Vacuum Patents (Class 419/60)
  • Patent number: 5051231
    Abstract: A method for the fabrication of a superplastic composite material having metallic aluminum reinforced with silicon nitride includes thoroughly mixing silicon nitride with metallic aluminum, pressure-sintering the resultant mixture, further heating and pressing the sintered mixture, hot extrusion-molding the resultant sintered article, subjecting the molded article, when necessary, to a heat treatment such as the T6 treatment thereby forming a superplastic composite material, and deforming the composite material in a temperature region in which the material exhibits superplasticity.
    Type: Grant
    Filed: September 14, 1990
    Date of Patent: September 24, 1991
    Assignees: Agency of Industrial Science & Technology, Ministry of International Trade & Industry
    Inventors: Tsunemichi Imai, Mamoru Mabuchi
  • Patent number: 5045278
    Abstract: An aluminum based metal matrix composite is produced from a charge containing a rapidly solidified aluminum alloy, a carbidiferous agent and particles of a reinforcing material present in an amount ranging from about 0.1 to 50% by volume of the charge. The charge is ball milled energetically to uniformly mix the carbidiferous agent within the aluminum matrix, and to enfold metal matrix material around each of the particles while maintaining the charge in a pulverulent state. Upon completion of the ball milling step, the charge is hot consolidated at suitable temperatures to decompose the carbidiferous agent and result in the formation of carbide and oxide particles, and to provide a powder compact having a formable, substantially void-free mass. The compact is especially suited for use in aerospace, automotive, electronic, wear resistance critical components, and the like, which often encounter service temperatures approaching 500.degree. C.
    Type: Grant
    Filed: November 9, 1989
    Date of Patent: September 3, 1991
    Assignee: Allied-Signal Inc.
    Inventors: Sontosh K. Das, Michael S. Zedalis, Paul S. Gilman
  • Patent number: 5043137
    Abstract: This invention relates to a method and a device to produce a coating from metal powder metallurgically bonded to a metallic part, said metal powder being compacted over the surface of said metallic part to form the coating using cold isostatic pressing, then coupling an open metallic container to the coating leaving a space between said open metallic container and said coating, completely filling the space between the metallic container and the coating with a ceramic material and sealing, so that the ceramic material exerts pressure due to the thermal expansion over the coating during the heating in a sintering furnace in order to get a metallurgical bond between the metallic part and the coating and simultaneously sintering the coating to achieve the desirable the desirable thickness and the required properties.
    Type: Grant
    Filed: February 6, 1991
    Date of Patent: August 27, 1991
    Assignee: Instituto Mexicano de Investigaciones Siderugrgicas
    Inventors: Arturo Lazcano-Navarro, Gregorio Vargas-Gutierrez, Andres Geronimo-Torres, Francisco M. Flores-Malacara
  • Patent number: 5041261
    Abstract: A method for manufacturing a dense cermet article including about 80-95% by volume of a granular hard phase and about 5-20% by volume of a metal binder phase. The hard phase is (a) the hard refractory carbides, nitrides, carbonitrides, oxycarbides, oxynitrides, carboxynitrides, borides, and mixtures thereof of the elements selected from the group consisting of Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, W, and B, or (b) the hard refractory carbides, nitrides, carbonitrides, oxycarbides, oxynitrides, and carboxynitrides, and mixtures thereof of a cubic solid solution of Zr--Ti, Hf--Ti, Hf--Zr, V--Ti, Nb--Ti, Ta--Ti, Mo--Ti, W--Ti, W--Hf, W--Nb, or W--Ta. The binder phase is a combination of Ni and Al having a Ni:Al weight ratio of from about 85:15 to about 88:12, and 0-5% by weight of Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, W, Co, B, and/or C. The method involves presintering the hard phase/binder phase mixture in a vacuum or inert atmosphere at about 1475.degree.-1675.degree. C., then HIPing at about 1575.degree.-1675.degree. C.
    Type: Grant
    Filed: December 21, 1990
    Date of Patent: August 20, 1991
    Assignee: GTE Laboratories Incorporated
    Inventors: Sergej T. Buljan, Helmut Lingertat, Steven F. Wayne
  • Patent number: 5039476
    Abstract: A method for the production of a metallic powder molding material is disclosed which comprises a step of imparting mechanical energy due to at least one of such physical actions as vibration, pulverization, attrition, rolling, shocks, agitation, and mixing a metallic particles in a vessel whose interior is held under vacuumized atmosphere or an atmosphere of inert gas thereby enabling the metallic particles to contact each other and acquire improvement in surface quality and a step of hot molding the metallic particles thereby producing a molding material.
    Type: Grant
    Filed: July 19, 1990
    Date of Patent: August 13, 1991
    Assignee: Ube Industries, Ltd.
    Inventors: Mitsuru Adachi, Akio Okamoto, Hideki Iwai, Yoshiharu Waku
  • Patent number: 5033939
    Abstract: Shaped parts are formed from a powder having the desired chemistry of the finished part by mixing the powder with a thermosetting condensation resin that acts as a binder. The resin may be partially catalyzed, or additives or surfactants added to improve rheology, mixing properties, or processing time. Upon heating, the inherently low viscosity mixture will solidify without pressure being applied to it. A rigid form is produced which is capable of being ejected from a mold. Pre-sintered shapes or parts are made by injection molding, by using semi-permanent tooling, or by prototyping. Binder removal is accomplished by thermal means and without a separate debinding step, despite the known heat resistance of thermosetting resins. Removal is due to the film forming characteristic of the binder leaving open the part's pores, by providing oxidizing conditions within the part's pores as the part is heated, and by insuring that the evolving resin vapor diffuses through the pores by heating the part in a vacuum.
    Type: Grant
    Filed: October 29, 1990
    Date of Patent: July 23, 1991
    Assignee: Megamet Industries
    Inventor: Gregory M. Brasel
  • Patent number: 5017217
    Abstract: A method for manufacturing ceramic/metal or ceramic/ceramic composite articles is disclosed. The articles can be useful for the production of aluminum in fused salt electrolysis cells, as armor plates for the protection against projectiles, cutting tools, or in abrasion resistance applications. The temperature slope of the process if optimized such that one of the reactants in the manufacturing proceeds through peritectic decomposition at a heating rate of low temperature increase for desirably uniform temperature distribution over the reaction mixture. Then the temperature increase is greatly elevated to obtain a reaction sintering condition for avoiding grain growth of undesired reaction products. Elevated temperature reaction sintering conditions can be maintained to decompose undesired components before they are entrapped by the reaction product.
    Type: Grant
    Filed: August 21, 1990
    Date of Patent: May 21, 1991
    Assignee: Eltech Systems Corporation
    Inventors: Thomas M. Clere, Gholamreza J. Abbaschian, Douglas J. Wheeler, Albert L. Barnes
  • Patent number: 5015440
    Abstract: Light weight refractory aluminides, such as Al.sub.3 Nb and related aluminides may be produced from metallic powders by a high temperature exothermic reaction of refractory metals with molten aluminum. Mixtures of refractory metals and aluminum may be prepared and densified by powder metalurgy techniques. Applicant's process permits near net formations of stock shapes and parts by conducting the reaction in situ in a die.
    Type: Grant
    Filed: September 1, 1989
    Date of Patent: May 14, 1991
    Assignee: McDonnell Douglas Corporation
    Inventor: David M. Bowden
  • Patent number: 5009706
    Abstract: Rare-earth alloy anisotropic powders consist of, in atomic percent, over 12 percent and not more than 20 percent of R (R is at least one on neodymium and praseodymium or at least one of them and or more rare-earth elements), not less than 4 percent and not more than 10 percent of boron, not less than 0.05 percent and not more than 5 percent of copper and the rest that consists of iron and unavoidable impurities. Up to 20 percent of the iron contained is replaceable with cobalt. The alloy powders are made up of flat crystal grains having mean thickness h (the shortest measure), d not smaller than 0.01 .mu.m and not larger than 0.5 .mu.m and ratio d/h not smaller than 2, where d is the means measure of the grains taken at right angles to the widthwide direction thereof, and the alloy powders are magnetically anisotropic.
    Type: Grant
    Filed: July 18, 1990
    Date of Patent: April 23, 1991
    Assignee: Nippon Steel Corporation
    Inventors: Hiroaki Sakamoto, Masahiro Fujikura, Toshio Mukai
  • Patent number: 5009704
    Abstract: A nickel-based superalloy article formed from particles of the superalloy is processed to have a microstructure which is resistant to failure when processed using high strain thermomechanical processes. Articles having the desired microstrucuture are produced by hot isostatically pressing powder of the superalloy in a specified temperature range bounded by the incipient melting temperature as a minimum and the solvus temperature of stable high temperature phases. The compact is held under pressure in the specified temperature range to diffuse deleterious phases which exist as a result of the initial powder atomization operation. The powder compact thus formed can be processed using conventional processes to produce material for subsequent thermomechanical processing using high strain rate forging equipment and retain the benefits of chemical uniformity and cleanliness associated with traditional powder metal processes.
    Type: Grant
    Filed: June 28, 1989
    Date of Patent: April 23, 1991
    Assignee: Allied-Signal Inc.
    Inventor: Anthony Banik
  • Patent number: 5000781
    Abstract: The invention provides an aluminum based alloy consisting essentially of the formula Al.sub.bal Fe.sub.a X.sub.b, wherein X is at least one element selected from the group consisting of Zn, Co, Ni, Cr, Mo, V, Zr, Ti, Y and Ce, "a" ranges from about 7-15 wt %, "b" ranges from about 2-10 wt % and the balance is aluminum. The alloy has a predominately microeutectic microstructure. The invention also provides a method and apparatus for forming rapidly solidifed metal, such as the metal alloys of the invention, within an ambient atmosphere. Generally stated, the apparatus includes a moving casting surface which has a quenching region for solidifying molten metal thereon. A reservoir holds molten metal and has orifice means for depositing a stream of molten metal onto the casting surface quenching region. A heating mechanism heats the molten metal contained within the reservoir, and a gas source provides a non-reactive gas atmosphere at the quenching region to minimize oxidation of the deposited metal.
    Type: Grant
    Filed: November 28, 1988
    Date of Patent: March 19, 1991
    Assignee: Allied-Signal Inc.
    Inventors: David J. Skinner, Paul A. Chipko, Kenji Okazaki
  • Patent number: 5000780
    Abstract: Disclosed is a fragrance emitting metal composed of a sintered metallic body prepared by press-molding a metal powder for sintering within a mold having a required shape, followed by sintering of the resulting molded product at a required temperature, characterized by the constitution wherein the molding pressure is controlled so that the resulting sintered product may have a porosity which permits infiltration of a liquid perfumery therethrough; and the surface of the sintered metallic body is partially polished so as to reduce the porosity of the polished surface, thereby improving the property of sustaining the diffusion of the fragrance from the liquid perfumery infiltrated therethrough and also to impart gloss and luster thereto.
    Type: Grant
    Filed: June 16, 1988
    Date of Patent: March 19, 1991
    Assignee: Daido Tokushuko Kabushiki Kaisha
    Inventor: Shigeo Tokunaga
  • Patent number: 4999157
    Abstract: A method for molding powders comprises the steps of forming a mold support having at least an opening and a cavity, forming a film of latex on inner surfaces of the mold support by pouring the latex from the opening into the cavity of the mold support and discharging a substantial portion of the latex poured into the cavity, forming a thin-wall resilient mold inside the mold support by drying the film of latex formed, charging powders as materials for a compact from the opening into the thin-wall resilient mold, exhausting air out of the thin-wall resilient mold filled up with the powders through the opening and sealing the opening of the thin-wall resilient mold, separating the thin-wall resilient mold filled up with the powders from the mold support, and subjecting the thin-wall resilient mold to a cold isostatic press method treatment.
    Type: Grant
    Filed: March 5, 1990
    Date of Patent: March 12, 1991
    Assignee: NKK Corporation
    Inventors: Hiroaki Nishio, Akira Kato, Sazo Nakamura
  • Patent number: 4995905
    Abstract: When V is added to an Nd--Fe--B sintered magnet so as to modify the minority phase such that B in excess of a stoichiometric composition of R.sub.2 Fe.sub.14 B compound-phase, essentially does not form RFe.sub.4 B.sub.4 -compound minority phases but forms a finely dispersed V--T--B compound minority phase (T is Fe, and in a case containing Co, T is Fe and Co), the coercive force (iHc) is enhanced to 15 kOe or more but becomes very sensitive to heat treatment temperature. This drawback is eliminated by the addition of from 0.01 to 1 at % of Cu.
    Type: Grant
    Filed: May 23, 1989
    Date of Patent: February 26, 1991
    Assignee: Masato Sagawa
    Inventor: Masato Sagawa
  • Patent number: 4990410
    Abstract: A surface refined sintered alloy with a burnt surface, comprising 75 to 95% by weight of a hard phase containing Ti, C and N as the essential components and otherwise comprising at least one of Zr, Hf, V, Nb, Ta, Cr, Mo and W and the balance of the alloy comprising a binder phase composed mainly of Co and/or Ni and inevitable impurities, wherein the sintered alloy satisfies at least two conditions selected from the group consisting of the following (1) to (3):(1) the average grain size of the hard phase in a surface layer to the inner portion of 0.05 mm from the burnt surface of the sintered alloy is 0.8 to 1.2-fold of the average grain size of the hard phase in the inner portion of the sintered alloy excluding the surface layer;(2) the average content of the binder phase in the surface layer to the inner portion of 0.05 mm from the burnt surface of the sintered alloy is 0.7 to 1.
    Type: Grant
    Filed: March 7, 1989
    Date of Patent: February 5, 1991
    Assignee: Toshiba Tungaloy Co., Ltd.
    Inventors: Takeshi Saitoh, Tuyoshi Saito, Mitsuo Ueki, Hisashi Suzuki, Keiichi Kobori
  • Patent number: 4980122
    Abstract: A superplastic composite material is produced by thoroughly and homogeneously mixing particles or whiskers of silicon nitride and aluminum metal powder in a solvent, then removing the solvent from the resultant mixture, sintering the residual mixture at an elevated temperature, further compressing it at an elevated temperature, then hot extrusion-molding the compressed mixture thereby forming a shaped article, and heat-treating this shaped article.
    Type: Grant
    Filed: March 23, 1990
    Date of Patent: December 25, 1990
    Assignee: Agency of Industrial Science & Technology, Ministry of International Trade & Industry
    Inventors: Tsunemichi Imai, Mamoru Mabuchi
  • Patent number: 4980126
    Abstract: A single step is relied on in the canning process for hot isostatic pressing metallurgy composites. The composites are made from arc-sprayed and plasma sprayed monotape. The HIP can is of compatible refractory metal and is sealed at high vacuum and temperature. This eliminates out-gassing during hot isostatic pressing.
    Type: Grant
    Filed: November 9, 1989
    Date of Patent: December 25, 1990
    Assignee: The United States of America as represented by the Administrator of the National Aeronautics and Space Administration
    Inventor: John J. Juhas
  • Patent number: 4979984
    Abstract: A process is claimed for the manufacture of an insert. The process includes the steps of filling a die cavity defined by a die mold with powdered metal, the die cavity conforming to the required shape of the insert. The powdered metal is compressed within the die cavity such that a compact of the insert is formed within the die cavity. The compact is sintered within a sintering furnace so that a first porton of the compact is in the solid phase and a second portion of the compact is in the liquid phase. The compact is rapidly cooled within the sintering furnace to a temperature below the melting point of the powdered metal. Such temperature is maintained so that densification of the first portion to substantially full density is achieved. The arrangement is such that the profile integrity of the compact is retained. the resltant insert is then subsequently cooled.
    Type: Grant
    Filed: March 16, 1990
    Date of Patent: December 25, 1990
    Assignee: Inserts Ltd.
    Inventor: Linwood R. Anderson
  • Patent number: 4970050
    Abstract: A method of producing a sintered, very high density dental prosthesis from a suspension containing noble-metal powder mixtures with bi or multimodal particle-size distribution and a mixing liquid. The suspension is molded to the desired shape and then the dental prosthesis is dried. The molded dental prosthesis is then heat-treated 5 to 45 minutes between 100.degree. and 400.degree. C., then heated with an average temperature elevation of 50 to 300 K/min. to 800.degree. C. and then brought to the sintering temperature T at 20 to 200 K/min. The sintering temperature T is between T.sub.solidus - 200) and T.sub.solidus - 70), whereby T.sub.solidus is the solidus temperature of the sintered alloy. The cooling-down of the dental prosthesis takes place under a vacuum or a protective gas.
    Type: Grant
    Filed: December 13, 1989
    Date of Patent: November 13, 1990
    Inventors: Werner Groll, Angela Klaus, Thomas Lange
  • Patent number: 4963320
    Abstract: A method for producing an anisotropic rare earth magnet is improved by applying compressing stress on a free surface of an compacted material at the time of extruding the compacted material in order to prevent forming cracks, and improved by using a double action punch provided with a core punch and a sleeve punch so as to mold a compacted material and extrude the compacted material into the anisotropic magnet material in a single heat process continuously.
    Type: Grant
    Filed: April 11, 1990
    Date of Patent: October 16, 1990
    Assignee: Daido Tokushuko Kabushiki Kaisha
    Inventors: Makoto Saito, Teruo Watanabe, Shinichiro Yahagi, Yasuaki Kasai, Norio Yoshikawa, Yutaka Yoshida, Toshiya Kinami, Hiyoshi Yamada
  • Patent number: 4963321
    Abstract: There are disclosed a surface sintered alloy with a burnt surface, comprising 75 to 95% by weight of a hard phase containing Ti, C and N as the essential components and otherwise comprising at least one of Zr, Hf, V, Nb, Ta, Cr, Mo and W and the balance of the alloy comprising a binder phase composed mainly of Co and/or Ni and inevitable impurities, wherein the sintered alloy satisfies at least one condition selected from the group consisting of the following (1) to (3):(1) the average grain size of the hard phase in a surface layer to the inner portion of 0.05 mm from the burnt surface of the sintered alloy is 0.8 to 1.2-fold of the average grain size of the hard phase in the inner portion of the sintered alloy excluding the surface layer;(2) the average content of the binder phase in the surface layer to the inner portion of 0.05 mm from the burnt surface of the sintered alloy is 0.7 to 1.
    Type: Grant
    Filed: October 19, 1989
    Date of Patent: October 16, 1990
    Assignee: Toshiba Tungaloy Co., Ltd.
    Inventors: Takeshi Saitoh, Tuyoshi Saito, Mitsuo Ueki, Hisashi Suzuki, Keiichi Kobori
  • Patent number: 4961902
    Abstract: A method for manufacturing ceramic/metal or ceramic/ceramic composite articles is disclosed. The articles can be useful for the production of aluminum in fused salt electrolysis cells, as armour plates for the protection against projectiles, cutting tools, or in abrasion resistance applications. The temperature slope of the process if optimized such that one of the reactants in the manufacturing proceeds through peritectic decomposition at a heating rate of low temperature increase for desirably uniform temperature distribution over the reaction mixture. Then the temperature increase is greatly elevated to obtain a reaction sintering condition for avoiding grain growth of undesired reaction products. Elevated temperature reaction sintering conditions can be maintained to decompose undesired components before they are entrapped by the reaction product.
    Type: Grant
    Filed: January 6, 1987
    Date of Patent: October 9, 1990
    Assignee: Eltech Systems Corporation
    Inventors: Thomas M. Clere, Gholamreza J. Abbaschian, Douglas J. Wheeler, Albert L. Barnes
  • Patent number: 4960563
    Abstract: The invention relates to a process for the production of a heavy tungsten-nickel-iron alloy with high mechanical characteristics comprising the steps of using powders of each of the elements of a FISHER diameter between 1 and 15 .mu.m, mixing the powders in proportions corresponding to the composition of the desired alloy, compressing the powders in the form of compacted items, sintering the compacted items at a temperature of between 1490 and 1650.degree. C. for 2 to 5 hours, treating the sintered compacted items under vacuum at between 1000.degree. and 1300.degree. C., and subjecting the compacted items after treatment under vacuum to at least three cycles of operation, each cycle comprising a working step followed by a heat treatment.
    Type: Grant
    Filed: March 7, 1990
    Date of Patent: October 2, 1990
    Assignee: Cime Bocuze
    Inventor: Guy Nicolas
  • Patent number: 4954058
    Abstract: A apex seal is formed by cold pressing and sintering a mixture of Clevite and tungsten carbide powders to form a seal wherein harder rounded carbide particles are distributed within a softer matrix.
    Type: Grant
    Filed: January 25, 1990
    Date of Patent: September 4, 1990
    Assignee: Deere & Company
    Inventor: Gopal S. Revankar
  • Patent number: 4954313
    Abstract: A method for providing void-free low-electrical-resistance conductive cores in vias having an aspect ratio of greater than approximately 6 includes the steps of providing a conductive thixotropic paste on the top surface of a substrate having vias provided therein, applying pressure to the paste and concurrently applying pressure to the paste and bottom surface of the substrate to force the thixotropic paste into the vias. Vibratory motion may also be applied to the substrate and paste concurrently with the application of pressure and vacuum. The paste is then dried in a vacuum, and subsequently sintered in a two-step process including a slow ramp up to temperature to allow the paste to outgas followed by a high temperature treatment.
    Type: Grant
    Filed: February 3, 1989
    Date of Patent: September 4, 1990
    Assignee: Amdahl Corporation
    Inventor: John F. Lynch
  • Patent number: 4950450
    Abstract: A method of making high energy Nd-Fe-B magnets having a mass less than 30 grams wherein an alloy of said materials having a grain size less than that desired in the finished magnet is first prepared and subsequently hot worked to the desired configuration with increased magnetic properties and density by introducing into a cavity formed by a die and punch a Nd-Fe-B alloy powder having a particle size of from 45 .mu.m to 250 .mu.m and a grain size of from 100 to 1500 angstroms, compressing the powder at a temperature of from about 550.degree. C. to 750.degree. C. under a die-punch pressure of at least 10 kpsi under a vacuum of less than 200 millitorr to achieve a permanent magnet having a remanence of at least 7 kilogauss.
    Type: Grant
    Filed: July 21, 1988
    Date of Patent: August 21, 1990
    Assignee: Eastman Kodak Company
    Inventors: Dilip K. Chatterjee, Thomas W. Martin, Paul D. Askins
  • Patent number: 4940404
    Abstract: A method of making a tungsten tantalum material comprising generally 80 percent by weight tungsten and 20 percent by weight tantalum and forming the material into a high strength full density round bar, which can be utilized in a high velocity armor penetrator.
    Type: Grant
    Filed: April 13, 1989
    Date of Patent: July 10, 1990
    Assignee: Westinghouse Electric Corp.
    Inventors: Robert L. Ammon, Raymond W. Buckman, Jr., Ram Bajaj
  • Patent number: 4938798
    Abstract: A high melting metal silicide sputtering target which comprises a fine texture whose stoichiometric composition grains of MSi.sub.2, where M represents a high melting metal, have a maximum grain size of 20 .mu.m, whose free silicon grains have a maximum grain size of 50 .mu.m and whose oxygen content is not more than 200 ppm and has a density ratio to the theoretical density of 99% or more has good film characteristics including the reduction in the number of grains formed on the sputtered film and is useful as an electrode material or a wiring material in semi-conductor devices.
    Type: Grant
    Filed: March 7, 1988
    Date of Patent: July 3, 1990
    Assignee: Hitachi Metals, Ltd.
    Inventors: Yoshitaka Chiba, Noriyoshi Hirao, Toru Sugihara, Kenji Hasegawa
  • Patent number: 4938799
    Abstract: The invention relates to heavy tungsten-nickel-iron alloys with high mechanical characteristics and a specific gravity between 15.6 and 18. The alloys include a tungsten .alpha.-phase in the shape of butterfly wings with dislocation cells of dimensions between 0.1 and 1 .mu.m, and a nickel-iron bonding .gamma.-phase having a mean free path of less than 15 .mu.m and an Ni/Fe ratio greater than or equal to 2.
    Type: Grant
    Filed: October 5, 1988
    Date of Patent: July 3, 1990
    Assignee: Cime Bocuze
    Inventor: Guy Nicolas
  • Patent number: 4936912
    Abstract: A apex seal is formed by cold pressing and sintering a mixture of Clevite and tungsten carbide powders to form a seal wherein harder rounded carbide particles are distributed within a softer matrix.
    Type: Grant
    Filed: June 27, 1988
    Date of Patent: June 26, 1990
    Assignee: Deere & Company
    Inventor: Gopal S. Revankar
  • Patent number: 4923512
    Abstract: Cobalt-bound tungsten carbide metal matrix composites having a unique microstructure are produced by consolidating partially sintered greenware under high pressures, e.g., 120,000 psi, at temperatures less than those used for conventional liquid phase sintering in a relatively short time, e.g., from less than one minute to less than about one hour. The composites have a binder phase which contains less than about 80 weight percent of the tungsten found in a composite prepared from the same or similar compositions via liquid phase sintering. These composites provide cutting tools with both toughness and wear resistance which exceed that of cutting tools made from the same or similar compositions via liquid phase sintering.
    Type: Grant
    Filed: April 7, 1989
    Date of Patent: May 8, 1990
    Assignee: The Dow Chemical Company
    Inventors: Ed E. Timm, Douglas B. Schwarz
  • Patent number: 4917859
    Abstract: The present invention provides a dewaxing process for metal powder compact which comprises the steps of embeding in alumina powder an injection-molded metal powder compact consisting of metal powder and an organic binder including low melting point substances; heating the embeded compact to a temperature of 200.degree. C. in a chemically inert atmosphere in a dewaxing furnace, thereby removing the low melting point substances from the compact without deformation of the compact; placing the compact in a closed sintering vessel so as to keep the surrounding temperature constant and disposing the vessel in a vacuum furnace; evacuating the vacuum furnace; and removing the organic binder by heating to a temperature of 550.degree. to 650.degree. C. at a heating rate of 300.degree. to 600.degree. C./hr while supplying an inert gas into the vacuum furnace.
    Type: Grant
    Filed: September 6, 1989
    Date of Patent: April 17, 1990
    Assignee: Mitsubishi Steel Mfg. Co., Ltd.
    Inventor: Kazunori Hamo
  • Patent number: 4911989
    Abstract: A coated cemented carbide alloy having jointly a high toughness and high wear resistance is produced by specifying the cooling rate during sintering in efficient manner, which alloy comprises a cemented carbide substrate consisting of a hard phase of at least one member selected from the group consisting of carbides, nitrides and carbonitrides of Group IVa, Va and VIa metals of Periodic Table and a binder phase consisting of at least one member selected from the iron group metals, and a monolayer or multilayer, provided thereon, consisting of at least one member selected from the group consisting of carbides, nitrides, oxides and borides of Group IVa, Va and VIa metals of Periodic Table, solid solutions thereof and aluminum oxide, in which the hardness of the cemented carbide substrate in the range of 2 to 5 .mu.m from the interface between the coating layer and substrate is 800 to 1300 kg/mm.sup.
    Type: Grant
    Filed: April 10, 1989
    Date of Patent: March 27, 1990
    Assignee: Sumitomo Electric Industries, Ltd.
    Inventors: Nakano Minoru, Tobioka Masaaki, Nomura Toshio
  • Patent number: 4906430
    Abstract: A titanium-based metal matrix microcomposite material. About 1% to about 25% by weight TiB.sub.2 is substantially uniformly incorporated in a titanium-based alloy matrix. The microcomposite material is formed by sintering at a temperature selected to preclude diffusion of TiB.sub.2 into the matrix. The microcomposite material may be used in a process for cladding a macrocomposite structure.
    Type: Grant
    Filed: July 29, 1988
    Date of Patent: March 6, 1990
    Assignee: Dynamet Technology Inc.
    Inventors: Stanley Abkowitz, Harold L. Heussi, Harold P. Ludwig, David M. Rowell, Stephen A. Kraus
  • Patent number: 4904538
    Abstract: A single step is relied on in the canning process for hot isostatic pressing powder metallurgy composites. The binders are totally removed while the HIP can of compatible refractory metal is sealed at high vacuum and temperature. This eliminates out-gassing during hot isostatic pressing.
    Type: Grant
    Filed: March 21, 1989
    Date of Patent: February 27, 1990
    Assignee: The United States of America as represented by the Administrator of the National Aeronautics and Space Administration
    Inventor: John J. Juhas
  • Patent number: 4904445
    Abstract: A tough cermet made from 20-92 weight % of TiC and/or TiCN, 5-50 weight % of WC and 3-30 weight % of an iron-gorup metal. This tough cermet has a three phase grain microstructure and is made is mixing titanium carbonitride powder and up to 70 weight % of the total amount of the tungsten carbide fine powder. The resulting mixture is melted to form a solid solution, pulverized, mixed with the remaining amount of tungsten carbide fine powder, and sintered at temperatures of 1325.degree.-1650.degree. C.
    Type: Grant
    Filed: March 23, 1988
    Date of Patent: February 27, 1990
    Assignees: Hitachi Metals, Ltd., Hitachi Carbide Tools, Inc.
    Inventors: Yusuke Iyori, Hisaaki Ida
  • Patent number: 4886639
    Abstract: Structural component made of powder metallurgical materials, particularly temperature resistant alloys, nickel base alloys, are produced by injection molding or pressing. The sintering is divided into individual work steps for producing dense and smooth structural components which are true to shape.
    Type: Grant
    Filed: April 30, 1987
    Date of Patent: December 12, 1989
    Assignee: MTU Motoren- und Turbinen-Union Muenchen GmbH
    Inventors: Gerhard Andrees, Josef Kranzeder, Wilhelm Vogel
  • Patent number: 4885133
    Abstract: A wear-resistant sintered iron-based alloy and a process for producing the alloy are described, wherein the alloy comprises a first phase having a martensite composition which comprises from 0.5 to 3.0 wt % of Cr, from 0.4 to 1.0 wt % of Mn, from 0.1 to 0.4 wt % of Mo, and the balance of Fe, based on the total amount of said first phase; a second phase having a martensite and Cr carbide composition which comprises from 10 to 20 wt % of Cr and the balance of Fe, based on the total amount of said second phase; and from 1.0 to 2.5 wt % of C, based on the total amount of said alloy; wherein said first phase and said second phase are present as a mixture containing from 10 to 80% by volume of said second phase, based on the total volume of said alloy; and said alloy is substantially free from any residual austenite.
    Type: Grant
    Filed: April 6, 1989
    Date of Patent: December 5, 1989
    Assignee: Sumitomo Electric Industries, Ltd.
    Inventor: Satoshi Fujii
  • Patent number: 4880598
    Abstract: A tubular compact (14) obtained by compacting a powder is applied with one circumferential surface (16) at a minimum distance required for said application, from an abutment surface (15) corresponding to said one circumferential surface (16). The space between said one circumferential surface (16) and the abutment surface (15) is evacuated, such that the compact (14), while undergoing a certain deformation to bridge said space, is sucked against the abutment surface (15) so as to be firmly retained against it.
    Type: Grant
    Filed: December 15, 1988
    Date of Patent: November 14, 1989
    Assignee: Cips KB
    Inventors: Flemming Hansen Kaad, Ola Pettersson
  • Patent number: 4880599
    Abstract: A composite comprised of a sintered matrix of spinel ferrite and an electrically conductive phase of elemental silver is produced by co-firing a laminated structure of ferrite powder-containing tapes containing a silver metallization-forming material having two end portions wherein only the end portions are exposed.
    Type: Grant
    Filed: March 25, 1988
    Date of Patent: November 14, 1989
    Assignee: General Electric Company
    Inventors: Richard J. Charles, Achuta R. Gaddipati
  • Patent number: 4878967
    Abstract: A rapidly solidified aluminum-base alloy consists essentially of the formula Al.sub.bal Fe.sub.a Si.sub.b X.sub.c wherein X is at least one element selected from the group consisting of Mn,V,Cr,Mo,W,Nb,Ta, "a" ranges from 2.0 to 7.5 atom percent, "b" ranges from 0.5 to 3.0 atom percent, "c" ranges from 0.05 to 3.5 atom percent and the balance is aluminum plus incidental impurities, with the proviso that the ratio {Fe+X}:Si ranges from about 2.0:1 to 5.0:1. The alloy exhibits high strength, ductility and fracture toughness and is especially suited for use in high temperature structural applications such as gas turbine engines, missiles, airframes and landing wheels.
    Type: Grant
    Filed: September 8, 1987
    Date of Patent: November 7, 1989
    Assignee: Allied-Signal Inc.
    Inventors: Colin M. Adam, Richard L. Bye, Santosh K. Das, David J. Skinner
  • Patent number: 4855101
    Abstract: Particles are sinter-fused onto the surface of a prosthesis shaft of titanium or titanium alloys. Before sinter-fusing, a coating material which forms below the .alpha.-.beta.-transition temperature a liquid phase with the material of the prosthesis and particles is applied to provide a coating between the shaft and particles.
    Type: Grant
    Filed: July 1, 1988
    Date of Patent: August 8, 1989
    Assignee: Fried. Krupp GmbH
    Inventors: Rudolf Mohs, Gunter Bensmann
  • Patent number: 4851042
    Abstract: A tungsten heavy alloy system is modified by replacing from 2% to 10% of the tungsten by weight with tantalum to increase the strength and hardness characteristics for the alloy. This renders the alloy particularly useful for kinetic energy penetrators.
    Type: Grant
    Filed: July 18, 1988
    Date of Patent: July 25, 1989
    Assignee: Rensselaer Polytechnic Institute
    Inventors: Animesh Bose, Randall M. German
  • Patent number: 4847045
    Abstract: A process is disclosed for producing a sheet of tungsten heavy alloy which involves uniformly blending elemental metal powder components of the alloy by forming a slurry of the powder components in a liquid medium, introducing the slurry onto a filter medium and applying vacuum to the bottom of the slurry to form a planar cake of the powder components. The cake is then dried and sintered to a density equal to or greater than about 90% of the theoretical density of the alloy to form the sheet.
    Type: Grant
    Filed: February 29, 1988
    Date of Patent: July 11, 1989
    Assignee: GTE Products Corporation
    Inventors: Preston B. Kemp, Jr., Walter A. Johnson
  • Patent number: 4838935
    Abstract: Tungsten-titanium sputtering targets with improved characteristics are made from high-purity tungsten powder and a second powder consisting of high-purity titanium hydride powder or high-purity titanium hydride powder and high-purity titanium powder. The second powder contains at least 5%, preferably 25% to 100% by weight of titanium hydride powder. A powder mixture having a binodal particle size distribution with respect to the tungsten and second powders is placed under a containment pressure in a die. The die is heated in a vacuum hot-press chamber to a temperature sufficient to dehydride the titanium hydride, and to remove gases and alkali metals. The die is then heated to a second temperature in the range of 1350.degree. to 1550.degree. C. while maintaining the containment pressure and vacuum. A compaction force in the range of 2000 to 5000 psi is then applied to form a compact. The compaction force and vacuum are subsequently released and the compact is cooled.
    Type: Grant
    Filed: May 31, 1988
    Date of Patent: June 13, 1989
    Assignee: Cominco Ltd.
    Inventors: John A. Dunlop, Hans Rensing
  • Patent number: 4830821
    Abstract: A contact forming material for a vacuum valve or vacuum circuit breaker comprising (a) a conductive material consisting of copper and/or silver, and (b) an arc-proof material consisting of chromium, titanium, zirconium, or an alloy thereof wherein the amount of said arc-proof material present in said conductive material matrix is no more than 0.35% by weight. This contact forming material is produced by a process which comprises the steps of compacting arc-proof material powder into a green compact, sintering said green compact to obtain a skeleton of the arc-proof material, infiltrating the voids of said skeleton with a conductive material, and cooling the infiltrated material. The contact forming material can provide contacts for a vacuum valve or vacuum circuit breaker which has excellent characteristics such as temperature rise characteristic and contact resistance characteristic.
    Type: Grant
    Filed: July 26, 1988
    Date of Patent: May 16, 1989
    Assignee: Kabushiki Kaisha Toshiba
    Inventors: Tsutomu Okutomi, Seishi Chiba, Mikio Okawa, Tadaaki Sekiguchi, Hiroshi Endo, Tsutomu Yamashita
  • Patent number: 4824481
    Abstract: Sputtering targets are made by melting at least one rare earth and at least one transition metal to produce an amorphous alloy melt, forming a powder of the alloy in an oxygen free atmosphere, introducing the powdered alloy into a reducing mold, adding a layer of powdered oxygen-getter on top of the powdered alloy, and hot pressing the alloy.
    Type: Grant
    Filed: January 11, 1988
    Date of Patent: April 25, 1989
    Assignee: Eaastman Kodak Company
    Inventors: Dilip K. Chatterjee, Srinivas T. Rao
  • Patent number: 4769071
    Abstract: There is provided a process for infiltrating a compacted ferrous powder metal body with copper or a copper alloy which process is characterized by presintering the ferrous metal body at a temperature of from about 1875.degree. F. to a temperature below the melting point of the infiltrant, and then in the same furnace, raising the temperature above the melting point of the copper or copper alloy infiltrant for a period sufficient to infiltrate the powder metal body. This process is more economical than the prior double run infiltration processes and provides excellent impact strengths and tensile strengths.
    Type: Grant
    Filed: August 21, 1987
    Date of Patent: September 6, 1988
    Assignee: SCM Metal Products, Inc
    Inventors: Erhard Klar, Mark Svilar
  • Patent number: 4762679
    Abstract: A process for manufacturing powder metallurgy (P/M) preforms which are conditioned for optimum intrinsic workability is described which comprises steps of heating a quantity of P/M material in a can to a first preselected temperature under vacuum to degas the material, compacting the canned material at a second preselected temperature under pressure to provide a compact of the material; or cold compacting the powder to about 75% density and degassing it at suitable temperature and then vacuum hot pressing the powder at about 0.
    Type: Grant
    Filed: July 6, 1987
    Date of Patent: August 9, 1988
    Assignee: The United States of America as represented by the Secretary of the Air Force
    Inventors: Harold L. Gegel, Yellapregada V. R. K. Prasad, Sokka M. Doraivelu, Raghavan Srinivasan, J. S. Gunasekera, Douglas R. Barker, James T. Morgan, Jr., James C. Malas, Kristine A. Lark, Lawrence E. Matson
  • Patent number: 4761264
    Abstract: A method for molding powders which comprises introducing a thin-wall resilient mold inside a ventilative mold support, reducing the outside pressure of the ventilative mold support to less than the atmospheric pressure (760 Torr), putting a thin-wall resilient mold exactly close to the inside wall of the ventilative mold support, supplying powder material into the thin-wall resilient mold, exhausting air existing in the voids formed in the powder material, and taking the ventilative mold support apart to apply cold isostatic press treatment to the thin-wall resilient mold. The shape of the thin-wall resilient mold is similar to the shape of the ventilative mold support.
    Type: Grant
    Filed: June 12, 1987
    Date of Patent: August 2, 1988
    Assignee: Nippon Kokan Kabushiki Kaisha
    Inventors: Hiroaki Nishio, Jun Harada