Abstract: A crankcase explosion relief valve with an external flame trap made from compressed and sintered porous metal powder. Should an explosion take place, the valve plate will lift, allowing the flame front and exhaust gasses to enter the device. The exhaust gasses exit the valve though a circular flame trap made of porous metal. The circular flame trap is of a ribbon shape as to increase the amount of permeable area on the component. Due to the narrow interconnected porosity, flames will not be able to propagate past the porous material, while the exhaust gasses are able to freely pass through. In another embodiment, the porous material component is in the form of a plurality of cups.

Abstract: A method for manufacturing a titanium acetabular cup shell includes obtaining a titanium powder. A three part mold having a first part with a part-spherical inner surface, a second ram part with a part-spherical outer impact surface and a third ram part with an annular impact surface are provided to compact the titanium powder. The second and third parts are aligned along an axis within the first part. The second part is aligned along a center axis within the annular impact surface of the third part. The first mold part is filled with the titanium powder. The second mold part-spherical outer surface and the third part annular surface are moved towards the part-spherical inner surface of the first part into contact with the powder. The powder is compacted with the second part part-spherical outer impact surface and the third part annular impact surface to about 50% of its initial volume.

Abstract: Systems and methods in accordance with embodiments of the invention implement bulk metallic glass matrix composites in the fabrication of objects. In one embodiment, a method of fabricating an object including a bulk metallic glass matrix composite includes: forming a bulk metallic glass matrix composite composition into the shape of the object to be fabricated; and developing the bulk metallic glass matrix composite composition to include non-equilibrium inclusions that are softer than the surrounding matrix as measured by one of: the shear modulus, the elastic limit, and the hardness; where the bulk metallic glass matrix composite composition is such that the extent of the presence of the inclusions can be made to vary.

Abstract: A method for producing a moulded body is proposed, comprising: applying a layer of particles and applying a binder and curing a moulded body; and a device for producing a metallic or ceramic moulded body, having a storage volume, which is configured for receiving a suspension of metallic or ceramic particles that are dispersed in a suspension fluid, a layer-forming application device, which is configured for removing an amount of suspension repeatedly from the storage volume and transferring it into a working volume and applying it there as a layer, a dehumidfying device, which is configured for dehumidifying the applied layer in the working volume, a binder application device, which is configured for applying a binder locally to the dehumidified layer in accordance with a layer model of the moulded body to be produced, in such a way that particles in the dehumidified layer are adhesively bonded locally to one another and optionally in addition to particles of at least one layer lying under the dehumidified l

Abstract: Apparatus and methods for manufacturing magnets, and magnets, having magnetically oriented grains, and apparatus including such magnets. The field of a permanent magnet may be shaped by applying an external field to the material from which the magnet is made in such a way as to magnetize different regions of the material in different directions. The apparatus may include, and the methods may involve, a metal-powder press that may press metal powder in the presence of a magnetic field. The press may compress the powder in an axial direction. The field may have flux lines that are transverse to the axial direction. The field may have flux lines that are along the axial direction.

Abstract: There is provided a soft magnetic core including: a composite metal powder in which surfaces of iron (Fe) particles are coated with an insulating layer; a body part formed by compressing the composite metal powder; and an alloying element diffused from a surface of the body part to an inside thereof.

Abstract: A multiphase composite system is made by binding hard particles, such as TiC particles, of various sizes with a mixture of titanium powder and aluminum, nickel, and titanium in a master alloy or as elemental materials to produce a composite system that has advantageous energy absorbing characteristics. The multiple phases of this composite system include an aggregate phase of hard particles bound with a matrix phase. The matrix phase has at least two phases with varying amounts of aluminum, nickel, and titanium. The matrix phase forms a bond with the hard particles and has varying degrees of hard and ductile phases. The composite system may be used alone or bonded to other materials such as bodies of titanium or ceramic in the manufacture of ballistic armor tiles.

Abstract: A method of making an explosive charge liner comprises introducing powdered material into a basin defined by a die block, where a punch is shaped to interact with the basin, excluding the powdered material from a central portion of the basin, pressing the punch into the powdered material in the basin to form the explosive charge liner, and removing the explosive charge liner from the die block. The explosive charge liner comprises an aperture in an apex area of the explosive charge liner corresponding to the central portion when removed from the die block.

Abstract: A fuel cell for a portable electronic device having a liquid fuel reservoir (100) wherein at least a part of the inner surface (103) and a part of an outer surface (104) of the fuel reservoir wall (102) are gas permeable, wherein said wall is adapted such that the area of the open parts of the inner surface (103) of the wall is larger than the area of the open parts of said outer surface (104) of the wall, wherein said wall is porous and adapted to allow gas to enter said wall and to be transported along said wall in a direction substantially parallel with the plane of the wall and to leave said wall, and wherein said wall is adapted such that the inner surface is hydrophobic. The invention further provides a portable electronic device and a method of manufacturing a liquid fuel reservoir.

Abstract: A method for manufacturing a cutting insert green body from a sinterable powder, a tool set for manufacturing the cutting insert green body by that method and the green body manufactured by the tool set. The tool set has axially moving upper and lower punches and radially moving side punches. The side punches move slidably on die rods. The side punches and die rods move in channels in a base body on which a cover plate is mounted. The upper and lower punches move in through holes in the cover plate and base body, respectively. The die rods are stationary during compaction of the sinterable powder. The upper, lower and side punches form surfaces of the green body and the die rods form some of the edges of the green body. The green body can have undercuts and the edges formed by the die rods can be non-linear in shape.

Abstract: The method of manufacturing the thermoelectric material including a plurality of phases that are phase-separated from a supersaturated solid solution includes: a process of performing a mechanical alloying treatment to a starting raw material that is prepared with a composition deviated from a composition range existing in an equilibrium state of a compound to generate the supersaturated solid solution; and a process of performing phase separation into the plurality of phases and solidification by heating and pressing the supersaturated solid solution, or by further performing a heat treatment according to the circumstances.

Abstract: A method of making a composite downhole article is disclosed. The method include forming at least one removable core member comprising a first metallic material that is removable in a wellbore fluid at a first removal rate; and disposing at least one outer member on the core member, the outer member comprising a second material that is removable in the wellbore fluid at a second removal rate, wherein the removable core member has a composition gradient or a density gradient, or a combination thereof, and wherein the first removal rate is substantially greater than the second removal rate. A method of using a composite downhole article is also disclosed. The method includes forming a composite downhole article as described above; using the article to perform a first wellbore operation; exposing the article to the wellbore fluid; and selectively removing the second removable member.

Abstract: A rotary implement includes a metallic body that is rotatable around an axis. The metallic body includes a tapered leading edge having an interface surface and an opposite, free surface. The metallic body has a first composition. A metallic layer has a first side surface that is attached to the interface surface and a free, second side surface opposite from the first side surface. The metallic layer has a second, different composition from the first composition. A rotary machine can include an actuator and the rotary implement operably coupled to the actuator. A method for making a rotary implement includes providing the metallic body that has the tapered leading edge having the interface surface and the opposite, free surface. The metallic layer is then attached to the interface surface of the metallic body.

Abstract: The invention relates to a method for producing a toothed wheel (1) in net shape or near-net shape quality, in particular a chain wheel, for a VVT system from a powder, with the toothed wheel (1) having an at least approximately cylindrically shaped housing (2) which is delimited in axial direction by one respective end face (6, 7) and which has an outside surface (3), and at the outside surface (3), a toothing (8) having teeth (9) and tooth roots (10) between the teeth (9) is embodied at a distance to both of the end faces (6, 7), and the toothing (8) has a tooth root circle (25) having a tooth root circle diameter, and the powder is filled into a mold (28) and pressed by means of at least one punch, and protrusions (11, 20) are embodied at least in the region of the teeth (9) at the outside surface (3) of the housing (2) and projecting over the latter in radial direction.

Abstract: An apparatus for the generation of thermal energy comprises a reactor vessel containing a volume of pressurized hydrogen; a hydrogen-storing nickel alloy structure in the reactor vessel and configured to have an electric potential applied across it and to be heated to at least about 100 C; and a heat exchange conduit configured to carry a heat exchange medium past the nickel alloy structure so as to allow thermal energy generated in the nickel alloy structure to be transferred to the heat exchange medium. The hydrogen-storing nickel alloy structure comprises a nickel alloy skeletal catalyst mixed with an oxide. The applied electric potential, and the increase in the gas pressure and temperature of the hydrogen from the applied heat, create a reaction between hydrogen nuclei and nickel nuclei in the nickel alloy structure whereby thermal energy is generated by the emission of phonons from the nickel alloy structure.

Abstract: A liner wall insert is provided for a compressor rotor stage of a gas turbine engine. Several liner wall inserts are provided radially outboard of the tips of the rotor blades. The liner wall inserts have bleed flow channels formed therein. The bleed flow channels are arranged to remove flow from a trailing edge region of the stage and re-inject the bleed flow at an upstream region. The re-injected bleed flow alters the flow field around the tips of the rotor blades, for example the tip leakage flow. Thus, the bleed flow is used to improve the efficiency of the compressor rotor stage, and thus of the gas turbine engine.

Abstract: A method of making a sputtering target includes providing a backing structure, and forming a copper indium gallium sputtering target material on the backing structure by cold spraying. The step of cold spraying includes spraying a powder comprising copper, indium and gallium in a process gas stream, and at least one of an average particle size of the powder is at least 35 ?m, a velocity of the process gas stream is at least 150 m/s, or a process gas pressure is 20 bar or less.

Abstract: A method of producing at least a portion of a wellbore isolation device comprising: providing a fusible alloy matrix in a powdered form; placing at least the particles of the fusible alloy matrix powder into a mold; compacting the particles located inside the mold via an application of pressure; and fusing the particles together to form a solid material, wherein the solid material forms the at least a portion of the wellbore isolation device.

Abstract: A method of manufacturing improved thin-film solar cells entirely by sputtering includes a high efficiency back contact/reflecting multi-layer containing at least one barrier layer consisting of a transition metal nitride. A copper indium gallium diselenide (Cu(InXGa1-X)Se2) absorber layer (X ranging from 1 to approximately 0.7) is co-sputtered from specially prepared electrically conductive targets using dual cylindrical rotary magnetron technology. The band gap of the absorber layer can be graded by varying the gallium content, and by replacing the gallium partially or totally with aluminum. Alternately the absorber layer is reactively sputtered from metal alloy targets in the presence of hydrogen selenide gas. RF sputtering is used to deposit a non-cadmium containing window layer of ZnS. The top transparent electrode is reactively sputtered aluminum doped ZnO. A unique modular vacuum roll-to-roll sputtering machine is described.

Abstract: A process of fabricating a shield, a process of preparing a component, and an erosion shield are disclosed. The process of fabricating the shield includes forming a near-net shape shield. The near-net shape shield includes a nickel-based layer and an erosion-resistant alloy layer. The nickel-based layer is configured to facilitate secure attachment of the near-net shaped to a component. The process of preparing the component includes securing a near-net shape shield to a substrate of a component.

Abstract: A process for the production of cutting tool inserts is described. A bottom punch is positioned into a powder compaction mold. A metallurgical powder is introduced into a mold cavity. A top punch is positioned into the powder compaction mold in an orientation opposed to the bottom punch. The metallurgical powder is compressed between the bottom punch and the top punch to form a powder compact. Also disclosed are cutting tool inserts produced in accordance with the process and powder pressing apparatuses for the production of cutting tool inserts.

Abstract: A compression molding apparatus for particulate matter comprising a magnetostrictive actuator functioning as an impact force applying means arranged at least between an upper ram or a lower ram and an upper punch or a lower punch. Particulate matter is compressed by a static pressure, and then an impact force is applied to the particulate matter to reduce internal stress. After compressing the particulate matter by the static pressure, the upper ram is allowed to fall gravitationally to shorten a molding time.

Abstract: Inductor core including: a base core portion having a first surface and an opposite second surface; an inner core portion extending from the first surface in a direction transverse to the first surface; an outer core portion extending, in the direction transverse to the first surface, from the first surface to an end surface of the outer core portion, the outer core portion at least partly surrounding the inner core portion, thereby forming a space around the inner core portion for accommodating a winding; wherein the first surface includes a recess for accommodating a connection portion of the winding, said recess extending at least a part of a distance between the inner core portion and the outer core portion, and wherein the outer core portion presents a slit extending from said end surface towards the recess, and wherein the second surface comprises a first protrusion oppositely arranged to the recess.

Abstract: The explosive consolidation of semiconductor powders results in thermoelectric materials having reduced thermal conductivity without a concurrent reduction in electrical conductivity and thereby allows the construction of thermoelectric generators having improved conversion efficiencies of heat energy to electrical energy.

Abstract: A metal particulate fuel system is described. The metal fuel system may include particulate metal fuel for use in nuclear reactors. The particulate metal fuel may include a plurality of particles of at least one enriched alloy where the particles are compacted into a fuel column. The metal particulate fuel system may also include a cladding and/or a gas-filled plenum.

Abstract: Disclosed is a coating for protecting a component against high temperatures and aggressive media, which coating has at least one subregion whose main constituent is chromium. The layer additionally comprises aluminum, the chromium content at least in the subregion in which chromium is the main constituent being greater than 30% by weight and the aluminum content being greater than or equal to 5% by weight. The invention further provides a process for producing such a coating, comprising chromizing the surface to be coated and subsequently alitizing the chromium-rich layer produced during chromizing.

Abstract: A powder metallurgy method includes (a) forming a metallic powder into a shape, (b) thermo-mechanically forming the shape into an article having a polycrystalline microstructure, (c) heat treating the article to cause coarsening of the polycrystalline microstructure, and (d) controlling the grain size homogeneity and distribution in the article formed during coarsening in step (c) by selecting the metallic powder in step (a) to include a metallic powder particle size distribution that is truncated on fine and coarse particle size sides, the selected metallic powder particle size distribution reducing abnormal grain growth such that the polycrystalline microstructure coarsens to a predefined target grain size range.

Abstract: A method for manufacturing a cutting insert green body from a sinterable powder, a tool set for manufacturing the cutting insert green body by that method and the green body manufactured by the tool set. The tool set has axially moving upper and lower punches and radially moving side punches. The side punches move slidably on die rods. The side punches and die rods move in channels in a base body on which a cover plate is mounted. The upper and lower punches move in through holes in the cover plate and base body, respectively. The die rods are stationary during compaction of the sinterable powder. The upper, lower and side punches form surfaces of the green body and the die rods form some of the edges of the green body. The green body can have undercuts and the edges formed by the die rods can be non-linear in shape.

Abstract: There is provided chips for injection molding wherein the surfaces of chips made of an aluminum-containing magnesium alloy are coated with carbon powder. A molded article produced by injection molding of such chips for injection molding had excellent bending properties and tensile strength, which vary in a small range. Furthermore, a scrap formed during injection-molding of the chips for injection molding has improved recyclability.

Abstract: A composite article (1; 10; 40) comprises a plurality of inclusions (5) of a magnetocalorically active material embedded in a matrix (4) of a magnetocalorically passive material. The inclusions (5) and the matrix (4) have a microstructure characteristic of a compacted powder.

Abstract: This invention addresses the problem of providing an iron base soft magnetic powder for a powder magnetic core that does not use rare metals, that can maintain the electrical insulating properties between the iron powder particles even when subjected to high temperature thermal processing, and that has excellent thermal stability and mechanical strength. This invention also addresses the problem of providing a fabrication method for the iron base soft magnetic powder for the powder magnetic core, and providing the powder magnetic core. In this iron base soft magnetic powder for the powder magnetic core, a phosphatized coating film is formed on the surface of the iron base soft magnetic powder, and a silicon resin coating film is formed on the surface of the phosphatized coating film. The phosphatized coating film contains P, B, Mg, and Al.

Abstract: A method of making a nanocomposite permanent magnet is provided. The method comprises applying an extreme shear deformation to hard magnetic phase nanoparticles and soft magnetic phase nanoparticles to align at least a portion of the hard phase magnetic particles and to produce a nanocomposite permanent magnet.

Abstract: A method for manufacturing a cutting insert green body from a sinterable powder, a tool set for manufacturing the cutting insert green body by that method and the green body manufactured by the tool set. The tool set has axially moving upper and lower punches and radially moving side punches. The side punches move slidably on die rods. The side punches and die rods move in channels in a base body on which a cover plate is mounted. The upper and lower punches move in through holes in the cover plate and base body, respectively. The die rods are stationary during compaction of the sinterable powder. The upper, lower and side punches form surfaces of the green body and the die rods form some of the edges of the green body. The green body can have undercuts and the edges formed by the die rods can be non-linear in shape.

Abstract: Provided are methods of preparing high density compacted components that increase that lubricity of metallurgical powder compositions while reducing the overall organic content of the compacted component. Method of preparing high density compacted components having a high density include the steps of providing a metallurgical powder composition having particles at least partially coated with a metal phosphate layer, and compacting the metallurgical powder composition in the die at a pressure of at least about 5 tsi. The metallurgical powder composition comprises a base-metal powder, optional alloying powders, and a particulate internal lubricant. The metal phosphate at least partially coats the base-metal powder, the optional alloying powder, or both. The metal phosphate coating increases the lubricity of metallurgical powders without the need for large quantities of organic material, e.g., lubricants and binders.

Abstract: A reactor core, which has a pair of press surfaces (a-b planar surfaces) formed by compression molding with an edge part of each of the press surfaces being plastically formed by pressure treatment, is disposed in a direction in which a magnetic flux generated upon energization of a coil does not penetrate each of the press surfaces.

Abstract: A robotic, prosthetic or orthotic member includes a body formed of a solidified metallic powder. At least one working fluid cylinder is formed in the body. A piston is provided in the working fluid cylinder for pressurizing a fluid in the cylinder. At least one working fluid conduit receives the pressurized fluid from the cylinder. The body, working fluid cylinder and working fluid conduit have a unitary construction. A method of making a robotic member is also disclosed.

Abstract: Described herein is a method of combining discrete pieces of BMG in to a BMG feedstock that has at least one dimension greater than a critical dimension of the BMG, by methods such as thermoplastic forming, pressing, extruding, folding or forging. Other embodiments relate to a bulk metallic glass (BMG) component or feedstock having discrete pieces of a BMG, wherein the BMG component or feedstock has at least one dimension greater than a critical dimension of the BMG.

Abstract: A layered manufacturing method for forming a desired three-dimensional object by using a powder as a raw material. The method forms a desired solid body, which is employed in a layered manufacturing device, including a stage member having stage surface; a transparent member having an optical window to cover the stage surface to form an enclosed region together with the stage surface; and an exhaust system for exhausting gasses in the enclosed region. The optical window is positioned at a vertical upper direction when the enclosed region is formed.

Abstract: The present invention is directed to improved compaction techniques for use in powder metallurgical applications using lower temperatures and pressures than are traditionally used in the field.

Abstract: The master batch for molding includes at least one inorganic powder, advantageously ceramic or metallic; an organic mixture, advantageously polymer, comprising: a stable polymer having good ductility features, from 30 to 90% by mass of the mixture; a lubricant, from 5 to 50% by mass of the mixture; a plasticizing polymer, from 5 to 30% by mass of the mixture; with a [% by mass of the lubricant]/[% by mass of the stable polymer] ratio smaller than or equal to 1, advantageously strictly smaller than 1.

Abstract: A core for an airfoil includes a refractory metal structure having a variable thickness. An airfoil includes a body having leading and trailing edges joined by spaced apart pressure and suction sides to provide an exterior airfoil surface defined by a perimeter wall. An interior wall is arranged interiorly and adjacent to the perimeter wall to provide a cooling passage there between. A cooling passage with first and second portions is tapered and respectively has first and second thicknesses. The first thickness is greater than the second thickness, and the second thickness is less than 0.060 inch (1.52 mm). A method of manufacturing a refractory metal core includes depositing multiple layers of powdered metal onto one another, joining the layers to one another with reference to CAD data relating to a particular cross-section of a refractory metal core, and producing the core having a variable thickness.

Abstract: A tubular welding wire includes a granular core and a metal sheath encircling the granular core. Furthermore, the metal sheath includes at least approximately 0.3% manganese by weight and at least approximately 0.05% silicon by weight.

Abstract: A method includes a step of compacting an insulation-coated pure iron powder or an iron-based alloy powder mainly containing iron using a die to obtain a dust core, a step of heat-treating the obtained dust core, and a step of post-machining at least one portion of the heat-treated dust core using a grinding wheel. In the post-machining step, grinding is performed in such a manner that the dust core and the grinding wheel are rotated, whereby isotropic machining marks are formed on a machined surface of the dust core.

Abstract: In a process for producing a hearing aid, comprising a housing made out, at least partially, of a metallic or ceramic part using powder injection molding technique (PIM) within the housing (1) at least one additional element (3) made out of a polymeric material is arranged for placing functional parts (5, 7, 13) within or at the housing (1) to reduce complexity of P parts and/or to compensate any tolerances due to the PIM process.

Abstract: A method is provided for producing magnetic green compacts. Material powder including a rare earth alloy and containing not less than 15 mass % of fine particles with particle diameter of not more than 2 ?m is filled into a compacting mold, then compacted and compressed, and subjected to magnetic fields to give a green compact. A powder compact having a packing density 1.05 to 1.2 times the bulk density is subjected to a weak magnetic field of 1 to 2 T to give a compact. The magnetic field strength is increased to not less than 3 T at an excitation rate of 0.01 to 0.15 T/sec, and the strong magnetic field of not less than 3 T is applied to the compact by a high-temperature superconducting coil. The magnetic field is applied by the high-temperature superconducting coil in a direction opposite to a direction applied by a normal conducting coil.

Abstract: A powder metal insert for overmolding and method of making it has retention features on the outer surface extending from each end and angularly offset from one another.

Abstract: Various methods of treating a chromium iron interconnect for a solid oxide fuel cell stack and coating the interconnect with a ceramic layer are provided.

Abstract: A method of making a medical device which is at least partially bio-erodible and which exhibits controlled elution of therapeutic agent.

Abstract: A method of making an explosive charge liner comprises introducing powdered material into a basin defined by a die block, where a punch is shaped to interact with the basin, excluding the powdered material from a central portion of the basin, pressing the punch into the powdered material in the basin to form the explosive charge liner, and removing the explosive charge liner from the die block. The explosive charge liner comprises an aperture in an apex area of the explosive charge liner corresponding to the central portion when removed from the die block.

Abstract: The present invention is directed to metallurgical powder compositions having improved lubricant properties. These compositions of the invention include at least 90 wt. % of an iron-based metallurgical powder; a Group 1 or Group 2 metal stearate; a first wax having a melting range of between about 80 and 100° C.; a second wax having a melting range of between about 80 and 90° C.; inc phosphate; boric acid; acetic acid; phosphoric acid; and polyvinylpyrrolidone. Methods of compacting the compositions, as well as compacted articles prepared using those methods, are also described.