Abstract: A method, control system, computer program, and article of manufacture for controlling hydraulic press systems, and a new press system that utilizes a number of improvements over the assignee's original system. The control system is designed to control a hydraulic press having a die, at least two separate sets of workpiece forming punches, and at least two hydraulic pistons, each operatively associated with one set of workpiece-forming punches. The control system includes a means for controlling a magnitude of a pressing force applied by each set of workpiece-forming punches, and a means for controlling a position of each set of workpiece-forming punches relative to the die.

Abstract: The present invention provides a PM main bearing cap, and its precursor compact, with an undercut breathing window that is formed during a compaction process. By fabricating the undercut during the compaction process, the invention eliminates the need for a secondary machining operation to form the undercut feature in the bearing caps.

Abstract: In various embodiments, composite materials containing a metal matrix having at least one metal and a carbon nanotube-infused fiber material are described herein. Illustrative metal matrices include, for example, aluminum, magnesium, copper, cobalt, nickel, zirconium, silver, gold, titanium and various mixtures thereof. The fiber materials can be continuous or chopped fibers and include, for example, glass fibers, carbon fibers, metal fibers, ceramic fibers, organic fibers, silicon carbide fibers, boron carbide fibers, silicon nitride fibers and aluminum oxide fibers. The composite materials can further include a passivation layer overcoating at least the carbon nanotube-infused fiber material and, optionally, the plurality of carbon nanotubes. The metal matrix can include at least one additive that increases compatibility of the metal matrix with the carbon nanotube-infused fiber material. The fiber material can be distributed uniformly, non-uniformly or in a gradient manner in the metal matrix.

Abstract: A dental handpiece (10) of the type having a body (11), a head (13) and a neck (12), is improved by having at least one portion of the handpiece (10) formed by metal injection molding or MIM. The use of MIM allows for improved fabrication and function. According to one aspect of the invention, the head (13) and neck (12) of the handpiece (10) are MIM-formed as a single or unitary piece.

Abstract: A method for preparing a metal-doped ruthenium oxide material by heating a mixture of a doping metal and a source of ruthenium under an inert atmosphere. In some embodiments, the doping metal is in the form of iridium black or lead powder, and the source of ruthenium is a powdered ruthenium oxide. An iridium-doped or lead-doped ruthenium oxide material can perform as an oxygen evolution catalyst and can be fabricated into electrodes for electrolysis cells.

Abstract: Disclosed herein is an engine 52, in particular a combustion engine or a jet-power unit, or an engine part 54, 56 made from metal, and in particular Al or Mg, or an alloy comprising one or more thereof. The engine or engine part is made from a compound material of said metal reinforced by nanoparticles, in particular CNT, wherein the reinforced metal has a microstructure comprising metal crystallites at least partly separated by said nanoparticles.

Abstract: A compression limiter is disclosed that comprises an upper surface and a lower surface The compression limiter further comprises an inner surface that defines a passageway configured to accommodate a fastener and an outer surface configured to engage a structure in which the compression limiter is placed. A first retainer projects outwardly from the outer surface and includes a first retention surface that has at least a planar portion. The first retainer further includes an undercut surface disposed in inwardly from the first retention surface so as to create a corner extending in a direction with at least a component perpendicular to the longitudinal direction. A method of forming the compression limiter is also disclosed.

Abstract: A powder mixture, which contains a soft magnetic powder and an insulating powder lubricant in an amount of 0.1% by mass or more relative to the soft magnetic powder, is formed by compacting at a compacting pressure of 800 MPa or less, thereby obtaining a powder compact that has a space factor of the soft magnetic powder of 93% or more. The powder compact can be used as a soft magnetic powdered core. The soft magnetic powdered core has a specific resistance or 10,000 ??cm or more. A powder of a metal soap such as barium stearate or lithium stearate is used as the insulating powder lubricant.

Abstract: The disclosed method provides a way to fabricate a powder metal compact implementing a top fill through one or more of the upper tool members. The top fill step allows for pre-compaction chamber, defined at least in part by at least one of the upper tool members, to be filled with a powder metal after the upper tool member is initially lowered, but before compaction of the powder metal. The manner in which the pre-compaction chamber is filled allows for the formation of complex geometries in powder metal compacts that are not obtainable using conventional lower tool powder transfer motions and further minimizes or avoids unacceptable variations in powder fill to final part ratios across the powder metal compact.

Abstract: A method for producing an inorganic particle composite body formed of a mixture of a plastically deformable metal, and inorganic particles that do not plastically deform under a condition under which the metal plastically deforms, wherein the method comprises: a step of preparing an inorganic particles structural body that is formed of a mixture of the metal and the inorganic particles and that contains a vacant space therein, and a step of plastically deforming the metal in the structural body.

Abstract: A powder metallurgy method includes the steps of forming a member, such as a work piece or an aerospace component, from a titanium alloy powder. The average size of a carbide phase in the titanium alloy powder is controlled in order to control an average size of a carbide phase in the member. In one example, an amount of carbon within the titanium alloy and size of the carbide phase are selected to provide a desirable balance of good hot workability, resisting formation of an alpha-titanium phase within the member and a desired level of fatigue performance.

Abstract: A magnetic field interactive material being part of a machine component or mechanism utilizing magnetic or electro-magnetic field forces in said components operation and comprising specifically located magnetic particles incorporated into a non homogeneous amalgamation within the matrix or structural matrix of primarily a metal material differing from that of the magnetic particles therein forming an integrated component possessing magnetic field interactive capabilities, allowing such magnetic field interactive components to have a wide array of uses one of which is associated with Hybrid and Electric Vehicles.

Abstract: A powder mixture composition for forming a jewelry article is described, comprising about 20-44% by weight tungsten carbide, and one or more of titanium carbide, chromium, nickel, and molybdenum. Methods of forming a jewelry article also are described, as are formed jewelry articles.

Abstract: A platform assembly for use in a digital manufacturing system, where the platform assembly comprises a deformable platform having a surface configured to operably receive a deposited material from a deposition head, and at least one mechanism configured to adjust at least a portion of the first surface to compensate for at least one vertical deviation from at least one horizontal axis that the deposition head is directed to move in.

Abstract: A method for forming a compact from a powder wherein a forming portion 1A in a mold body 2 is filled with a raw powder and upper and lower punches 3,4 are fitted into the forming portion 1A to form the compact. Prior to filling the forming portion 1A with the raw powder M, a solution L with a lubricant being uniformly dissolved in a solvent is applied to a peripheral portion of the forming portion 1A, and then the solution is evaporated, thus forming a crystallized layer B thereon. Thus, the reduction of a force for ejecting the compact is realized, while improving the density of the compact, realizing the stable and successive production of the compact.

Abstract: A galvanic element includes a mercury-free negative electrode which consists essentially of a metal or a metal alloy and a nonmetallic conductive agent. A method for producing a galvanic element includes a mercury-free negative electrode produced from a powder of metal or metal alloy particles, surfaces of which are at least partially coated with a nonmetallic conductive agent.

Abstract: The invention is a high-strength, pre-coated, aluminum or aluminum-alloy component comprising an aluminum or aluminum-alloy article having ultra-fine, submicron grain microstructure and an organic coating of phenolic resin applied to the surface of the article. The article is prepared from a coarse grain aluminum or aluminum-alloy material that is cryomilled into an ultra-fine, submicron grain material, degassed, and densified. The densified material is formed into an article, and coated with an organic coating containing phenolic resin prior to installation or assembly.

Abstract: Mixed targets are generally disclosed for sputtering an intermixed layer of cadmium sulfide and cadmium telluride. The mixed target can include cadmium sulfide, and cadmium telluride. Methods of forming the mixed target are also provided. For example, a powdered blend can be formed from powdered cadmium sulfide and powdered cadmium telluride, and pressed into a mixed target Methods are also generally disclosed for manufacturing a cadmium telluride based thin film photovoltaic device having an intermixed layer. For example, a mixed target of cadmium sulfide and cadmium telluride can be sputtered directly on a cadmium sulfide layer to form an intermixed layer, and a cadmium telluride layer can be formed on the intermixed layer.

Abstract: One embodiment includes compacting a powder material using at least a first magnetic field to form a compact and selectively sintering a first portion of the compact and leaving a second portion of the compact unsintered to form a component.

Abstract: High compressibility iron powder that is suitably used for parts with excellent magnetic characteristics or high density sintered parts and that has good productivity is provided from pure iron powder which includes, as impurities in percent by mass, C: 0.005% or less, Si: more than 0.01% and 0.03% or less, Mn: 0.03% or more and 0.07% or less, P: 0.01% or less, S: 0.01% or less, O: 0.10% or less, and N: 0.001% or less, and whose particle includes four or less crystal grains on average and has a micro Vickers hardness (Hv) of 80 or less on average. The circularity of the iron powder is preferably 0.7 or more.

Abstract: A method for a vacuum process of isostatic pressing of powder material comprises preparing an explosive charged rubber bag by charging a rubber bag with powder, forming a vacuum environment by putting the explosive charged rubber bag in a vacuum box, sealing an inlet of the explosive charged rubber bag which is in a vacuum state, and maintaining the vacuum state by putting the explosive charged rubber bag in a fluid contained in a reservoir by a predetermined depth in a state that the inlet of the explosive charged rubber bag has been sealed.

Abstract: An anode with a pellet wherein the pellet has a bottom surface. The anode further also has an anode wire with a primary axis and extending beyond the pellet along the primary axis wherein the anode wire has a cross-section perpendicular to the primary axis wherein the cross-section of the anode wire breaches the bottom surface.

Abstract: Provided are corrosion resistant metallurgical powder compositions, corrosion resistant compacted articles prepared from metallurgical powder compositions, and methods of preparing the same. Corrosion resistant metallurgical powder compositions include as a major component, an iron-based powder and, as a minor component, alloy additives that include chromium, and carbon. Upon compaction and sintering, the iron-based powder and alloy additives form a dual phase alloy system. The dual phase alloy system is denoted by an admixed martensite and ferrite microstructure. This unique microstructure results in beneficial physical properties, such as for example, high strength, hardness, and ductility, impact energy, and fatigue endurance, while maintaining resistance to corrosion.

Abstract: A method for producing a metal article according to one embodiment may involve the steps of: Providing a composite metal powder including a substantially homogeneous dispersion of molybdenum and molybdenum disulfide sub-particles that are fused together to form individual particles of the composite metal powder; and compressing the molybdenum/molybdenum disulfide composite metal powder under sufficient pressure to cause the mixture to behave as a nearly solid mass.

Abstract: A method is disclosed of forming a powder metal compact. Powder metal is placed in an annular space of a compaction die tool set in which the annular space has inner and outer cylindrical surfaces that form inner and outer cylindrical surfaces of the powder metal compact. An elastomeric tool has a first cylindrical surface adjacent to a fixed cylindrical surface of the compaction die tool set that is radially fixed and further has a second cylindrical surface, opposite to the first cylindrical surface, that touches the powder metal. The powder metal is compressed to form the powder metal compact by applying an external axial force on the elastomeric tool while maintaining the diameter of the fixed cylindrical surface so as to cause the elastomeric tool to compress the second cylindrical surface of the elastomeric tool against the powder metal.

Abstract: A cylindrical bonded magnet is provided which is multipolar-magnetized in the axial direction and can be produced with high productivity. The cylindrical bonded magnet includes magnetic powder and resin. The cylindrical bond magnet is an integrally formed member. The cylindrical bond magnet is magnetized so that a plurality of N and S poles are alternately provided in the axial direction. In the cylindrical bonded magnet, a totally even number of at least four N and S poles are alternately provided. The surface magnetic flux density distribution has a substantially sinusoidal wave with the both ends of the sinusoidal wave corresponding to nodes when the surface magnetic flux of the cylindrical bonded magnet is measured as viewed from the side surface of the cylindrical bond magnet along the axial direction.

Abstract: Maraging steel compositions, methods of forming the same, and articles formed therefrom comprising, by weight, 15.0 to 20.0% Ni, 2.0 to 6.0% Mo, 3.0 to 8.0% Ti, up to 0.5% Al, the balance Fe and residual impurities. The composition may be a first layer of a composite plate, and may have a second layer deposited on the first layer, the second layer having a composition comprising, by weight, 15.0 to 20.0% Ni, 2.0 to 6.0% Mo, 1.0 to 3.0 Ti, up to 0.5% Al, the balance Fe and residual impurities. The first layer may have a hardness value ranging from 58 to 64 RC, and the second layer may have a hardness value ranging from 48 to 54 RC. The first layer may be formed employing powdered metallurgical techniques. Articles formed from the compositions include armored plate.

Abstract: The present invention relates to a method of manufacturing a pipe, which method comprises cold-gas dynamic spraying of particles onto a suitable support member thereby producing a pipe, and separating the pipe from the support member.

Abstract: A mold is provided for making a cutting tool insert from a material to be molded, the cutting tool insert having an edge defined by two intersecting surfaces. The mold includes a first surface, a second surface intersecting with the first surface to define an edge, and an air gap between the first surface and the second surface at the edge, the width of the air gap varying in a controlled way along its length. A method for making a cutting tool insert is also disclosed.

Abstract: The invention relates to a method for forming a molded article during sterilization and under high pressure utilizing a supercritical fluid as a sterilization fluid, whereby the pressurization and depressurization rates are controlled to form molded articles.

Abstract: The invention relates to a process for producing binderless briquettes from metal chips and metal dusts in which the metal chips are pressed into a cup-shaped form and the upwardly open cavity produced as a result is filled with metal dust, after which the opening is closed with a cover consisting of pressed metal chips.

Abstract: A rotor comprising bonded magnet portions mainly composed of magnet powder and a binder, which are embedded in a soft magnetic portion mainly composed of soft magnetic powder and a binder, the rotor being produced by a compression-molding method, and the magnetic pole surfaces of the bonded magnet portions being embedded in the soft magnetic portion.

Abstract: A device and a method for manufacturing an end mill in which the amount of grinding of a blank end mill is small. The device for manufacturing an end mill includes: upper and lower punches; a die; a feed box for supplying a powder of material for the end mill; and a cleaner for eliminating the powder from a top surface of the die. The upper and lower punches are movable up and down relative to each other and have a lengthwise molding cavity formed thereon. The die has a penetrating slit sized to be approximated to the width of the upper and lower punches. The penetrating slit allows the up-and-down movements of the upper and lower punches. The feed box supplies the powder into a space formed by the wall of the penetrating slit and the lower punch.

Abstract: A product which at least partly comprises an agglomerate formed from a powder having a pre-determined wettability.

Abstract: A process for producing a foamed metal article comprises the steps of combining together at least one metal powder, silicon powder a gas-producing blowing agent to form a mixture; including graphite along with said mixture; compacting the mixture into a foamable metal precursor; placing the foamable metal precursor in a carrier; and heating the foamable metal precursor in the carrier to at least a predetermined temperature for at least a predetermined amount of time, to thereby cause the foamable metal precursor to foam, thus producing a foamed metal article.

Abstract: Titanium-containing metal is extracted from its oxide(s) by way of a redox chemical reaction with a reducing metal. Specifically, an intimate mixture of the reducing metal and the titanium-containing oxide(s) is produced, in a preferred embodiment, by forming a metal-ceramic composite material featuring these two constituents. In a preferred embodiment, the composite body is made by infiltrating the reduced metal in molten form, into a permeable mass containing the titanium-bearing oxide(s). Concurrently or subsequent to infiltration, the redox reaction is carried out to transform the composite material, thereby forming a complex intimate mixture containing one or more oxides of the reducing metal, a titanium-containing metal, which could include an alloy of titanium with the reducing metal and/or one or more intermetallic compounds of titanium and the reducing metal, and possibly also some residual reducing metal, which itself possibly contains some titanium metal.

Abstract: A camshaft journal and method of producing the same. The method uses dynamic magnetic compaction in conjunction with austenitic manganese steel powder metal precursors. Journals formed along the camshaft are configured to cooperate with complementary bearing surfaces, and can be used in cooperation with one or more sensors such that the journal does not magnetically interfere with signals travelling to such sensors. The journals may also be subjected to machining, sintering or both once the dynamic magnetic compaction has been completed.

Abstract: A method of forming a crankshaft bushing or similar component is provided. A compaction die is provided having an axial, generally cylindrical internal opening. An upper and a lower punch are provided with exterior surfaces corresponding to the internal opening of the compaction die. An upper core rod passes through an axial opening in the upper punch. A lower core rod passes through an axial opening in the lower punch. The upper core rod and the lower core rod each may have a generally flat external surface section. A metal powder is compacted in the compaction die by the combined action of the upper and lower punches and the upper and lower core rods.

Abstract: A sputtering target includes a copper indium gallium sputtering target material on a backing structure. The sputtering target material has a density of at least 100% or more as defined by the rule of mixtures applied to densities of component elements of the sputtering target material. The sputtering target material has an overall uniform composition.

Abstract: In a punch die for powder compacting, a powder compacting equipment equipped with the punch die, and a forming method with the equipment, for suppressing the occurrence of stress concentration in the die without changing a shape of a powder compacting body, the punch die is used to form a cylindrical member by powder compacting, which has a substantially cylindrical shape and has a protrusion portion formed on the inner peripheral side thereof to protrude in the axial direction or a stepped portion or a concave portion formed on the inner peripheral side thereof in the radial direction. The punch die has a substantially cylindrical shape, and has a protrusion portion formed on at least a part of the inner peripheral surface or the outer peripheral surface thereof to protrude toward the center axis.

Abstract: A slag conditioner containing MgO, carbon or a filler and a binder is mixed and formed under pressure to produce aggregates which can have the form of a briquette. The slag conditioner is used to improve the operating performance and refractory life in steel melting furnaces. A slag conditioner comprising by weight a mixture and 2% to 25% binder for bonded agglomerates or larger particles of said mixture, the mixture comprising: 20% to 90% burned aggregates comprised of particles less than 8 mm of which at least 30% is 0.2 mm or greater and containing between 35% and 94% MgO; up to 50% slag-making carbonaceous or other additive; and up to 50% light burned magnesite.

Abstract: An electrically conductive cadmium sulfide sputtering target, the method of making the same, and the method of manufacturing a photovoltaic cell using the same.

Abstract: A method for producing a magnetizable metal shaped body comprising a ferromagnetic starting material that is present in powder and in particulate form, using the following steps: (a) first compaction of the starting material (S3) such that adjoining particles become bonded to each other by means of positive adhesion and/or integral bonding in sections along the peripheral surfaces thereof and while forming hollow spaces, (b) creating an electrically isolating surface coating on the peripheral surfaces of the particles in regions outside the joining sections (S4), and (c) second compaction of the particles (S5) provided with the surface coating, such that the hollow spaces are reduced in size or eliminated.

Abstract: A method of processing a bimetallic part includes depositing an intermediary material having a metal powder onto a tooling surface of a cavity of a tool, transforming the intermediary material into a metal layer having a first composition on the tooling surface, and forming a metal core having a second, different composition in the cavity such that the metal layer bonds to the metal core to form a bimetallic part.

Abstract: An elongated rod assembly is made by preparing a plurality of rods. Each rod is prepared by the steps of furnishing at least one nonmetallic precursor compound, thereafter chemically reducing the precursor compounds to produce the metallic material, and thereafter consolidating the metallic material to form the rod, wherein the rod has a rod length equal to the assembly length. The rods are bundled together to form a bundled rod assembly. The rod assembly may be used as a consumable feedstock in a melting-and-casting operation.

Abstract: A method for making bulk silicon material consisting of silicon pellets for making silicon ingots from an agglomerate-free source of high purity, ultra fine silicon powder includes feeding a controlled amount of silicon powder into a pellet die and dry compacting the powder at ambient temperature with pressure to produce a pellet that has a density of about 50-85% of the theoretical density of elemental silicon, a weight within a range of about 1.0 gram to about 3.0 grams, a diameter in the range of 10 mm to 20 mm and preferably of about 14 mm, and a height in the range of 5 mm to 15 mm and preferably of about 10 mm.

Abstract: The invention discloses the internal structures and processes to synthesize the structure of self-healing materials, specially metallic materials, metal matrix micro and nanocomposites. Self healing is imparted by incorporation of macro, micro or nanosize hollow reinforcements including nanotubes, filled with low melting healing material or incorporation of healing material in pockets within the metallic matrix; the healing material melts and fills the crack. In another concept, macro, micro and nanosize solid reinforcements including ceramic and metallic particles, and shape memory alloys are incorporated into alloy matrices, specially nanostructured alloy matrices, to impart self healing by applying compressive stresses on the crack or diffusing material into voids to fill them.

Abstract: A compaction tool is provided for compacting an element from metal powder where the element has uniform axially displaced protrusions, and the tool comprises a die and a top and a bottom punch with punch surfaces. The top and bottom punch comprises displaceable opposing punch surfaces for displacing the metal powder there between before compacting the element. Additionally provided are a method for compacting an element from metal powder and an element made from such a method.

Abstract: The invention relates to a method for manufacturing a dental scaler tip using a powder injection molding process, a mould, and a scaler tip that is excellent in shape-reliability and injects fluid to a front end thereof along a curved section of the tip. The method comprises the steps of preparing feedstock and injecting the feed stock into a mould to form a molding body, wherein, the mould comprises an operating section to which cylindrical core pins having multi steps and an eccentric end formed at a front end thereof for forming the fluid passage is mounted; and a pair of slide cores disposed for supporting the eccentric ends of the core pins such that the slide cores face each other and are slid in the direction perpendicular to the movement direction of the core pins to form a cavity corresponding to a shape of an article to be formed.

Abstract: In a first embodiment the invention relates to a process for producing a dispersoid-strengthened material, comprising the steps of: (i) providing metal particles, wherein the metal is selected from platinum group metals, gold, silver, nickel and copper, as well as alloys thereof; (ii) mixing the metal particles with a precursor compound of the dispersoid and solvent; (iii) removing the solvent, so as to obtain metal particles provided with precursor compound; and (iv) compacting the metal particles provided with precursor compound in order to obtain the dispersoid-strengthened material, wherein the precursor compound is converted into the dispersoid during the compacting operation.