Vacuum Patents (Class 419/60)
  • Patent number: 8795489
    Abstract: [Problems] To provide a sputtering target that is capable of forming a Cu—Ga film to which Na is favorably added by a sputtering method, and a method for producing the same. [Means for Solving the Problems] The sputtering target is provided wherein 20 to 40 at % of Ga and 0.05 to 1 at % of Na are contained as metal components except fluorine (F) of the sputtering target, a remaining portion has a component composition consisting of Cu and unavoidable impurities, and Na is contained in the state of a NaF compound. Also, a method for producing the sputtering target includes the steps of forming a molded article consisting of a mixed powder of NaF powder and Cu—Ga powder or a mixed powder of NaF powder, Cu—Ga powder, and Cu powder; and sintering the molded article in a vacuum atmosphere, an inert gas atmosphere, or a reducing atmosphere.
    Type: Grant
    Filed: November 4, 2010
    Date of Patent: August 5, 2014
    Assignee: Mitsubishi Materials Corporation
    Inventors: Shoubin Zhang, Yoshinori Shirai
  • Patent number: 8728389
    Abstract: A method for producing high strength aluminum alloy tanks and other vessels containing L12 dispersoids from an aluminum alloy powder containing the L12 dispersoids. The powder is consolidated into a billet having a density of about 100 percent. Tanks are formed by rolling consolidated billets into sheets, cutting preforms from said sheets, roll forming the performs into cylindrical shapes and friction stir welding the seams to form cylinders. L12 alloy domes are spin formed from the rolled sheet and friction stir welded to the cylinder. Circular bases are cut from the rolled sheet and friction stir welded to the domed cylinder to form bottoms of the tank.
    Type: Grant
    Filed: September 1, 2009
    Date of Patent: May 20, 2014
    Assignee: United Technologies Corporation
    Inventor: Awadh B. Pandey
  • Publication number: 20140127072
    Abstract: A continuous sintering method for rare earth permanent magnetic alloy comprises: connecting a preparation chamber, a glove chamber and a sealed transmission chamber, a sealed chamber, a charging chamber, a preheating chamber, a heating and de-airing chamber, a sintering chamber and a cooling chamber one after another. A press formed blank of rare earth permanent magnetic alloy powder is transmitted under oxygen free condition, and processed with heating and de-airing, sintering and cooling. The preparation chamber, the glove chamber and the sealed transmission chamber are transmitted by bottom rollers, transmissions of other chambers are provided on a top portion of each chamber, and conveyed by roller rails. The rollers of the charging rack are suspended on rails of the transmissions. The drawer model charging rack is capable of loading multiple charging box.
    Type: Application
    Filed: November 8, 2013
    Publication date: May 8, 2014
    Applicant: SHENYANG GENERAL MAGNETIC CO., LTD
    Inventors: Xiaodong Chen, Baoyu Sun
  • Publication number: 20130287590
    Abstract: The present invention relates to a method for producing gas turbine components, in particular aircraft turbine components, preferably low-pressure turbine blades, from a powder which is sintered selectively in layers by locally limited introduction of radiant energy, wherein the sintering is carried out in a closed first housing (2), so that a defined atmosphere can be set, wherein the powder or at least a part of the powder is generated in the same first housing (2) or in a second housing connected to the first housing in a gas-tight manner. The invention further relates to a corresponding apparatus and to a gas turbine blade produced thereby.
    Type: Application
    Filed: January 11, 2012
    Publication date: October 31, 2013
    Applicant: MTU AERO ENGINES AG
    Inventors: Stefan Neuhaeusler, Bertram Kopperger, Josef Waermann, Andreas Jakimov, Erwin Bayer, Wilhelm Meir
  • Patent number: 8431071
    Abstract: A method of sintering by: placing a compacted metal powder inside a cylindrically-shaped susceptor and in an inert atmosphere or a vacuum, and applying microwave or millimeter-wave energy to the powder until the powder is sintered.
    Type: Grant
    Filed: August 27, 2010
    Date of Patent: April 30, 2013
    Assignee: The United States of America, as represented by the Secretary of the Navy
    Inventors: M Ashraf Imam, Arne W Fliflet
  • Patent number: 8409496
    Abstract: A method and apparatus produces high strength aluminum alloys from a powder containing L12 intermetallic dispersoids. The powder is degassed, sealed under vacuum in a container, consolidated by vacuum hot pressing, and superplastically formed into a usable part.
    Type: Grant
    Filed: September 14, 2009
    Date of Patent: April 2, 2013
    Assignee: United Technologies Corporation
    Inventor: Awadh B. Pandey
  • Patent number: 8377373
    Abstract: Disclosing herein is a method for manufacturing nickel-titanium compositions. The method includes disposing a powdered composition in a mold; the powdered composition comprising nickel and titanium; the titanium being present in an amount of about 38 to about 42 wt % and the nickel being present in an amount of about 58 to about 62 wt %; sintering the powdered composition to produce a sintered preform; compacting the preform; machining the preform to form an article; heat treating the article; the annealing being conducted at a temperature of about 1650° F. to about 1900° F. at a pressure of about 3 Torr to about 5 Kg-f/cm2 for a time period of about 10 minutes to about 5 hours; and quenching the article.
    Type: Grant
    Filed: August 20, 2009
    Date of Patent: February 19, 2013
    Assignees: The United States of America, Abbott Ball Company
    Inventors: Glenn N. Glennon, Christopher DellaCorte
  • Publication number: 20120051962
    Abstract: A method of sintering by: placing a compacted metal powder inside a cylindrically-shaped susceptor and in an inert atmosphere or a vacuum, and applying microwave or millimeter-wave energy to the powder until the powder is sintered.
    Type: Application
    Filed: August 27, 2010
    Publication date: March 1, 2012
    Applicant: THE GOVERNMENT OF THE UNITED STATES OF AMERICA, AS REPRESENTED BY THE SECRETARY OF THE NAVY
    Inventors: M. Ashraf Imam, Arne W. Fliflet
  • Patent number: 8083831
    Abstract: The present invention relates to a lightweight, anti-scratch and fracture resistant material for use in manufacture of jewelry prepared by sintering a powered mixture consisting essentially of 20% by weight of titanium carbide, 25% by weight of tungsten carbide, 35% by weight of titanium nitride, and balance being a binder consisting essentially of nickel, molybdenum and cobalt.
    Type: Grant
    Filed: March 4, 2010
    Date of Patent: December 27, 2011
    Assignee: BTR Limited
    Inventor: Zhijian Xia
  • Patent number: 8075661
    Abstract: An ultra-hard composite material and a method for manufacturing the same, including mixing a metal carbide powder and a multi-element high-entropy alloy powder to form a mixture, green compacting the mixture, and sintering the mixture to form the ultra-hard composite material. The described multi-element high-entropy alloy consists of five to eleven principal elements, with every principal element occupying a 5 to 35 molar percentage of the alloy.
    Type: Grant
    Filed: April 25, 2008
    Date of Patent: December 13, 2011
    Assignee: Industrial Technology Research Institute
    Inventors: Chi-San Chen, Chih-Chao Yang, Jien-Wei Yeh, Chin-Te Huang
  • 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
  • Publication number: 20110268599
    Abstract: The present invention provides a process for preparing a ZnAl alloy target material by providing a mixture of zinc powder and aluminum powder and obtaining a ZnAl alloy by sintering the mixture of zinc powder and aluminum powder by using a spark plasma sintering process. The present invention also describes a ZnAl alloy target material prepared by the above-described process.
    Type: Application
    Filed: January 11, 2010
    Publication date: November 3, 2011
    Applicant: E.I. DU PONT DE NEMOURS AND COMPANY
    Inventors: Shengcong Liufu, Hao Zeng
  • Patent number: 7883661
    Abstract: A method for providing a porous metal implant. A mixture of a biocompatible metal, a spacing agent, and a binder is provided. The mixture is formed into a shaped the spacing agent is removed to form a plurality of pores in the implant. A shaped porous metal implant is also provided.
    Type: Grant
    Filed: September 11, 2009
    Date of Patent: February 8, 2011
    Assignee: Biomet Manufacturing Corp.
    Inventors: Ned M. Hamman, James B. Fleming, Isaac Janson, Mukesh Kumar, Jason D. Meridew, Elizabeth A. Schlueter
  • Patent number: 7635447
    Abstract: A method for providing a porous metal implant. A mixture of a biocompatible metal, a spacing agent, and a binder is provided. The mixture is formed into a shaped the spacing agent is removed to form a plurality of pores in the implant. A shaped porous metal implant is also provided.
    Type: Grant
    Filed: February 17, 2006
    Date of Patent: December 22, 2009
    Assignee: Biomet Manufacturing Corp.
    Inventors: Ned M. Hamman, James Fleming, Elizabeth A. Schlueter, Isaac Janson, Jason D. Meridew, Mukesh Kumar
  • 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: 7566415
    Abstract: The method is suitable for the manufacture of flat or shaped titanium aluminide articles and layered metal matrix composites such as lightweight plates and sheets for aircraft and automotive applications, thin cross-section vanes and blades, composite electrodes, heat-sinking lightweight electronic substrates, bulletproof structures for vests, partition walls and doors, as well as for sporting goods such as helmets, golf clubs, sole plates, crown plates, etc.
    Type: Grant
    Filed: November 18, 2002
    Date of Patent: July 28, 2009
    Inventors: Vladimir S. Moxson, Eugene Ivanov
  • Patent number: 7517492
    Abstract: Methods for sintering aluminum powder comprise providing aluminum powder and heating the aluminum powder in a nitrogen atmosphere containing a partial pressure of water vapor in the range of about 0.001 kPa to about 0.020 kPa to sinter the aluminum powder to a transverse rupture strength of at least about 13.8 MPa. The aluminum powder is not pressed together by a mechanical force that substantially deforms particles of said aluminum powder either prior to or during the step of heating. Articles comprising sintered aluminum powder. The sintered aluminum powder has a transverse rupture strength of at least about 13.8 MPa. The microstructure of the sintered aluminum powder contains no compositional concentration gradients indicative of the use of a sintering aid and no evidence of particle deformation having occurred by an application of a mechanical force prior to or during the sintering of the aluminum powder.
    Type: Grant
    Filed: December 1, 2003
    Date of Patent: April 14, 2009
    Assignee: The Ex One Company
    Inventor: Jianxin Liu
  • Patent number: 7473296
    Abstract: A wear-resistant iron-based sintered contact material is provided which is sintered by powder sintering so as to have high density, high seizure resistance and wear resistance. A wear-resistant iron-based sintered composite contact component composed of the wear-resistant iron-based sintered contact material sinter-bonded to a backing metal and its producing method are also provided. To this end, at least Cr7C3-type carbide and/or M6C-type carbide which have an average particle diameter of 5 ?m or more are precipitately dispersed in an amount of 20 to 50% by volume within an iron-based martensite parent phase which has a hardness of HRC 50 or more even when tempered at up to 600° C.
    Type: Grant
    Filed: September 2, 2005
    Date of Patent: January 6, 2009
    Assignee: Komatsu, Ltd.
    Inventors: Takemori Takayama, Kazuo Okamura, Yoshikiyo Tanaka, Tetsuo Ohnishi
  • Patent number: 7384445
    Abstract: The invention concerns a sintered metal part which has a densified surface and sintered density of at least 7.35 g/cm3 and a core structure distinguished by a pore structure obtained by single pressing to at least 7.35 g/cm3 and single sintering of a mixture of a coarse iron or iron-based powder and optional additives.
    Type: Grant
    Filed: April 19, 2005
    Date of Patent: June 10, 2008
    Assignee: Höganäs AB
    Inventors: Paul Skoglund, Mikhail Kejzelman, Anders Bergmark
  • Patent number: 7309466
    Abstract: A sintered cemented carbide body (e.g., a cutting tool) and a method of making the same. The sintered cemented carbide body includes tungsten carbide, a binder phase of at least one metal of the iron group or an alloy thereof, and one or more solid solution phases. Each one of the solid solution phases has at least one of the carbides and carbonitrides of a combination of zirconium, niobium, and tungsten. The method includes the steps of providing a powder mixture that contains tungsten carbide, a binder metal powder comprising at least one metal of the iron group or an alloy thereof, and at least one of the carbides and carbonitrides of both zirconium and niobium including a powder of the carbides or carbonitrides of zirconium and niobium, forming a green compact of said powder mixture, and vacuum sintering or sinter-HIP said green compact at a temperature of from 1400 to 1560° C.
    Type: Grant
    Filed: March 31, 2006
    Date of Patent: December 18, 2007
    Assignee: Kennametal Inc.
    Inventors: Hans-Wilm Heinrich, Manfred Wolf, Dieter Schmidt
  • Patent number: 7300488
    Abstract: The present invention concerns a powder metal composition for producing powder metal components comprising a Co-based pre-alloyed powder, with irregularly shaped particles comprising at least 15% by weight Cr and less than 0.3% by weight C, admixed with graphite. The invention also concerns a method for producing PM components by pressing of articles to shape from the powder metal composition according to the invention and sintering them.
    Type: Grant
    Filed: March 17, 2004
    Date of Patent: November 27, 2007
    Assignee: Höganäs ab
    Inventors: Christophe Szabo, Owe Mårs
  • Patent number: 7163657
    Abstract: A sintered cemented carbide body (e.g., a cutting tool) and a method of making the same. The sintered cemented carbide body includes tungsten carbide, a binder phase of at least one metal of the iron group or an alloy thereof, and one or more solid solution phases. Each one of the solid solution phases has at least one of the carbides and carbonitrides of a combination of zirconium, niobium, and tungsten. The method includes the steps of providing a powder mixture that contains tungsten carbide, a binder metal powder comprising at least one metal of the iron group or an alloy thereof, and at least one of the carbides and carbonitrides of both zirconium and niobium including a powder of the carbides or carbonitrides of zirconium and niobium, forming a green compact of said powder mixture, and vacuum sintering or sinter-HIP said green compact at a temperature of from 1400 to 1560° C.
    Type: Grant
    Filed: December 3, 2003
    Date of Patent: January 16, 2007
    Assignee: Kennametal Inc.
    Inventors: Hans-Wilm Heinrich, Manfred Wolf, Dieter Schmidt
  • Patent number: 7097685
    Abstract: A cemented carbide comprises a binder phase consisting essentially of an iron family metal, a first hard phase consisting essentially of WC having a hexagonal crystal structure, and a second hard phase consisting essentially of one or more types of a compound of a metal or metals of group 4, 5 or 6 of the periodic table having an NaCl-type cubic crystal structure. The cemented carbide is formed by a surface region with a thickness of 2 to 50 ?m consisting of the binder phase and the first hard phase, and an inner region present underneath the surface region consisting of the binder phase, the first hard phase and the second hard phase. A ratio of an average grain size of the first hard phase in the surface region to an average grain size of the first hard phase in the inner region is 1 or less, and a ratio of an area of the binder phase in the surface region to an area of the binder phase in the inner region is greater than 1.
    Type: Grant
    Filed: August 25, 2004
    Date of Patent: August 29, 2006
    Assignee: Tungaloy Corporation
    Inventors: Hiroyuki Miura, Satoshi Kinoshita
  • Patent number: 6958084
    Abstract: A sintered material and a method for the production thereof is described. The material comprises an alloy selected from one of the groups having a composition comprising in weight %: either Cr 5-30/Mo 0-15/Ni 0-25/W 0-15/C 0-5/Si 0-5/Fe 0-5/Mn 0-5/others 10 max/Co balance, or Cr 10-20/Mo 0-15/Co 0-20/W 0-5/Fe 0-20/Al 0-5/Ti 0-5/others 15 max/Ni balance; said alloy having incorporated therein from 3-15 weight % of Sn; and optionally from 1-6 weight % of a solid lubricant material.
    Type: Grant
    Filed: June 25, 2002
    Date of Patent: October 25, 2005
    Assignee: Federal-Mogul Sintered Products Limited
    Inventors: Iain Robert Whitaker, Richard Jameson Pavey
  • Publication number: 20040131492
    Abstract: A valve seat is produced by (a) using, as a raw material powder for forming a matrix, an Fe-based alloy powder with an average particle size of 20 to 50 &mgr;m, and using, as a raw material powder for forming a hard dispersion phase, a Co-based alloy powder with an average particle size of 20 to 50 &mgr;m, (b) conducting solid phase sintering, under vacuum, of a pressed compact formed from a mixed powder generated by mixing the Co-based alloy powder into the Fe-based alloy powder in sufficient quantity to account for 25 to 35% by weight of the combined weight with the Fe-based alloy powder, and causing the Co, Cr and Si components of the Co-based alloy powder to diffuse and migrate into the matrix, and the Fe component of the Fe-based alloy powder to diffuse and migrate concurrently into the hard dispersion phase, thereby markedly improving adhesion of the hard dispersion phase to the matrix, and forming, as a result, an Fe-based sintered alloy substrate with a porosity of 10 to 20%, and comprising an Fe&mdas
    Type: Application
    Filed: September 30, 2003
    Publication date: July 8, 2004
    Applicant: MITSUBISHI MATERIALS CORPORATION
    Inventors: Atsushi Kawakami, Kazuyuki Hoshino, Kunio Hanata
  • Patent number: 6669898
    Abstract: A process for preparation of molded articles, such as golf club heads, by metal injection molding and the resulting product.
    Type: Grant
    Filed: June 6, 2002
    Date of Patent: December 30, 2003
    Assignee: RA Brands, L.L.C.
    Inventors: Stephen H Gressel, Matthew M Marley, Maryann Wright
  • 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: 6547550
    Abstract: This specification discloses a method and apparatus for forming and extruding ceramic materials. The apparatus utilizes a vacuum chamber mounted within a heating chamber or element; and the ceramic forming chamber is mounted within the vacuum chamber. A press is slidably mounted within vacuum and forming chambers in order to apply pressure to the ceramic materials during the heating step and subsequently during the ceramics extrusion step. The heating chamber applies heat to the vacuum chamber and forming chamber during the sintering and extrusion step. The forming chamber preferably remains in position within the vacuum chamber during the entire ceramic article manufacturing process.
    Type: Grant
    Filed: June 16, 2000
    Date of Patent: April 15, 2003
    Inventor: Ross Guenther
  • Patent number: 6506338
    Abstract: A pressureless sintering process for producing FeAl wherein the heating rate is controlled in a manner which minimizes expansion of a mixture of elemental powders of iron and aluminum. During the process, the heating rate is maintained below 1° C./min to minimize the volume expansion during the formation of the intermediate phase Fe2Al5. As a result of the process, the final density can be increased up to 95% of the theoretical density. The sequence of phases formed during the heating of Fe+Al mixture were identified by X-ray diffraction, optical microscopy, SEM and along with DSC data were correlated to the expansion and shrinkage behavior of the samples.
    Type: Grant
    Filed: April 14, 2000
    Date of Patent: January 14, 2003
    Assignee: Chrysalis Technologies Incorporated
    Inventors: Shalva Gedevanishvili, Seetharama C. Deevi
  • Patent number: 6475428
    Abstract: A method of producing high purity, low oxygen content titanium powder utilizes a hydrided titanium powder crushed to desired percentage of particles of not more than a desired size. These hydrided particles are dehydrided by a slow heating process under partial vacuum to draw the hydrogen out of the particles with a minimum of sintering of the particles. The hydrided particles may be initially heated relatively rapidly, over a period of between about two hours and six hours to a temperature of between about 450° C. and 500° C. and then slowly over a period of four to five days to a temperature of between 650° C. and 700° C., all under a partial vacuum, until the hydrogen content of the powder reaches a desired value. The now dehydrided titanium powder is cooled, again crushed if and as necessary to break up any sintered particles, screened, and packaged. The method of the invention minimizes the sintering of the particles during the dehydriding process.
    Type: Grant
    Filed: April 21, 2001
    Date of Patent: November 5, 2002
    Inventors: Joseph T. Fraval, Mitchell T. Godfrey
  • Patent number: 6464934
    Abstract: In a method for manufacturing a permanent magnet, a powder of a magnetic base alloy and powders of at least two binder alloys are mixed. The magnetic base alloy has a general formula SE2T14B, wherein SE is at least one rare earth element, including Y, and T is Fe or a combination of Fe and Co, wherein Co does not exceed 40 wt % of the combination of Fe and Co. The two binder alloys have respective general formulas SE6(Fe,Co)13−xGa1+x and SE2Co3. The base alloy and the at least two binder alloys are mixed in a weight ratio between 99:1 and 89:11. The mixture is then compressed and is subsequently sintered in a vacuum and/or in an inert gas atmosphere.
    Type: Grant
    Filed: January 29, 2001
    Date of Patent: October 15, 2002
    Assignee: Vacuumschmelze GmbH
    Inventors: Peter Schrey, Mircea Velicescu
  • Patent number: 6428744
    Abstract: There are disclosed copper-base and/or iron-base contact materials which contain a Pb intermetallic compound dispersedly precipitated therein and which have highly improved sliding properties. Double layered contact elements improved in oil impregnation and lubricity are formed by sinter bonding the above contact materials to an iron-base metal backing, respectively. Economical producing methods for such double layered contact materials are also disclosed. In the copper-base and/or iron-base contact materials, one or more kinds of Pb intermetallic compounds are dispersedly precipitated.
    Type: Grant
    Filed: September 12, 2000
    Date of Patent: August 6, 2002
    Assignee: Komatsu Ltd.
    Inventors: Takemori Takayama, Yoshikiyo Tanaka
  • Patent number: 6375705
    Abstract: Oxide dispersion strengthening of porous metal articles includes the incorporation of dispersoids of metallic oxides in elemental metal powder particles. Porous metal articles, such as filters, are fabricated using conventional techniques (extrusion, casting, isostatic pressing, etc.) of forming followed by sintering and heat treatments that induce recrystallization and grain growth within powder grains and across the sintered grain contact points. The result is so-called “oxide dispersion strengthening” which imparts, especially, large increases in creep (deformation under constant load) strength to the metal articles.
    Type: Grant
    Filed: March 26, 1999
    Date of Patent: April 23, 2002
    Assignee: U. T. Battelle, LLC
    Inventor: Roddie R. Judkins
  • Patent number: 6368551
    Abstract: The method for preparation of sintered permanent magnets according to the present invention comprises the steps of: mixing fully fine powder of a crystalline mother alloy for permanent magnet containing a rare-earth element, Fe and B as the essential components with fine powder of zinc oxide, compaction molding the resulted mixture in the presence of a magnetic field, sintering the compacted mixture in vacuum to cause generation of oxygen and metallic zinc by thermal decomposition of the zinc oxide; segregation of a part of metallic component in the mother alloy at the boundary and inside of the mother alloy crystal; formation of amorphous metallic oxide by forced oxidation of the segregated metal with the generated oxygen; crystallization of the amorphous metallic oxide; formation of an epitaxial junction between the crystallized metallic oxide and the mother alloy crystal; and evaporation of the metallic zinc into the vacuum, and quenching the sintered compact.
    Type: Grant
    Filed: August 16, 2000
    Date of Patent: April 9, 2002
    Assignee: Sanei Kasei Co., Ltd.
    Inventors: Shigenobu Sekine, Yuko Kawasaki, Yoshiki Kuwabara, Hiroji Sato, Minoru Narita, Kazushi Suzuki, Koichi Tono, Keiji Okada, Kenji Sakaguchi, Mitsuhisa Hirata
  • Patent number: 6332906
    Abstract: Aluminum-silicon alloys having high stiffness are used in forming computer memory disks and actuator arms. Disks formed with the alloy have low flutter and can be spun at 12,000 RPM or greater with a flutter of 10 Å or less.
    Type: Grant
    Filed: March 24, 1998
    Date of Patent: December 25, 2001
    Assignee: California Consolidated Technology, Inc.
    Inventors: Tom Haynes, Kevin Anderson
  • Patent number: 6299831
    Abstract: A method is provided for fabricating Cu/Cr sputter targets having a density of at least about 90% of theoretical density and an oxygen content of less than about 1000 ppm. According to the principles of the present invention, Cu and Cr powders, each having particles in the size range of about 20 &mgr;m to about 150 &mgr;m and having oxygen contents preferably less than about 1200 ppm and 600 ppm, respectively, are blended and pressed by hot pressing. A low-oxygen content, high-density Cu/Cr target is thereby achieved for the sputtering of thin films having a defect generation of about 0%.
    Type: Grant
    Filed: July 14, 1999
    Date of Patent: October 9, 2001
    Assignee: Praxair S.T. Technology, Inc.
    Inventor: Chi-Fung Lo
  • Patent number: 6042780
    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: December 15, 1998
    Date of Patent: March 28, 2000
    Inventor: Xiaodi Huang
  • Patent number: 6038461
    Abstract: There are disclosed a high temperature superconductive material which can be plastically deformed, processed optionally into predetermined configurations and industrially mass produced and a method of manufacturing a formed body of the high temperature superconductive material. Mixed is a powder raw material which is mainly composed of: 10 to 50 mol % of at least one amide or nitride of alkali metal of Li, Na or K; 10 to 60 mol % of cyanide containing at least one metal selected from aluminum, copper, silver or gold; 5 to 50 mol % of at least one pure metal selected from aluminum, copper, silver or gold; and 10 mol % or less of at least one alkaline earth metal selected from Be, Mg, Ca, Sr or Ba. The powder raw material is pressed, and heated and sintered at the temperature of 673 K to 1553 K. In this manner, obtained is the plastically deformable high temperature superconductive material which can be optionally processed through forging, rolling and the like.
    Type: Grant
    Filed: April 24, 1998
    Date of Patent: March 14, 2000
    Inventors: Yoshifumi Sakai, Itsuko Sakai
  • Patent number: 6033789
    Abstract: The tool includes at least one cutting edge formed by a compacted mixture of carbide containing alloy steel and an oxide containing ceramic material, preferably zirconium oxide in an amount of 0.01-15 wt % of the mixture, preferably in the region of 1 to 6 wt %, advantageously in the region of 3 wt %. The mixture may additionally include particles of a hard or abrasive material, such as silicon carbide or aluminum carbide or a boride/carbide such as aluminum titanium diboride-titanium carbide.
    Type: Grant
    Filed: September 11, 1997
    Date of Patent: March 7, 2000
    Inventors: Jonathan James Saveker, Trevor David Bonnell
  • Patent number: 6024914
    Abstract: Conventional anodes for solid electrolytic capacitor have small numbers of spaces and gaps therein and, when made into a capacitor, have shown insufficient (high) tan d and ESR. An anode having enlarged numbers of spaces and gaps and giving a capacitor of improved tan d and ESR can be produced by using, as a material for shaped material (anode before sintering), a mixed powder of a granulated valve metal powder of 50 to 200 .mu.m in particle diameter and a solid organic substance of 20 .mu.m or less in average particle diameter.
    Type: Grant
    Filed: August 31, 1998
    Date of Patent: February 15, 2000
    Assignee: NEC Corporation
    Inventor: Katsuhiro Yoshida
  • Patent number: 5993506
    Abstract: Disclosed are a plate-crystalline tungsten carbide-containing hard alloy which comprises 4 to 40% by volume of a binder phase containing at least one of iron group metals selected from Co, Ni and Fe as a main component; and the balance of a hard phase comprising tungsten carbide alone, or tungsten carbide and 50% by volume or less of a compound with a cubic structure selected from at least one of carbide and nitride of the 4a (Ti, Zr and Hf), 5a (V, Nb and Ta) or 6a (Cr, Mo and W) group element of the periodic table and mutual solid solutions thereof, and inevitable impurities,wherein when peak intensities at a (001) face and a (101) face in X-ray diffraction using K.alpha. rays with Cu being a target are represented by h(001) and h(101), respectively, the tungsten carbide satisfies h(001)/h(101) .gtoreq.0.50, a composition for forming a plate-crystalline tungsten carbide, and a process for preparing the plate-crystalline tungsten carbide-containing hard alloy.
    Type: Grant
    Filed: November 25, 1997
    Date of Patent: November 30, 1999
    Assignee: Toshiba Tungaloy Co., Ltd.
    Inventors: Masaki Kobayashi, Kozo Kitamura, Satoshi Kinoshita
  • Patent number: 5980820
    Abstract: A ball linear guide includes a ball-cyclic-running path composed of a loaded ball groove and a non-loaded ball groove, wherein said ball linear guide main body is of a single structure including: a dovetail groove having at both ends thereof an inlet and an outlet for balls; and a tunnel-like non-loaded ball hole being continuous to said dovetail groove with said inlet and said outlet being as both ends thereof. The tunnel-like non-loaded ball hole is manufactured by forming, around a tunnel-like core, an iron alloy containing about 0.85 wt % of C, about 0.3% of Si, about 0.3 wt % of Mo, about 4.0 wt % of Cr, about 5.0 wt % of Mn, about 6.0 wt % of W, about 2.0 wt % of V, and/or about 0.6 wt % of Ti. The ball linear guide allows smooth rotation of balls at a high speed with reduced noise, and also it exhibits a long service life. Further, in the manufacturing method, the number of parts and the number of working steps are reduced, and the assembly is easily performed without great care.
    Type: Grant
    Filed: July 28, 1998
    Date of Patent: November 9, 1999
    Assignee: Takeuchi Precision Works Co., Ltd.
    Inventor: Mitsuo Takeuchi
  • Patent number: 5976459
    Abstract: A method for producing compacted, fully dense articles from atomized tool steel alloy particles by placing the particles in an evacuated, deformable container, and isostatically pressing the particles at an elevated temperature to produce a precompact having an intermediate density. The precompact is heated to a temperature above the elevated temperature used to produce the precompact. The precompact is isostatically pressed to produce the fully-dense article.
    Type: Grant
    Filed: January 6, 1998
    Date of Patent: November 2, 1999
    Assignee: Crucible Materials Corporation
    Inventors: William B. Eisen, Walter Haswell, Kenneth J. Wojslaw, Jeryl K. Wright
  • Patent number: 5960249
    Abstract: A method for forming an exterior surface of a high-temperature component, such as a blade or vane of a gas turbine engine. The method entails forming a shell by a powder metallurgy technique that yields an airfoil whose composition can be readily tailored for the particular service conditions of the component. The method generally entails providing a pair of inner and outer mold members that form a cavity therebetween. One or more powders and any desired reinforcement material are then placed in the cavity and then consolidated at an elevated temperature and pressure in a non-oxidizing atmosphere. Thereafter, at least the outer mold member is removed to expose the consolidated powder structure. By appropriately shaping the mold members to tailor the shape of the cavity, the consolidated powder structure has the desired shape for the exterior shell of a component, such that subsequent processing of the component does not require substantially altering the configuration of the exterior shell.
    Type: Grant
    Filed: March 6, 1998
    Date of Patent: September 28, 1999
    Assignee: General Electric Company
    Inventors: Ann Melinda Ritter, Paul Leonard Dupree, Melvin Robert Jackson, Donald Norman Wemple, Jr.
  • Patent number: 5930583
    Abstract: This invention relates to a method for forming a titanium alloy by powder metallurgy, which comprises the processes of mixing uniformly a powder of titanium or an alloy thereof with a low-melting point metal or alloy powder, injecting the mixture into a press forming die, then press forming them under heating to a temperature near and over the melting point of the low-melting point metal, or to a temperature between the liquidus and the solidus of the low-melting point alloy, or to a temperature near and over the liquidus to obtain the targeted compact, and holding this compact in the pressurized state to cause the molten low-melting point metal or alloy to infiltrate the powder grain boundary of the titanium or alloy thereof, and then sintering the compact thus obtained in an inert atmosphere or a vacuum to diffuse the titanium or alloy thereof and the low-melting point metal or alloy into each other and to make alloys of them.
    Type: Grant
    Filed: August 25, 1997
    Date of Patent: July 27, 1999
    Assignee: Japan as represented by Director General of Agency of Industrial Science and Technology
    Inventors: Kazuo Yasue, Gongli Yu
  • Patent number: 5849244
    Abstract: A method and apparatus for loading tool steel and high speed steel powder to a deformable mold for compacting is disclosed. The particles are exposed to a uniform vacuum during transfer from a sealed container through a sealed conduit and into a sealed deformable mold. By this method and apparatus, the particles are uniform throughout the container and substantially free of impurities, without requiring conventional outgassing.
    Type: Grant
    Filed: April 4, 1996
    Date of Patent: December 15, 1998
    Assignee: Crucible Materials Corporation
    Inventors: Terry C. Rhodes, Henry E. Brinzer, Jr., Frank J. Rizzo
  • Patent number: 5761593
    Abstract: A cemented carbide insert with improved toughness and resistance against plastic deformation containing WC and cubic phases of carbide and/or carbonitride in a binder phase based on Co and/or Ni with a binder phase enriched surface zone is disclosed. The binder phase content in the insert is 3.5-12 weight-%. In a zone below the binder phase enriched surface zone, the binder phase content is 0.85-1 of the binder phase content in the inner portion of the insert and the content of cubic phases is essentially constant and equal to the content in the inner portion of the insert. The insert is formed by sintering a cemented carbide containing a nitrogen-containing material in a vacuum or inert atmosphere and heat treating the sintered insert in nitrogen at 40-400 mbar at a temperature of 1280.degree.-1430.degree. C. for a time of 5-100 min.
    Type: Grant
    Filed: March 15, 1996
    Date of Patent: June 2, 1998
    Assignee: Sandvik AB
    Inventors: Ake Ostlund, Ulf Oscarsson, Per Gustafson, Leif Akesson
  • Patent number: 5758253
    Abstract: A process for producing sintered titanium-graphite having improved wear resistance and low frictional characteristics is described. The said process which produces titanium-graphite composites having a triphasic structure with controlled porosity and a graphite lubricating film, comprises sintering a mixture of titanium and graphite powders in which the percentage of graphite may vary from 4 to 8 percent at temperatures from about 800.degree. C. to 1600.degree. C., for about 1/2 to 2 hours, under a compaction pressure of 0.17 to 0.62 MPa. The composites have applications in biomedical engineering and other fields of engineering due to their biocompatibility, strength and improved wear resistance.
    Type: Grant
    Filed: October 7, 1996
    Date of Patent: May 26, 1998
    Assignee: National University of Singapore
    Inventors: Swee Hin Teoh, Rajendran Thampuran, James Cho Hong Goh, Winston Kar Heng Seah
  • Patent number: 5733427
    Abstract: A sputtering target formed of a refractory metallic silicide having a composition MSi.sub.x including a mixture composition of an MSi.sub.2 phase in the form of particles (M: at least one refractory metal selected from a group consisting of W, Mo, Ti, Zr, Hf, Ni and Ta), and an Si phase provided as a matrix phase. Interface layers having a predetermined thickness are formed at the interfaces between the MSi.sub.2 phase and the Si phase. The value X in the composition formula MSi.sub.x is set to a range of 2.0 to 4.0, and the thickness of the interface layers formed between the MSi.sub.2 phase and the Si phase, the dispersion of the composition, the density ratio of the target, the electrical resistivity of the Si phase and the surface roughness are set to predetermined values. An uniform high-quality thin film in which a composition distribution is uniform can be manufactured stably by using this target.
    Type: Grant
    Filed: March 30, 1995
    Date of Patent: March 31, 1998
    Assignee: Kabushiki Kaisha Toshiba
    Inventors: Michio Satou, Takashi Yamanobe, Mitsuo Kawai, Tatsuzo Kawaguchi, Kazuhiko Mitsuhashi, Toshiaki Mizutani
  • Patent number: 5722037
    Abstract: There is provided a process for producing titanium composite, comprising the steps of: molding titanium powder, titanium alloy powder, or powder comprising titanium into a certain shape by a cold isostatic press or cold press; reacting the shape with hydrocarbon gas at its decomposition temperature or higher, to form TiC therein; and providing the shape with high density by vacuum sintering, hot isostatic pressing, hot forging, hot rolling and/or the combinations thereof. TiC a reinforcing material, is in-situ formed by reacting a cold-pressed body of the powder with hydrocarbon gas and cleaner than the externally added one and distributed more uniformly and finely in the Ti matrix, leading to a significant improvement in wear resistance and high temperature property.
    Type: Grant
    Filed: May 9, 1996
    Date of Patent: February 24, 1998
    Assignee: Korea Institute of Machinery & Materials
    Inventors: Hyung-Sik Chung, Yong-Jin Kim, Byung-Kee Kim, Jian-Qing Jiang