Making Composite Or Hollow Article Patents (Class 419/5)
  • Patent number: 5568652
    Abstract: A method of making a homogeneous formable mixture involves simultaneously mixing organic binder which can be cellulose ethers, cellulose ether derivatives, and combinations of these, powder material capable of being formed into a body when combined with the organic binder, water-insoluble wax, and vehicle of which at least about 90 wt % is water, at a temperature which is at least as high the temperature at which the wax begins to deform under shear. A method of making a shaped body involves shaping the above-described mixture into a green body, followed by drying and heating the green body at a temperature and for a time sufficient to form the product body. Preferably the mixture is extruded at a temperature between room temperature and the melting point of the wax, into a honeycomb. The honeycomb has no voids and a smooth skin. A formable mixture made up of organic binder, powder, and wax as described above, wherein the wax which makes up at least 3 wt.
    Type: Grant
    Filed: November 25, 1994
    Date of Patent: October 22, 1996
    Assignee: Corning Incorporated
    Inventor: Shy-Hsien Wu
  • Patent number: 5564064
    Abstract: A method for forming a gas-filled consolidated metal billet, involving preparing a metallic shell container, filling the shell with a metal core material and pressurized gas, and consolidating the shell and its contents to form the billet. The consolidated billet is further formed in the same manner as solid metal components by conventional wrought mill working technologies. After thus forming a shaped billet having a predetermined, desired geometry, it is subjected to a heat treatment that expands the gas trapped within the core, to produce in situ a metal body having an integral sandwich-type structure with a solid metal facing and a porous metal core.
    Type: Grant
    Filed: February 3, 1995
    Date of Patent: October 8, 1996
    Assignee: McDonnell Douglas Corporation
    Inventor: Ricky L. Martin
  • Patent number: 5564063
    Abstract: A method for manufacture of at least one micronozzle in an aerostatic bearing, wherein at least one hole is placed into a compacted bearing surface from porous sintered material by means of a laser beam and disposed so as to be distributed across the surface. The holes distributed across the compacted bearing surface constitute micronozzles of an aerostatic bearing.
    Type: Grant
    Filed: February 2, 1995
    Date of Patent: October 8, 1996
    Assignee: Joachim Heinzl
    Inventors: Joachim Heinzl, Michael Muth, Bernd Schulz
  • Patent number: 5561827
    Abstract: A nickel-base superalloy article has a coating having a composition, in weight percent, of from about 10 to about 20 percent cobalt, from about 14 to about 25 percent chromium, from about 2 to about 12 percent aluminum, from 0 to about 0.2 percent yttrium, from about 0.001 to about 3 percent boron, from about 1 to about 10 percent silicon, balance nickel and incidental impurities. The coating is preferably applied by mixing together two powders, one with a higher solidus temperature and one with a lower solidus temperature, whose net composition is that of the coating. The powder mixture is compacted with a binder, applied to a surface of the article, and heated to a temperature above the lower solidus temperature.
    Type: Grant
    Filed: December 28, 1994
    Date of Patent: October 1, 1996
    Assignee: General Electric Company
    Inventors: Jim D. Reeves, David E. Budinger, Robert A. Anderson
  • Patent number: 5554338
    Abstract: The invention relates to a method of preparing a composite sintered body having inner and outer portions fitted with each other. The method includes the steps of: (a) preparing an inner powder compact; (b) preparing an outer powder compact; (c) fitting the inner and outer powder compacts with each other so as to prepare a composite powder compact; and (d) sintering the composite powder compact so as to prepare the composite sintered body. The inner and outer powder compacts are respectively selected such that, during the step (d), the amount of growth of the inner powder compact becomes greater than that of the outer powder compact. Each of the inner and outer composite powder compacts is made of one member selected from the group consisting of a wax-type segregation prevention powder mixture and a metal-soap-type segregation prevention powder mixture. At least one of the inner and outer composite powder compacts is made of the wax-type segregation prevention powder.
    Type: Grant
    Filed: April 18, 1995
    Date of Patent: September 10, 1996
    Assignees: Nissan Motor Co., Ltd., Hitachi Powdered Metals Co., Ltd.
    Inventors: Hiroshi Sugihara, Hiroyuki Ishikawa, Tsutomu Uemura, Akira Fujiki, Hiromasa Imazato, Shinichi Umino
  • Patent number: 5552106
    Abstract: A method of making a bearing component for a rotary cone rock bit which obtains the beneficial strengthening effect of metalloids and their compounds without the undesirable effects of segregation. The method includes rolling a sintered compact to form a strip or plate of a particular composition that would be subject to segregation if produced by casting and thereafter forming the strip or plate into the bearing component. Additionally, the rolled sintered compact may be heat treated and machined after heat treating. A method of making a rotary cone rock bit is also disclosed.
    Type: Grant
    Filed: May 3, 1995
    Date of Patent: September 3, 1996
    Assignee: Smith International, Inc.
    Inventor: K. T. Kembaiyan
  • Patent number: 5543235
    Abstract: The present invention provides multiple grade, composite cemented carbide articles and a method of making such articles. The cemented carbide articles comprise carbides of different grades (or different compositions and/or microstructures) and, therefore, correspondingly different properties at different locations in the same article. The method of the present invention comprises filling different areas or portions of a die with metallurgical powders having different compositions and/or microstructures. The powder is then compressed as a single compact in the die cavity. The compressed compact is subsequently sintered to produce a multigrade cemented carbide article having composition and/or microstructural variations within the volume of the article.
    Type: Grant
    Filed: April 26, 1994
    Date of Patent: August 6, 1996
    Assignee: SinterMet
    Inventors: Prakash K. Mirchandani, Robert E. Thomas, Mark Cippel
  • Patent number: 5540884
    Abstract: Heat multilayer aluminum nitride greenware, a composite of layers of aluminum nitride green tape having refractory metal ink patterns deposited thereon, in a nonoxidizing atmosphere, at atmospheric pressure to effect liquid phase sintering of both the aluminum nitride greenware and the refractory metal ink. The resultant cofired structure is substantially free of warpage and has satisfactory thermal conductivity, surface finish, mechanical properties and resistance to delamination.
    Type: Grant
    Filed: November 7, 1994
    Date of Patent: July 30, 1996
    Assignee: The Dow Chemical Company
    Inventor: Yi-Hung Chiao
  • Patent number: 5534219
    Abstract: A method for producing a multifilamentary superconductor containing niobium-tin (Nb.sub.3 Sn). A fully bonded niobium/copper composite billet is formed having a plurality of longitudinally extending channels which are symmetrically distributed with reference to transverse cross-sections of the billet, each channel being filled with an inert removable filler material. The inert filler material is removed to open the longitudinally extending channels in the billet. Tin or a tin alloy is inserted into the channels, and the niobium/copper composite billet with the inserted tin or tin alloy is cold drawn to the desired final dimensions. The drawn composite is then heated to effect in situ formation of the niobium-tin.
    Type: Grant
    Filed: May 27, 1994
    Date of Patent: July 9, 1996
    Assignee: Oxford Instruments Inc.
    Inventors: William G. Marancik, Seungok Hong, Rouyi Zhou
  • Patent number: 5531956
    Abstract: A method for producing a ribbed electrode for a fuel cell including the steps of depositing a suspension of a powdered electrode metal onto the face of a substantially flat porous electrode metal substrate, forming a plurality of raised structures on the face of the electrode, and sintering the electrode.
    Type: Grant
    Filed: April 27, 1995
    Date of Patent: July 2, 1996
    Assignee: Institute of Gas Technology
    Inventors: Estela T. Ong, Nellie Burton-Gorman
  • Patent number: 5531957
    Abstract: A mounting object comprises a combination of a mounting object body wherein engaging portions of fastener elements of a metallic heat-resistant two-dimensional fastener are projected outside from a mounting surface, and base portions are embedded and integrally molded, and a mating fastener element base object wherein mating fastener elements in detachably engagement with said fastener elements are projected and integrally molded. Said mounting object body is obtained as a heat-resistant material integral with a metallic two-dimensional fastener by covering and fixing part of the fastener elements of the metallic two-dimensional fastener with a carbon powder having a high melting temperature and covering bases thereof with a metallic powder, a ceramics powder or a mixed powder of them to mold and sinter it.
    Type: Grant
    Filed: April 12, 1995
    Date of Patent: July 2, 1996
    Assignee: National Aerospace Laboratory of Science & Technology Agency
    Inventors: Osamu Okamoto, Teruomi Nakaya
  • Patent number: 5531955
    Abstract: Process of imparting conductivity to a three-dimensional net-shaped porous sheet can be performed efficiently before carrying out electroplating process. Fine metallic powders are applied to the porous sheet made of a foamed sheet, a nonwoven sheet, a mesh sheet or a plurality of sheets layered one on the other, so that a conductive metallic layer is formed on the porous sheet. Then, an electroplated layer is formed on the surface of the conductive metallic layer. The conductive metallic layer remains when the porous sheet burned out. Consequently, a metallic layer of the conductive metallic layer and the electroplated layer forms the metallic framework of the metallic porous sheet.
    Type: Grant
    Filed: February 8, 1995
    Date of Patent: July 2, 1996
    Assignee: Katayama Special Industries, Ltd.
    Inventor: Hirofumi Sugikawa
  • Patent number: 5525291
    Abstract: The invention relates to a method of forming honeycomb structures having cross-directional flow channels, such as cross-flow cellular bodies using a novel movable die which is adapted to move while extrudate is passing through the die, thus causing the cells or channels to alternate between straight-through flow, Z-flow, L-flow, U-flow or other similar cross-directional flow patterns. This novel die arrangement may be comprised of either a single movable die body, or a plurality of die parts or sections all of which are independently movable relative to the other.
    Type: Grant
    Filed: November 17, 1994
    Date of Patent: June 11, 1996
    Assignee: Corning Incorporated
    Inventor: Dell J. St. Julien
  • Patent number: 5521016
    Abstract: Subject boron carbide to a passivation treatment at a temperature within a range of 1350.degree. C. to less than 1800.degree. C. prior to infiltration with a molten metal such as aluminum. This method allows control of kinetics of metal infiltration and chemical reactions, size of reaction products and connectivity of B.sub.4 C grains and results in cermets having desired mechanical properties.
    Type: Grant
    Filed: January 24, 1995
    Date of Patent: May 28, 1996
    Assignee: The Dow Chemical Company
    Inventors: Aleksander J. Pyzik, Uday V. Deshmukh, Stephen D. Dunmead, Jack J. Ott, Timothy L. Allen, Harold E. Rossow
  • Patent number: 5520880
    Abstract: This invention relates to a method for producing a self-supporting body comprising the steps of:(a) forming a permeable mass comprising at least one solid-phase oxidant selected from the group consisting of the halogens, sulphur and its compounds, metals, metal oxides other than the silicates, and metal nitrides other than those of boron and silicon;(b) orienting said permeable mass and a source of said parent metal relative to each other so that formation of said oxidation reaction product will occur into said permeable mass;(c) heating said source of parent metal to a temperature above the melting point of said parent metal but below the melting point of said oxidation reaction product to form a body of molten parent metal;(d) reacting said body of molten parent metal with said at least one solid-phase oxidant at said temperature to permit said oxidant at said temperature to permit said oxidation reaction product to form; and(e) maintaining at least a portion of said at least one oxidation reaction product
    Type: Grant
    Filed: September 19, 1994
    Date of Patent: May 28, 1996
    Assignee: Lanxide Technology Company, LP
    Inventors: William B. Johnson, Eugene S. Park, Gerhard H. Schiroky, Danny R. White, Terry D. Claar
  • Patent number: 5520878
    Abstract: An unsintered aluminum nitride body including:(a) 1 to 5 weight percent of a vitreous solid of boria, alumina, and calcia in the proportions of (1) boria between 3 and 25 weight percent, (2) alumina between 10 and 50 weight percent, and (3) calcia between 40 and 80 weight percent; and(b) aluminum nitride powder as the balance of the aluminum nitride body.The invention further relates to a method of forming the unsintered aluminum nitride body and then sintering it at a temperature between 1550 and 1650 degrees Centrigrade so as to form a dense, thermally conductive aluminum nitride body.
    Type: Grant
    Filed: May 10, 1995
    Date of Patent: May 28, 1996
    Assignee: International Business Machines Corporation
    Inventors: Peter R. Duncombe, Subhash L. Shinde, Takeshi Takamori
  • Patent number: 5518683
    Abstract: A metal alloy article is proved with an improved fretting wear resistant coating combination for use in the temperature range of about 650.degree.-1100.degree. F. on an article contact surface shaped to cooperate with an abutting member. An example is a gas turbine engine blade base carried by an abutting support slot. The coating combination includes an inner portion of a Ni base alloy having a room temperature annealed yield strength of greater than about 30 ksi to less than about 57 ksi and densely deposited from a powder, for example by the high velocity oxygen--fuel thermal spray process rather than by other processes such as air plasma spray. Cured on the inner portion is an outer portion of graphite particles mixed in an inorganic binder capable of stable use in the range of about 650.degree.-1100.degree. F., for example silicates or phosphates, such as of aluminum.
    Type: Grant
    Filed: February 10, 1995
    Date of Patent: May 21, 1996
    Assignee: General Electric Company
    Inventors: Kevin P. Taylor, Jerry D. Schell
  • Patent number: 5518383
    Abstract: To manufacture a reflector formed by a reflective metallic layer on a metallic matrix composite support, a metallic layer having a reflective surface whose shape is at least approximately identical to the required geometrical shape is disposed on a mold surface having a geometrical shape complementary to the required geometrical shape of the reflector. Fibers to constitute the composite support are draped on the metallic layer. They are metallized by the metallic or intermetallic material to form the metallic matrix. This layer and the metallized fibers are subjected to temperature and pressure conditions adapted to press the reflective surface strongly against the mold surface and to cause diffusion welding of the layer with the metallized fibers and of the metallized fibers with themselves so as to integrate the layer to the composite support during consolidation of the latter.
    Type: Grant
    Filed: May 9, 1994
    Date of Patent: May 21, 1996
    Assignee: Aerospatiale Societe Nationale Industrielle
    Inventor: Henri Abiven
  • Patent number: 5514347
    Abstract: A honeycomb structure having a periphery and two ends, including a plurality of passages which are defined by partition walls and extend in an axial direction between the ends, wherein the partition walls are formed of a plurality of through holes for forming turbulent flow so that the fluid pass through the through holes from one of the passages to the adjacent passage, each of the through holes having an open area of at least 0.25 mm.sup.2, thereby a stream of the fluid passing through the honeycomb structure is efficiently mixed to increase its contact with a catalyst composition coated on a surface of the partition walls. The honeycomb structure may have a corrugated thin metal foil. Alternatively, the honeycomb structure may have a unitary structure formed by sintering an extruded body comprising a powder material.
    Type: Grant
    Filed: February 24, 1994
    Date of Patent: May 7, 1996
    Assignee: NGK Insulators, Ltd.
    Inventors: Tsuneaki Ohashi, Nobuo Tsuno
  • Patent number: 5514326
    Abstract: In order to form internal conductors of a multilayer ceramic electronic component such as a multilayer ceramic capacitor, copper paste containing copper powder having a mean particle size of 0.3 to 2 .mu.m in a particle size range of 0.1 to 4 .mu.m and ceramic powder having a main component which is common to that of a ceramic material contained in the multilayer ceramic electronic component and being in a particle size range of 0.5 to 8 .mu.m, as well as an organic vehicle and a solvent with the contents of the copper powder and the ceramic powder and the total content of the organic vehicle and the solvent in ranges of 40 to 70 percent by weight, 1 to 15 percent by weight and 25 to 60 percent by weight respectively is applied onto ceramic green sheets. The ceramic green sheets provided with such copper paste films are stacked and fired so that occurrence of voids in the laminate and deformation of the laminate are suppressed in the as-obtained multilayer ceramic electronic component.
    Type: Grant
    Filed: November 14, 1994
    Date of Patent: May 7, 1996
    Assignee: Murata Manufacturing Co., Ltd.
    Inventors: Hiroji Tani, Kazuhito Ohshita, Mitsuyoshi Nishide
  • Patent number: 5508116
    Abstract: A metal matrix composite reinforced with shape memory alloy is disclosed ch is formed by blending metal particles and shape memory alloy particles to form a homogeneous powder blend, and consolidating the powder blend to form a unitary mass. The unitary mass is then plastically deformed such as by extrusion in the presence of heat so as to cause an elongation thereof, whereby the metal particles form a matrix and the shape memory alloy partices align in the direction of elongation of the unitary mass. The composite can be used in structural applications and will exhibit shape memory characteristics.
    Type: Grant
    Filed: April 28, 1995
    Date of Patent: April 16, 1996
    Assignee: The United States of America as represented by the Secretary of the Navy
    Inventor: David J. Barrett
  • Patent number: 5489411
    Abstract: A high strength titanium alloy or titanium aluminide metal foil having improved strength and density is produced, preferably in coilable strip form, by plasma-depositing the selected titanium-based material on a receiving surface, separating the deposited material from the receiving surface to provide two metal foil preforms each having a relatively smooth side as cast against the receiving surface and a relatively rough, opposite side as deposited from the plasma, disposing the two metal preforms together with the relatively rough sides of the two metal preforms in facing engagement with each other, and squeezing the two preforms together between pressure bonding rolls to metallurgically bond the preforms to each other and to consolidate the materials of the preforms to form a fully dense metal foil.
    Type: Grant
    Filed: September 23, 1991
    Date of Patent: February 6, 1996
    Assignee: Texas Instruments Incorporated
    Inventors: Sunil C. Jha, James A. Forster, Robert W. Howard
  • Patent number: 5487865
    Abstract: A complex body and method of making same which includes forming an assembly of green bodies, each body having an inlet end and an outlet end and having a multiplicity of cells extending from inlet to outlet end, and sintering the assembly at a temperature and time sufficient to cause interdiffusion of the metals between the bodies to join them and form the complex body.
    Type: Grant
    Filed: September 2, 1994
    Date of Patent: January 30, 1996
    Assignee: Corning Incorporated
    Inventors: Leslie E. Hampton, David S. Weiss
  • Patent number: 5487952
    Abstract: There are sintered Bi.sub.2 Te.sub.3 -based thermoelectric materials containing Ag.sub.2 S, which prevent p- to n-type transition of Bi.sub.2 Te.sub.3 -based thermoelectric materials during polycrystalline sintering and have improved thermoelectric properties.
    Type: Grant
    Filed: November 18, 1994
    Date of Patent: January 30, 1996
    Inventors: Han-Ill Yoo, Tae Ho Park, Dae Suk Kang, Beoung Doo Yoo
  • Patent number: 5482671
    Abstract: A method is provided for manufacturing interlocking parts, in which at least one part is manufactured by powder injection molding. To compensate for the amount of contraction of one of the parts manufactured by powder injection molding and, if desired, to produce an additional clearance, a separation layer of plastic material is applied between the interlocking parts. After the injection process to form the separation layer, the separation layer and the binder are removed by a binder-removing and sintering process step. The method is also applicable to powdered metal extrusion for manufacture of double-layered metal parts.
    Type: Grant
    Filed: September 23, 1994
    Date of Patent: January 9, 1996
    Assignee: fischerwerke, Artur Fischer GmbH & Co. KG
    Inventor: Wilfried Weber
  • Patent number: 5480472
    Abstract: A method for forming an electrical contact material comprises the steps of melting a mixture of Cu and Cr into a molten alloy, atomizing the molten alloy into fine particles to obtain alloyed particles. Cr particles in the alloyed powder disintegrate to less than 5 .mu.m in mean particle diameter. The alloyed powder is sintered thereafter and a mean particle diameter of chromium in the sintered article is fined in a range of 2 to 20 .mu.m. An electrical contact material is composed of a copper matrix and chromium particles having a mean particle diameter of 2 to 20 .mu.m. The chromium particles are homogeneously dispersed in the copper matrix.
    Type: Grant
    Filed: July 30, 1991
    Date of Patent: January 2, 1996
    Assignee: Kabushiki Kaisha Meidensha
    Inventors: Yasushi Noda, Nobuyuki Yoshioka, Nobutaka Suzuki, Toshimasa Fukai, Tetsuo Yoshihara, Koichi Koshiro
  • Patent number: 5472661
    Abstract: Method of distributing and retaining insoluble additive particles uniformly throughout a mass of moldable metal particles. The additive particles are suspended in a solution of a polymeric binder and spray-coated onto the metal particles. When the solvent evaporates, the additives remain glued to the metal particles by the binder.
    Type: Grant
    Filed: December 16, 1994
    Date of Patent: December 5, 1995
    Assignee: General Motors Corporation
    Inventor: David E. Gay
  • Patent number: 5470524
    Abstract: A method is provided for manufacturing a bladed ring for drum-shaped rotors of turbomachinery, especially rotors for axial compressors of gas turbine engines. The bladed ring is to be manufactured by hot isostatic pressing (HIP) and the fiber rings are formed in a metallic powder material for the bladed ring arranged in a circumferential direction. The fiber rings are bonded with spacing therebetween. The fiber rings are reinforced by fibers embedded in a metal matrix. The bladed ring prefabricated in this fashion by HIP is machined down to its required dimensions.
    Type: Grant
    Filed: June 14, 1994
    Date of Patent: November 28, 1995
    Assignee: MTU Motoren- Und Turbinen-Union Muenchen GmbH
    Inventors: Wolfgang Krueger, William Wei
  • Patent number: 5466415
    Abstract: Thick-skinned extruded metal honeycomb structures, and a method and apparatus for making them, are disclosed wherein a plasticized powder metal extrusion batch is extruded though a die assembly comprising a die and annular mask, the mask having a central outlet for extrusion of the skin and honeycomb core and an extrudate reservoir adjacent the central outlet, the die and mask cooperating to form a skinforming gap fed by the die and by the extrudate reservoir, such that batch material supplied from the reservoir and directly from the die combines to form a thickened outer skin which is integral with, and resistant to separation from, the honeycomb core.
    Type: Grant
    Filed: October 20, 1994
    Date of Patent: November 14, 1995
    Assignee: Corning Incorporated
    Inventors: Kevin R. Brundage, Lawrence S. Rajnik
  • Patent number: 5460774
    Abstract: A method of manufacturing an axisymmetric component made of a composite material having a metallic matrix is described in which at least one ceramic fiber and at least one wire of the metal which is to constitute the matrix are wound simultaneously side by side to form a number of layers on a suitably shaped mandrel and in such a manner as to ensure absence of contact between the fiber turns of each individual layer and between the fiber turns of adjacent layers, and the formed layers are subsequently subjected to hot isostatic compaction. The ceramic fiber may be of the silicon carbide type and the metal wire forming the matrix may be of titanium or titanium-alloy.
    Type: Grant
    Filed: December 15, 1994
    Date of Patent: October 24, 1995
    Assignee: Societe Nationale d'Etude et de Construction de Moteurs d'Aviation "SNECMA"
    Inventor: Eric Bachelet
  • Patent number: 5455000
    Abstract: The invention provides a method for in-situ powder metallurgy processing of a functionally gradient material (FGM) which uses a preceramic polymer binder system with the metal and/or ceramic powders used to produce the intermediate layers of the composite. The invention also provides a method for controlling shrinkage of the functionally gradient material during processing while still preserving the desired density of the intermediate layers by controlling the preceramic polymer binder content within the functionally gradient material.
    Type: Grant
    Filed: July 1, 1994
    Date of Patent: October 3, 1995
    Assignee: Massachusetts Institute of Technology
    Inventors: Dietmar Seyferth, Pawel Czubarow
  • Patent number: 5447680
    Abstract: Microcracks in fiber-reinforced/titanium aluminide matrix composite materials are inhibited by employing a matrix comprising a titanium aluminide alloy having (1) from ten to twelve atomic percent niobium and (2) a critical admixture of from two to six atomic percent of a member selected from a group consisting of molybdenum, tungsten and vanadium. The tendency of the fiber/matrix interfacial reaction to increase the stability of the Alpha 2 phase in the matrix adjacent to the interface and the tendency to form a "beta phase depletion zone" are unexpectedly negated. Suppression of the beta depletion zone formation inhibits the formation and growth of interfacial microcracks, and allows the fabrication of crack-free titanium matrix composite materials. The need for an extraneous beta phase stabilization treatment at the fiber/matrix interface is eliminated.
    Type: Grant
    Filed: March 21, 1994
    Date of Patent: September 5, 1995
    Assignee: McDonnell Douglas Corporation
    Inventor: David M. Bowden
  • Patent number: 5447681
    Abstract: A method for manufacturing a metal graphite brush comprises steps of preparing natural graphite powders of 60-70 wt %, electrolytic copper powders of 30-40 wt %, molybdenum disulfide and lead of 2.5 wt % and the mixed resin of novolak phenol resin and furfural resin powders of 1-15 wt % which are adhesives, wet-mixing graphite powders with adhesives, pulverizing mixed powders to diameters of less than 200 .mu.m, press-molding all the powders under a pressure of 2-3 ton/cm.sup.2 and heating at a temperature 700.degree. C., and attaching a lead wire thereto, simultaneously, wherein the average particle distribution of the powders is 27 .mu.m. The compound ratio of graphite powders: copper powders: molybdenum disulfide: lead is 62.5 wt %: 35 wt %: 1.5 wt %: 1.0 wt %, the adhesives comprising the mixed resin of novolak phenol resin and furfural resin by 50:50 is added by a weight ratio of 7.5 wt % to the graphite powders.
    Type: Grant
    Filed: December 27, 1993
    Date of Patent: September 5, 1995
    Assignee: Mando Corporation
    Inventors: Chung Tai Seung, Kim Seong Soo, Lee Jae Sung
  • Patent number: 5445787
    Abstract: The process of forming an extruded product of tantalum or niobium requires a cold isostatic pressing of a charge of the powder to a density sufficient to form a green compact which is then placed in a capsule. The capsule is then sealed and heated to a temperature and for a time sufficient to anneal the green compact. Thereafter, the capsule and encapsulated compact are subjected to a cold isostatic pressing to achieve a density of from 70% to 85%. This is followed by subsequent heating and extrusion of the heated capsule and encapsulated compact to form the extruded product. The outer layer on the capsule which has been formed by the capsule material can be removed, as by pickling, in the case of the capsule being a carbon steel.
    Type: Grant
    Filed: November 2, 1993
    Date of Patent: August 29, 1995
    Inventors: Ira Friedman, Christer Aslund
  • Patent number: 5437833
    Abstract: This invention relates generally to a novel method of manufacturing a composite body, such as a ZrB.sub.2 --ZrC--Zr (optional) composite body, by utilizing a post-treatment process and to the novel products made thereby. More particularly, the invention relates to a method of modifying a composite body comprising one or more boron-containing compounds (e.g., a boride or a boride and a carbide) which has been made by the reactive infiltration of a molten parent metal into a bed or mass containing boron carbide, and optionally one or more inert fillers, to form the body.
    Type: Grant
    Filed: March 25, 1994
    Date of Patent: August 1, 1995
    Assignee: Lanxide Technology Company, LP
    Inventors: Terry D. Claar, Gerhard H. Schiroky, William B. Johnson
  • Patent number: 5437834
    Abstract: A porous living body repairing member obtained by compression-molding a metal fiber material into a desired shape, sintering the fiber mesh body or thereafter, and imparting a compressive stress of not more than 4.00 to 40.0 MPa to provide a porous living body repairing member having a compressive elasticity of not more than 2000 MPa and a permanent deformation of not more than 1% under a stress below a compressive yield stress.The compressive yield stress becomes approximately equal to the above compressive stress, and almost complete elasticity of a permanent deformation rate of not more than 0.1% is shown with respect to a compressive stress below this compressive yield stress. Accordingly, even when the porous living body repairing member is used at a high compressive load site such as man's lumbar body, permanent deformation hardly occurs.
    Type: Grant
    Filed: October 7, 1993
    Date of Patent: August 1, 1995
    Assignee: Kyocera Corporation
    Inventors: Hideaki Okimatsu, Yasunori Tamura
  • Patent number: 5429876
    Abstract: Disclosed is a copper-lead based bearing material having excellent corrosion resistance, comprising a steel back metal and a bearing layer of a copper-lead based bearing alloy, the latter consisting essentially, by weight, 0.5 to 10% Bi, 0.5 to 8% Sn, 15 to 30% Pb, 2 to 10% Ni, not greater than 0.2% P, the balance Cu and incidental impurities.By adding Bi in a copper-lead based bearing alloy it becomes possible to obtain excellent corrosion resistance without impairing the conformability and seizure resistance of the bearing material in comparison with the conventional copper-lead based bearing alloys.
    Type: Grant
    Filed: April 12, 1994
    Date of Patent: July 4, 1995
    Assignee: Daido Metal Company Ltd.
    Inventors: Tadashi Tanaka, Masaaki Sakamoto, Koichi Yamamoto, Tsukimitsu Higuchi
  • Patent number: 5429791
    Abstract: An article and method of manufacture of a (Bi,Pb)--Sr--Ca--Cu--O superconductor comprisingcalcinating powders of superconductor precursors of PbO, Bi.sub.2 O.sub.3, SrCO.sub.3 or SrO, CaCO.sub.3 or CaO in air to obtain a 2223 superconductor lump and second phases;crushing the lump into powder;molding the powder into a superconductor body;disposing the body within silver powder to form a composite;molding the composite;heat treating the composite to increase the bond strength of the silver powder; andworking the composite into a useable shape by rolling and drawing while applying intermediate and final heat treatments to obtain a final product.
    Type: Grant
    Filed: June 23, 1994
    Date of Patent: July 4, 1995
    Assignees: Korea Atomic Energy Research Institute, Korea Electric Power Corporation
    Inventors: Hee-Gyun Lee, Seon-Chil Kweon, Dong-Yeon Won, Gye-Won Hong
  • Patent number: 5424138
    Abstract: A copper-alloy slide bearing for a low-rigidity housing having a three-layer structure of a steel back-metal, a copper-alloy layer and an overlay, the back metal containing 0.03 to 0.26% by weight of carbon. During the production of the slide bearing, a bimetal is prepared in such a manner that a back-metal portion is rolled at a total rolling reduction of 10 to 35%, and the resultant bimetal is heat-treated at a relatively low temperature, so that the slide bearing includes a back metal having a 0.01% elastic limit of not less than 300 N/mm.sup.2. When the copper-alloy slide bearing is used in a low-rigidity housing of an internal combustion engine, the slide bearing is capable of more excellently following the deformation of the housing, as well as capable of providing more excellent intimate contact and more excellent fretting resistance, than a conventional multi-layer slide bearing.
    Type: Grant
    Filed: October 26, 1993
    Date of Patent: June 13, 1995
    Assignee: Daido Metal Co., Ltd.
    Inventors: Tadashi Tanaka, Masaaki Sakamoto, Koichi Yamamoto, Tsukimitsu Higuchi
  • Patent number: 5418071
    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.
    Type: Grant
    Filed: February 4, 1993
    Date of Patent: May 23, 1995
    Assignee: Kabushiki Kaisha Toshiba
    Inventors: Michio Satou, Takashi Yamanobe, Takashi Ishigami, Mituo Kawai, Noriaki Yagi, Toshihiro Maki, Minoru Obata, Shigeru Ando
  • Patent number: 5415833
    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.
    Type: Grant
    Filed: March 31, 1994
    Date of Patent: May 16, 1995
    Assignee: Samsung Electronics Co., Ltd.
    Inventors: Ho-jin Kweon, Hai-soo Chun, Ha-chull Chung, Je-hong Youn, Gwun-pil Park
  • Patent number: 5413753
    Abstract: Methods of forming composite articles of superconducting materials and metal at ambient temperature by applying a mixture of metal and binder to a ceramic oxide preform to yield a coated preform which is then heat treated to provide composite articles of superconducting ceramic and metal.
    Type: Grant
    Filed: September 17, 1993
    Date of Patent: May 9, 1995
    Assignee: E. I. Du Pont de Nemours and Company
    Inventor: George E. Zahr
  • Patent number: 5409660
    Abstract: A release agent for producing sintered metal parts using the release agent. The method includes applying a release agent to contacting surfaces of at least two green metal parts, forming an assembly of the parts, sintering the assembly, and separating the parts which are in contact with the release agent. The release agent is a mixture of alumina and a vehicle having a vaporization temperature of less than about 100.degree. C. at atmospheric pressure, and is nonreactive with the alumina and the green metal parts. When at least one of the parts having a contacting surface is a honeycomb structure, the median particle diameter of the alumina is no greater than about 3 micrometers.
    Type: Grant
    Filed: April 8, 1993
    Date of Patent: April 25, 1995
    Assignee: Corning Incorporated
    Inventors: Christopher G. Alpha, Leslie E. Hampton, David S. Weiss
  • Patent number: 5405571
    Abstract: A fiber reinforced composite tape is made by casting a mixture comprising high temperature metal or intermetallic particles, substantially continuous ceramic fibers and a polymeric binder. The particles are preferably titanium alloy or titanium aluminide particles having a top size of greater than about 50 microns and the binder is preferably a polyisobutylene. The cast composite tape is combined with other tapes, heated in a vacuum to remove the binder and pressed at an elevated temperature and pressure to form a composite structure suitable for high temperature applications.
    Type: Grant
    Filed: November 8, 1993
    Date of Patent: April 11, 1995
    Assignee: Aluminum Company of America
    Inventors: William G. Truckner, Jon F. Edd
  • Patent number: 5403544
    Abstract: A method for forming a wear surface on a metal substrate has a slurry which includes wear resistant particles, powdered steel, and binder system positioned on the metal substrate by retaining walls for a time sufficient for drying the slurry and forming a composite material of preselected thickness "T". The retaining walls are then removed and the substrate and the composite material are heated and passed through a rolling mill compressing the composite material.
    Type: Grant
    Filed: December 20, 1993
    Date of Patent: April 4, 1995
    Assignee: Caterpillar Inc.
    Inventors: Richard L. Adrian, James C. Henehan, Phillip J. Shankwitz
  • Patent number: 5399438
    Abstract: Disclosed is a stainless steel member with a high corrosion resistance suitable for a structural member used in highly corrosive environments, such as an edge seal plate of a molten carbonate fuel cell. This stainless steel member includes a base material consisting of stainless steel containing chromium, and a corrosion-protective layer formed on the surface of the base material. In this corrosion-protective layer, a granular heterophase containing chromium is precipitated in an ordered alloy consisting of aluminum and the constituent elements of the base material.
    Type: Grant
    Filed: September 14, 1993
    Date of Patent: March 21, 1995
    Assignee: Kabushiki Kaisha Toshiba
    Inventors: Hiroshi Tateishi, Kiyoshi Imai, Hideyuki Ohzu, Kazuaki Nakagawa, Yoshihiro Akasaka
  • Patent number: 5399311
    Abstract: A magnet is formed as a ring magnet and magnetized by radial application of a magnetic field while the intensity of the magnetic field is changed periodically along the circumference of the ring magnet to give a circumferentially sinusoidal waveform distribution of magnetic flux density to the ring magnet in the magnetized state of the magnet.
    Type: Grant
    Filed: November 12, 1992
    Date of Patent: March 21, 1995
    Assignee: Daido Tokushuko Kabushiki Kaisha
    Inventors: Yasuaki Kasai, Hiyoshi Yamada, Norio Yoshikawa
  • Patent number: 5393484
    Abstract: A process for producing a sintered body, comprising inserting a separately formed first molded article in a mold for injection molding, injection-molding a material identical to or different from that of the first molded article in the mold so that the injected material and the first molded article form together a second molded article, degreasing the second molded article, sintering the degreased article thereby obtaining a sintered body having a difference in shrinkage during the sintering between the first molded article and the injection molded portion of the second molded article other than the first molded article portion being 5% or less. The resulting sintered body is useful as a magnet base.
    Type: Grant
    Filed: October 16, 1992
    Date of Patent: February 28, 1995
    Assignee: Fujitsu Limited
    Inventors: Yoshihiko Seyama, Yutaka Shimizu
  • Patent number: 5384088
    Abstract: Wire, bulk, film, etc. of a superconductive material is manufactured from a powdery precursor. The superconductive material has a superconductive crystal of 1223 phase and/or 1234 phase as a main component, and the powdery precursor comprises at least 1212 phase as a main component.
    Type: Grant
    Filed: October 23, 1992
    Date of Patent: January 24, 1995
    Assignees: Hitachi Cable, Ltd., Hitachi Ltd.
    Inventors: Junichi Sato, Masahiro Seido, Akira Nomoto, Tomoichi Kamo, Katsuzo Aihara
  • Patent number: 5376462
    Abstract: A thixoformable material and a method for forming it are provided in which the material comprises a series of sequentially deposited layers of substantially metallic material, at least some of the layers having different properties. The layers may be of different materials or the layers may differ in that some are provided with reinforcing material whereas other are not. The reinforcing material may consist of particles of spherical, fiberous or other shapes and may be made of various carbides or other suitable reinforcing materials.The thixoformable material may be formed in sheets, cylindrical forms or any other shape and subsequently cut to the volume and/or shape required for the forming stage.A layered material of this sort offers the advantages of thixoformable materials but with enhanced toughness and damage resistance due to the layered 3-dimensional structure.
    Type: Grant
    Filed: May 18, 1993
    Date of Patent: December 27, 1994
    Assignee: Lucas Industries public limited company
    Inventor: Peter R. G. Anderson