Abstract: A composition for fixing a metal powder molding at sintering, which is used, in the case of disposing a metal powder molding formed by rolling a mixture of a metal powder and a synthetic resin-based binder on a metal base material and sintering the metal powder molding in a non-oxidizing atmosphere, by interposing between the metal powder molding and the base material, comprising a thermosetting resin composition containing a thermosetting resin as the essential component, the amount of the residual carbon of which after the completion of sintering is at least about 0.5% by weight.

Abstract: A copper infiltrated ferrous powder metal part infiltrated with copper or a copper alloy characterized as having after infiltration a residual uninfiltrated porosity of less than about 7 volume percent and a maximum pore size of the residual uninfiltrated porosity of less than about 125 micrometers, said porosity and pore size values being taken from a worst field of view in a functionally critical area of said metal part.

Abstract: Method of manufacturing a metallic composite article, with which the surface area of a base member, which surface area consists of a metallic base material, is bonded to a plating material over the entire surface. The base member is to be plated with a layer which is as far as possible homogeneous and thin and the composition of which is freely selectable. For this purpose, the plating material is placed in a sheet-metal cap which is adapted to the surface area to be plated as well as to the adjacent area of the base member surrounding this surface area and overlaps this adjacent area. Once the plating material and sheet-metal cap have been pressed against the base member the sheet-metal cap is evacuated and welded by electron beam, under vacuum, to the base member, whereupon base member, plating material and sheet-metal cap are hot-isostatically pressed. The sheet-metal cap is then removed, leaving the desired, plated base member.

Abstract: A method of producing a cylindrical permanent magnet having a multipole surface anisotropy. The method comprises the steps of: preparing a metal mold cooperating with a lower punch in defining therein a cylindrical compacting cavity, the metal mold being provided in the inner peripheral surface thereof with field coils corresponding in number to the number of the magnetic poles of the magnet to be produced; charging the compacting cavity with a ferromagnetic powder having a magnetic anisotropy; energizing the field coils to impart a magnetic anisotropy to the ferromagnetic powder while compacting the powder between an upper punch and the lower punch to form a compact; demagnetizing the formed compact followed by a firing; and magnetizing the fired compact in the same direction as the anisotropy. The method is characterized in that the field coils produce pulse magnetic field the intensity of which is not smaller than 3.5.times.10.sup.

Abstract: A process for the production of valve seat rings by powder metallurgy wherein molybdenum disulfide in the range of about 0.5% to 1.5% by weight is added to a powder mixture containing 0.8% to 1.5% by weight graphite, 1.0% to 4% by weight lead, 0.5% to 5% by weight nickel, 1.2% to 1.8% by weight molybdenum, 9.6% to 14.4% by weight cobalt, and the remainder iron. The resulting powder mixture is pressed into valve seat rings at a pressing force between 40 and 60 and preferably 50 KN/cm.sup.2. The rings are then sintered in a neutral atmosphere at a temperature of 1100.degree. C. to 1200.degree. C., finally compressed at a pressing force above 120 KN/cm.sup.2 and heat-treated if required. The resulting valve seat rings have greatly improved wear properties when used in internal combustion engines using lead-free gasoline.

Abstract: A composite camshaft having a plurality of ferrous fitting members, such as cam lobes and journals, firmly bonded to a steel shaft by sintering in the presence of a liquid phase. The fitting members are fabricated as a green compact from metal powders and pre-sintered to axially shrink the compact by one-half a preselected allowance of shrinkage. Thereafter the pre-sintered fitting members are fitted on the shaft and sintered to axially shrink the compact by the remaining allowance of shrinkage and metallurgically join the shaft.

Abstract: A process for molding a structural body of ceramic or other granular materials which has hollow portions inwardly enlarged or complicatedly configured, which process comprises preparing a removable insert member which is fusible at temperatures not affecting an unbaked structural body and has the contours corresponding to an intended hollow portion, molding a structural body with ceramic or other granular material integrally with the removable insert member as by injection or transfer molding, heating as by electricity or hot fluids the insert member to cause the latter to be fused and formed with a through hole extending from end to end of the member, and blowing hot air into the through hole during a preliminary baking of the unbaked structural body so as to completely remove the insert member thereby to obtain a molded structural body of granular material provided with complicated hollow portions therein.

Abstract: An article comprising a first portion which is formed porously by sintering of an alloy or cermet material and a second portion which is formed of a metal and intimately bonds to the first portion. For example, the article is a rocker arm for an automotive internal combustion engine, in which first portion is the wear-resistant tip portion and the second portion the body portion. The second portion is formed by molten metal forging, with the sintered first portion set in the mould as an insert, such that the molten metal under pressure is forced to infiltrate into the pores of the sintered first portion at least in a region contiguous to the interface between the first and second portions. This article features very high strength of the bond at the interface between the first and second portions.

Abstract: Amorphous metal alloy compositions are synthesized by solid state incorporation/reduction reactions wherein a high-surface area support is brought in contact with a precursor metal-bearing compound in such a manner that the compound is incorporated into the support or caused to deposit metal onto the surface of the support. The composition obtained is an amorphous alloy composition or can be made so by heat treating at a temperature below the crystallization temperature of the amorphous metal alloy desired to be formed.

Abstract: A method of making pipes by powder metallurgy, in which powder of metal and/or metal alloys (17) is filled into a thin-walled casing consisting of inner pipe wall (12), outer pipe wall (11) and a bottom (13), subsequently the casing is closed on its side remote from the bottom (13) by an annular cover (14) and is subjected to a cold-isostatic pressure whereby the powder (17) is compacted within the casing to produce a solid or dimensionally stable pipe blank or compact (10), which is then hot-worked, e.g. extruded. In order to prevent thermal cracks on the inner pipe or inner pipe wall (12), especially in the region of the ends thereof, the inner pipe or inner pipe wall (12) is provided prior to hot-working on at least one end region thereof with at least one circumferentially extending bulge (15 or 16, respectively).

Abstract: A method of producing rocket combustors wherein in forming an outer cylin by a powder metallurgical method on the outer side of a cylinder provided on its outer periphery with a cooling wall of channel construction having a plurality of grooves, a low-melting alloy is used as a filler to be filled into the grooves. It is also possible to form the outer cylinder after forming a Cu plating shell on the periphery of the inner cylinder filled with the low-melting alloy.

Abstract: An acoustical transducer is provided with an acoustically absorbant backing material having an acoustical impedance precisely matching the impedance of the piezoelectric element in the transducer. The backing material is a multiphase mixture of selected materials, such as a low melting point alloy (InPb) and one or more powders having high impedance characteristics (tungsten and copper). The slope of the curve impedance versus volume fraction of the backing components is low, thus allowing the impedance of the material to be precisely controlled. The backing material is preferably electrically conductive and is fuzed to one surface of the piezoelectric element to further improve the output characteristics of the transducer.

Abstract: An improved inert electrode composition is suitable for use as an inert electrode in the production of metals such as aluminum by the electrolytic reduction of metal oxide or metal salt dissolved in a molten salt bath. The composition comprises one or more metal alloys and metal compounds which may include oxides of the metals comprising the alloy. The alloy and metal compounds are interwoven in a network which provides improved electrical conductivity and mechanical strength while preserving the level of chemical inertness necessary for such an electrode to function satisfactorily. The electrode composition further includes a metal compound dopant which will aid in controlling the thickness of a protective oxide layer on at least the bottom portion of an electrode made therefrom during use.

Abstract: An acoustical transducer is provided with an acoustically absorbant backing material having an acoustical impedance precisely matching the impedance of the piezoelectric element in the transducer. The backing material is a multiphase mixture of selected materials, such as a low melting point alloy (InPb) and one or more powders having high impedance characteristics (tungsten and copper). The slope of the curve impedance versus volume fraction of the backing components is low, thus allowing the impedance of the material to be precisely controlled. The backing material is preferably electrically conductive and is fuzed to one surface of the piezoelectric element to further improve the output characteristics of the transducer.

Abstract: A composite camshaft having a plurality of fitting members, such as cam lobes and journals, fabricated from metal powders having a composition of an Fe-C-Cu system which contains 17-35% by weight of Cu and joined to a steel shaft by a binding effect of Cu, which melts out of the fitting member and full penetrate a clearance between the fitting member and the steel shaft to join them as one body.

Abstract: A method for improving the handling characteristics of a flaked tantalum powder composition comprising heat treating the flaked powder component of the composition in order to pre-agglomerate the flaked component prior to mixing it with the granular tantalum powder component of the composition.

Abstract: A method is provided for forming articles from difficult to fabricate materials with precise internal dimensions. The article is first formed to approximate dimensions as a body using the material in powdered form. Plasma spray forming is proposed. The powder formed body is then brought to its final dimensions by consolidating and densifying the body about a densifying mandrel having a coefficient of expansion which is higher and outer dimensions which are slightly smaller than that of the body.

Abstract: Apparatus for the production of a metal article comprises means for maintaining a reservoir of molten metal with a free surface, means for rotating the free surface of the reservoir about an axis such that the molten metal is atomized and thrown outwardly away from the said surface by centrifugal action, and a substrate in the path of the atomized particles of said molten metal, whereby a solid article may be built up on the substrate by solidifying the atomized particles thereon. The molten metal may be produced by melting an electrode or otherwise.An annular solid metal article is disclosed having excellent mechanical properties. The solid metal article is produced in a single step by a spray deposition process. Molten metal is centrifugally atomized to splat and build up on a cooled mold surface disposed around the centrifuge means. Controlled relative reciprocatory movement in the direction of the rotational axis of the centrifuge is provided.

Abstract: The present invention is directed particularly to an improved method using owder metallurgy for the manufacture of the grooved cooling wall of a liquid-propellant rocket combustion chamber. The surface of an inner cylinder constituting the cooling wall is formed with cooling grooves, and these grooves are densely filled up with a filler such as paraffin wax. Thereafter, metal powder which will provide an outer cylinder is compression-molded to a predetermined thickness around the inner cylinder. This metal powder is the same material as the material of the inner cylinder. After the paraffin wax which is the filler is evaporated and removed, the compression-molded metal powder body is sintered in a furnace. During this sintering heat treatment, the inner and outer cylinders are rigidly joined together by the sintering reaction between the atoms of the inner cylinder and the atoms of the metal powder.

Abstract: A process for making a mechanical part of a complicated profile by preparing a compact having a projection or shaft (hereinafter called the inner part) and a compact having relative recess or opening (hereinafter called the outer part) by the compression of iron base metal powders, and by fitting the inner part into the outer part followed by sintering. This process is characterized in that the said inner part contains carbon as an essential component in an amount that is larger than the carbon content of the said outer part by 0.2% by weight or higher.

Abstract: A uniform reticulated intrastructure (56) is placed in a container (58) and surrounded by beryllium powder (72). After closing the container (58) and applying heat and pressure, a hardened form is taken out of the container. The intrastructure (56) is then removed leaving a lightweight solid beryllium body (72) suitable for use as a mirror (52). Means (62, 66) are provided to control the spacing of the intrastructure elements during the forming process.

Abstract: In a method for undetachably interconnecting discrete structural parts by means of a connecting or bonding material, the structural parts which are to be interconnected are arranged in an aligned manner in a hollow mold, and the interspaces between the hollow mold and the structural parts are filled with a sinterable metal powder. After the arrangement is heated to the sintering temperature of the metal powder, a sintered body results with at least partially embedded, rigidly interconnected structural parts, due to a diffusion bonding. Heat exchanger blocks may especially be produced according to such a method in a simple manner, without requiring that the separate structural parts must be pre-machined for an exact shape accuracy.

Abstract: A process is described for the sintering and densification of ceramic materials containing hydrocarbon materials to produce ceramic bodies substantially free from carbonaceous residues of such hydrocarbon materials by compacting ceramic particles and a binder containing a pyrolysis catalyst selected from the group consisting of nickel and palladium ions, heating in a low oxygen atmosphere to a temperature in the range of 350.degree. to 780.degree. C. to remove the carbonaceous residue and further heating the material to produce a sintered, dense ceramic body.

Abstract: A valve seat or similar article produced by sintering a compound body is improved in economy and producibility by employing a method wherein the amount of a second powder for forming the compound body is controlled so as to be minimized. A first powder is initially charged into a compression space and lightly compressed to form a preparatory compact of a desired shape. Subsequently, the second powder is charged in over the preparatory compact to a degree controlled by the displacement of the compact, and the preparatory compact and the second powder are forcefully compressively integrally molded to form a final compact which is then sintered to form the finished product.

Abstract: Sintered silicon carbide materials are described, which have a metallized surface consisting essentially of a composition comprising 10 to 90% by weight of Si, balance a mixture of at least two components selected from Fe, Ni and Co.A process for producing the silicon carbide sintered materials having the metallized surface is also described.

Abstract: A blade member for cutting tools comprises a cermet substrate having on a surface thereof a reaction layer. The reaction layer is composed of carbo-nitride of at least two metals in groups IV.sub.A, V.sub.A and VI.sub.A, the metals including Ti. The reaction layer may be composed of oxy-carbo-nitride of the above metals. The reaction layer may consist of inner and outer layers, the inner layer being composed of carbo-nitride of the above metals while the outer layer is composed of oxy-carbo-nitride of the above metals. The blade members with the reaction layer exhibits excellent toughness, wear resistance and thermoplastic deformation resistance. There is also disclosed a process for producing the above blade member.

Abstract: The invention relates to a method for manufacturing tubes by sintering and infiltration, the characteristic features of the invention being that the tube wall is formed from a metal powder on a mandrel and is sintered and that the tube wall, during one sintering stage, is sealed by infiltration by means of an infiltration material which solidifies in situ when the temperature is lowered after sintering and which is capable, when in the liquid state, of wetting the metal powder particles, the molding of the tube from the metal powder being preferably carried out by a wet or dry pressing process or by extrusion of the metal powder.

Abstract: Ceramic substrates are pinned using powdered metallurgy pins formed in situ on the substrate.

Abstract: A sintered powdered aluminum core for an inductor used in the tuning stages of high frequency equipment is disclosed. Such cores have threads ground on them having sharp thread profiles, as opposed to the flat thread profiles produced by screw machines, and plating the cores produces superior electrical properties.

Abstract: This invention relates to a capsule for pressings pressed by isostatic pressure and to these pressings used for extruding metallic objects, particularly tubes, of stainless steel, the outer and inner wall of the capsule consisting of thin-walled sheet metal, and at least the outer wall having substantially the same strength properties in the axial direction along its circumference and particularly consisting of a spiral-welded tube, and preferably at least on the front end of the capsule an insert being provided, which consists of one or more pieces of a ductile solid material or a ductile material pressed from powder. The invention further relates to a process for the production of such capsules and pressings and to a process for extruding tubes and to the tubes obtained according to this process.

Abstract: A process for producing a formed member, and a formed member which includes spherical fragments embedded in a metallic matrix is effected through cold pressure rolling. The spheres are arranged in the interspace between a basic support member, which may be a thin-walled inner casing, and an outer casing. Forging of the outer casing causes the material of the support member and the outer casing to be pressed into the spaces between the spheres, densifies the support member and the outer casing, and prestresses the outer casing and spheres, thus allowing the inner casing to be extremely thin-walled. The prestressing of the spheres and outer casing, together with the inner casing imparts a high degree of energy to the casing fragments and to the spheres, affords economies in manufacture and a substantial increase in fragmenting energy at detonation of the formed member.

Abstract: An improved sintered cemented carbide body and method for making same is disclosed. The improved sintered cemented carbide body contains at least one metal carbide and a binder metal, on which body there is applied at least one thin, wear resistant surface layer consisting essentially of aluminum oxide and is characterized in that at least 85% of the aluminum oxide consists of the kappa form, the remainder, which mainly constitutes the alpha form, being formed as surface portions or spots having a size of at the most 10 .mu.m, .[.the size and the occurrence of the surface portions being so adjusted that they lie within the area AOB in FIG. 1 of the attached drawing..].The body is made by a method wherein a cemented carbide substrate is contacted with a gas containing an aluminum halide and a reducing agent at high temperature, characterized in that a dopant addition of tetravalent titanium, zirconium and/or hafnium ions is added to the gas in an amount of 0.03-0.5% of the totally supplied amount of gas.