitride and silicon dioxide and densifying the shaped component.
    Type: Grant
    Filed: October 27, 2008
    Date of Patent: January 7, 2014
    Assignees: Lam Research Corporation, Ceradyne Inc.
    Inventors: Travis R. Taylor, Mukund Srinivasan, Bobby Kadkhodayan, K. Y. Ramanujam, Biljana Mikijelj, Shanghua Wu
  • Patent number: 8557175
    Abstract: The invention relates to a method for making a metal part that comprises a reinforcement (15) made of ceramic fibers. The method comprises the following steps: forming at least one annular-shaped insert (15) by assembling a bundle of metal-coated fibers; placing the insert into a hollow metal mold (10) such that the insert is spaced between the walls (10a, 10b) of the mold; filling the mold with a metal powder; generating vacuum in the mold and closing the same; hot isostatic compressing the assembly at a temperature and under a pressure sufficient for binding the powder particles between them and for binding the insert fibers between them; removing the mold and optionally machining to the desired shape.
    Type: Grant
    Filed: December 24, 2008
    Date of Patent: October 15, 2013
    Assignee: Messier-Bugatti-Dowty
    Inventor: Richard Masson
  • Patent number: 8501048
    Abstract: 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: Grant
    Filed: October 14, 2008
    Date of Patent: August 6, 2013
    Assignee: Shimane Prefectural Government
    Inventors: Toshiyuki Ueno, Takashi Yoshioka
  • Publication number: 20130142686
    Abstract: An endplate for a hot isostatic pressing canister comprises a central region, and a main region extending radially from the central region and terminating in a corner about a periphery of the endplate. The thickness of the endplate increases along the main region, from the central region to the corner, defining a taper angle. The corner includes an inner surface comprising a radiused portion by which the main region smoothly transitions into the lip. A hot isostatic pressing canister including at least one of the endplates also is disclosed, along with a method of hot isostatic pressing a metallurgical powder using the hot isostatic canister.
    Type: Application
    Filed: December 2, 2011
    Publication date: June 6, 2013
    Applicant: ATI Properties, Inc.
    Inventors: Peter Lipetzky, Joseph F. Perez, Edward A. Kosol, Jean-Philippe A. Thomas
  • Patent number: 8454933
    Abstract: 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: Grant
    Filed: January 27, 2009
    Date of Patent: June 4, 2013
    Assignees: Nippon Tungsten Co., Ltd., Ube Material Industries, Ltd.
    Inventors: Mitsuyoshi Nagano, Masanobu Takasu, Yo Arita, Satoru Sano
  • Publication number: 20130115126
    Abstract: A hot isostatic pressing tool includes a plurality of canister members and the hot isostatic pressing tool including at least one set of adjacent canister members. The plurality of canister members form a chamber to receive a powder material to be hot isostatically pressed. The at least one set of adjacent canister members have interlocking features forming a U-shaped, or a Z-shaped, leakage flow path between the at least one set of adjacent second canister members. The adjacent canister members are welded together to form a joint and the U-shaped, or Z-shaped, leakage flow path reduces the likelihood of failure of the welded joint during hot isostatic pressing.
    Type: Application
    Filed: October 31, 2012
    Publication date: May 9, 2013
    Applicant: ROLLS-ROYCE PLC
    Inventor: ROLLS-ROYCE PLC
  • Publication number: 20130115127
    Abstract: A hot isostatic pressing tool comprises a canister and a support structure. The canister forming an annular chamber to receive a powder material to be hot isostatically pressed, the annular chamber having an annular portion having a predetermined radial dimension and at least one annular sub portion at a predetermined axial position having a radial dimension greater than the predetermined radial dimension. The support structure comprising at least one annular member arranged radially within the canister. The at least one annular member is located radially within the at least one annular sub portion of the annular chamber to support the canister at the predetermined axial position.
    Type: Application
    Filed: October 31, 2012
    Publication date: May 9, 2013
    Applicant: ROLLS-ROYCE PLC
    Inventor: ROLLS-ROYCE PLC
  • Publication number: 20130071627
    Abstract: A process is provided for producing a component. The process comprising the steps of: producing a former corresponding to the internal dimensions of the component to be formed; providing a layer of a second material on at least one surface of the former; locating the former in a containment and filling the containment with a first material; subjecting the containment to hot isostatic pressing such that the second material diffuses into the first material.
    Type: Application
    Filed: December 22, 2010
    Publication date: March 21, 2013
    Inventor: Geoffrey Frederick Archer
  • Patent number: 8390122
    Abstract: 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: Grant
    Filed: September 19, 2011
    Date of Patent: March 5, 2013
    Assignee: Primestar Solar, Inc.
    Inventor: Scott Daniel Feldman-Peabody
  • Patent number: 8366994
    Abstract: 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: Grant
    Filed: November 4, 2010
    Date of Patent: February 5, 2013
    Assignee: China Steel Corporation
    Inventors: Rong-Zhi Chen, Chun-Hao Chiu, Jui-Tung Chang, Deng-Far Hsu, Chih-Huang Lai
  • 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
  • Publication number: 20120301344
    Abstract: A method of manufacturing integral head and tube replacement sections includes the steps of providing a reverse mold of a head and tube replacement section, providing an atomized steel powder, and filling the reverse mold with the atomized steel powder. The method further includes the step of inserting the mold into a hot isostatic processing (HIP) furnace to consolidate and sinter the powder into the shape of the head and tube replacement section.
    Type: Application
    Filed: May 3, 2012
    Publication date: November 29, 2012
    Applicant: ELECTRIC POWER RESEARCH INSTITUTE, INC.
    Inventors: David W. Gandy, Kent K. Coleman, John Shingledecker
  • Patent number: 8298313
    Abstract: A cold-forming steel article which comprises an alloy that comprises carbon, manganese, silicon, chromium, molybdenum, vanadium, tungsten and optionally, niobium in certain concentrations, as well as up to about 0.4 wt. % of accompanying elements, remainder iron and contaminants. The article is formed by atomization of a melt and hot isostatic pressing of the resultant powder. The article exhibits a hardness of at least about 60 HRC and a toughness in terms of impact strength of higher than about 50 J. This abstract is neither intended to define the invention disclosed in this specification nor intended to limit the scope of the invention in any way.
    Type: Grant
    Filed: March 5, 2010
    Date of Patent: October 30, 2012
    Assignee: Boehler Edelstahl GmbH & Co KG
    Inventors: Gerhard Jesner, Devrim Caliskanoglu
  • Publication number: 20120270059
    Abstract: Disclosed herein is a connection means 58 made from metal, and in particular Al, Mg, Cu or Ti, or an alloy comprising one or more thereof. The connection means 58 is made from a compound material of said metal reinforced by nanoparticles, in particular CNT, wherein the reinforced metal has a microstructure comprising metal crystallites at least partly separated by said nanoparticles.
    Type: Application
    Filed: January 28, 2010
    Publication date: October 25, 2012
    Inventors: Henning Zoz, Michael Dvorak, Horst Adams
  • Patent number: 8262817
    Abstract: A first-stage turbine that is adapted for receiving high energy air directly from a combustion chamber in a gas turbine engine auxiliary power unit includes a disk formed from a first alloy and having an outer surface, and a unitary blade wheel formed from a second alloy that is different than the first alloy. The unitary blade wheel includes an annular member having an inner surface that is joined to the disk, and blades that are integrally formed with the annular member.
    Type: Grant
    Filed: June 11, 2007
    Date of Patent: September 11, 2012
    Assignee: Honeywell International Inc.
    Inventors: Scott J. Marshall, Victor M. Reyes, Timothy R. O'Brien, Huy Tran, Andrew F. Szuromi
  • Publication number: 20120177527
    Abstract: There is provided a novel bearing steel composition and a method of forming a bearing. The bearing steel composition comprises: Carbon 0.4 to 0.8 wt %; Nitrogen 0.1 to 0.2 wt %; Chromium 12 to 18 wt %; Molybdenum 0.7 to 1.3 wt %; Silicon 0.3 to 1 wt %; Manganese 0.2 to 0.8 wt %; and Iron 78 to 86.3 wt %.
    Type: Application
    Filed: July 20, 2010
    Publication date: July 12, 2012
    Applicant: AKTIEBOLAGET SKF
    Inventors: Aidan Michael Kerrigan, Mohamed Sherif, Henrik Karlsson
  • Patent number: 8211358
    Abstract: A cemented carbide including WC, a binder phase based on Co, Ni or Fe, and gamma phase, in which said gamma phase has an average grain size <1 ?m. A method of making the cemented carbide is provided in which the powders forming gamma phase are added as mixed cubic carbides of one or more of Ti, Ta, Nb, Zr, Hf and V, and a ratio, fWC, between an amount of WC (in mol fraction of WC) and an equilibrium gamma phase WC content at a sintering temperature (in mol fraction WC) is given by fWC=xWC/xeWC, wherein fWC is 0.6 to 1.0.
    Type: Grant
    Filed: February 12, 2007
    Date of Patent: July 3, 2012
    Assignee: Sandvik Intellectual Property AB
    Inventors: Bo Jansson, Susanne Norgren
  • Patent number: 8197885
    Abstract: A method for producing a metal article according to one embodiment may include: Providing a supply of a sodium/molybdenum composite metal powder; compacting the sodium/molybdenum composite metal powder under sufficient pressure to form a preformed article; placing the preformed article in a sealed container; raising the temperature of the sealed container to a temperature that is lower than a sintering temperature of molybdenum; and subjecting the sealed container to an isostatic pressure for a time sufficient to increase the density of the article to at least about 90% of theoretical density.
    Type: Grant
    Filed: February 25, 2009
    Date of Patent: June 12, 2012
    Assignee: Climax Engineered Materials, LLC
    Inventors: Dave Honecker, Christopher Michaluk, Carl Cox, James Cole
  • Patent number: 8192563
    Abstract: An actuator (12) is disclosed for example controlling gas flow in a gas turbine engine. The actuator (12) comprises a first portion (14) having shape memory properties, and a second portion (16) formed of substantially the same material as the first portion and having reduced shape memory properties relative to the first portion. The first portion (14) is movable from a first position to a second position at a temperature above the phase transition temperature of the shape memory material of the first portion (14). The second portion (16) is arranged to urge the first portion (14) from the second position to the first position at a temperature below the phase transition temperature of the shape memory material.
    Type: Grant
    Filed: May 17, 2010
    Date of Patent: June 5, 2012
    Assignee: Rolls-Royce plc
    Inventors: Daniel Clark, John R. Webster
  • Patent number: 8182617
    Abstract: The present invention comprises the nitrogen alloying of stainless steel with a gaseous nitrogen compound such as nitrogen gas (N2), or ammonia (NH3) at high temperature wherein the reaction pressure is lowered. A base powder with properties similar to those of a martensitic stainless steel is prepared from a molten metal with the subsequent incorporation of selective additives such as cobalt, chromium, boron, copper, vanadium, niobium and mixtures thereof to improve high temperature resistance to scuffing and adhesive wear. The molten mixture is then atomized by water- or air-atomization to yield a base powder which is mixed with nitrogen or ammonia gas at various pressures in a static or fluidized bed to provide a nitrogen alloyed particulate, i.e., a nitrided particulate alloy. The powder is heated in a hot isostatic press under vacuum with argon gas at reduced pressure and later cooled to ambient temperature.
    Type: Grant
    Filed: November 22, 2010
    Date of Patent: May 22, 2012
    Inventor: Kenneth A. Moyer
  • Patent number: 8168118
    Abstract: A method of forming a sputtering target and other metal articles having controlled oxygen and nitrogen content levels and the articles so formed are described. The method includes surface-nitriding a deoxidized metal powder and further includes consolidating the powder by a powder metallurgy technique. Preferred metal powders include, but are not limited to, valve metals, including tantalum, niobium, and alloys thereof.
    Type: Grant
    Filed: September 2, 2009
    Date of Patent: May 1, 2012
    Assignee: Cabot Corporation
    Inventors: Christopher A. Michaluk, Shi Yuan, James D. Maguire, Jr.
  • Publication number: 20120100033
    Abstract: This invention relates to a mould assembly for a hot isostatic pressing, HIP, process for fabricating a component, comprising: a first part which includes a shaped surface for forming a first surface of the component, the shaped surface having at least one recess; a second part arranged to move relative to the first part during the HIP process so as to compress a powder in-fill held therebetween, wherein the second part includes a formation configured to focus pressure toward the recess so as to aid consolidation of the powder in-fill at a distal end thereof.
    Type: Application
    Filed: October 5, 2011
    Publication date: April 26, 2012
    Applicant: ROLLS-ROYCE PLC
    Inventors: Wayne E. VOICE, Thomas P. JARVIS
  • Publication number: 20120100032
    Abstract: The invention relates to a mould assembly for a hot isostatic pressing, HIP, process, comprising: an insert comprising a plurality of pieces which combine to provide a recess in which a protrusion of the component can be formed; and, a holding piece having at least one cavity in which the insert is mateably received.
    Type: Application
    Filed: October 5, 2011
    Publication date: April 26, 2012
    Applicant: ROLLS-ROYCE PLC
    Inventors: Wayne E. VOICE, Junfa MEI, Thomas P. JARVIS
  • Patent number: 8128865
    Abstract: A method of fabricating a shrouded impeller is disclosed. The method includes providing an open faced impeller, the open faced impeller including a plurality of blades extending at least partially radially from a hub. The method also includes performing a first powder metallurgical process to form a first material over at least part of the open faced impeller. The method further includes forming a shroud circumferentially disposed about the hub and connected to one of more of the blades. Forming the shroud includes performing a second powder metallurgical process to metallurgically bond the shroud to at least some of the blades.
    Type: Grant
    Filed: October 31, 2007
    Date of Patent: March 6, 2012
    Assignee: Solar Turbines Inc.
    Inventors: David Brian Jahnz, Jess Lee Freeman
  • Publication number: 20120051919
    Abstract: A forging preform for a turbine rotor disk is disclosed. The preform includes a body of a superalloy material having a mass of about 5000 lbs or more, the superalloy material having a substantially homogeneous grain morphology and an ASTM average grain size of 10 or smaller. 5. A turbine rotor disk is also disclosed. The disk includes a substantially cylindrical disk of a superalloy material having a mass of about 5000 lbs or more, the superalloy material having a substantially homogeneous grain morphology and an ASTM average grain size of about 10 or smaller. A method of making a turbine rotor disk is also disclosed. The method includes providing a superalloy powder material and pressing the superalloy powder material to form a forging preform for a turbine rotor disk.
    Type: Application
    Filed: August 31, 2010
    Publication date: March 1, 2012
    Applicant: GENERAL ELECTRIC COMPANY
    Inventors: Raymond Joseph Stonitsch, George Albert Goller, Joseph Jay Jackson, David Paul Mourer, Daniel Yeuching Wei
  • Publication number: 20120039739
    Abstract: Disclosed herein is a ring cutter for a tunneling apparatus, the ring cutter formed by a process in one form comprising several steps. In one form, this mold is sacrificial, and may be a pair of parallel cylinders such as an outer and an inner cylinder with a gap there between. In one manufacturing process, a single mold is used to produce multiple cutters which are cast simultaneously within the single mold. In one form, the mold is formed in the final shape of the cutter, such that the cutter requires no further machining to be used in a tunneling apparatus. Another step being: disposing a volume of powdered metal, such as a nickel based alloy, into the mold. The powdered metal may then be subjected to isostatic gas pressures, and elevated sintering temperatures simultaneously (HIP) with the isostatic gas pressure to consolidate the powdered metal.
    Type: Application
    Filed: August 10, 2011
    Publication date: February 16, 2012
    Inventor: David Krauter
  • Publication number: 20120012460
    Abstract: A metal article formed by compacting a sodium/molybdenum composite metal powder under sufficient pressure to form a preformed article; placing the preformed article in a sealed container; raising the temperature of the sealed container to a temperature that is lower than a sintering temperature of molybdenum; and subjecting the sealed container to an isostatic pressure for a time sufficient to increase the density of the metal article to at least about 90% of theoretical density.
    Type: Application
    Filed: September 26, 2011
    Publication date: January 19, 2012
    Applicant: Climax Engineered Materials, LLC
    Inventors: Dave Honecker, Christopher Michaluk, Carl Cox, James Cole
  • Publication number: 20120009080
    Abstract: 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: Application
    Filed: July 11, 2011
    Publication date: January 12, 2012
    Applicant: Climax Engineered Materials, LLC
    Inventors: Matthew C. Shaw, Carl V. Cox, Yakov Epshteyn
  • Patent number: 8087143
    Abstract: A method for the manufacture through diffusion bonding of metallically encapsulated ceramic armor providing enhanced ballistic efficiency and physical durability.
    Type: Grant
    Filed: June 18, 2008
    Date of Patent: January 3, 2012
    Assignee: Exothermics, Inc.
    Inventor: Stephen DiPietro