Abstract: A method of producing a green compact which includes the steps of forming a generally homogeneous powder blend of powder components; consolidating the powder blend into a green body wherein the green body includes a flashing; impinging the green body with a fluid stream so as to dislodge the flashing; and removing the dislodged flashing from the surface of the green body.

Abstract: A sputtering target comprising a body of metal such as aluminum and its alloy with an ultrafine grain size and small second phase. Also described is a method for making an ultra-fine grain sputtering target comprising melting, atomizing, and depositing atomized metal to form a workpiece, and fabricating the workpiece to form a sputtering target. A method is also disclosed that includes the steps of extruding a workpiece through a die having contiguous, transverse inlet and outlet channels of substantially identical cross section, and fabricating the extruded article into a sputtering target. The extrusion may be performed several times, producing grain size of still smaller size and controlled grain texture.

Abstract: This invention provides a method of molding which can feed the high-viscosity material quickly and accurately as well as with good operability. For achieving quick heating and cooling cycles in a mold, the mold is constructed from a mold material having superior heat-conductivity in such a way that the high-viscosity material can be heated and cooled from outside of the mold.Thereby, this invention comprises:a step for preparing a mold fabricated with high orientation graphite material,a step for feeding high-viscosity material into the recess portion for molding inside said mold in the non-molten state,a step for heating and melting the high-viscosity material in the recess portion via said mold from the outside, anda step for cooling the molten high-viscosity material via said mold and molding it into a desired shape.

Abstract: A method of producing a flux-cored brazing composition for brazing aluminum that can be produced in lengths ranging from 500 to 10,000 feet long. The flux, preferably a finely powdered potassium fluoroaluminate complex, is deposited in an extremely small channel of aluminum filler material using a volumetric feeder to ensure an even distribution of flux to metal alloy.

Abstract: The present invention provides a ceramic based composite powder and a method for applying the composite powder using a H.V.O.F. gun to form a self-lubricating coating for metal parts. The composite powder and coating are comprised of a ceramic powder, a metal powder, and a solid lubricant powder.

Abstract: The present invention relates to a packing method in which a material (p) is fed into a space comprising an opening (4c) for feeding the material and a space (4d) to be packed with said material, and said space is subjected to air tapping, that is, switching of air-pressure from a low air-pressure state to a high air-pressure state alternately, thereby packing the material into the space (4d) at a high packing-density. The use of air tapping for packing a material into a space makes the packing-density of the material uniform.

Abstract: A moulded alum composition is formed by mixing crushed solid alum with a polyol plasticiser followed by heating to form a slurry, and then pouring the mixture into a mould. No mechanical cutting and grinding is required and weakening cracks and fissures present in the raw alum are removed.

Abstract: An aluminum alloy structural member is crystalline. In producing this aluminum alloy structural member, a procedure is employed which includes forming a green compact by use of aluminum alloy having an amorphous phase, and subjecting the green compact to a powder forging technique. An aluminum alloy powder exhibiting an exotherm E smaller than 20 J/g at the time of the crystallization of the amorphous phases is used. By setting the exotherm E in such a range, cracking of the green compact due to a degassing can be avoided, even if the green compact is rapidly heated in a temperature-rising or heating course.

Abstract: A method for manufacturing a component for use in an electromagnetically actuated clutch, such as an armature or a pole piece, having one or more flux breaks provided therein includes the initial step of providing a mold having an upstanding central post which defines an annular mold cavity. A quantity of powdered metal material is disposed within the mold cavity. The powdered metal material is formed from a magnetically permeable material, such as a ferromagnetic material. Next, one or more preforms of a non-magnetically permeable material are disposed within the mold cavity. The preform is placed on top of the quantity of powdered metal material axially above the desired location for the magnetically non-conductive region of the component to be formed. Then, a ram of a press machine is moved axially downwardly into engagement with the preform and the powdered metal material contained within the mold.

Abstract: The present invention is a novel method for freeform fabrication. Specifically, the method of solid freeform fabrication has the steps of:(a) preparing a slurry by mixing powder particles with a suspension medium and a gelling polysaccharide;(b) making a layer by depositing an amount of said powder slurry in a confined region;(c) hardening a selected portion of the layer by applying a gelling agent to the selected portion; and(d) repeating steps (b) and (c) to make successive layers and forming a layered object. In many applications, it is desirable to remove unhardened material followed by heating to remove gellable polysaccharide then sintering.

Abstract: Structure and a method for producing very dense bodies from particulate materials. An electrically conductive drive member is positioned adjacent the particulate material. A significant magnitude of electrical current is caused to flow through the electrically conductive drive member. A magnetic field is established and large magnitudes of magnetic pressure are created, and pressure directly from or indirectly from the magnetic pressure is applied upon the particulate material, and the particulate material is compressed and compacted. In one embodiment of the invention electrical current creates a magnetic field which is applied to an electrically conductive pressure member which moves and applies compaction pressure upon the particulate material. Electromagnetic pressure in accordance with this invention may be applied to a compacted body of particulate material, and the compressibility and density of the body of particulate material is increased.

Abstract: The present invention relates to a method for making sponge iron briquettes from fine ore with a maximum grain size of less than 2 mm, preferably less than 0.5 mm, wherein hot fine ore is fed to a roller press comprising two press rolls and is briquetted by opposite briquette pockets of the press rolls in the nip to form sponge iron briquettes. The direct pressing of fine ore into sponge iron briquettes has largely been unknown in the prior art. The invention proposes that one of the press rolls be operated as a loose roll which is substantially movable in a direction transverse to the roller axis, the nip adapting to the amount of material supplied to the press rolls and the nip substantially having such a mean width that a briquette strip is produced. In comparison with a former method, the method of the invention achieves a markedly increased service life of the molding bodies which are provided with press pockets.

Abstract: A disclosed gradient function material is produced by molding and thereafter firing a slurry which contains a plurality of groups of particles having different specific gravities. The plurality of groups of particles include at least a first group of particles and a second group of particles. The first group of particles comprises a group of nonmetal particles having a specific gravity ranging from about 3 to 7 and a maximum particle diameter equal to or smaller than a deflocculation limit, said nonmetal particles being made of one or more materials selected from the group consisting of an oxide, a carbide, a nitride, and an oxynitride. The second group of particles comprises a group of metal particles having a specific gravity which is about 1.5 times the specific gravity of said first group of particles, and particle diameters distributed across the deflocculation limit.

Abstract: The present invention relates to a method for making sponge iron briquettes from fine ore with a maximum grain size of less than 2 mm, preferably less than 0.5 mm, wherein hot fine ore is fed to a roller press and is briquetted by the roller press to form sponge iron briquettes. Apart from briquettes, fine ore which is compacted in the spaces of briquette pockets of the roller press, as well as fines in dust form are produced during briquetting. These components are designated as returns and separated from the sponge iron briquettes. The returns are then fed to the fine ferrous ore prior to briquetting. The processing of fine ore has so far entailed great problems in the technical field. The invention suggests that the returns be directly fed to a conveyor system after having been separated from the sponge iron briquettes and that the returns which are still hot be fed by the conveyor system substantially evenly and continuously to the hot fine ore to be still briquetted.

Abstract: A method of manufacturing a radially oriented magnet comprises disposing magnetic particles in a mold comprised of an insulating material, applying a pulsed magnetic field to the magnetic particles using a pair of pulse coils to impart a radial direction of magnetization to the magnetic particles, and press-forming the magnetic particles. The effective amount of magnetic flux which is applied to the magnetic particles can be effectively increased by introducing a pair of conducting rings between the pair of pulse coils for generating an eddy current effect between the pair of pulse coils to control the magnetic flux of the pulsed magnetic field. Such a method enables the manufacture of a downsized radially oriented magnet having a high degree of orientation.

Abstract: A sputtering target comprising a body of metal such as aluminum and its alloy with an ultrafine grain size and small second phase. Also described is a method for making an ultra-fine grain sputtering target comprising melting, atomizing, and depositing atomized metal to form a workpiece, and fabricating the workpiece to form a sputtering target. A method is also disclosed that includes the steps of extruding a workpiece through a die having contiguous, transverse inlet and outlet channels of substantially identical cross section, and fabricating the extruded article into a sputtering target. The extrusion may be performed several times, producing grain size of still smaller size and controlled grain texture.

Abstract: A precious-metal material for articles of jewelry and having low specific weight, high resistance to corrosion, in spite of a low content of precious metals, and free from toxic constituents which consists of 33 to 99 wt. % precious metal powder, 1 to 67 wt. % of a thermosetting organic plastics and 0 to 10% filler.

Abstract: Articles of manufacture are made of aluminum-beryllium alloys having substantially randomly distributed aluminum-rich and beryllium rich phases to provide substantially isotropic mechanical properties, such as high stiffness and low coefficients of thermal expansion, whereby the articles of manufacture provide more rapid and accurate responses.

Abstract: A method and apparatus for manufacturing a powder metallurgy article comprising two or more individually compacted layers is described. The apparatus includes a number of powder deposition means for depositing powder into at least one die cavity, the number of powder deposition means corresponding to at least the number of different powder compositions in an article being compacted, a die assembly having a female die body which is moveable with respect to a first press ram, a mechanically driven second press ram, means for driving said second press ram, control system means for controlling the relative positions and movements of said female die body, said first press ram, said second mechanically driven press ram and said powder deposition means such that they operate in synchronism, characterised by said control system means including an angle counter having proportional drive means from the press apparatus such that one cycle of the angle counter corresponds to a required number of press compaction strokes.

Abstract: A method for manufacture of at least one micronozzle in an aerostatic bearing, wherein at least one hole is placed into a compacted bearing surface from porous sintered material by means of a laser beam and disposed so as to be distributed across the surface. The holes distributed across the compacted bearing surface constitute micronozzles of an aerostatic bearing.

Abstract: A process for pneumatically isostatically compacting a sintered compact to densify the compact wherein the surface of the compact is oxidized to form a gas impervious oxide barrier on said surface before the compact is subjected to the pneumatic isostatic compaction process. Oxidation of the compact surface is preferably accomplished by steaming the compact before or after sintering.

Abstract: Disclosed is a practical aluminum based alloy containing 1 to 99 weight percent beryllium, and improved methods of semi-solid processing of aluminum alloys containing beryllium. The present methods avoid molten beryllium, agitation of molten aluminum-beryllium alloys and the need for introducing shear forces by utilizing atomized or ground particles of beryllium mixed with solid, particulate or liquidus aluminum.

Abstract: The present invention provides lubricant compositions for the powder metallurgical field. The lubricant compositions contain a solid phase lubricant such as graphite, molybdenum disulfide, and polytetrafluoroethylene in combination with a liquid phase lubricant that is a binder for the solid phase lubricant. The binder can be chosen from various classes of compounds including polyethylene glycols, polyethylene glycol esters, partial esters of C.sub.3-6 polyhydric alcohols, polyvinyl esters, and polyvinyl pyrrolidones. The binder is solubilized in an organic solvent.

Abstract: A formable composite magnetic flux concentrator material is composed of about 65% to 90% ferromagnetic material, such as iron powder, and about 35% to 10% binder, the binder being a mixture of an epoxy and one or more catalysts. The concentrator material is provided in a formable state as a putty-like body which can be worked into any desired shape dictated by the configuration of the induction heating coil used in a particular application. In one form, the density of the concentrator material is increased by application of vibration, compression and vacuum to de-air the material and to reduce voids therein. In another form, the iron powder comprises spherical-shaped particles and non-spherical shaped powders chosen in a ratio to maximize the density of material available.

Abstract: A lead frame for use in an integrated circuit package is herein disclosed wherein the lead frame is produced by molding an electrically conductive material into a desired lead frame shape. There is also disclosed several possible arrangements for a lead frame produced using the molding method including, protrusions on the lead frame adapted to provide a mechanical connection to the integrated circuit package, a heat sink molded as an integral part of the lead frame with heat dissipating characteristics specific to the application in which the lead frame will be used, and an arrangement which provides a heat conducting portion adapted to thermally connect a component attached to the lead frame to an external heat sink.

Abstract: Apparatus for use in cooling an integrated circuit structure. The apparatus includes a heat sink having a first portion configured for thermal engagement with an integrated circuit device and a second portion configured for the dissipation of heat into an ambient fluid, such as air. The heat sink is made from a powdered metal which, in one preferred embodiment, includes copper. The heat sink may be formed from the plurality of discrete layers, each layer having a button projecting from one surface, and a depression formed in an opposing surface. The depression is configured to receive a projecting button portion from another layer. In an alternative embodiment the heat sink includes a plurality of plugs projecting from the generally flat surface.

Abstract: In a fine structure of a thermoelectric material, fine particles of a material exhibiting Seebeck effect are electrically linked in a loosely contacted state with one another without fusing, having spaces formed at clearances among the fine particles. A method of manufacturing the thermoelectric material comprises a step of compacting fine particles made of a material exhibiting Seebeck effect through a cold pressing. Also, disclosed is a sensor for quantitatively sensing a substance, which comprises a pellet of a powder thermoelectric material, where a temperature difference is generated between two points inside the piece of thermoelectric material. The sensor further includes thermocouples connected to a heater plate (6) and a cooling plate, and a controller which is electrically connected in the loop circuit of the thermocouples for detecting thermoelectric current corresponding to the temperature difference, thereby to control the heating of the heater plate.

Abstract: A method for preparing deagglomerated fibres and/or particles and for providing the fibres and/or particles with a substantially uniform protective coating, the fibres and/or particles being of a material selected from the group consisting of carbides oxides, nitrides, silicides, borides, metals and graphite, including SiC, TiC, ZrC, WC, NbC, AlN, TiN, BN, Si.sub.3 N.sub.4, MgO, Al.sub.2 O.sub.3, SiO.sub.2, ZrO.sub.2, Fe.sub.2 O.sub.3, Y.sub.2 O.sub.3, steel, tungsten, molybdenum and carbon, the method comprising (a) preparing an inorganic colloid sol, and (b) mixing the fibres and/or particles are deagglomerated and substantially homogeneously distributed. The fibres and/or particles, e.g. SiC whiskers provided with an aluminum oxide coating by treatment with an aluminum hydroxide-based sol, are used for the preparation of metal matrix composite materials, e.g. based on aluminum or an aluminum alloy.

Abstract: Method for continuously extruding powdered, comminuted, or particulated feed material with a Conform extrusion machine or the like in cooperation with a forming wheel rotatably disposed within a portion of the Conform wheel to compress the feed material into a compacted feedstock. Compressing of the feed material into a compacted feedstock enables uniform and reliable conveyance of the feed material into the extrusion machine without unnecessarily subjecting the compressed feedstock to air or oxygen. An auxiliary shoe member conforming to the outer periphery of the forming wheel and to the Conform shoe enables separation of the compacted feedstock from the forming wheel. The auxiliary shoe directs the compacted feedstock into a passageway formed by the Conform machine extrusion wheel and extrusion shoe.

Abstract: Methods for forming compacts having reduced elephant's feet effect are disclosed. The apparatus utilized includes a press for dry bag isostatic pressing, the press body having a cavity with at least one open end formed therein, an elastic mould, operatively positioned inside the cavity for compacting metal powder, means, operatively connected to the mould for expanding the mould and compacting the metal powder, and at least one press member having a base section substantially normal to the cavity and an insert section extending from base section into the cavity, the insert section being formed in the shape of any one of a plurality of geometric shapes.

Abstract: An Al-based alloy represented by the general formula Al.sub.bal Ti.sub.a M.sub.b and Al.sub.bal Ti.sub.a M.sub.b Q.sub.c wherein M represents at least one element selected from among V, Cr, Mn, Co, Cu, Y, Zr, Nb, Mo, Hf, Ta and W; Q represents at least one element selected from Mg and Si; and a, b and c are, in percentages by weight, 7.ltoreq.a.ltoreq.20, 0.2.ltoreq.b.ltoreq.20 and 0.1.ltoreq.c.ltoreq.5. A compacted and consolidated material are produced by melting a material having the above alloy composition, rapidly solidifying the melt into powder or flakes; compacting the resultant powder or flakes; and subjecting the compacted powder or flakes to press forming and consolidating by a conventional plastic working. The aluminum-based alloy and the compacted and consolidated material thereof have a high strength and a good ductility and an excellent strength at high temperature.

Abstract: A method of making a permanent magnet wherein 1) a melt is formed having a base alloy composition comprising RE, Fe and/or Co, and B (where RE is one or more rare earth elements) and 2) TR (where TR is a transition metal selected from at least one of Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, W, and Al) and at least one of C and N are provided in the base alloy composition melt in substantially stoichiometric amounts to form a thermodynamically stable compound (e.g. TR carbide, nitride or carbonitride). The melt is rapidly solidified in a manner to form particulates having a substantially amorphous (metallic glass) structure and a dispersion of primary TRC, TRN and/or TRC/N precipitates. The amorphous particulates are heated above the crystallization temperature of the base alloy composition to nucleate and grow a hard magnetic phase to an optimum grain size and to form secondary TRC, TRN and/or TRC/N precipitates dispersed at grain boundaries.

Abstract: An automatic adaptive fill cavity adjust system for a powder metal press to control trend variations in the weight of multi-level parts as the result of the flowability and apparent density characteristics of the powder metal. The system comprises a monitoring component to monitor compacting load or tonnage changes, or part weight changes. A computer control is provided to receive the monitor signals, to keep a running average of a small sample of parts, to execute the proper logic to determine when a fill adjustment is needed, and to calculate the new fill position for each moveable platen bearing a tooling member to assure that the percent change in powder column height is the same for all columns. The system further includes a motor drive component responsive to the control computer output to position the up stop of each moveable platen bearing a tooling member and the core rod mechanism (if used), to achieve proportionally correct adjustments to the fill cavity.

Abstract: The pelletisation or granulation of a material or mixture of materials the or at least one of which is reactive in a liquid to produce a gas is improved by treating the reactive material prior to final compaction to form a coating thereon of a substance which is less soluble in the liquid than the reactive material. The preferred reactive material is calcium hydride and the preferred coating is calcium carbonate with or without calcium hydroxide.

Abstract: A compacted and consolidated material of an aluminum-based alloy obtained by compacting and consolidating a rapidly solidified material having a composition represented by the general formula: Al.sub.a Ni.sub.b X.sub.c M.sub.d, Al.sub.a Ni.sub.b X.sub.c Q.sub.e or Al.sub.a 'Ni.sub.b X.sub.c M.sub.d Q.sub.e, wherein X represents at least one element selected from the group consisting of La, Ce, Mm (misch metal), Ti and Zr; M represents at least one element selected from the group consisting of V, Cr, Mn, Fe, Co, Y, Nb, Mo, Hf, Ta and W; Q represents at least one element selected from the group consisting of Mg, Si, Cu and Zn; and a, a', b, c, d and e are, in atomic percentages, 85.ltoreq.a.ltoreq.94.4, 83.ltoreq.a.ltoreq.94.3, 5.ltoreq.b.ltoreq.10, 0.5.ltoreq.c.ltoreq.3, 0.1.ltoreq.d.ltoreq.2 and 0.1.ltoreq.e.ltoreq.2.

Abstract: A plastic working method for making a holed metal part. A holed blank with a through hole is placed at the center in a die member which has a die and a container continuing to the die. The die is pushed toward a punch, inserting into the through hole a first portion of a mandrel which has cross sections with at least two different cross-sectional areas. The blank is compressed by a counter punch fitting with the container and a punch pressing the die end face of the die member toward the counter punch to cause the blank plasticly to flow into a space formed between the die hole of the die and the first portion of the mandrel and while applying a compressive force to the blank by the punch and the counter punch, pulling out the first portion of the mandrel out of the blank through hole while inserting a further portion of the mandrel into the through hole so as plastically to flow the blank into a gap between the first portion of the mandrel and the through hole.

Abstract: According to the method of making a magnetic coating material, 100 parts by weight of a magnetic metal powder, 1 to 10 parts by weight of fatty acid, 1 to 5 parts by weight of a dispersing agent, and a solvent are combined in the absence of a binding agent, wherein the solvent is present in sufficient amount to yield an admixture having a solids concentration of the magnetic metal powder in the range from 65 to 70 percent. The admixture is kneaded using a pressure kneader. The kneaded admixture is then blended with a binding agent to provide the magnetic coating material.

Abstract: The subject invention relates to method for briquetting fines and ultrafines comprising mixing the fines and ultrafines on a continuous basis with a binder system having low viscosity of up to about 200 cps and at least 50% solids, such that the resulting briquette contains less than about 3% binder by weight of the briquette.

Abstract: The present invention provides a method of preparing a molded body good in processing properties, having fine contiguous pores throughout it. The surface texture of the body is fine. The body is excellent in thermal conductivity and heat-resistance properties, can be readily prepared, and is usable as a transferring mold.The method comprises compounding and mixing 5-20 parts by weight of a binder consisting of a modified amine and a modified M. D. I. that are both liquid with 100 parts by weight of an aggregate consisting of aluminum powders or aluminum-based alloy powders, filling the mixture in a molding flask, and compressing it under a pressure per unit area of 20-80 kg/cm.sup.2, and maintaining it under the same pressure until the binder is hardened.

Abstract: A densified high performance rare earth-iron-nitrogen permanent magnet obtained from a powder of a Th.sub.2 Zn.sub.17 compound containing nitrogen at interlattice sites, without using autogeneous sintering and yet preventing decomposition and/or denitrification from occurring. The process for producing the same need not necessarily use a binder, and it comprises compaction molding, or charging while applying a magnetic field, a powder of a nitrogen intrusion T--R--N compound having a specified composition and a Th.sub.2 Zn.sub.17 crystal structure, and applying thereto shock compression at a drive pressure of from 10 to 25 GPa as reduced to an equivalent drive pressure in an iron capsule.

Abstract: Disclosed is a method and an apparatus for extruding a powder material to form a pellet. The method includes the steps of: preparing a semicompacted powdered material for temporary placement in a die cavity with a constricting passage for receiving a charge of the powdered material; charging the die cavity containing the semicompacted powdered material with a predetermined amount of the powdered material; and pressing the charged powder material into the die cavity against the semicompacted material and extruding the semicompacted material from the die cavity through the constricting passage, whereby the semicompacted material is completely compressed to form a pellet, and the charged powdered material is incompletely compressed into a semicompacted form. The charging and pressing steps are repeated to successively form the powdered material into pellets via the semicompacted material.

Abstract: An Al-based alloy represented by the general formula Al.sub.bal Ti.sub.a M.sub.b and Al.sub.bal Ti.sub.a M.sub.b Q.sub.c wherein M represents at least one element selected from among V, Cr, Mn, Co, Cu, Y, Zr, Nb, Mo, Hf, Ta and W; Q represents at least one element selected from Mg and Si; and a, b and c are, in percentages by weight, 7.ltoreq.a.ltoreq.20, 0.2.ltoreq.b.ltoreq.20 and 0.1.ltoreq.c.ltoreq.5. A compacted and consolidated material is produced by melting a material having the above alloy composition, rapidly solidifying the melt into powder or flakes; compacting the resultant powder or flakes; and subjecting the compacted powder or flakes to press forming and consolidating by a conventional plastic working. The aluminum-based alloy and the compacted and consolidated material thereof have a high strength, a good ductility and an excellent strength at high temperatures.

Abstract: Structure and a method for producing very dense bodies of material from powderous materials. A powderous material is placed within an electrically conductive container. A solenoid encompasses the electrically conductive container, and a large magnitude of electrical current is caused to flow through the solenoid or coil. As the electrical current flows through the solenoid or coil, large magnitudes of pressures are created upon the electrically conductive container, and the electrically conductive container is compressed, and the transverse dimension thereof is reduced. Thus, the powderous material within the electrically conductive container is very firmly compacted. A body of superconductive material of any desired size and shape can be produced by this method by the use of superconducting powderous material.

Abstract: A method of making an orthodontic appliance such as a bracket includes the step of forming a preform of molding material while a portion of the molding material is in contact with a textured portion of a web. The web is subsequently degraded by a thermal or solvent degrading process to leave a witness impression on the underside of the preform. The web optionally serves as a conveyor to move the preform from one processing area to another, and optionally has the appearance of a woven material such that the resulting appliance resembles a mesh base appliance having undercut regions.

Abstract: The invention provides a method for manufacturing sintered parts, which uses as a debinder solvent a substance harmless to the human body and which can enhance the strength of an injection-molded product.

Abstract: Dual phase sputter targets consisting essentially of TiN and Al, methods of manufacture thereof, and cathodic sputtering methods using such targets are disclosed. The targets are prepared by blending TiN and Al powders followed by compaction to full density. The thus compacted materials are optionally sintered and are then formed into the desired target shape. The targets are used in cathodic sputtering processes to form opaque, dark colored decorative and wear resistant coatings.

Abstract: Anisotropic rare-earth permanent magnets characterized in that an aggregate of a plurality of blocks, to each of which anisotropy is imparted, is formed using powders of magnetic material containing rare-earth elements, and the adjoining blocks are powder-metallurgically bonded together under pressure into one piece; a method of making anisotropic rare-earth permanent magnets by molding anisotropic blocks by magnetic-field molding, arranging, aggregating and sealing a plurality of blocks in a bag, and cold hydrostatic pressing the aggregate of blocks in the absence of magnetic field; and a suitable metal mold for magnetic-field molding anisotropic permanent magnets of a relatively large size.

Abstract: The present invention provides a compacted and consolidated aluminum-based alloy material which has been obtained by compacting and consolidating a rapidly solidified material having a composition represented by the general formula: Al.sub.a Ni.sub.b X.sub.c wherein X is one or two elements selected from Zr and Ti and a, b and c are, in atomic percentages, 87.5.ltoreq.a.ltoreq.92.5, 5 .ltoreq.b.ltoreq.10, and 0.5.ltoreq.c.ltoreq.5; and a production process comprising melting a material of the above composition; quenching and solidifying the resultant molten material into powder or flakes; compacting, compressing, forming and consolidating the powder or flakes by conventional plastic working. The consolidated material of the present invention has. elongation (toughness) sufficient to withstand secondary working, even when secondary working is applied. Moreover, the material allows the secondary working to be performed easily while retaining the excellent properties of its raw material.

Abstract: A method for preparing a treated nanocrystalline metallic material. The method of preparation includes providing a starting nanocrystalline metallic material with a grain size less than about 35 nm, compacting the starting nanocrystalline metallic material in an inert atmosphere and annealing the compacted metallic material at a temperature less than about one-half the melting point of the metallic material.

Abstract: Continuous powder metallurgy compacts are produced from metal powder (1) placed in a tapered powder consolidation region (2) of a forming die (1). The die is made to undergo ultrasonic radial vibration about the consolidation region to effect radial compaction of the powder. The powder is progressively densified as it moves through the die, due to the tapered construction of the consolidation region, and emerges from the die at sufficient density to allow handling and further processing.