Abstract: Very fine grain metal billets are produced by loading alloy metal powder of desired composition into a metal extrusion container in successive layers of two or four inches deep. Each layer after loading is compacted by a high energy rate forming ram so as to introduce energy on the order of 3.times.10.sup.6 psi per layer and at least 18.times.10.sup.6 psi total. An inner plate is then loosely placed on the compacted powder. On top of the inner plate is placed a cover plate which is welded to the container. The filled container is then heated in a furnace to an extrusion temperature below the melting point of the alloy and is extruded in an extrusion press having a ratio of about 3:1 with a force of about 3,000 tons. The inner plate does not move at the same rate as the container and in effect is partially extruded against the powder so as to raise the density of the extruded billet to substantially 100% of its theoretical density.

Abstract: In a process and apparatus for forming an ingot having a length at least twice as great as its characteristic sectional dimension, droplets of molten metal are sprayed onto a catching surface of a dummy bar which is rotated about its axis and moved in a removal direction along its axis. Layers of spray built up on the catching surface form an ingot. Boundary surfaces may be provided for shaping one of the surfaces of the formed ingot. In the case of a hollow ingot, the boundary surfaces are in the form of a partially cylindrical mandrel extending axially into a hollow dummy bar.

Abstract: In a process wherein parts are pressed into a predetermined shape by filling a die cavity with a powder material, compressing the powder under pressure to form a compressed part of said shape, an improvement to that process comprises subjecting a portion of the cavity to vibrations during the filling of the die cavity.

Abstract: The present invention relates to a method for producing multifilament superconductive wires of Nb.sub.3 Sn or V.sub.3 Ga filaments embedded in a Cu or Cu alloy matrix, with the wires containing metal additive elements from the group including Ti, Zr, Hf, V, Nb, Ta, Fe, Co, Ni in the filaments and/or in the matrix. The superconductive characteristics of the wires are predetermined for medium magnetic fields (below 12 T) as well as for high magnetic fields (12 T and above). The percentage of the additive (or additives) can be set to a predetermined value and thus the superconductive properties can be set as desired. This is accomplished by mixing metal additives in powder form with a powder of niobium or a niobium alloy, or of vanadium or a vanadium alloy, in a defined grain size and in a defined quantity. The resulting powder mixture is compacted in a container of copper or a copper alloy, the compacted container is shaped into a wire and, upon removal of the container layer, is processed further into wires.

Abstract: A process and apparatus for producing a pressed powder body from at least two different kinds of ultrafine particles. Ultrafine particles of at least two different materials are uniformly mixed together and the mixture is sprayed onto an objective surface whereby the spray pressure causes the particles to adhere and form the pressed powder body. The apparatus includes mixing means, means for conveying the mixture of ultrafine particles, and a pressed powder body forming chamber including nozzle means for spraying the mixture of ultrafine particles, an objective surface and means for evacuating the chamber and introducing an inert gas therein.

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 process for the production by power metallurgy of a material based on an aluminum alloy, a solid lubricant and at least one ceramic is disclosed. The process is characterized by using a ceramic in powder form with a granulometry of between 1 and 10 .mu.m.This invention finds application in the manufacture of components which are subjected to friction, in particular under hot condition, such as engine liners. These components provide an optimum compromise coefficient of friction and resistance to seizure and wear.

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 base is according to the formula:(Ni.sub.1-x Al.sub.x).sub.100-y B.sub.ywhere x is between 0.23 and 0.25, and where y is 0.1 to 2.0.The consolidated body is suitable for machining and may be annealed for a couple of hours at temperatures between 800.degree. C. and 1200.degree. C. following such machining.

Abstract: In a forming method and a mold wherein a slip is cast into the mold and wherein the mold is removed after hardening of the slip, the mold is patterned by the use of a water-soluble binder. The mold absorbs a water content in the slip to soften and to become easy of removal, while the slip has the water content absorbed to harden promptly. Therefore, the forming method and the mold are especially suited to produce a cast article of complicated shape.

Abstract: Alloy powder is packed into a mold which comprises a complex-shaped solid aphite inner core and a similarly complex-shaped thin glass outer wall. The mold is evacuated, sealed, and then heated to the alloy sintering temperature, the glass softens and applies an isostatic pressure on the alloy as the alloy particles consolidate. After the consolidation step, the mold and its contents are cooled and the glass and graphite materials are removed from the alloy object. This method is particularly useful for preparing complex fittings of Nitinol shape memory alloys.

Abstract: A piston ring is formed by annular upper and lower parts which contact one another at respective surfaces normal to the axis of the piston ring. The parts can be injection moulded from thermoplastics materials with the parts themselves having no re-entrant portions, so allowing quick and easy manufacture, but with the parts together defining re-entrant portions such as a spring-receiving recess at the inward side of the ring or a pair of spaced oil control rails at the outward side of the ring.

Abstract: This invention relates to the manufacture of compacts of ceramic composition, cermets, and other high hardness materials by applying explosive shock during exothermic sintering of such powders.

Abstract: A powder-metallurgy method for producing tubular product having at least one surface and preferably an internal surface thereof clad with an alloy different from and preferably more resistant to destructive media than the material from which the remainder of the tubing is constructed. An assembly is constructed of a metal tubing having an internal surface to be clad and a tubular insert mounted generally axially within the tubing in spaced-apart relation to the internal surface thereof, which provides a generally annular cavity between the internal surface of the tubing and the tubular insert. This cavity is filled with metal particles of a composition to be clad on the tubing internal surface. The cavity is sealed and the assembly is heated to an elevated temperature at which it is forged to compact the metal particles introduced to the cavity to substantially full density and metallurgically bond the particles to the internal surface of the tubing to provide a desired destructive-media resistant cladding.

Abstract: Metal powder of the desired composition having a particle size of -80 mesh is charged into an extrusion container, preferably a piece of carbon steel pipe, in successive layers about two inches thick. Each layer is compacted after deposition by a high energy rate forming ram so as to raise the tap density of the powder to about 80% of theoretical. An inner cover plate is then placed loosely on the compacted powder in the extrusion container, and is not attached to the container shell. On top of this inner plate is placed an outer cover plate which is welded to the container shell. Both plates are also of carbon steel, but are much thicker than the container wall. The container so prepared is heated in a heating furnace to a temperature below the melting temperature of the container and the powder alloy thus raising the density of the powder to about 90-93% of theoretical.

Abstract: A method for consolidating powder utilizing slurry extrusion or rolling techniques. A metallic powder, binder and boron containing activator are mixed together to form a slurry. The slurry is introduced into an active forming apparatus whereupon it is formed into an object of predetermined shape and sintered.

Abstract: A method of manufacturing by a powder metallurgy process a rotary drill bit including a bit body having a plurality of cutting elements mounted on the outer surface thereof comprises the steps of forming a hollow mould for moulding at least a portion of the bit body, packing the mould with powdered matrix material, and infiltrating the material with a metal alloy in a furnace to form a matrix. Before packing the mould with powdered matrix material, there are positioned in spaced locations on the interior surface of the mould a plurality of cutting elements, each of which is formed of a material, such as a polycrystalline diamond material, which is thermally stable at the temperature necessary to form the matrix. Also positioned in the mould, adjacent the rearward side of each cutting element, is a support material such that, at least after formation of the matrix, the support material has a higher modulus of elasticity than the matrix.

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 novel target material for use in the sputter formation of a metal silicide film in electrode wiring in a semiconductor device, and a process for producing such target material are disclosed.The process for producing the target material is characterized by first impregnating molten silicon into a calcined body containing at least one silicide forming metal component and a silicon component and then forming a sintered body with a reduced oxygen content containing both a metal silicide and silicon.The target material prepared in accordance with the invention is extremely low not only in oxygen content but also in the concentrations of other impurities and has high deflective strength as compared with the conventional sintered target.The film formed by sputtering the target of the invention has appreciably reduced impurity levels and hence, very low electric resistivities. The target of the invention enables sputtering to be performed 5 times as fast as in the case using the conventional sintered target.

Abstract: The invention relates to a process for the treatment of a metal oxide powder, particularly a UO.sub.2 or PuO.sub.2 powder, with a view to its fritting.This process consists of oxidizing the powder, so as to form on its surface a hydrated oxide layer of the same metal. When the oxide is UO.sub.2 or PuO.sub.2 and mixtures thereof, as well as those prepared with ThO.sub.2, the treated powder can be used for producing nuclear fuel pellets by cold compression, followed by fritting.

Abstract: A process for placing conductive paths on to the surface of a heat softenable substrate by applying a layer of metal powder to the substrate, compacting the powder in a pre-determined pattern by applying a heated die under pressure, and embedding the compacted powder by the continued application of the die at a pressure less than the compacting pressure.

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 of making a porous metal article is disclosed comprising:(a) applying a stabilized suspension of a dispersed metal particulate in a fluid medium to a porous metal support;(b) working the support to fill the openings with the stabilized suspension and remove entrained gas;(c) heating the filled support to dry the stabilized suspension and provide the filled support with green or unsintered strength;(d) preferably compressing the dried, filled support to provide better contact between adjacent particles and greater mechanical strength; and(e) sintering the compressed, dried, filled support to remove volatile material and to fuse the individual particles of the metal particulate to the metal support and to each other.The porous metal articles find particular use as filters. They comprise a porous metal support and metal particulate material with the individual particles sinter bonded to each other and to the support.

Abstract: Amorphous metal powders or ribbons are fabricated into solid shapes of appreciable thickness by the application of compaction energy. The temperature regime wherein the amorphous metal deforms by viscous flow is measured. The metal powders or ribbons are compacted within the temperature range.

Abstract: A cermet is produced by providing a bulk reaction mixture of particulate reactants plus elemental metal, which reaction mixture is in admixture with a ceramic diluent that is the same as ceramic material formed during sintering of the reaction mixture. Sintering produces a boride-oxide ceramic with the oxide being a metal oxide of the elemental metal. However, the elemental metal is present in the reaction mixture in substantial excess over that amount stoichiometrically required. Sintering is conducted under inert atmosphere, generally after pressing. The invention is particularly directed to boride-based ceramics containing aluminum, which materials are suitable as components of electrolytic cells for the production of aluminum by molten salt electrolysis.

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: 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.

Abstract: An improvement is disclosed in a process for recovery of cobalt from cobalt bearing material to obtain fine cobalt metal powder of high purity, the improvement being mechanically compacting the powder into a billet and sintering the billet in a hydrogen atmosphere at a sufficient temperature for a sufficient time to densify the billet and form a high purity cobalt article having an oxygen content of no greater than about 500 weight parts per million.

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.

Abstract: A copper-rich metal shape is produced by forming a coherent forerunner shape consisting essentially of cupreous powder, said powder containing a proportion of copper oxide sufficient for facilitating the obtaining of a high sinter density in sintered porous mass, and in a reducing atmosphere at temperature that will sinter copper present, converting said forerunner shape into a porous sintered mass virtually devoid of copper oxide. Said porous mass can be worked so virtually full density if desired.

Abstract: Composite cermets having a central core of a first cermet composition and one or more surrounding layers of different cermet compositions are formed by a multi-step pressing operation, followed by sintering. A tungsten/alumina or molybdenum/alumina composite cermet is useful as an end closure for alumina arc tubes of metal halide discharge lamps.

Abstract: The disclosure relates to a feedstock of particulate material for use in formation of articles therefrom, the feedstock including a homogeneous combination of large particles, small particles and a binder. The large particles comprise less than about 60% by volume of the feedstock and are defined as particles having a diameter greater than their diffusion length. The fine particles and binder combined comprise more than about 40% by volume of the feedstock, the fine particles being defined as particles having a diameter less than their diffusion length.

Abstract: A process for the production of valve seat rings by powder metallurgy wherein molybdenum disulfide in the range of about 0.5% to 1.5% by weight is added to a powder mixture containing 0.8% to 1.5% by weight graphite, 1.0% to 4% by weight lead, 0.5% to 5% by weight nickel, 1.2% to 1.8% by weight molybdenum, 9.6% to 14.4% by weight cobalt, and the remainder iron. The resulting powder mixture is pressed into valve seat rings at a pressing force between 40 and 60 and preferably 50 KN/cm.sup.2. The rings are then sintered in a neutral atmosphere at a temperature of 1100.degree. C. to 1200.degree. C., finally compressed at a pressing force above 120 KN/cm.sup.2 and heat-treated if required. The resulting valve seat rings have greatly improved wear properties when used in internal combustion engines using lead-free gasoline.

Abstract: A hermetically sealed capsule (10) containing degased metal powder (11) is embedded in a soft metal flow die (20). Subsequently the flow die (20) is compressed in a cavity block, thereby compressing the metal powder (11) by the hydrostatic pressure of the flow die and simultaneously shaping the said powder. This results in the reforming of the structure right down to the interior of the particles with compression of up to 100%. The shaping process can be aided by moulding dies (17, 18) embedded in the flow die (10) around the capsule (10) at a distance from each other and, when closed, forming a cavity, the shape of which deviates from that of the original shape of the capsule (10). The capsule (10) containing the metal powder is formed during closure of the moulding cavity.

Abstract: In a method of producing unbaked agglomerates, green pellets or briquettes are produced by adding 5 to 30% of reduced iron powder, mill scale powder or iron sand and also adding a binder consisting of a cement or granulated blast furnace slag and then the green pellets or briquettes are dry cured thereby producing agglomerates having excellent reducing performance.

Abstract: High strength and high toughness are combined in an aluminum-based metallic product by dispersing particles of an aluminum-based metal having a toughness of at least about 20 foot-pounds through a matrix of aluminum-based metal having a yield strength of at least about 30 ksi.

Abstract: Broadly, the present invention provides for improvements in the manufacture of compacted or molded articles of blended mixtures of additive metals for use in the preparation of alloys of base metals. The improvements comprise the addition to blended mixtures of additive metals of at least one processing aid comprising at least one polyglycol or a derivative thereof to the blended mixture of metals in a stabilizing and lubricating amount.

Abstract: A process for the production of depleted uranium metal particles comprising heating depleted uranium metal to red heat, rapidly chilling the heated metal, grinding the resulting brittlized metal to form powder size particles, annealing the particles and coating the particles with silver, copper, or lead, wherein the grinding and annealing are carried out in an inert argon atmosphere. The invention also contemplates the resulting depleted uranium metal powder, compositions containing the same as well as the liners for shaped charges formed therefrom.

Abstract: A method and apparatus for pressing magnetic powder in a toroidal-shape we in a radial magnetic field. A magnetic flux is produced and carried by a die rod through the axial center of toroidally-shaped magnetic powder. An annular portion coaxially surrounding the die rod and magnetic powder is connected to a yoke member which carries the magnetic flux back to the magnetic flux producing means. This completes the magnetic circuit, and creates a radial magnetic field across the toroidally-shaped magnetic powder between the die rod and the annular portion. This radial magnetic field aligns the granules of the toroidally shaped magnetic powder during pressing.

Abstract: In the installation, a strip is shaped from a split tube which is welded or seamed to give a closed tube in a welding or seaming station. Associated with the welding or seaming station is a suction mechanism used for the removal of on the one hand the cold air flow produced by the moving open tube and on the other the air flow heated during welding and flowing back from the closed tube, as a result of the reduction of the internal cross-section thereof. This obviates air turbulence in the welding or seaming station, which could whirl up the pulverulent material introduced into the open tube in a dosing station and could be deposited on the longitudinal edges of the split tube. This could unfavorably influence the seaming or welding process.

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.

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 composite camshaft having a plurality of fitting members, such as cam lobes and journals, fabricated from metal powders having a composition of an Fe-C-Cu system which contains 17-35% by weight of Cu and joined to a steel shaft by a binding effect of Cu, which melts out of the fitting member and full penetrate a clearance between the fitting member and the steel shaft to join them as one body.

Abstract: A method of consolidating metallic body means comprises(a) applying to the body means a mixture of:(i) metallic powder(ii) fugitive organic binder(iii) volatile solvent(b) drying the mixture, and(c) burning out the binder and solvent at elevated temperature,(d) and applying pressure to the powdered metal to consolidate same on said body means.

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.

Abstract: A flux-path forming member of a motor is prepared from a mixture mass by evenly mixing up to 4% of a thermosetting resin binder and molybdenum disulfide with at least 96% of a metal powder, fibrous metal, or a combination thereof; a second step of compacting in a mold under pressure the mixture mass into a desired shape; and a third step of heating, concurrently with or subsequently to the second step, the mixture mass to an elevated temperature to cure the binder portion thereof. The compact prepared by the above process is also disclosed. The content of the thermosetting resin at least 0.2 percent by weight, and the content of the molybdenum disulfide is at least 0.1 percent by weight. The curing operation is conducted at a temperature not higher than 300.degree. C.

Abstract: A high density shot made of a cold-compacted mixture of at least two metal powders, a first one of such powders more dense than lead and a second one of such being flowable under compaction to serve as a binder. The shot has an extended range as compared to conventional lead shot.

Abstract: An annular die and a matingly provided annular punch cooperate for stepwise building-up a hollow; the punch has one or two channels to which powder is fed; the amount for each feed is limited so that the height of the powder compressed in each step is about 0.6 to 0.8 times the annular dimension of the product to be made.

Abstract: Disclosed herein is a powdered metal casing and an apparatus and method for making the powdered metal casing, which casing is useful for shaped explosive charges for perforating oil and gas wells.