Abstract: A sintered metal body is disclosed of composition consisting essentially of in weight percent about 5 to 40 Cr, about 2 to 30 Al, 0 to about 5 special metal, 0 to about 4 rare earth oxide additive, and the balance Fe group metal and unavoidable impurities,the composition including at least one component selected from component A and/or component B, component A being special metal, and component B being at least an effective amount of rare earth oxide additive,the special metal being a first special metal component, and optionally, a second special metal component when rare earth oxide additive is 0, the first special metal component consisting of at least one of: Y, lanthanides, Zr, Hf, Ti, Si, and B, and the second special metal component consisting of at least one of: alkaline earth metal, Cu, and Sn, and the special metal being a third special metal component when rare earth oxide additive is >0, the third special metal component consisting of at least one of Y, lanthanides, Zr, Hf, Ti, Si, alkaline ear

Abstract: Disclosed is a hard alloy with high hardness, high abrasion resistance, high corrosion resistance and high rigidity, which is excellent in performance in use for tools. The hard alloy contains more than 80% by weight of WC with less than 2 .mu.m of average particle size, more than 0.2% by weight and less than 2% by weight of Co and the remaining part of one or more metals, carbides, nitrides and carbonitrides of the metals in the IVa, Va and VIa families in the periodic table, such as 2.0 to 7.0% by weight of one or more of Mo and Mo.sub.2 C, and the alloy contains Co.sub.x W.sub.y C.sub.z in the sintered product. By the addition of Mo or Mo.sub.2 C and VC the growth of particles in the hard phase is inhibited and at the same time the wettability of WC--Co is increased.

Abstract: In the present invention, metal silicide grains form an interlinked structure of a metal silicide phase, and Si grains which form a Si phase are discontinuously dispersed between the metal silicide phase to provide a sputtering target having a high density two-phased structure and having an aluminum content of 1 ppm or less. Because of the high density and high strength of the target, the generation of particles from the target during sputtering is reduced, and due to the reduced carbon content of the target, the mixing of carbon into the thin film during sputtering can be prevented.

Abstract: A method for the preparation of an open cell porous metallic material is provided. The method includes first molding a metal oxide powder into a desired gas-permeable body, then firing the body to obtain a sintered body of metal oxide. Lastly, oxygen is removed from the sintered metal oxide by firing in a reducing atmosphere. In a preferred embodiment, metal oxides such as NiO are combined with polyvinyl alcohol (PVA) and compressed into a molded body which is then air-fired and reduced. Pore sizes of less than 1 .mu.m are characteristic. Porosity of up to 64 percent has been demonstrated for nickel. In another preferred embodiment, mixed systems of metal alloys are demonstrated. In particular, results are shown for a NiO--MoO.sub.3 system.

Abstract: A formable composite magnetic flux concentrator is composed of about 65 to 90 percent ferromagnetic material, such as iron powder, and about 35 to 10 percent binder, the binder being a mixture of an epoxy and one or more catalysts. The concentrator is provided in a formable state as a putty-like body which can be worked into any desired shape dictated by the configuration of the induction heating coil used in a particular application.

Abstract: A method for forming molten carbonate fuel cell (MCFC) anodes by adjusting the reaction condition of pack cementation is disclosed. The method includes the steps of embedding a base metal sheet containing at least Ni in a pack containing alloy metal powder, an activator and a filler, pre-heating the pack to remove the organic material included in the base metal sheet, and maintaining the pack under a H.sub.2 /N.sub.2 atmosphere at a temperature of 500.degree. C. to 800.degree. C. for one to eight hours to form a Ni alloy. The method has a simplified procedure and is very useful to manufacture MCFC anodes having a very low creep deformation rate while porosity is in an appropriate range.

Abstract: Metal injection-molded green bodies (2) are formed from a granulated feedstock comprising metal powder and a binder comprising:a) 15-25 volume % paraffin waxb) 20-30 volume % microcrystalline waxc) 45-60 volume % polyethylene.The paraffin wax has two melting regions around 45.degree. C. and 63.degree. C. and the microcrystalline wax exhibits four melting regions in the range 62.degree. C. and 144.degree. C. By raising the temperature of the oven in a controlled manner, first the paraffin wax and then the microcrystalline wax melts and is vapourised and entrained in a flow of carrier gas which flows over supporting trays (5), as indicated by the horizontal arrows (a). The requirement for wicking powder is eliminated by the staged removal of the wax and the polyethylene can subsequently be removed at a higher temperature by thermal depolymerisation in the same apparatus.

Abstract: A method for heating metal powder, e.g., iron powder, comprises irradiating the powder with microwaves. The powder may be coated with various materials to enhance the heating effects of the microwave. For example, the powder may be coated with a non-emissive material, such as a ceramic material. The powder may also be coated with a dipole material, such as water or plastic, or a dielectric material.

Abstract: A method for obtaining a product from pre-alloyed powders in which the powders are subjected to compaction treatment. The powders are first subjected to pre-treatment under low pressure (or without pressure) at a temperature such that segregating materials precipitate out in stable phases.

Abstract: Metal particulates and porous metal media, which have enhanced resistance to undesirable oxidation, and methods of producing the same are provided. The porous metal media comprise sintered metal particulates each typically having a core and a surface and a diameter in the range of 0.25 to 50 micrometers, the particulates comprising at least about 60 wt. % of a base metal including at least one of iron and nickel, at least about 11 wt. % chromium and no more than about 0.03 wt. % carbon. The surfaces of the particulates are enriched with at least one treatment element in an amount and depth sufficient to enhance the resistance of the particulates to undesirable oxidation. The invention also includes a fine metal filter medium formed from sintered metal fibers, which has enhanced resistance to corrosion and/or to high temperature oxidation.

Abstract: A high capacity, long cycle life positive electrode for use in an alkaline rechargeable electrochemical cell comprising: a solid solution nickel hydroxide material having a multiphase structure that comprises at least one polycrystalline .gamma.-phase including a polycrystalline .gamma.-phase unit cell comprising spacedly disposed plates with at least one chemical modifier incorporated around the plates, the plates having a range of stable intersheet distances corresponding to a 2.sup.+ oxidation state and a 3.5.sup.+, or greater, oxidation state; and at least one compositional modifier incorporated into the solid solution nickel hydroxide material to promote the multiphase structure.

Abstract: A method for manufacturing a sintered body by a) forming a slurry comprising a powder mixture, a dispersant providing steric stabilization for the powders and an organic solvent with a possible addition of one or more soluble polymers; b) transferring the slurry into a mold; and c) changing the temperature sufficient to cause gelation of the sterically stabilized suspension to form a green body. The method also includes d) removing the green body from the mold; e) transferring the green body to a chamber where the gelation temperature can be maintained and the pressure decreased to facilitate removal of the solvent to form a dried body; f) heating the body for a time sufficient to substantially remove the dispersant from the body and; g) sintering the body. The sintered body can be an insert for metal cutting tools.

Abstract: A process for making a non magnetic Ni-WC cemented carbide composition and articles made from the same. The process comprises:(a) dewaxing a green Ni-WC cemented carbide substrate in the presence of hydrogen gas at a pressure less than about 1000 torr and at a sufficient flow rate and a sufficient time to affect the saturation magnetization and magnetic permeability of the Ni-WC cemented carbide substrate;(b) pumping out the hydrogen gas and introducing argon at a pressure in the range of about 1 torr to 1000 torr;(c) increasing the temperature up to the sintering temperature to facilitate sintering of the Ni-WC cemented carbide substrate; and;(d) cooling the furnace to room temperature.The articles made according to this invention are useful as wear parts for electronic instruments and as punches form aluminum beverage cans.

Abstract: A process for controlling the carbon content in a metallic piece molded by injection or other process comprising,a) heating the shaped piece under a 100% hydrogen atmosphere up to about 200.degree. C.,b) replacing the 100% H.sub.2 atmosphere by a substantially 100% nitrogen atmosphere and heating the pieces from 200.degree. C. to 450.degree. C.,c) maintaining the temperature in the enclosure at substantially 450.degree. C. while subjecting the pieces to an atmosphere comprising from 15% to 100% vol. hydrogen, the complement being nitrogen, thend) replacing the atmosphere by a substantially 100% nitrogen ande) heating the pieces from 450.degree. C. to substantially 700.degree. C. in order to further eliminate the remaining binder.

Abstract: A porous electrode for pacemakers is comprised of a plurality of platinum globules sintered together to form a porous mass of semi-hemispherical shape at the end of a platinum electrode stem. The globules, which are themselves made by sintering together spherically-shaped particles of approximately one micron diameter, provide the globules with an irregular outer surface of high total surface area. The globules have diameters within a critical range of 40-200 microns. The large total surface area of the globules improves the sensing function of an electrode configuration of given size and surface area, while the globule diameters of 40-200 microns have been found to beneficially accommodate tissue ingrowth within the electrode. In a preferred method of making the electrode, the platinum globules, which are formed by sintering together platinum particles of much smaller size, are mixed with organic solvent and organic binder to form a paste.

Abstract: A process for producing a ceramic sintered body having a metallized via hole previously formed after lamination of the ceramics is disclosed and said process comprises immersing in a first liquid a ceramic semi-sintered body formed through heating at 500 to 900.degree. C. and having a large number of pores and a straight via hole, thereby to allow the first liquid to penetrate into the pores of the semi-sintered body, subsequently immersing the resulting semi-sintered body in a suspension of electrically conductive powder particles having an average particle size of 2 to 3 .mu.m in a second liquid incompatible with the first liquid, thereby to fill the via hole with the suspension, and then sintering the resulting semi-sintered body in a non-oxidizing atmosphere.

Abstract: A process for producing a thermoelectric material comprises molding a material powder comprising two or more elements selected from the group consisting of bismuth, tellurium, antimony and selenium and having average diameter in the range from 0.05 to 100 .mu.m and sintering the molded material powder with or without hot isostatic pressing. The material powder may be calcinated before the molding. A process for producing a thermoelectric element comprises cutting out pieces of a pillar-like shape from each of a p-type thermoelectric material and a n-type thermoelectric material, connecting the pieces cut out from the p-type thermoelectric material and the pieces cut out from the n-type thermoelectric material alternately with electrodes at the upper faces or the lower faces of the pieces and attaching insulating base plates to the surfaces of the electrodes. The p-type thermoelectric material and the n-type thermoelectric material are respectively produced by the process described above.

Abstract: The present invention describes a process for the compaction and densification of discrete powder materials utilizing a high amplitude stress wave which produces a high pressure condition at a surface of the particles thereby driving said stress wave into and through the particles.

Abstract: Porous metal components for high temperature fuel cells which are made by integrating the heretofore employed, separate tape casting and pack cementation processes. Particles of a base metal and a master alloy are suspended in a liquid medium in which a binding agent and a halide activator are dispersed. The suspension is cast into the shape wanted in the component, typically by tape casting; and the cast structure is heated to remove the liquid medium, leaving a flexible, green cast structure commonly referred to as a tape. The green tape is so heated as to: (a) burn out the binder in the tape; (b) form an alloy of the base metal and an alloying metal in the master alloy; and (c) sinter the alloy particles into a porous, coherent metal structure.

Abstract: An aluminum-alloy main-starting powder for producing a sintered aluminum-alloy consists of from 0.1 to 3.0% of Cu, the balance being Al and unavoidable impurities. Mother alloy powder consists of from 4 to 20% of Mg, from 12 to 30% of Si, and Al and unavoidable impurities in balance.

Abstract: A titanium-tungsten target material used to form, by sputtering, a barrier metal or the like for use in semiconductor devices. The titanium-tungsten target material is substantially composed of tungsten particles and a titanium-tungsten alloy phase surrounding the tungsten particles. The area ratio at which tungsten grains occupy in a cross section of the titanium-tungsten target material is, preferably, not more than 15%, more preferably, not more than 10%. If the average crystal grain size of the target material is not more greater 15 .mu.m, a uniform thin film can be obtained by sputtering. The target material can be obtained by sintering a titanium powder and a tungsten powder.

Abstract: A method for controlling the remanance of a sintered magnet by varying the time when the orienting field is applied during cold compression. The method comprises obtaining powders of an appropriate particle size, compressing the powders in an oriented field, sintering, heat treating, machining and magnetizing to technical saturation. The cold compressing in an orienting field takes place at a precompression rate of more than 15% before the orienting field is applied. The method applies to magnets of all shapes which must have magnetic induction well defined in modulus and in direction, particularly annular magnets for traveling wave tubes.

Abstract: A process for producing a precision metal part of a sintered body by powder molding comprises using a metal powder of which the oxygen content and the hydrogen reduction loss are controlled to 0.5-6 wt. % and 1-7 wt. %, respectively. The sintered body has a high density near the theoretical density and is excellent in dimensional accuracy. The molding is facilitated, and the process is simple.

Abstract: A coated cemented carbide alloy, excellent in toughness as well as wear resistance and which is used for cutting tools and wear resistance tools is provided herein. This coated cemented carbide alloy is composed of a cemented carbide substrate consisting of a hard phase of at least one member selected from carbides, nitrides and carbonitrides of the Group IVb, Vb and VIb metals of Periodic Table and a binder phase consisting of at least one member selected from the iron group metals, and a monolayer or multilayer provided on the substrate consisting of at least one member selected from the carbides, nitrides, oxides and borides of Group IVb, Vb and VIb metals of Periodic Table, solid solutions thereof and aluminum oxide, and wherein a binder phase-enriched layer is provided in a space 0.01 mm and 2 mm below the surface of the substrate with A-type and/or B-type pores inside the binder phase-enriched layer.

Abstract: A method is provided for producing a high strength iron based component by powder metallurgical techniques but without sintering. A powder composition of iron-based particles coated or admixed with a thermoplastic material is compacted under heat and pressure by traditional powder metallurgical techniques. The pressed component is then heat treated at a temperature above the glass transition temperature of the thermoplastic material for a time sufficient to bring the component to the heat treatment process temperature. The resulting component has increased strength and can be used as a structural component or as a magnetic core component.

Abstract: The present invention relates to a process for producing sinters, including a steps of mixing a powder material with a binder, injection molding the mixture, and then dewaxing and sintering the resulting injection molded article, wherein the binder comprises at least one of: copolymer, a mixture of copolymer, paraffine wax, carnauba wax, a mixture of the paraffine wax and the carnauba wax, a plasticizer, and a lubricant. According to the present invention, the dewaxing step comprises heating the injection molded article to a temperature of 250.degree.-500.degree. C. in a heating rate of 5.degree.-100.degree. C./hour under the pressure not higher than 1 Torr in order to remove 40%-95 % by weight of the binder components. Further, the temperature elevation in the sintering step is started in a vacuum atmosphere and replacing the atmosphere with an inert gas atmosphere in the process of temperature elevation.

Abstract: A high speed tool steel produced by sintering powder, consisting essentially, by weight, of more than 1.5% but not more than 2.2% C, not more than 1.0% Si, not more than 0.6% Mn, 3.0 to 6.0% Cr, an amount of W and Mo in which the content of W+2Mo is in the range of 20 to 30% and in which the ratio of W/2Mo is not less than 1, not more than 5.0% V, 2.0 to 7.0% Nb, the ratio of Nb/V being not less than 0.5, and the balance Fe and incidental impurities, the value of C-Ceq, which Ceq is defined by 0.24+0.033.times.W+0.063.times.Mo+0.2.times.V+0.1.times.Nb, being in a range of -0.20 to 0.05, the density of carbides in the sintered steel having grain size of 2 to 5 .mu.m being in a range of 10,000 to 30,000 pieces/mm.sup.2.

Abstract: A process for producing strip products which comprises forming an aqueous slurry of a suspension of metallic particles in a film forming cellulose derivative, depositing a quantity of the slurry onto a support surface, drying the slurry to form a self supporting flat product, removing the dried product from the support surface and roll compacting the same to produce a green strip. The green strip is supported on a moving surface as it travels to and enters a heater in which it is heated in an oxidising atmosphere to a temperature at which substantially all traces of the cellulose derivative are removed. The heated strip is fed while still on the moving support surface to and through a sinter furnace to form a coherent strip of the required composition.

Abstract: A Fe-base sintered alloy for a valve seat for use in internal combustion engines, which constitutes a chemical composition of 0.4 to 2% of C, 0.5 to 5% of Cr, 5 to 15% of Mo, 0.2 to 2% of Ni, 0.4 to 2% of Co, 8 to 20% of Cu, 0.01 to 0.5% of S, and the balance Fe, wherein percentages are by weight. The Fe-base sintered alloy possesses high strength and high rigidity, and hence exhibits excellent abrasive and corrosion wear resistance properties, as well as excellent lubricity.

Abstract: This patent covers the concept of putting a previously sintered carbide tool or part back through the sintering process. This resintering, heals stress related microcracks which, when allowed to progress, could ultimately be a cause of the failure for the object. This produces a longer life, better quality cemented carbide tool to be used for cyclically applying pressure and/or heat.

Abstract: The invention relates to a composite hard metal body of hard material, a binder and embedded reinforcing material, as well as to a process for the production of the composite hard metal body by methods of powder metallurgy.In order to create a composite hard metal body with improved toughness under load, improved hardness and a lower fracture susceptibility, the invention proposes to build in monocrystalline, preferably needle-shaped and/or platelet-shaped reinforcing materials, coated with an inert layer with respect to the binder metal phase and consisting of borides and/or carbides, and/or nitrides and/or carbonitrides of the elements of Groups IVa or Va or mixtures thereof and/or coated monocrystalline reinforcing material of SiC, Si.sub.3 N.sub.4, Si.sub.2 N.sub.2 O, Al.sub.2 O.sub.3, ZrO.sub.2, AlN and/or BN.

Abstract: Ti-W target material for sputtering includes a structure composed of a W phase, a Ti phase, and a Ti-W alloy phase of which 20% or more consist of the area ratio of a micro structure covering the cross section of the Ti-W target material. The Wi-W target material further includes dispersed tungsten particles, the Ti-W alloy phases substantially surrounding the W grains, and the Ti phases dispersed adjacent to the Ti-W alloy phase or the W grains. The formation of the Ti-W alloy phases is capable of reducing a substantial amount of the Ti phase in the target material. It is thus possible to prevent the generation of particles attributable to a difference between sputtering speeds of Ti and Ti-W.

Abstract: The present invention relates to a method of producing a mold material used for obtaining a mold for casting metals such as Zn, Al and the like or molding resins. In the method, the short fibers having an aspect ratio of 30 to 300 and obtained by cutting ferritic stainless steel long fibers having a width of 100 .mu.m or less, ferritic stainless steel powder and at least one of Cu powder and Cu alloy powder are used as raw materials. The raw materials are blended to obtain a material mixture which is then compressed under pressure in a Cold Isostatic Press process. The thus obtained compressed product is sintered in a vacuum atmosphere. The sintered material is held in an atmosphere of nitrogen gas or decomposed ammonia gas so that 0.3 to 1.2 wt % of nitrogen is added to the stainless steel in the sintered material. The thus obtained mold material has a hardness of HMV 250 to 500.

Abstract: In a method of manufacturing a sintered ceramic material using the heat generated in a thermit reaction as a heating source, a pre-heating is applied preceding to the sintering step or a mixture comprising: (A) at least one ceramic powder, (B) at least one non-metallic powder selected from the group consisting of carbon, boron and silicon, and (C) a metal powder and/or a non-metallic powder other than the above-mentioned (B) is used. Homogeneous and dense sintered ceramic material or sintered composite ceramic material can be obtained by this method, and the fine texture thereof, and the phase constitution, the phase distribution and the like of the composite ceramic phase can be controlled sufficiently.

Abstract: Magnet material of the Sm-Fe-N system having a crystalline, hard magentic phase with a Th.sub.2 Zn.sub.17 crystal structure, wherein N atoms are incorporated into the crystal lattice, is produced. First a preliminary product is formed by sintering a Sm-Fe powder which is oriented in a magnetic field to provide a sintered body having a two-component Sm-Fe phase. The sintered body is heat treated in a nitrogen atmosphere to form the Sm-Fe-N hard magnetic phase. The nitrogen atomosphere may advantageously be reactive nitrogen.

Abstract: A shaped body of anisotropic magnetic material based on the Sm-Fe-N system which has a crystalline, hard magnetic phase with a Th.sub.2 Zn.sub.17 crystal structure, wherein N atoms are incorporated in the crystal lattice, is produced by compacting a powder Sm-Fe preliminary product with an Sm-Fe phase having a magnetically isotropic structure, followed by hot-shaping to provide an intermediate product with a Sm-Fe phase having a magnetically anisotropic structure, followed by heat treating the intermediate product in a nitrogen atmosphere to provide a Sm-Fe-N hard magnetic phase.

Abstract: A method and apparatus are disclosed for fabrication of hollow articles by hot consolidation of metal alloy powder between a hollow core and a fluid pressure resistant outer shell. The hollow core is formed, a disposable layer is applied to define the object contour, a fluid pressure resistant metallic layer is formed over the disposable layer, which is then melted, removed and replaced by the metal alloy powder, and this assembly is hot isostatically pressed. The powder and core materials are preferably selected to be metallurgically compatible, so the core becomes an integral part of the finished article. The hollow article is inflated in a form die to establish the finished article contour.

Abstract: A method for manufacturing a brake fitting comprising a plurality of studs each surrounded by a less fragile belt, the studs being non-contiguously secured to a metal support. According to the method, the support is provided with a slip-resistant surface by coating with a braze welding suspension which is oxidized and reduced. Stud blanks then are molded and compacted from powdered friction products and belt blanks are molded and compacted from metal powders and given an internal diameter 1.005 to 1.05 times the external diameter of the stud blanks, and the belt blanks are disposed around the stud blanks and sintered, obtaining sheathed stud blanks which are placed on the slip resistant surface of the support, and welded thereto by heat treatment. Finally, the sheathed stud blanks are forged at over 400 degree C., shortening them by at least 15%.

Abstract: A process for producing high-strength, substantially nonporous alloys by means of a three-component mixture, including admixing a first component of one or more low-melting temperature metals or alloys thereof, a second component of one or more high-melting temperature metals or alloys thereof, and a substantially inert third component of one or more refractory compounds, subjecting the mixture to changes in temperature so as to form a mixture capable of being shaped at a temperature well below the melting or decomposition temperature of the highest melting metal and the inert refractory compound.

Abstract: Methods for preparing sintered components from iron-containing and alloy steel powder are provided. The methods includes compacting a powder mixture in a die set at a pressure of at least about 25 tsi to produce a green compact which is then presintered at a temperature of about 1100.degree.-1600.degree. F. (593.degree.-870.degree. C.) for at least about 5 minutes to produce a presintered preform. The presintered preform is then compacted at a pressure of at least about 25 tsi to produce a double-pressed presintered preform, which is, in turn, sintered at a temperature of at least about 1000.degree. C. for at least about 5 minutes to produce a sintered component having improved transverse rupture strength and a higher density.

Abstract: A process for the production of a varistor material having a nonlinear index (.alpha.) of at least 20, which comprises adding a manganese compound to zinc oxide; heating the obtained mixture in the form of a powder in the atomosphere at 1050.degree. to 1150.degree. C.; grinding the material to give a particle size of 150 mesh or below; molding the powder into a desired shape; and sintering the same at 1200.degree. to 1350.degree. C.; is disclosed.

Abstract: A preparation method of bulk YBa.sub.2 Cu.sub.3 O.sub.x superconductors with high transport critical current and critical current density (Jc), wherein x is 7-.delta., obtained by a modified melt-textured growth method. A continuous dc current carrying capacity exceeding 120 A with critical current density, Jc, higher than 37300 A/cm.sup.2 at 77K has been obtained for the prepared superconductor.

Abstract: A varistor material comprising two crystalline phases of ZnO and ZnMn.sub.2 O.sub.4, wherein Zn and Mn are present at such a ratio that 3 to 7% by mol of ZnO is contained per 100% by mol of ZnO+MnO and the nonlinear index (.alpha.) of the varistor properties is at least 10; and a process for the production of the same, which comprises adding a manganese compound to ZnO at such a ratio as to give a content of MnO, sintering the mixture at 1100.degree. to 1350.degree. C., and further annealing the obtained sintered material at a temperature lower than the sintering temperature by at least 50.degree. C. and higher than 1000.degree. C. are disclosed.

Abstract: Thermoelectric elements with excellent thermoelectric characteristics such as Seebeck coefficient thermoelectromotive force and thermal conductivity can be produced by molding a powder of metal or metal alloy as the raw material and then sintering; by using as such raw material, ultra fine powders containing Fe and Si as main components and having a mean particle diameter of 50 to 5,000.ANG..

Abstract: A method for manufacturing a dense cermet article including about 80-95% by volume of a granular hard phase and about 5-20% by volume of a metal binder phase. The hard phase is (a) the hard refractory carbides, nitrides, carbonitrides, oxycarbides, oxynitrides, carboxynitrides, borides, and mixtures thereof of the elements selected from the group consisting of Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, W, and B, or (b) the hard refractory carbides, nitrides, carbonitrides, oxycarbides, oxynitrides, and carboxynitrides, and mixtures thereof of a cubic solid solution of Zr--Ti, Hf--Ti, Hf--Zr, V--Ti, Nb--Ti, Ta--Ti, Mo--Ti, W--Ti, W--Hf, W--Nb, or W--Ta. The binder phase is a combination of Ni and Al having a Ni:Al weight ratio of from about 85:15 to about 88:12, and 0-5% by weight of Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, W, Co, B, and/or C. The method involves presintering the hard phase/binder phase mixture in a vacuum or inert atmosphere at about 1475.degree.-1675.degree. C., then HIPing at about 1575.degree.-1675.degree. C.

Abstract: A titanium or titanium alloy composite having a porous surface layer, which comprises a titanium or titanium alloy substrate and a porous titanium or titanium alloy layer that adheres strongly to said substrate, said porous layer being formed by first providing said substrate with a firmly adhering sinter of a mixture of a titanium or titanium alloy powder and a magnesium powder, and then removing magnesium from the sinter. A process for producing a titanium or titanium alloy composite having a porous surface layer, comprising: providing a coating composition comprising a binder added to a mixture of a titanium or titanium alloy powder and a magnesium powder; applying said composition to the surface of a titanium or titanium alloy substrate; heating the substrate at a temperature of from 650.degree. to 800.degree. C. in vacuo or an inert atmosphere so as to form a sinter of the powders of titanium or titanium alloy and magnesium which firmly adheres to said substrate; and removing magnesium from said sinter.

Abstract: Shaped parts are formed from a powder having the desired chemistry of the finished part by mixing the powder with a thermosetting condensation resin that acts as a binder. The resin may be partially catalyzed, or additives or surfactants added to improve rheology, mixing properties, or processing time. Upon heating, the inherently low viscosity mixture will solidify without pressure being applied to it. A rigid form is produced which is capable of being ejected from a mold. Pre-sintered shapes or parts are made by injection molding, by using semi-permanent tooling, or by prototyping. Binder removal is accomplished by thermal means and without a separate debinding step, despite the known heat resistance of thermosetting resins. Removal is due to the film forming characteristic of the binder leaving open the part's pores, by providing oxidizing conditions within the part's pores as the part is heated, and by insuring that the evolving resin vapor diffuses through the pores by heating the part in a vacuum.

Abstract: The invention provides a method of manufacturing a thin metallic body composite structure. First, an inner layer of a first metal is cleaned to remove oxides and promote metallurgical bonding. The inner layer has a plurality of penetrating holes piercing the thickness of the inner layer. The penetrating holes are filled with metal powder of a second metal. Two outer layers of the second metal are placed on opposite sides of the cleaned and filled inner layer to form a sandwich structure. The sandwich structure is heated to a temperature at which recrystallization will occur in a non-oxidizing atmosphere. The sandwich structure is then hot worked to reduce thickness of the sandwich structure forming the thin metallic body composite structure.

Abstract: A consolidated tungsten alloy body consisting essentially of from about 70% to about 98% by weight of tungsten, balance nickel and iron in essentially an 8:2 weight ratio. A process for producing the consolidated bodies where the tungsten content is greater than about 88% by weight comprises forming a relative uniform blend of the described metal powders, compacting the powders to form a green body then liquid phase sintering the green body to full density. For alloys containing less than about 90% tungsten solid state sintering can be used.

Abstract: A sintered body is produced by a process comprising the steps of mixing one or more metal powder particles with an organic binder, injection-molding the mixture to form a green body of a predetermined shape, removing the binder from the green body to form a porous body substantially made of the metal powder, and heating the porous body to a sintering temperature and holding it at that temperature to produce a sintered body, in which process the binder is removed through the sequence of the following steps: preheating the green body in an inert gas atmosphere in a temperature range that creates open pores in it; placing the green body, in which open pores have started to form, in a hydrogen gas atmosphere optionally mixed with an inert gas; holding the green body in a temperature range where the metal powder is not carburized and where the open pores will be maintained, so that the greater part of the binder is removed to form a porous body that is substantially made of the metal powder alone; and further hold