Abstract: A process for producing an alloy product of improved ductility from metal powder. It includes the steps of: providing metal powder having at least 5 wt. % of one or more reactive elements from the group consisting of titanium, aluminum, hafnium, niobium, tantalum, vanadium and zirconium; consolidating the powder to an essentially fully dense shape; and progressively melting and solidifying localized areas of the consolidated shape so as to produce a product of improved ductility.

Abstract: Disclosed is a composite metal powder made from a base iron powder milled with an alloying component such as nickel, copper, managnese, chromium, silicon, phosphorus, boron, vanadium, and molybdenum, where the composite metal powder has a compressibility comparable to the compressibility of the soft base iron powder prior to milling. Such a composite is obtained by using a short mill time followed by an annealing step.

Abstract: A metal matrix composite is produced by plastically deforming a metal powder, either or after blending the powder with ceramic fibers, and compacting the mixture at elevated temperatures to achieve substantially full density. Imparting strain energy to the metal allows reduction of the compaction temperature to eliminate reaction between the fibers and the metal or degradation of the fibers. Silicon nitride fibers are thermodynamically superior for use in aluminum or titanium metal matrix composites, since silicon nitride fibers are more stable at the temperatures required for full compaction. Secondary phase reactions are avoided.

Abstract: A process and apparatus for treating finely divided powders of brittle materials capable of sintering or injection molding, such as ceramics or intermetallic phases in a predetermined maximum size of the powder particles which is maintained with reliability.

Abstract: This invention relates to a method of manufacturing thermoelectric material which has the steps of quenching a thermoelectric alloy in a molten state at a quenching rate higher than 10.sup.3 .degree. C./sec into a membrane or powdery form and subjecting the membrane or powder to cold-forming or sintering. The thermoelectric alloy is a Bi--Sb series alloy having a composition represented by{(Bi.sub.100-x .multidot.Sb.sub.x).sub.100-y .multidot.E.sup.II.sub.y }.sub.100-z .multidot.E.sup.I.sub.zwhere E.sup.I represents a group III or group IV element, E.sup.II represents a group IV or group VI element, x represents a number of 5-20, y represents an integer of 0-20 and z represents a number of 0.05-10, respectively.

Abstract: Apparatus is provided for the production of ultrafine powder. The powder is produced by spark erosion within an electric discharge cell. The starting material for production of the powder is a body in chunk form of the material to be pulverized. The material is contained in an electric discharge cell having a fine mesh screen bottom. The cell and its contents are immersed in a dielectric fluid such as water, liquified gas or an organic base liquid. The cell and its contents are vibrated to cause the chunks to separate repeatedly and momentarily. A sparking voltage is impressed repeatedly through the body to develop sparks between confronting portions of separated chunk surfaces. Small particles produced as a result of the sparking fall through the screen of the cell and are collected as product.

Abstract: A process is disclosed for producing discontinuous metal foils. The process involves entraining metal powder particles in a carrier gas and passing the powder particles through a high temperature zone at a temperature above the melting point of the powder particles to melt at least about 50% by weight of the powder particles and thereafter resolidifying the resulting high temperature treated material by impacting the material against a substrate to form the foils.

Abstract: A sintered magnet of Fe-B-rare earth alloy having an axis of easy magnetization oriented at an angle to a major axis can be directly produced from the alloy material by (a) press molding the material in an applied magnetic field into a compact of the dimensions determined by taking into account factors of shrinkage expected in X, Y and Z directions, and (b) sintering the compact.

Abstract: Aluminum alloy, suitable for rapid quenching from a melt supersaturated with alloy components, which contains 2 to 5.5% by weight of Cr and 2 to 5.5% by weight of V, the remainder being Al, and may contain further added amounts of Mo, Zr, Ti or Fe, individually or in combination, up to a total content of not more than 1% by weight, the total content of all alloy elements being no more than 10% by weight. The simultaneous occurrence of the phases Al.sub.13 Cr.sub.2 and Al.sub.10 V in silid solution and as hardness-imparting dispersoids having a particle diameter of not more than 0.1 .mu.m results in good high-temperature strength and thermal stability coupled with good ductility and toughness of the material. The comparatively Low Vickers hardness of, on average, only about 130 (HV) for the rapidly solidified alloys initially obtained make the powders readily processable. After the heat treatment, the Vickers hardness of the workpiece reaches values up to about 200 (HV).

Abstract: Method of preparing an anisotropic permanent magnet by a powder metallurgical technique, in which, the step of orientation of anisotropically magnetic particles during shaping by compression to give a green body prior to sintering, the magnetic field is applied pulse-wise to the mass of magnetic particles and an impacting compressive force is applied to the thus oriented particles in the direction parallel to the magnetic field during the period in which a pulse of the pulse-wise magnetic field is sustained. This method ensures a much higher degree of particle orientation than in the conventional static-field method by virtue of the possibility of obtaining a much stronger magnetic field without problems which otherwise are unavoidable. The principle of the method is applicable to the preparation of a cylindrical or annular permanent magnet magnetizable in a plurality of radial directions.

Abstract: Improvements in the positive temperature dependence of yield strength and in the work hardening rate of tri-nickel aluminide base alloys are achieved. The novel alloy composition has seven alloying ingredients as follows:______________________________________ Concentration Ingredient in Atomic % ______________________________________ Ni balance Co 8-12 Al 16-20 Si 4-6 Nb 0.26-0.30 Zr 0.02-0.04 B 0.2-0.7 ______________________________________The novel composition may be prepared by forming a melt of the composition and atomizing the melt with an inert gas to form fine particles with Ll.sub.2 type crystal structure. The powder is densified by heat and pressure to a novel alloy composition having the improvements in positive temperature dependence of yield strength and work hardening rate as noted above.

Abstract: A metal body having high tensile strength and ductility at temperatures over 1000.degree. F. is provided. The body is prepared by hot isostatic pressing of powder formed by atomization of a melt of an alloy. The alloy composition is according to the formula(Ni.sub.1-x-z Co.sub.x Al.sub.z).sub.100-y B.sub.ywherein x is at least 0.05, andwherein y is 0.10 to 2.0, andwherein z is 0.23 to 0.25.The consolidated body is suitable for machining to final dimensions. To relieve stresses developed from the machining the body may be annealed for a couple of hours at temperatures between 800.degree. C. and 1200.degree. C.

Abstract: Aluminum-base alloys and a method of preparing aluminum-base alloys by mechanical alloying in the presence of a carbidiferous processing aid wherein a strong carbide former such as titanium is included so as to produce carbides in the final alloy more thermally stable at temperatures in excess of 100.degree. C. than Al.sub.4 C.sub.3.

Abstract: A process is disclosed for the preparation of metallic products from metal salts admixed with solvent wherein at least one of the metal salt and the solvent is easily reducible. The admixture is heated under hypercritical conditions of temperature and pressure to produce metallic products and a hypercritical fluid. The hypercritical fluid is subsequently removed from the reaction zone and the metallic product is collected. The metallic product includes pure metals selected from the group of silver, gold, platinum, palladium, ruthenium, rhodium, mercury, arsenic, rhenium, tellurium, iridium, osmium, and copper, and alloys and mixtures thereof. The metallic product ordinarily exists as finely divided powders which may be highly porous.

Abstract: A tri-nickel aluminide base composition is provided which has good ductility at all temperatures. The composition has a relatively high concentration of cobalt substituent and is doped by boron. It also has minor concentrations of at least two other substituent metals selected from the group consisting of niobium, hafnium, vanadium, molybdenum and zirconium.

Abstract: Improvements in the strength of atomized and consolidated boron doped tri-nickel aluminides are made possible. The improved strength is achieved by cold rolling and annealing a HIPped aluminide. The improvements are to room temperature properties.

Abstract: A method is taught for rendering a boron-doped tri-nickel aluminide resistant to mechanical failure while at intermediate temperatures of 600.degree. C. to 800.degree. C. due to a hot-short phenomena. The method involves incorporating between 0.05 and 0.30 of cobalt in the composition according to the expression(Ni.sub.1-x-z Co.sub.x Al.sub.z).sub.100-y B.sub.y.The concentration of aluminum, z, is between 0.23 and 0.25 and the concentration of boron, y, is between 0.2 and 1.50 atomic percent. The composition is formed into a melt and the melt is rapidly solidified by atomization and consolidated. The consolidation may be simultaneous with the rapid solidification, as in spray forming, or sequential by atomization to a powder and consolidation of the powder by HIPping. The consolidated body is cold worked to increase the resistance of the body to failure at intermediate temperatures and may be annealed following the cold working.

Abstract: Metal powder-oxide compositions are provided suitable for forming high strength composite products. The compositions comprise powdered flake-like metal alloys having a thickness between 0.5 and 2 microns wherein the oxide comprises between 0.5 and 5 weight percent of the composite compositions.

Abstract: A process for producing alloy steel powder, particularly, low-oxygen, low-carbon alloy steel powder is disclosed. The process comprises: preparing molten steel which contains at least one easily oxidizable element selected from the group consisting of chromium, manganese, vanadium, niobium, boron and silicon; atomizing said molten steel by means of an atomizing agent containing a non-oxidizing medium to provide as-atomized alloy steel powder containing 0.2% by weight or less of oxygen and 0.1% by weight or more of carbon; decarburizing the resulting powder by maintaining it in an atmosphere containing at least H.sub.2 and H.sub.2 O gases under specified conditions; and cooling the thus decarburized alloy steel powder to room temperature in an inert or reducing atmosphere.