Different Temperatures Patents (Class 419/54)
  • Patent number: 9101984
    Abstract: A manufacturing method for making components includes: providing at least one of a prealloyed powder of a composition of Ni—Ti in the range of Ni-36Ti to Ni-45Ti or a mix of powders that forms a composition of Ni—Ti in the range of Ni-36Ti to Ni-45Ti; loading at least one of the prealloyed powder and the mix powders into a container; hot isostatically pressing (HIP) the container to full density to obtain a compact; rolling the compact in a mill with multiple passes to produce a sheet or other mill form material; and cutting blanks for the components from the sheet material to produce a component blank.
    Type: Grant
    Filed: November 15, 2012
    Date of Patent: August 11, 2015
    Inventors: Eric S. Bono, Charles Frederick Yolton
  • Patent number: 8992828
    Abstract: A method for manufacturing a high ductility Ti-, Ti-alloy or NiTi-foam, meaning a compression strain higher than 10%, includes: preparing a powder suspension of a Ti-, NiTi- or Ti-alloy powder, bringing the said powder suspension into a desired form by gelcasting to form a green artifact. The method also includes a calcination step wherein the green artifact is calcined, and sintering the artifact. The calcination step includes a slow heating step wherein said green artifact is heated at a rate lower or equal to 20° C./hour to a temperature between 400° C. and 600° C. and the Ti-, NiTi- or Ti-alloy powder has a particle size less than 100 ?m. A high ductility Ti-, Ti-alloy or NiTi foam, with a compression higher than 10%, with a theoretical density less than 30%, pore size (cell size) between 50 to 1000 ?m can be obtained with such a method.
    Type: Grant
    Filed: June 7, 2006
    Date of Patent: March 31, 2015
    Assignee: Vlaamse Instelling Voor Technologisch Onderzoek (VITO)
    Inventors: Steven Mullens, Ivo Thijs, Jozef Cooymans, Jan Luyten
  • Patent number: 8968641
    Abstract: The present invention relates to a process for producing porous metallic materials comprising the steps of: (a) miming metallic particles with a carbonate additive and a binder, wherein the quantity of carbonate additive in the mixture is in the range of 40 to 90 vol % and compressing the mixture beyond the yield strength of the metallic particles; (b) heating the mixture to a first temperature sufficient to evaporate the binder; (c) heating and maintaining the temperature of the mixture to a second temperature sufficient to sinter the metallic particles but insufficient to decompose or melt the carbonate additive; (d) removing the carbonate additive from the sintered porous metallic material; and optionally (e) heating and maintaining the temperature of the porous metallic material to a third temperature greater than the second temperature so as to enhance the sintering. The present invention also relates to metallic materials produced by such a process.
    Type: Grant
    Filed: May 19, 2005
    Date of Patent: March 3, 2015
    Assignee: The University of Liverpool
    Inventor: Yuyuan Zhao
  • Publication number: 20140271325
    Abstract: Provided in one embodiment is a method, comprising: sintering a plurality of nanocrystalline particulates to form a nanocrystalline alloy, wherein at least some of the nanocrystalline particulates may include a non-equilibrium phase comprising a first metal material and a second metal material, and the first metal material may be soluble in the second metal material. The sintered nanocrystalline alloy may comprise a bulk nanocrystalline alloy.
    Type: Application
    Filed: March 14, 2014
    Publication date: September 18, 2014
    Inventors: Christopher A. Schuh, Mansoo Park
  • 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
  • Publication number: 20140132377
    Abstract: An alloy for R-T-B-based rare earth sintered magnets which contains R which is a rare earth element; T which is a transition metal essentially containing Fe; a metallic element M containing one or more metals selected from Al, Ga and Cu; B and inevitable impurities, in which R accounts for 13 at % to 15 at %, B accounts for 4.5 at % to 6.2 at %, M accounts for 0.1 at % to 2.4 at %, T accounts for balance, a proportion of Dy in all rare earth elements is in a range of 0 at % to 65 at %, and the following Formula 1 is satisfied, 0.0049Dy+0.34?B/TRE?0.0049Dy+0.36??Formula 1 wherein Dy represents a concentration (at %) of a Dy element, B represents a concentration (at %) of a boron element, and TRE represents a concentration (at %) of all the rare earth elements.
    Type: Application
    Filed: July 6, 2012
    Publication date: May 15, 2014
    Applicant: SHOWA DENKO K.K.
    Inventors: Kenichiro Nakajima, Takashi Yamazaki
  • 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
  • Patent number: 8323790
    Abstract: Multimodal cermet compositions having lower melting point metal binders and methods of making are provided. The multimodal cermet compositions having a low melting point metal binder include: a) a ceramic phase, and b) a low melting point metal binder phase, wherein the ceramic phase is a metal boride with a multimodal distribution of particles, wherein the metal of the metal boride is chosen from Group IV, Group V, Group VI elements of the Long Form of the Periodic Table of Elements, and mixtures thereof, and wherein the low melting metal binder phase is represented by the formula (DEF), wherein D is a base metal chosen from Fe, Ni, Co, Mn and mixtures thereof, E is an alloying metal comprising Cr, Si, and B, and F is an alloying element chosen from C, N, P, Al, Ga, Ge, As, In, Sn, Sb, Pb, Sc, La, Y, Ce, Ti, Zr, Hf, V, Nb, Ta, Mo, W, Re, Ru, Rh, Ir, Pd, Pt, Cu, Ag, Au and mixtures thereof, and wherein said low melting metal binder phase has a melting point less than 1250° C.
    Type: Grant
    Filed: November 14, 2008
    Date of Patent: December 4, 2012
    Assignee: ExxonMobil Research and Engineering Company
    Inventors: ChangMin Chun, Narasimha-Rao Venkata Bangaru
  • Patent number: 8110049
    Abstract: An RE-containing alloy, which is represented by a compositional formula of RrTtAa (wherein R represents at least one rare earth element selected from among La, Ce, Pr, Nd, Sm, Eu, Tb, Dy, Ho, Tm, Yb, Gd, and Lu; T collectively represents transition metal elements containing at least Fe atoms, a portion of the Fe atoms being optionally substituted by at least one species selected from among Co, Ni, Mn, Pt, and Pd; A represents at least one element selected from among Al, As, Si, Ga, Ge, Mn, Sn, and Sb; and r, t, and a have the following relationships: 5.0 at. %?r?6.8 at. %, 73.8 at. %?t?88.7 at. %, and 4.6 at. %?a?19.4 at. %) and having an alloy microstructure containing an NaZn13-type crystal structure in an amount of at least 85 mass % and ?-Fe in an amount of 5-15 mass % inclusive.
    Type: Grant
    Filed: February 17, 2010
    Date of Patent: February 7, 2012
    Assignee: Showa Denko K.K.
    Inventor: Kenichiro Nakajima
  • Patent number: 8071015
    Abstract: Disclosed is a process of producing a porous metal body containing a metal component which is likely to be oxidized, by which process the amounts of residual carbon and residual oxygen therein are decreased, and by which the performance of the product porous body can be largely promoted. The process for producing a porous metal body by sintering a material of the porous metal body, which material is obtained by coating a slurry containing a metal powder and an organic binder on an organic porous aggregate, comprises a defatting step of treating the material of the porous metal body at a temperature not higher than 650° C.
    Type: Grant
    Filed: March 17, 2009
    Date of Patent: December 6, 2011
    Assignee: Taiyo Nippon Sanso Corporation
    Inventors: Tomohiro Wada, Tomoyuki Haneji, Shinichi Takahashi, Kiichi Kanda, Kenichi Watanabe
  • Patent number: 8025710
    Abstract: Provided are an ancillary material, used for shape processing, which is capable of shortening a processing time, avoiding a reduction in quality of a shape provided to a workpiece material, and allowing a relatively low manufacturing cost; a processing method using the ancillary material; and a method of manufacturing the ancillary material. The tungsten alloy grains (1) comprise: tungsten of greater than or equal to 80% by mass and less than or equal to 98% by mass; nickel; at least one kind of metal selected from the group consisting of iron, copper, and cobalt; and an inevitable impurity, a maximum diameter thereof is greater than or equal to 0.1 mm and less than or equal to 5.00 mm, and a specific surface area thereof is less than or equal to 0.02 m2/g. The tungsten alloy grains (1, 10), the workpiece material (30), an abrasive (20) are blended in a container (100) and the container is rotated, thereby processing the shape of the workpiece material (30).
    Type: Grant
    Filed: November 20, 2006
    Date of Patent: September 27, 2011
    Assignee: A.L.M.T. Corp.
    Inventors: Shinji Kikuhara, Hitoshi Inoue, Noboru Uenishi, Satoshi Umemoto
  • Patent number: 7993577
    Abstract: The invention relates to manufacture of titanium articles from sintered powders. The cost-effective initial powder: 10-50 wt % of titanium powder having ?500 microns in particle size manufactured from underseparated titanium sponge comprising ?2 wt % of chlorine and ?2 wt % of magnesium; 10-90 wt % of a mixture of two hydrogenated powders A and B containing different amount of hydrogen; 0-90 wt % of standard grade refined titanium powder, and/or 5-50 wt % of alloying metal powders. The method includes: mixing powders, compacting the blend to density at least 60% of the theoretical density, crushing titanium hydride powders into fine fragments at pressure of 400-960 MPa, chemical cleaning and refining titanium powders by heating to 300-900° C. and holding for ?30 minutes, heating in vacuum at 1000-1350° C., holding for ?30 minutes, and cooling.
    Type: Grant
    Filed: June 11, 2007
    Date of Patent: August 9, 2011
    Assignee: Advance Materials Products, Inc.
    Inventors: Volodymyr A. Duz, Orest M. Ivasishin, Vladimir S. Moxson, Dmitro G. Savvakin, Vladislav V. Telin
  • Patent number: 7731776
    Abstract: Multimodal cermet compositions comprising a multimodal grit distribution of the ceramic phase and method of making are provided by the present invention. The multimodal cermet compositions include a) a ceramic phase and b) a metal binder phase, wherein the ceramic phase is a metal boride with a multimodal distribution of particles, wherein at least one metal is selected from the group consisting of Group IV, Group V, Group VI elements of the Long Form of The Periodic Table of Elements and mixtures thereof, and wherein the metal binder phase comprises at least one first element selected from the group consisting of Fe, Ni, Co, Mn and mixtures thereof, and at least second element selected from the group consisting of Cr, Al, Si and Y, and Ti.
    Type: Grant
    Filed: December 2, 2005
    Date of Patent: June 8, 2010
    Assignee: ExxonMobil Research and Engineering Company
    Inventors: ChangMin Chun, Narasimha-Rao V. Bangaru, Neeraj S. Thirumalai, Hyun-Woo Jin, Jayoung Koo, John R. Peterson, Robert L. Antram, Christopher J. Fowler, Emery B. Lendvai-Lintner
  • Patent number: 7718117
    Abstract: A method of manufacturing a tungsten sputtering target includes pressing a high purity tungsten powder to form a pressed compact, first sintering the pressed compact at a temperature of 1450-1700° C. for one hour or longer after the pressed compact is heated at a heating-up rate of 2-5° C./min on the way to a maximum sintering temperature, second sintering the pressed compact to form a sintered body at a temperature of 1900° C. or higher for 5 hours or longer, working the sintered body to obtain a shape of a target, subjecting the target to a grinding work of at least one of rotary grinding and polishing, and subjecting the target to a finishing work of at least one of etching and reverse sputtering.
    Type: Grant
    Filed: September 3, 2001
    Date of Patent: May 18, 2010
    Assignee: Kabushiki Kaisha Toshiba
    Inventors: Koichi Watanabe, Yoichiro Yabe, Takashi Ishigami, Takashi Watanabe, Hitoshi Aoyama, Yasuo Kohsaka, Yukinobu Suzuki
  • Patent number: 7585458
    Abstract: A feedstock composition and a method of forming metal articles using powder metallurgy techniques comprise mixing metal powders and a novel aromatic binder system. The composition of the novel feedstock comprises an aromatic binder system and a metal powder. The aromatic binder system comprises an aromatic species and can further comprise lubricants, surfactants, and polymers as additives. The metal powder comprises elemental metals, metal compounds, and metal alloys, particularly for highly-reactive metals. The method of forming metal articles comprises the steps of providing and mixing the metal powder and the aromatic binder system to produce a novel feedstock. The method further comprises processing the novel feedstock into a metal article using a powder metallurgy forming technique. Metal articles formed using the present invention have an increase in carbon and oxygen contents each less than or equal to 0.2 wt % relative to the metal powder used to fabricate the article.
    Type: Grant
    Filed: November 17, 2006
    Date of Patent: September 8, 2009
    Assignee: Battelle Memorial Institute
    Inventors: Eric A. Nyberg, Kenneth Scott Weil, Kevin L. Simmons
  • Patent number: 7540996
    Abstract: Methods and powder blends are provided for fabricating a metal part. One method includes the first steps of spreading a layer of a powder blend on a platform, the powder blend including a titanium base metal or alloy, and an alloying metal having a lower melting temperature than that of the base metal or alloy. Next, an energy beam is directed onto selected areas of the powder blend layer to thereby melt the alloying metal. Then, the alloying metal is re-solidified by withdrawing the energy beam from the powder blend layer. Then, a preform part is built up by iteratively performing the spreading, melting, and re-solidifying steps on additional adjacently formed layers. A metal liquid phase sintering process is performed at a temperature sufficient to melt the alloying metal but not the base metal or alloy.
    Type: Grant
    Filed: November 21, 2003
    Date of Patent: June 2, 2009
    Assignee: The Boeing Company
    Inventor: Clifford C. Bampton
  • Patent number: 7524475
    Abstract: A cerium oxide powder for one-component CMP slurry, which has a specific surface area of 5 m2/g or more, and a ratio of volume fraction of pores with a diameter of 3 nm or more to that of pores with a diameter less than 3 nm of 8:2˜2:8, is disclosed. A method for preparing the same, a one-component CMP slurry comprising the same as an abrasive material, and a method of shallow trench isolation using the one-component CMP slurry are also disclosed. The CMP slurry causes no precipitation of the cerium oxide powder even if it is provided as a one-component CMP slurry, because the CMP slurry uses, as an abrasive material, cerium oxide powder that is obtained via a low-temperature calcination step, optionally a pulverization step, and a high-temperature calcination step and has a high pore fraction and low strength.
    Type: Grant
    Filed: September 1, 2006
    Date of Patent: April 28, 2009
    Assignee: LG Chem, Ltd.
    Inventors: Seung Beom Cho, Jun Seok Nho, Dong Mok Shin, Jong Pil Kim, Myoung Hwan Oh, Jang Yul Kim, Eun Mi Choi, Min Jin Ko
  • Patent number: 7520940
    Abstract: A method of forming an oxide layer on a powder metal part includes subjecting the powder metal part to a steam oxidation process. An oxide layer is formed on the powder metal part. The oxide layer has a thickness greater than 7 microns.
    Type: Grant
    Filed: July 29, 2004
    Date of Patent: April 21, 2009
    Assignee: Caterpillar Inc.
    Inventors: Hyung Kyu Yoon, Thomas E. Clements, Daniel Patrick Vertenten, David Anthony Cusac
  • Publication number: 20080101978
    Abstract: A method of fabricating yttria parts is provided herein. In one embodiment, the method includes sintering a yttria sample, machining the sintered sample to form a part, and annealing the part in a three-stage process that includes heating the part at a predetermined heating rate, maintaining the part at a constant annealing temperature, and cooling the part at a predetermined cooling rate.
    Type: Application
    Filed: October 30, 2006
    Publication date: May 1, 2008
    Inventors: Elmira Ryabova, Richard Lewington, Madhavi R. Chandrachood, Amitabh Sabharwal, Darin Bivens
  • Patent number: 7226492
    Abstract: Tungsten-based alloy material sintered at a high sintering power that may contain additive elements soluble in the nickel and selected from the group constituted, for example, by rhenium, molybdenum, tantalum, niobium, vanadium or a mixture of these, wherein, after sintering in liquid phase at a temperature of around 1500° C., it has: a two-phased ?-? microstructure that is fully densified, has no porosities or has negligible porosities of a low mean grain size (L?) and a contiguity (C??) that is very low with respect to the size of the tungsten crystals, and a dispersion of micro-oxides with no loss of ductility properties.
    Type: Grant
    Filed: September 20, 2002
    Date of Patent: June 5, 2007
    Inventors: Pascal Mahot, Guy Nicolas, Marc Voltz
  • Patent number: 7144546
    Abstract: Nitrided valve metals are described, such as nitrided tantalum and nitrided niobium. The nitrided valve metals preferably have improved flow properties, higher Scott Densities, and/or improved pore size distribution which leads to improved physical properties of the valve metal and improved electrical properties once the valve metal is formed into a capacitor anode. Processes for preparing a nitrided valve metal are further described and involve nitriding the valve metal at a sufficient temperature and pressure during a heat treatment that is prior to the deoxidation step. Capacitor anodes and other products incorporating the valve metals of the present invention are further described.
    Type: Grant
    Filed: November 25, 2003
    Date of Patent: December 5, 2006
    Assignee: Cabot Corporation
    Inventors: Shi Yuan, legal representative, Bhamidipaty K. D. P. Rao, deceased
  • Patent number: 7135141
    Abstract: A method of manufacturing a sintered body, in which a material powder composed of metallic powder or alloy powder, a getter material having a higher oxidation potential than that of the material powder, and a hydride, which constitutes a hydrogen source, are sealed under reduced pressure in a metallic container, and subjected to pressurized sintering while being heated. The pressurized sintering is performed by keeping the metallic container at pressure not higher than 50 MPa and at temperature not lower than 500° C. for 1 to 50 hours, and then sintering the metallic powder and the alloy powder at pressure higher than 50 MPa and at temperature not higher than 1340° C.
    Type: Grant
    Filed: March 29, 2004
    Date of Patent: November 14, 2006
    Assignee: Hitachi Metals, Ltd.
    Inventors: Gang Han, Tomonori Ueno, Eiji Hirakawa, Shujiro Uesaka
  • Patent number: 7060222
    Abstract: An infiltrant is used to fill a metal powder skeleton. The infiltrant is similar in composition to the base powder, but contains a melting point depressant. The infiltrant will quickly fill the powder skeleton, then as the melting point depressant diffuses into the base powder, the liquid will undergo solidification and the material will eventually homogenize. This process allows more accurate control of dimensions in large parts with uniform or homogeneous microstructure or bulk properties.
    Type: Grant
    Filed: May 21, 2001
    Date of Patent: June 13, 2006
    Assignee: Massachusetts Institute of Technology
    Inventors: Emanuel M. Sachs, Adam M. Lorenz, Samuel Allen
  • Patent number: 6967001
    Abstract: The invention refers to a new method for preparing sintered structural parts of carbon or tool steels or high speed steel having a carbon content of up to 2% by weight, wherein an agglomerated spherical powder comprising at least 0.5% of a thermo-reversible hydrocolloid is pressed to a green body of high density which is then heated at 450–650° C. to remove the non-carbon content of the hydrocolloid and subsequently sintered at about 1100–1400° C. to structural parts having high strength properties.
    Type: Grant
    Filed: April 26, 2001
    Date of Patent: November 22, 2005
    Assignee: Metals Process Systems
    Inventor: Christer Aslund
  • Patent number: 6838046
    Abstract: Improved drying, binder evaporation, and sintering processes which may be used in conjunction with specialized sintering tools to provide for the geometrically stable sintering of large, complex, metal injection molded preform parts or flowbodies. The improved process includes a three-stage drying process, a single stage binder evaporation process, and a two-stage sintering process.
    Type: Grant
    Filed: May 9, 2002
    Date of Patent: January 4, 2005
    Assignee: Honeywell International Inc.
    Inventors: Jyh-Woei J. Lu, Kenneth J. Bartone, Donald M. Olson, Dwayne M. Benson, John N. Tervo
  • Patent number: 6761852
    Abstract: Although MIM (metal injection molding) has received widespread application, aluminum has not been widely used for MIM in the prior art because of the tough oxide layer that grows on aluminum particles, thus preventing metal—metal bonding between the particles. The present invention solves this problem by adding a small amount of material that forms a eutectic mixture with aluminum oxide, and therefore aids sintering, to reduce the oxide, thereby allowing intimate contact between aluminum surfaces. The process includes the ability to mold and then sinter the feedstock into the form of compacted items of intricate shapes, small sizes (if needed), and densities of about 95% of bulk.
    Type: Grant
    Filed: March 11, 2002
    Date of Patent: July 13, 2004
    Assignee: Advanced Materials Technologies Pte. Ltd.
    Inventors: Chee-Tian Yeo, Lye-King Tan
  • Patent number: 6726740
    Abstract: A sintered, magnetically soft composite is proposed, especially for use in solenoid valves, and a process for producing such a composite, in which initially a starting mixture from which the magnetically soft composite is formed after sintering is produced, having a ferromagnetic, especially powdery first starting component (11) as main constituent, and a ferritic second starting component (12) as secondary constituent, as well as possibly a pressing aid. After the starting mixture is sintered, the second starting component (12) is present in the produced composite at least largely as grain boundary phase. The proposed manufacturing process includes the process steps: provision of the starting mixture; mixing of the starting mixture; compression of the starting mixture in a cavity mold under increased pressure; removal of the binder from the compressed starting mixture; and sintering of the compressed starting mixture to form the composite.
    Type: Grant
    Filed: November 13, 2001
    Date of Patent: April 27, 2004
    Assignee: Robert Bosch GmbH
    Inventors: Waldemar Draxler, Thomas Christmann, Horst Boeder
  • Patent number: 6682693
    Abstract: An inclined function material is formed with an iron layer on a surface of a carbon material. This material can be used in a carbon base member and does not limit the choice of desired characteristics in a carbon base member. The process by which the carbon base member is formed also ensures the iron layer is integrated firmly with the surface of the carbon material. A suitable amount of an iron powder having a particle diameter of 5 to 15 &mgr;m is placed directly on the surface of a carbon material, which is sintered in advance under suitable conditions, and stuck to the surface uniformly and flatly. The iron powder and the carbon material are sintered at 1000° C. to 1300° C. and preferably 1050 to 1150° C. for 1 to 2 hours and preferably about 1.5 hours to form a carbon base member in which the iron layer is formed on one surface of the carbon base member.
    Type: Grant
    Filed: July 17, 2002
    Date of Patent: January 27, 2004
    Assignee: Mitsuba Corporation
    Inventors: Yoshihiro Tanaka, Mitsunari Ishizaki, Motoaki Kuribara
  • Patent number: 6635357
    Abstract: The lightweight bulletproof metal matrix macrocomposites (MMMC) contain (a) 10-99 vol. % of permeable skeleton structure of titanium, titanium aluminide, Ti-based alloys, and/or mixtures thereof infiltrated with low-melting metal selected from Al, Mg, or their alloys, and (b) 1-90 vol. % of ceramic and/or metal inserts positioned within said skeleton, whereby a normal projection area of each of said inserts is equal to or larger than the cross-section area of a bullet or a projectile body. The MMMC are manufactured as flat or solid-shaped, double-layer, or multi-layer articles containing the same inserts or different inserts in each layer, whereby insert projections of each layer cover spaces between inserts of the underlying layer. The infiltrated metal contains 1-70 wt. % of Al and Mg in the balance, optionally, alloyed with Ti, Si, Zr, Nb, V, as well as with 0-3 wt. % of TiB2, SiC, or Si3N4 sub-micron powders, to promote infiltrating and wetting by Al-containing alloys.
    Type: Grant
    Filed: February 28, 2002
    Date of Patent: October 21, 2003
    Inventors: Vladimir S. Moxson, Eugene Ivanov
  • Patent number: 6630009
    Abstract: A paste composition, including a binding agent charged with metallic powder, to be used in a solid freeform fabrication procedure, comprising: a) a solidifiable binding agent comprised of at least one polymerizable resin, with a viscosity of less than 4000 mPa.s, measured at 25° C.; b) at least one initiator, in a concentration greater than about 0.1% by mass with respect to the mass of the resin; and c) a mixture of at least two metallic powders, said mixture having a volumetric concentration greater than 40% with respect to the composition, wherein said mixture of metal powders is either i) a bimodal or trimodal mixture in nature, or ii) is a majority of stainless steel with an amount of NiB or NiP and combinations thereof effective to lower the sintering temperature.
    Type: Grant
    Filed: April 3, 2002
    Date of Patent: October 7, 2003
    Assignee: 3D Systems, Inc.
    Inventors: Khalil M. Moussa, Kenneth J. Newell, Catherine Hinczewski, Charles H. Zenuk
  • Patent number: 6630101
    Abstract: A method of producing a gear from a metallurgical powder includes molding at least a portion of the powder to provide a gear preform. The gear preform is sintered and hot formed, and subsequently may be carburized. The gear preform is resintered and cooled at a cooling rate suitable to provide a bainitic microstructure in at least a surface region of the preform. The gear teeth of the preform may be shaved to, for example, adjust dimensions, and enhance dimensional uniformity.
    Type: Grant
    Filed: August 16, 2001
    Date of Patent: October 7, 2003
    Assignee: Keystone Investment Corporation
    Inventors: Gary L. Anderson, William J. Olson
  • Patent number: 6595821
    Abstract: A high-quality and high-reliability rotary anode target for X-ray tubes, of which the mechanical strength at high temperatures is increased and which is applicable not only to low-speed rotation (at least 3,000 rpm) but also even to high-speed rotation at high temperatures, and also a method for producing it. The rotary anode has a two-layered structure to be formed by laminating an Mo alloy substrate that comprises from 0.2% by weight to 1.5% by weight of TiC with the balance of substantially Mo, and an X-ray generating layer of a W—Re alloy that overlies the substrate.
    Type: Grant
    Filed: April 20, 2001
    Date of Patent: July 22, 2003
    Assignee: Tokyo Tungsten Co., Ltd.
    Inventors: Masayuki Itoh, Koji Asahi, Mitsuo Osada, Yoshinari Amano, Tomohiro Takida
  • Patent number: 6582651
    Abstract: A process for forming a shaped metallic article, including the steps of combining the starting materials, forming the starting materials into a shape to produce a nonmetallic metal precuror article of a certain geometry, and converting the nonmetallic article to a metallic article by reduction or decomposition, while substantially retaining the geometry of the nonmetallic article. The forming step in which the starting materials are fabricated into a shape can include extrusion, dry pressing, or slurry casting. Further, another embodiment is a metallic article produced by converting a nonmetallic article with a certain geometry, including a plurality of open-ended channels, substantially to the same geometry as the nonmetallic article from which it was converted.
    Type: Grant
    Filed: June 9, 2000
    Date of Patent: June 24, 2003
    Assignee: Geogia Tech Research Corporation
    Inventors: Joe Kennedy Cochran, Jr., Kon Juin Lee, Thomas H. Sanders, Jr.
  • Publication number: 20030091457
    Abstract: A Mo—Cu composite powder is provided which is comprised of individual finite particles each having a copper phase and a molybdenum phase wherein the molybdenum phase substantially encapsulates the copper phase. The composite powder may be consolidated by conventional P/M techniques and sintered without copper bleedout according to the method described herein to produce Mo—Cu pseudoalloy articles having very good shape retention, a high sintered density, and a fine microstructure.
    Type: Application
    Filed: September 20, 2002
    Publication date: May 15, 2003
    Inventors: Leonid P. Dorfman, Michael J. Scheithauer, David L. Houck, Anna T. Spitsberg, Jeffrey N. Dann
  • Patent number: 6517773
    Abstract: A method of directly fabricating metal parts with surface features only requires first preparing a mold of the desired metal part. A powder blend is poured into the mold, which includes a base metal, a lower melting temperature alloy of the base metal, and a polymer binder. The mold containing the powder blend is heated until the polymer binder melts and adheres the metal particles to form a green part. The green part is removed from the mold and placed in a crucible, and loose ceramic powder is packed around the part to support it. The supported green part is then heated as needed to vaporize the binder and consolidate the part via liquid phase sintering. Once cool, the consolidated part can be machined to meet precise dimensional tolerances, if necessary.
    Type: Grant
    Filed: September 23, 1999
    Date of Patent: February 11, 2003
    Assignee: Innovative Technology Licensing, LLC
    Inventors: Michael R. Mitchell, Scott A. Schroeder, Mark R. Appleford, Keiko Anne Halchak, Brian R. Zambrano
  • Patent number: 6503443
    Abstract: In a preliminary molding step 1, a metallic powder mixture 7 obtained by blending an iron-based metal powder 7a with graphite 7b such that the graphite is present in an amount of preferably not less than 0.1% by weight, more preferably not less than 0.3% by weight, is compacted into a preform 8 having a density of not less than 7.3 g/cm3. In a provisional sintering step 2, the preform 8 is provisionally sintered at a predetermined temperature to form a metallic powder-molded body 9 having a structure in which the graphite remains along a grain boundary of the metal powder. In a re-compaction step 3, the metallic powder-molded body 9 is re-compacted into a re-compacted body 10. In a re-sintering step 4, the re-compacted body 10 is re-sintered to obtain a sintered body 11. In a heat treatment step 5, the sintered body 11 is heat-treated to obtain a heat-treated sintered body 11.
    Type: Grant
    Filed: October 6, 2000
    Date of Patent: January 7, 2003
    Assignees: Unisia Jecs Corporation, Kawasaki Steel Corporation
    Inventors: Takashi Yoshimura, Hiroyuki Amma, Masashi Fujinaga, Mitsumasa Iijima, Yasuo Hatai, Takayuki Matsumoto, Satoshi Uenosono, Shigeru Unami
  • Publication number: 20020168282
    Abstract: Improved drying, binder evaporation, and sintering processes which may be used in conjunction with specialized sintering tools to provide for the geometrically stable sintering of large, complex, metal injection molded preform parts or flowbodies. The improved process includes a three-stage drying process, a single stage binder evaporation process, and a two-stage sintering process.
    Type: Application
    Filed: May 9, 2002
    Publication date: November 14, 2002
    Inventors: Jyh-Woei J. Lu, Kenneth J. Bartone, Donald M. Olson, Dwayne M. Benson, John N. Tervo
  • Patent number: 6436163
    Abstract: A porous metal filter possessing enhanced anticorrosive properties is provided including sintered metal particles composed of an alloy composition of iron aluminide having a range in concentration corresponding to Fe3Al to FeAl phases and having a Bubble Point ratio of about 1.6 or less.
    Type: Grant
    Filed: December 24, 1998
    Date of Patent: August 20, 2002
    Assignee: Pall Corporation
    Inventors: Stephen A. Geibel, Paul C. Koehler, John L. Hurley
  • Patent number: 6395406
    Abstract: A method for preparing an aluminum alloy-containing coating composition is described. A slurry containing a selected amount of aluminum is combined with at least one additional slurry containing a selected amount of a second metal which forms an alloy with aluminum. The resulting slurry mixture is applied to a metal substrate, and then heated to form a substantially devolatilized coating. The coating then receives a secondary heat treatment. Related compositions and articles are also described, as are processes for repairing a damaged or worn coating, utilizing the slurry.
    Type: Grant
    Filed: April 24, 2000
    Date of Patent: May 28, 2002
    Assignee: General Electric Company
    Inventor: D Sangeeta
  • Patent number: 6383446
    Abstract: The present invention is a method of automatically loading powder material into a sintering mold and subsequently effecting electrical sintering to the powder material in the sintering mold.
    Type: Grant
    Filed: March 30, 2000
    Date of Patent: May 7, 2002
    Assignee: Sumitomo Coal Mining Co., Ltd.
    Inventor: Masao Tokita
  • Patent number: 6355211
    Abstract: A method for producing high performance components by the consolidation of powdered materials under conditions of hot isostatic pressure. The method uses the inclusion of reactive materials mixed into pressure-transmitting mold materials and into the powder to be consolidated to contribute to in-situ materials modification including purification, chemical transformation, and reinforcement. The method also uses encapsulation of the mold in a sealed container to retain the mold material in position, and to exclude air and contaminants.
    Type: Grant
    Filed: February 7, 2000
    Date of Patent: March 12, 2002
    Inventor: Xiaodi Huang
  • Patent number: 6344169
    Abstract: A method for compacting powders for powder metallurgy comprises packing powders for powder metallurgy formulated with a lubricant in a compacting die applied with a lubricant on inner wall surfaces thereof, and subjecting the powders to warm or hot compaction. The powders contain the lubricant in an amount up to 0.2 wt %, non-inclusive of 0%, based on the total of the powders and the lubricant.
    Type: Grant
    Filed: November 3, 1999
    Date of Patent: February 5, 2002
    Assignee: Kabushiki Kaisha Kobe Seiko Sho (Kobe Steel, Ltd.)
    Inventors: Takehiro Tsuchida, Hiroshi Yaguchi, Tetsuya Sawayama, Masaaki Sato, Yoshikazu Seki, Nobuaki Akagi
  • Patent number: 6284191
    Abstract: A powder metallurgical process of preparing iron aluminide useful as electrical resistance heating elements having improved room temperature ductility, electrical resistivity, cyclic fatigue resistance, high temperature oxidation resistance, low and high temperature strength, and/or resistance to high temperature sagging. The iron aluminide has an entirely ferritic microstructure which is free of austenite and can include, in weight %, 20 to 32% Al, and optional additions such as ≦1% Cr, ≧0.05% Zr or ZrO2 stringers extending perpendicular to an exposed surface of the heating element, ≦2% Ti, ≦2% Mo, ≦1% Zr, ≦1% C, ≦0.1% B, ≦30% oxide dispersoid and/or electrically insulating or electrically conductive covalent ceramic particles, ≦1% rare earth metal, ≦1% oxygen, and/or ≦3% Cu.
    Type: Grant
    Filed: September 20, 1999
    Date of Patent: September 4, 2001
    Assignee: Chrysalis Technologies Incorporated
    Inventors: Seetharama C. Deevi, A. Clifton Lilly, Jr., Vinod K. Sikka, Mohammed R. Hajaligol
  • Patent number: 6280684
    Abstract: A sputtering target for fabricating a recording layer of a phase-change type optical recording medium contains a compound or mixture including as constituent elements Ag, In, Te and Sb with the respective atomic percent (atom. %) of &agr;, &bgr;, &ggr; and &dgr; thereof being in the relationship of 2≦&agr;≦30, 3≦&bgr;≦30, 10≦&ggr;≦50, 15≦&dgr;≦83 and &agr;+&bgr;+&ggr;+&dgr;=100, and a method of producing the above sputtering target is provided. A phase-change type optical recording medium includes a recording layer containing as constituent elements Ag, In, Te and Sb with the respective atomic percent of &agr;, &bgr;, &ggr; and &dgr; thereof being in the relationship of 0<&agr;≦30, 0<&bgr;≦30, 10≦&ggr;≦50, 10≦&dgr;≦80, and &agr;+&bgr;+&ggr;+&dgr;=100, and is capable of recording and erasing information by utilizing the phase changes of a recording material in the recording layer.
    Type: Grant
    Filed: January 19, 2000
    Date of Patent: August 28, 2001
    Assignee: Ricoh Company, Ltd.
    Inventors: Katsuyuki Yamada, Hiroko Iwasaki, Yukio Ide, Makoto Harigaya, Yoshiyuki Kageyama, Hiroshi Deguchi, Masaetsu Takahashi, Yoshitaka Hayashi
  • Publication number: 20010014568
    Abstract: Provided are a high-quality and high-reliability rotary anode target for X-ray tubes, of which the mechanical strength at high temperatures is increased and which is applicable not only to low-speed rotation (at least 3,000 rpm) but also even to high-speed rotation at high temperatures, and also a method for producing it. The rotary anode has a two-layered structure to be formed by laminating an Mo alloy substrate that comprises from 0.2% by weight to 1.5% by weight of TiC with the balance of substantially Mo, and an X-ray generating layer of a W—Re alloy that overlies the substrate.
    Type: Application
    Filed: April 20, 2001
    Publication date: August 16, 2001
    Inventors: Masayuki Itoh, Koji Asahi, Mitsuo Osada, Yoshinari Amano, Tomohiro Takida
  • Patent number: 6254998
    Abstract: A method for making foam structures suitable for use as mechanical energy absorbers, structural members, filters, catalyst carriers or the like. A composite rod comprising an outer shell and an inner core is formed of respective mixtures of powders. The mixture for the outer shell comprises a sinterable powdered structural material such as ceramics, metals, intermetallics, and a powdered binder such as paraffin, wax or polymer. The inner core comprises a powdered channel-forming filler material such as melamine or polymers, or soluble inorganic compounds or a metal that can differentially be removed from the structural material of the shell. The composite rod may be formed by extrusion. The composite rod is sectioned into a plurality of composite rod segments of predetermined length and a plurality of these segments is assembled in randomly oriented relationship to one another. The assemblage of rod segments is then consolidated, and the binder and filler are then removed, as by heating.
    Type: Grant
    Filed: February 2, 2000
    Date of Patent: July 3, 2001
    Assignee: Materials and Electrochemical Research (MER) Corporation
    Inventor: Lev J. Tuchinsky
  • Patent number: 6228508
    Abstract: Disclosed is a process for preparing a metal body via metal powder molding techniques. First and second component parts are conventionally injection molded from a metal powder molding material. The first ultrasonic part is molded to have an ultrasonic energy director surface, which may be, for example, a rib having a triangular cross section. In accordance with the disclosed process, the first and second component parts then are ultrasonically welded to form a green assembly, and this green assembly is debound and sintered in accordance with conventional metal powder molding techniques to form a metal body. The metal body thus formed will be hermetically sealed along the ultrasonic weld. The process of the invention thus may be employed in the preparation of metal objects that require a hermetic seal, such as fluid flow nozzles, pressure vessels, and the like.
    Type: Grant
    Filed: February 7, 2000
    Date of Patent: May 8, 2001
    Assignee: Spraying Systems Co.
    Inventors: Richard Kassanits, Timothy H. Hennessy
  • Patent number: 6224823
    Abstract: The invention relates to a process for producing sinterable metallic shaped parts from a metal powder, which is mixed with an auxiliary compacting agent containing at least in part components from the polyalkylene glycol family, is filled into a compacting mold and, following the compacting under pressure, is ejected from the mold as compacted shaped part.
    Type: Grant
    Filed: July 27, 1999
    Date of Patent: May 1, 2001
    Assignee: GKN Sinter Metals GmbH & Co. KG
    Inventors: René Lindenau, Klaus Dollmeier, Wieland Kynast, Jens Wahnschaffe
  • Patent number: 6214288
    Abstract: An improvement is proposed in the powder metallurgical method for the preparation of a rare earth-based permanent magnet comprising the steps of compression-molding a magnet alloy powder into a powder compact and sintering the powder compact into a sintered magnet body. The improvement, which has an effect of increasing the density of the sintered body and consequently increased magnetic properties of the magnet product, comprises conducting the sintering heat treatment in two steps consisting of a first partial sintering treatment in vacuum or under a subatmospheric pressure of an inert gas immediately followed by a second partial sintering treatment under a normal to superatmospheric pressure of, for example, up to 20 atmospheres.
    Type: Grant
    Filed: December 8, 1999
    Date of Patent: April 10, 2001
    Assignee: Shin-Etsu Chemical Co., Ltd.
    Inventors: Matou Kusunoki, Takehisa Minowa
  • Patent number: 6203753
    Abstract: The present invention provides a method for making metal parts from metal powder compositions comprising an iron base metal powder and an amide lubricant. The method comprises the steps of compacting said composition, pre-sintering the compacted composition, compacting the compacted and pre-sintered composition, and sintering the recompacted composition. The metal parts have improved physical and mechanical properties.
    Type: Grant
    Filed: May 13, 1997
    Date of Patent: March 20, 2001
    Assignee: The Presmet Corporation
    Inventor: Ian W. Donaldson