Vacuum Patents (Class 419/60)
  • Patent number: 4750932
    Abstract: A refractory metal silicide sputtering target is made by reacting refractory metal and silicon to about 70 to 90% completion of the reaction, comminuting the material, and then vacuum hot pressing the comminuted material to a high density compact.
    Type: Grant
    Filed: December 18, 1986
    Date of Patent: June 14, 1988
    Assignee: GTE Products Corporation
    Inventors: Edward D. Parent, Charles S. Purinton, Charles W. Sutter
  • Patent number: 4743425
    Abstract: A method of producing ferrous sintered alloys comprises the steps of preparing mixed alloy powder containing Fe-P-C eutectic alloy powder which includes phosphorus within the range of 2.0% to 3.0% by weight, carbon not more than 4.0% by weight and one of molybdenum within the range of 8.0% to 11.0% by weight and boron within the range of 0.5% to 3.0% by weight, graphite, and ferroalloy powder containing chromium within the range of 11% to 14% by weight; causing the mixed alloy powder to be subjected to compression molding to have a green compact; and sintering the green compact to have a ferrous sintered alloy containing compound carbides in a matrix structure thereof. The graphite is so selected that the sum total of the graphite and the carbon included in the Fe-P-C eutectic alloy powder constitutes a part within the range of 5% to 8% by weight of the sum total of the graphite and the Fe-P-C eutectic alloy powder.
    Type: Grant
    Filed: September 3, 1987
    Date of Patent: May 10, 1988
    Assignees: Mazda Motor Corporation, Kawasaki Steel Corp.
    Inventors: Shigemi Ohsaki, Sumio Kamino, Minoru Nitta
  • Patent number: 4731118
    Abstract: A copper or copper alloy infiltrated ferrous powder metal part, and method for making the same, characterized as having after infiltration an overall density of at least 7.50 g/cm.sup.3 and a diffusion depth of copper into the steel matrix of less than about 4 micrometers as determined by chemical etching or less than about 8 micrometers as determined by electron dispersive X-ray analysis (EDXA), wherein said ferrous metal is plain carbon steel having a combined carbon content in the range of about 0.15% to about 1.25%, or a low alloy steel.
    Type: Grant
    Filed: November 28, 1986
    Date of Patent: March 15, 1988
    Assignee: SCM Metal Products, Inc.
    Inventors: Mark Svilar, Erhard Klar
  • Patent number: 4729790
    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 1.5 to 7.5 atom percent, "b" ranges from 0.75 to 9.0 atom percent, "c" ranges from 0.25 to 4.5 atom percent and the balance is aluminum plus incidental impurities, with the proviso that the ratio [Fe+X]:Si ranges from about 2.01:1 to 1.0:1. 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: March 30, 1987
    Date of Patent: March 8, 1988
    Assignee: Allied Corporation
    Inventor: David J. Skinner
  • Patent number: 4729789
    Abstract: A process of making a composite of a sintered layer on a metal core member, such as an extruder screw having a sintered hard layer on a steel core, by charging a green compact sintering powder material into a space between an inner surface of a compressible mold and an outer surface of a mold core, sealing the compressible mold with the green compact material and the mold core therein, isostatic pressing the sealed compressible mold with the green compact material and the mold core therein, removing the mold core from the isostatically pressed green compact thus forming a cavity therein, inserting a metal core in the cavity in the isostatically pressed green compact with the metal core having a smaller transverse cross-section than the previously removed mold core and shrinking and bonding the isostatically pressed green compact onto the metal core by heating the isostatically pressed green compact and the metal core to a temperature at which the isostatically pressed green compact is sintered resulting in sh
    Type: Grant
    Filed: May 21, 1987
    Date of Patent: March 8, 1988
    Assignee: Toyo Kohan Co., Ltd.
    Inventors: Tsuneyuki Ide, Kazunori Nakano, Masaru Inoue, Yoshikazu Kondo
  • Patent number: 4722825
    Abstract: A method of producing a metal/ceramic composite structure in which an uncolidated metal or metal alloy powder is loaded into a sealable glass mold comprising a hollow ceramic sleeve and a sealable outer glass envelope surrounding the ceramic sleeve and forming with the outer wall of the ceramic sleeve a sealable chamber for the metal or metal alloy powder, wherein the glass is a type which becomes plastic when heated. The air in the mold is removed under vacuum and the mold is sealed and placed into a free flowing refractory powder in a crucible and consolidated by sintering under atmospheric pressure (CAP.RTM. process). Removal of the glass envelope leaves a composite article having a consolidated metal or metal alloy layer surrounding and placing a hollow ceramic liner (sleeve) under both radial and axial compression. A ceramic-line metal gun barrel insert can be produced by using a ceramic sleeve with rifling on its inner surface.
    Type: Grant
    Filed: July 1, 1987
    Date of Patent: February 2, 1988
    Assignee: The United States of America as represented by the Secretary of the Navy
    Inventor: David Goldstein
  • Patent number: 4722826
    Abstract: A method for utilizing a powder metallurgy ("P/M") slurry by employing water atomized metallic powders and subsequently reducing the oxide levels therein to acceptable levels. The slurry comprises a carbon containing binder. The slurry is consolidated and sintered under controlled conditions to reduce the oxide levels.
    Type: Grant
    Filed: September 15, 1986
    Date of Patent: February 2, 1988
    Assignee: Inco Alloys International, Inc.
    Inventor: Jon M. Poole
  • Patent number: 4721599
    Abstract: Metal or alloy articles having complicated shapes can be produced with high precision by injection molding a kneaded mixture of a metal or alloy powder and an organic binder comprising a special methylcellulose, a plasticizer, a lubricant and water, followed by removal of the organic binder and sintering.
    Type: Grant
    Filed: April 24, 1986
    Date of Patent: January 26, 1988
    Assignee: Hitachi Metals, Ltd.
    Inventor: Hideki Nakamura
  • Patent number: 4719073
    Abstract: A process and apparatus for measuring and regulating the variable pressure furnace gas chemistry is described. The method makes use of mass spectrometer measurements, in the preferred form of the invention, in which gas species percent composition is obtained quantitatively independent of total furnace pressure variation. Using such a real time measurement capability, active control of batch process furnace operations is possible by intrinsic measurement of the part outgassing rather than by assumption of batch part status as a function of extrinsic parameters such as temperature and total pressure. Thus, by a combination of batch process temperature ramp control and variable admittance of suitable gas into the furnace, uniform batch processing is possible by closed loop control, due to renormalization of furnace residual gas chemistry from day to day drift and from batch part chemistry variation.
    Type: Grant
    Filed: January 30, 1986
    Date of Patent: January 12, 1988
    Inventor: John D. Langan
  • Patent number: 4710345
    Abstract: A manufacturing method of super-heat-resisting alloy material characterized in comprising the steps of: (1) filling and sealing the powder of Ni-based super-heat-resisting alloy in a rubber mold; (2) subjecting the powder in the rubber mold to cold isostatic pressing; (3) sintering the compact in vacuum or in gas atmosphere at a temperature of 1000.degree. C. or more so that the sintered density increases to 95% or more than the theoretical density; and (4) next, subjecting the sintered compact to hot isostatic pressing.
    Type: Grant
    Filed: April 22, 1986
    Date of Patent: December 1, 1987
    Assignee: Japan as represented by Director-General, Agency of Industrial Science & Technology
    Inventors: Yoshihiko Doi, Nobuhito Kuroishi, Shigeki Ochi, Noboru Uenishi
  • Patent number: 4705565
    Abstract: A method of producing a sintering powder made from high speed steel and alumina. This sintering powder is sinterable over a broader range of temperatures than conventional high speed steel sintering powders and at lower temperatures, thereby making sintered objects which are crack resistant and also highly wear resistant. Additionally, the sintering powder flows readily when poured into a mold for production of a green object for sintering.
    Type: Grant
    Filed: June 25, 1986
    Date of Patent: November 10, 1987
    Inventors: Robert J. Beltz, Joseph D. Dankoff
  • Patent number: 4698096
    Abstract: This invention relates to a sintering process. More particularly, this invention relates to a process for preparing a sintered form having a tungsten content which comprises the steps of:(a) sintering a porous form of pressed tungsten alloy powders having a high tungsten content in solid phase, and(b) heat treating the sintered part from step (a) in a liquid phase.
    Type: Grant
    Filed: October 21, 1985
    Date of Patent: October 6, 1987
    Inventors: Rainer Schmidberger, Sylvia Hardtle
  • Patent number: 4687515
    Abstract: An electrical contact for vacuum interrupters of a pressed and sintered composition of copper (60-80 wt %), ferrovanadium alloy (40-100 wt % of the balance) with at least 80 wt % of any remainder consisting of a refractory metal of the group of chromium, vanadium and their compounds. The ferrovanadium alloy comprises 55-85 wt % of vanadium.
    Type: Grant
    Filed: April 10, 1986
    Date of Patent: August 18, 1987
    Assignee: General Electric Company
    Inventor: Joseph L. Talento
  • Patent number: 4684406
    Abstract: Permanent magnet materials of the Fe-B-R type are produced by:preparing a metallic powder having a mean particle size of 0.3-80 microns and a composition of 8-30 at % R, 2-28 at % B, and the balance Fe,compacting, andsintering, at a temperature of 900-1200 degrees C. Co up to 50 at % may be present. Additional elements M (Ti, Ni, Bi, V, Nb, Ta, Cr, Mo, W, Mn, Al, Sb, Ge, Sn, Zr, Hf) may be present. The process is applicable for anisotropic and isotropic magnet materials.
    Type: Grant
    Filed: June 30, 1986
    Date of Patent: August 4, 1987
    Assignee: Sumitomo Special Metals Co., Ltd.
    Inventors: Yutaka Matsuura, Masato Sagawa, Setsuo Fujimura
  • Patent number: 4684405
    Abstract: A sintered tungsten carbide material and method for manufacturing same in which the method includes the steps of combining metal particles composed of from 75 to 95 percent by weight of a composition containing at least 70 percent by weight of tungsten carbide and from 5 to 25 percent by weight of a binder metal composition, the binder metal composition consisting essentially of from 5 to 15 percent by weight of chromium and from 85 to 95 percent by weight of nickel; pressing the metal particles into a pressed body; sintering the pressed body in a sintering chamber for a period ranging from 20 to 200 minutes, at a temperature ranging from 1400.degree. to 1500.degree. C., and in a protective atmosphere which is one of a vacuum, a noble gas, a mixture of noble gases, and hydrogen gas to form a sintered body; and treating the sintered body for a period ranging from 20 to 200 minutes, at a temperature ranging from 1300.degree. to 1400.degree. C.
    Type: Grant
    Filed: March 28, 1986
    Date of Patent: August 4, 1987
    Assignee: Fried. Krupp GmbH
    Inventors: Johannes Kolaska, Norbert Reiter
  • Patent number: 4681629
    Abstract: Discrete copper-nickel-tin spinodal alloy articles, such as bearings, containing from about 5 to about 35 wt. % nickel, from about 4 to about 13 wt. % tin and the balance copper are produced by processing a prealloyed alloy powder to form a green body having substantially the desired shape of, and proportionally sized to, the final article and sintering the green body in a reducing atmosphere or a vacuum at a temperature of at least 1650.degree. F. for sufficient time to achieve at least 90% of the theoretical density. The green body may be formed by either compaction or injection molding of the prealloyed powder. The resulting sintered article may be age hardened to effect a spinodal decomposition of the copper-nickel-tin alloy. The age hardened articles exhibit excellent strength properties and homogeneity while retaining significant ductility.
    Type: Grant
    Filed: December 19, 1985
    Date of Patent: July 21, 1987
    Assignee: Pfizer Inc.
    Inventor: John H. Reinshagen
  • Patent number: 4670216
    Abstract: A three step process in which a metal alloy selected from a tungsten based alloy and molybdenum based alloys is provided to prevent the decarbonization of the alloys. The process involves a three step sintering process wherein the atmosphere during the initial heating step is a mixture of carbon monoxide and hydrogen, thereafter at a intermediate temperature range the atmosphere is hydrogen and a final heating step at a elevated temperature is employed and the atmosphere is a mixture of inert gas and a source of carbon.
    Type: Grant
    Filed: September 25, 1986
    Date of Patent: June 2, 1987
    Assignee: GTE Products Corporation
    Inventors: Thomas J. Patrician, Vito P. Sylvester, Harry D. Martin, III
  • Patent number: 4670215
    Abstract: There is disclosed a process for forming a wear-resistant, sintered layer on a metallic substrate. The process comprises steps of adhesively attaching to a surface of metallic substrate an alloy particle sheet containing 94 to 99 weight % of ternary eutectic alloy particles and 6 to 1 weight % of acryl binder, heating in a non-oxidating atmosphere to a temperature of 150.degree. to 380.degree. C. and holding at the temperature for at least 5 minutes, and heating a sintering temperature of the alloy particles.
    Type: Grant
    Filed: February 19, 1985
    Date of Patent: June 2, 1987
    Inventors: Tsuyoshi Morishita, Sigemi Osaki, Noriyuki Sakai, Yukio Shimizu, Toshiharu Konishi, Takahumi Sakuramoto
  • Patent number: 4663120
    Abstract: A refractory metal silicide sputtering target is made by reacting refractory metal and silicon to about 70 to 90% completion of the reaction, comminuting the material, and then vacuum hot pressing the comminuted material to a high density compact having a theoretical density greater than about 95 percent and forming the metal silicide.
    Type: Grant
    Filed: April 15, 1985
    Date of Patent: May 5, 1987
    Assignee: GTE Products Corporation
    Inventors: Edward D. Parent, Charles S. Purinton, Charles W. Sutter
  • Patent number: 4659548
    Abstract: Fabrication of a high precision mirror using a discontinuous metal matrix mposite is described. A metal matrix composite (MMC) is obtained by using one of the three methods described herein or any other method. The MMC material so obtained is machined to form a mirror substrate which is then coated and the coating so obtained is converted into the mirror surface. The mirror so obtained has better characteristics over the conventional high precision beryllium mirrors used for this purpose and is fabricated out of a nontoxic material which is cheaper and more easily available than the beryllium metal.
    Type: Grant
    Filed: February 13, 1986
    Date of Patent: April 21, 1987
    Assignee: The United States of America as represented by the Secretary of the Navy
    Inventors: Jacob D. Gubbay, Edward J. Hall
  • Patent number: 4657734
    Abstract: A method for preparing a sliding face of a machine tool, comprising the steps of: providing a flat surface as a slide surface to a slide component of a machine proper by gluing a plastic material prepared from a kneaded mixture of sintered metal powder and a synthetic resin binder to the slide component; and thermally dissolving out said synthetic resin binder contained in the plastic material and sintering said metal powder.
    Type: Grant
    Filed: April 16, 1985
    Date of Patent: April 14, 1987
    Assignee: Honda Giken Kogyo Kabushiki Kaisha
    Inventors: Hiroyasu Yamada, Motoatsu Shiraishi
  • Patent number: 4647426
    Abstract: Methods and apparatus are disclosed for consolidating loose or pre-compressed particulate materials, such as metal powder or metal flakes, in press equipment utilizing a reusable canister means that is sealed in vacuum from the atmosphere and heated prior to consolidation in the press equipment at elevated pressures and temperatures, thereby improving utilization of the press equipment.
    Type: Grant
    Filed: December 23, 1985
    Date of Patent: March 3, 1987
    Assignee: Battelle Memorial Institute
    Inventor: Robert J. Fiorentino
  • Patent number: 4618473
    Abstract: A method for forming an iron alloy article having increased toughness comprises compacting and sintering a powder mixture composed of predominantly iron powder and carbon powder and containing a powder of a liquating nickel boride compound. Limited nickel diffusion into the iron structure during sintering produces metastable retained austenite in regions about pores in the product structure that retards crack formation and thereby improves mechanical properties.
    Type: Grant
    Filed: June 14, 1985
    Date of Patent: October 21, 1986
    Assignee: General Motors Corporation
    Inventor: William F. Jandeska, Jr.
  • Patent number: 4617053
    Abstract: A refractory hard metal-metal composite is formed by impregnating a porous refractory hard metal article with molten metal.
    Type: Grant
    Filed: September 20, 1985
    Date of Patent: October 14, 1986
    Assignee: Great Lakes Carbon Corporation
    Inventors: Louis A. Joo, Kenneth W. Tucker, Jay R. Shaner
  • Patent number: 4614637
    Abstract: The invention relates to a process for the production of porous products of boron or boron compounds.This process comprises the following stages:(1) suspending the boron powder in a solution of an alkali metal salt, hydroxide and/or oxide,(2) then separating the powder from the suspension liquid by settling,(3) drying the thus separated powder to obtain an agglomerated powder, and(4) subjecting the thus obtained agglomerated powder to at least two heat treatments performed at different temperatures, the final stage of the heat treatment being performed at a temperature of 1500.degree. to 2200.degree. C. and the first stage being performed at a temperature below that of the final stage.The heat treatment can be performed in three stages, as shown in the attached graph.
    Type: Grant
    Filed: April 24, 1985
    Date of Patent: September 30, 1986
    Assignee: Commissariat a l'Energie Atomique
    Inventors: Marcel Boncoeur, Bernard Hansz, Thierry Lieven
  • Patent number: 4612048
    Abstract: Powder metal compositions of nickel, molybdenum, boron, carbon, phosphorus and iron which exhibit low shrinkage on sintering.
    Type: Grant
    Filed: July 15, 1985
    Date of Patent: September 16, 1986
    Assignee: E. I. Du Pont de Nemours and Company
    Inventors: Randall M. German, Chaman Lall, Deepak S. Madan
  • Patent number: 4608227
    Abstract: A process is provided for the preparation and fabrication of sintered titanium horseshoes whereby titanium powder is processed so that its characteristics are such that it is ideally suited for horseshoes.The sintered powder titanium horseshoes have many advantages over the present state of the art some of their advantages being that they are light weight, have high strength, are flexible, have excellent wearing characteristics, are abrasion resistant and are easily formed and shaped into the desired configuration.
    Type: Grant
    Filed: September 9, 1985
    Date of Patent: August 26, 1986
    Inventor: Mildred Preiss
  • Patent number: 4608317
    Abstract: A method for manufacturing a metal sintered body disclosed herein is characterized by the use of steps of: mixing 70 to 90 weight % of self-fluxing alloy powder and 10 to 30 weight % of metal powder of high melting point having a higher melting point than that of the self-soluble metal powder and in which the self-fluxing alloy powder is liable to be deposited thereon to obtain a metal powder having a sintering property; using a material in which 1 to 10 weight % of plastic binder is kneaded with the metal powder having a sintering property to obtain a molded body having a predetermined shape; and sintering the molded body at a temperature in excess of a liquid phase line of the self-fluxing alloy powder.
    Type: Grant
    Filed: April 15, 1985
    Date of Patent: August 26, 1986
    Assignee: Honda Giken Kogyo Kabushiki Kaisha
    Inventors: Osamu Kobayashi, Hiroshi Sasaki, Toshiki Kaneko, Hideaki Ikeda, Yoshihisa Yamamura
  • Patent number: 4606884
    Abstract: The present invention concerns the manufacture of bars, wires or profiled elements by hot transformation which may be followed by cold transformation. The invention particularly concerns a new process for the manufacture of a composite billet for hot transformation as well as a method for the manufacture of products which are difficult to transform by making use of such a composite billet.
    Type: Grant
    Filed: July 3, 1984
    Date of Patent: August 19, 1986
    Assignees: Microfusion, Commissariat a l'Energie Atomique
    Inventors: Jean Gavinet, Bruno Childeric
  • Patent number: 4606767
    Abstract: Disclosed is a decorative silver-colored sintered alloy comprising TiC, Cr.sub.3 C.sub.2 and Ni in amounts of 50 to 98% by weight, 1 to 20% by weight and 1 to 30% by weight, respectively, based on the three components. In this sintered alloy, TiC is present in the form of the dispersed phase of particles and Cr.sub.3 C.sub.2 and Ni are present in the form of a solid solution as the binder phase. This sintered alloy is excellent in the corrosion resistance and is capable of manifesting a mirror surface having a deep silver color.
    Type: Grant
    Filed: October 28, 1985
    Date of Patent: August 19, 1986
    Assignee: Kyocera Corporation
    Inventor: Yoshio Nagato
  • Patent number: 4606768
    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.
    Type: Grant
    Filed: July 15, 1985
    Date of Patent: August 19, 1986
    Assignee: SCM Corporation
    Inventors: Mark Svilar, Stephen Glancy, Erhard Klar
  • Patent number: 4604260
    Abstract: A solid electrolytic capacitor is made with an Aluminum-titanium body. Aluminum and titanium powders are press-molded into a body which is then heated sufficiently to provide a porous Al-Ti alloy with an oxide layer. Next, the body is heated in an atmosphere containing at least 0.1% by volume of oxygen at a temperature in the range of about 500.degree.-700.degree. C. Thereafter, a layer of manganese dioxide is formed over the oxide layer and a cathode electrode layer is then formed over the manganese dioxide layer.
    Type: Grant
    Filed: May 22, 1985
    Date of Patent: August 5, 1986
    Assignee: NEC Corporation
    Inventors: Shigeaki Shimizu, Yoshio Arai
  • Patent number: 4596692
    Abstract: A process for forming a wear-resistant, sintered layer on an iron based substrate which comprises steps of providing a first alloy sheet containing 94 to 99 weight % of Fe-Cr type alloy particles and 6 to 1 weight % of acryl binder and a second alloy sheet containing 94 to 99 weight % of eutectic alloy particles and 6 to 1 weight % of acryl binder, placing the first and second alloy sheets in a superposed condition on the substrate, and heating in a non-oxidating atmosphere to a temperature which is higher than a solidus temperature of the eutectic alloy but lower than a solidus temperature of the Fe-Cr type alloy.
    Type: Grant
    Filed: February 19, 1985
    Date of Patent: June 24, 1986
    Inventors: Tsuyoshi Morishita, Sigemi Osaki, Yasuhumi Kawado, Yukio Shimizu, Toshiharu Konishi, Takahumi Sakuramoto
  • Patent number: 4594220
    Abstract: A method of manufacturing a scandate dispenser cathode having a matrix at least the top layer of which at the surface consists substantially of tungsten (W) and scandium oxide (Sc.sub.2 O.sub.3) and with emitter material in or below said matrix. If said method comprises the following steps:(a) compressing a porous plug of tungsten powder(b) heating said plug in a non-reactive atmosphere and in contact with scandium to above the melting temperature of scandium,(c) cooling the plug in a hydrogen (H.sub.2) atmosphere(d) pulverizing the plug to fragments(e) heating said fragments to approximately 800.degree. C. and firing them at this temperature for a few to a few tens of minutes in a hydrogen atmosphere and slowly cooling in said hydrogen atmosphere(f) grinding the fragments to scandium hydride-tungsten powder (ScH.sub.2 /W)(g) compressing a matrix or a top layer on a matrix of pure tungsten from said ScH.sub.
    Type: Grant
    Filed: December 24, 1984
    Date of Patent: June 10, 1986
    Assignee: U.S. Philips Corporation
    Inventors: Jan Hasker, Pieter Hokkeling, Johannes van Esdonk, Josef J. van Lith
  • Patent number: 4591482
    Abstract: Pressure assisted sintering achieves full densification in short sinter times with low grain growth. This result is enabled by a stage of sintering to a condition of closed porosity (14) followed by a pressure assisted sinter (PAS) stage (16) carried out at a temperature close to, but just below, sinter temperature. Advantageously a small melt formation is induced by a brief temperature spiking (18) during the PAS stage to enable collapse of voids.
    Type: Grant
    Filed: August 29, 1985
    Date of Patent: May 27, 1986
    Assignee: Gorham International, Inc.
    Inventor: Andrew C. Nyce
  • Patent number: 4591480
    Abstract: A method for sealing porous metals, which comprises applying powder of a eutectic alloy containing an element having a good diffusibility in a porous metal or powder of a mixture of metals capable of forming the eutectic alloy, to the surface of a porous metal member and heating the surface applied with the powder at a temperature higher than the eutectic temperature of the eutectic alloy to thereby cause the molten eutectic alloy to intrude into pores from the surface of the porous metal member, whereby the melting point of the molten alloy in the pores is promptly increased by diffusion of the element in the porous metal member to solidify the molten metal in the pores, sealing only pores present in the vicinity of the surface of the porous metal member.
    Type: Grant
    Filed: February 19, 1985
    Date of Patent: May 27, 1986
    Assignee: Mazda Motor Corporation
    Inventors: Tsuyoshi Morishita, Sigemi Osaki, Noriyuki Sakai, Yasuhumi Kawado
  • Patent number: 4591481
    Abstract: The present invention discloses a method for densifying previously sintered parts constructed of powdered metals, ceramics or the like to nearly 100% theoretical density. The method of the present invention comprises heating the parts containing binder and hard phase above their liquid phase temperature and then applying a pressure in a predetermined range to the parts for a predetermined period of time and simultaneously maintaining the parts at or above their liquid phase temperature. This pressure range is set so that the pressure is below the pressure necessary to overcome the capillary force acting on the binder to keep the binder from entering the voids but above the pressure necessary to physically move or collapse the microstructure inwardly, thus filling the voids with a homogenous mixture of binder and hard phase. The method of the present invention achieves complete closure of even large voids and the elimination of substantially all porosity within the part.
    Type: Grant
    Filed: January 14, 1985
    Date of Patent: May 27, 1986
    Assignee: Ultra-Temp Corporation
    Inventor: Roy C. Lueth
  • Patent number: 4587096
    Abstract: A canless method for hot working a nickel-base gas atomized alloy powder. The powder is blended with nickel powder, consolidated and sintered to a sufficient green strength. The surface of the resultant form is sealed to create an oxygen impervious layer so as to prevent oxidation therein. The sealed surface, in a sense, acts as a can. The form is then reheated and hot worked.
    Type: Grant
    Filed: May 23, 1985
    Date of Patent: May 6, 1986
    Assignee: Inco Alloys International, Inc.
    Inventors: William L. Mankins, Lindy J. Curtis, Gene A. Stewart
  • Patent number: 4584171
    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.
    Type: Grant
    Filed: September 21, 1984
    Date of Patent: April 22, 1986
    Assignees: National Aerospace Laboratories of Science & Technology Agency, Yoshimichi Masuda, Ryuzo Watanabe, Junjiro Takekawa, Sumitomo Electric Industries
    Inventors: Masayuki Niino, Nobuyuki Yatsuyanagi, Akinaga Kumakawa, Akio Suzuki, Masaki Sasaki, Hiromi Gomi, Hiroshi Sakamoto, Yoshimichi Masuda, Ryuzo Watanabe, Junjiro Takekawa, Yoshihiko Doi, Nobuhito Kuroishi, Yoshinobu Takeda, Shigeki Ochi
  • Patent number: 4582682
    Abstract: A thin-walled elastic envelope or mold element is arranged within a divisible outer supporting mold of porous material and a vacuum is applied to the outer supporting mold. Thereupon powdered metal or ceramic is introduced into the elastic mold element and the mold element is closed and pressurized to form a preform. The preform is then subjected to cold isostatic pressurization which is applied to the outer surface of the elastic mold element. Prior to the cold isostatic pressurization, the vacuum applied to the outer supporting mold is terminated and a vacuum is produced within the elastic mold element.
    Type: Grant
    Filed: July 31, 1984
    Date of Patent: April 15, 1986
    Assignee: MTU Motoren-und Turbinen-Union Munchen GmbH
    Inventors: Wolfgang Betz, Werner Huther
  • Patent number: 4582680
    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.
    Type: Grant
    Filed: August 6, 1984
    Date of Patent: April 15, 1986
    Assignee: Systems Research Laboratories, Inc.
    Inventors: Yoseph Bar-Cohen, David A. Stubbs, Wally C. Hoppe
  • Patent number: 4579713
    Abstract: The present invention provides a method for controlling the carbon content of dewaxed carbide preforms in a carbon containing furnace. The method includes the steps of placing the preforms in a carbon containing furnace and then heating the furnace to a predetermined temperature range between 800 and 1100 degrees Centigrade. At that temperature, a mixture of methane and hydrogen is introduced into the furnace chamber such that the amount of methane is between 10 and 90 percent of the amount of methane present at equilibrium for the reaction C.sub.solid +2H.sub.2 .revreaction.CH.sub.4. The furnace chamber is maintained at its temperature for a first time period sufficient for the chemical reaction XC+2H2.revreaction.X+CH.sub.4 (where X is selected from the group of W, Ti, Ta, Hf and No) substantially reaches equilibrium but shorter than the a second time period in which the reaction C.sub.solid +2H2.revreaction.CH.sub.
    Type: Grant
    Filed: April 25, 1985
    Date of Patent: April 1, 1986
    Assignee: Ultra-Temp Corporation
    Inventor: Roy C. Lueth
  • Patent number: 4569823
    Abstract: A powder metallurgical method of producing metal bodies using spherical powder, produced by inert gas atomization, from magnetizable material with a particle size distribution closely approximating the so called Fuller curve for maximum density packing of spherical particles. Said powder is magnetized and filled into a form, which may take place before or after magnetization, said mixed and magnetized powder then sintered in said form with the exclusion of air, to produce a sintered body without communicating porosity.
    Type: Grant
    Filed: March 23, 1984
    Date of Patent: February 11, 1986
    Assignee: Kloster Speedsteel Aktiebolag
    Inventor: Leif Westin
  • Patent number: 4561889
    Abstract: A sintered ferrous alloy which is high in wear resistance and relatively weak in the tendency to abrade another metal material with which the sintered alloy makes rubbing contact and suitable for rocker arm tips in automotive engines for example. The sintered alloy is produced by compacting and sintering a powder mixture of 15-50 parts by weight of a Fe-Cr-B alloy powder, which contains 10-35% of Cr and 1.0-2.5% of B, 1.0-3.5 parts by weight of graphite powder, such an amount of a Cu-P alloy powder that the powder mixture contains 0.2-1.5% of P and 1.0-20.0% of Cu and the balance of an iron powder.
    Type: Grant
    Filed: October 25, 1983
    Date of Patent: December 31, 1985
    Assignee: Nissan Motor Co., Ltd.
    Inventors: Takaaki Oaku, Yasuzi Hokazono, Masahiko Shiota, Yoshihiro Maki
  • Patent number: 4545955
    Abstract: The present invention relates to a method of manufacturing widgets from components and/or particulate; and to a can for containing such components and/or particulate during the consolidation into widgets. The method of the present invention can be used to form widgets from metals, ceramics, plastics, polymers, and/or combinations thereof. The materials used to form the widgets can be in the form of particulate, pellets, shard, and/or ribbon. The method of the present invention can also be used to join widgets and/or to heal ingot cracks.
    Type: Grant
    Filed: May 18, 1983
    Date of Patent: October 8, 1985
    Inventor: James Dickson
  • Patent number: 4544523
    Abstract: A method for producing an alloy article, such as a valve or valve component, and an assembly for use therewith. The article is produced by hot isostatic compacting wherein a lining of prealloyed powdered metal of an alloy composition different than that of the remainder of the article is confined on a surface of an internal passage or cavity in the article. A solid lining element is provided contiguous with at least a portion of the powdered metal lining the surface of said internal passage, the lining element is of an alloy also different from that of the remainder of the article. The powdered metal and solid lining element are heated and then hot isostatically pressed to densify and bond the powdered metal and the lining element to the surface of the internal passage of the article to provide a clad lining of dissimilar metal.
    Type: Grant
    Filed: October 17, 1983
    Date of Patent: October 1, 1985
    Assignee: Crucible Materials Corporation
    Inventors: William L. McCollough, Frank J. Wulczynski
  • Patent number: 4541985
    Abstract: Process for the preparation of a composite material incorporating an inorganic matrix in which are distributed inclusions of carbon-containing material, where it comprises the following stages:(a) mixing an inorganic powder with a liquid or viscous resin, which can be transformed into vitreous carbon by heat treatment,(b) subjecting the mixture of resin and inorganic powder to a first heat treatment performed under conditions such that the resin is hardened by crosslinking or polycondensation, and(c) subjecting the thus obtained hardened product to a second heat treatment for transforming the resin into vitreous carbon and thus forming said vitreous carbon inclusions.The composite material obtained comprises a copper matrix in which are uniformly and homogeneously dispersed vitreous carbon inclusions, the vitreous carbon content being at the most 8% by weight.The material is used in the production of electric contacts.
    Type: Grant
    Filed: July 26, 1982
    Date of Patent: September 17, 1985
    Assignee: Commissariat a l'Energie Atomique
    Inventors: Jacques Devillard, Jean Granier
  • Patent number: 4534936
    Abstract: A method for removal of organic binders from powder compacts is disclosed in which the compact is heated while the weight change is monitored and controlled. The heating is regulated so that the removal rate of the binder is optimized. The removal time can be shortened without creating defects in the powder compact.
    Type: Grant
    Filed: June 9, 1983
    Date of Patent: August 13, 1985
    Inventors: Elis Carlstrom, Agneta I. Johnsson, Leif A. G. Hermansson
  • Patent number: 4528120
    Abstract: The invention is refractory, electrically conductive, mixed materials based on hexagonal boron nitride and at least one electrically conductive component such as titanium boride and zirconium boride, and having a density of at least about 95% of the theoretical density and nondirection-dependent properties, which have been manufactured from powder mixtures that are practically free of oxygen and metal and comprisefrom about 10 to 60% by weight of boron nitride,from about 0 to 60% by weight of aluminum nitride and/or silicon nitride, andfrom about 30 to 70% by weight of an electrically conductive component,without the concomitant use of sintering aids by means of isostatic hot pressing in a vacuum-tight casing at temperatures of from about 1400.degree. to 1700.degree. C. and under a pressure of from about 100 to 300 MPa. The powder mixtures are pre-densified to form green bodies in block form and are then introduced into casings or coated with a material forming a vacuum-tight casing.
    Type: Grant
    Filed: April 19, 1984
    Date of Patent: July 9, 1985
    Assignee: Elektroschmelzwerk Kempten GmbH
    Inventors: Klaus Hunold, Alfred Lipp, Klaus Reinmuth
  • Patent number: 4526616
    Abstract: A load-bearing thermal insulator, for example a brake piston thrust transmission element, which comprises platelets or flakes of thermally insulating material dispersed in a metal matrix and oriented normal to the direction of heat flow so as to impede the flow of heat through the matrix in one direction.
    Type: Grant
    Filed: July 12, 1983
    Date of Patent: July 2, 1985
    Assignee: Dunlop Limited
    Inventors: Thomas G. Fennell, Ronald Fisher