Abstract: This invention relates to a system and method for consolidating particulate material, such as particulate material, in order to achieve at least ninety-five percent (95%) or even ninety-eight percent (98%) of its maximum theoretical density using a relatively long duration, relatively low current density current flow through the material. In one embodiment, the consolidation system includes a feedback control for monitoring various characteristics associated with the particulate material being consolidated and providing feedback information to a power supply which controls the amount of current supplied to the particulate material in order to achieve the desired density. The consolidation system and method is characterized in that the duration of the current is greater than 0.

Abstract: The invention relates to a method of a composite material from superposed layers of solid and frothable metallic materials. The structural component consists of at least one layer of a solid metallic material and at least one layer of frothable metallic material. The structural component may be structured as a composite sheet or as a hollow body. The fabrication method of the structural component insures a good bond between the solid metallic layer and the frothable layer and that the frothable layer is securely attached to the solid metallic layer.

Abstract: Pressure powder metallurgy process for consolidating refractory or rhenium alloys using a reduced temperature and elevated pressure. Rhenium metal has high temperature strength and wear resistance but has a very high melting point as a pure metal and thus is difficult to use as a coating for many alloys having lower melting points. The reduced temperature and elevated pressure alloying process of the rhenium allows it to be used as a coating for other metal alloys, such as nickel and steel alloys, providing some high temperature and wear resistance due to the properties of the rhenium material in the coating.

Abstract: A self-service machine using a communications terminal and a service providing method thereof. The self-service machine includes an antenna for receiving a radio signal including identification information of the self-service machine and price information, a radio transceiver for processing the radio signal from the antenna, an information processor for extracting the price information from the signal processed by the radio transceiver if the identification information from the radio transceiver is identical to its actual identification information, a controller for controlling the self-service machine so as to provide a predetermined service according to the price information from the information processor, a service providing unit for providing the predetermined service under the control of the controller, and a memory for storing predetermined information about the service provided by the self-service machine after the provision of service by the service providing unit.

Abstract: A powder pressing apparatus comprises a die having a through hole, an upper punch and a lower punch. At least one of the upper and lower punches has a punching surface having an edge portion provided with a projection. The projection has a tip chamfered by a width not greater than 0.5 mm. The punching surface has a slope having a surface roughness Ra not greater than 1.0 &mgr;m. A rare-earth alloy powder is fed into a cavity formed in the through hole of the die. The rare-earth alloy powder in the cavity is oriented by magnetic field, and pressed by using the upper and lower punches. The upper punch and the lower punch are brought closest to each other at a minimum distance not smaller than 1.7 mm during the pressing. An obtained compact is used for manufacture of a sintered body and a voice coil motor.

Abstract: The invention relates to a process for determining pressing parameters for the pressing of compacts, whereby in one step a test compact is brought to the required density in order to achieve the nominal pressing force, and in order that consequently the machine is in a balanced deflected condition with regard to this nominal pressing force. In next step, in case a nominal height (hsi,Nominal) deviates from a height (hsi,Measure) measured on the test compact, there will be determined for the next pressing operation a required height (HPowderNew) of the material to be pressed in the pressing mould.

Abstract: Pressed material such as anodes are described and formed from oxygen reduced oxide powders using additives, such as binders and/or lubricants. Methods to form the pressed material are also described, such as with the use of atomizing, spray drying, fluid bed processing, microencapsulation, and/or coacervation.

Abstract: A method for forming a composite vapor-deposited film one side of which suitable for vapor-deposition on a phosphor surface of a CRT, such as a color television picture tube, has high light reflectivity, and the other side of which has a property to absorb radiant heat, and a composite vapor-deposition material suitable for vacuum deposition are disclosed. The composite vapor-deposition material has a high vapor-pressure metal envelope and a low vapor-pressure metal in the core region of the envelope. Low vapor-pressure metal powder should preferably be dispersed and held by high vapor-pressure metal powder in the core region. Vacuum deposition using this composite vapor-deposition material yields a composite deposited film having a composition comprising almost 100% of the high vapor-pressure metal formed in the initial stage of evaporation, and a composition comprising 100% of the low vapor-pressure metal formed in the final stage of evaporation.

Abstract: A clad article of a substrate of one powdered metal that is clad with a second dissimilar powdered metal. A separation layer may be provided between the substrate and the clad layer to separate these layers during consolidation and to facilitate bonding thereof. The consolidation operation may be performed by hot isostatic pressing of the powders within a deformable container.

Abstract: A soft magnetic material, and a method for manufacturing it, which is suitable, e.g., for use in solenoid valves is described. The individual powder particles of a metallic powdery initial component are equipped superficially at least largely with a high-resistance surface layer and the powder particles are densified into the material. Upon densification of the powdery metallic initial component into the soft magnetic material, the surface layers of the powder particles are additionally at least locally welded to one another. Welding can be achieved using shock densification.

Abstract: Lead-free solder metal powder material including two or more metals capable of forming an intermetallic compound and having an unreacted phase and an amorphous phase. Further, a lead-free solder paste is prepared by mixing the powder material with a soldering flux. The powder material is preferably formed using a mechanical milling process.

Abstract: In a process for handling green compacts made from a rare earth metal-based magnetic alloy powder by a press machine to slide, on a sintering support plate, the green compacts, the support plate used has a surface roughness degree Ra in a range of 0.6 to 47 &mgr;m. At a first step, the green compacts are disposed in a first position near a final transport position, and at a second step, the said green compacts disposed in the first position are slid on the sintering support plate and disposed in the final transport position. Thus, by using the support plate having a surface roughness degree in a particular range, the green compacts made from the rare earth metal-based magnetic alloy powder can be sintered without occurrence of the deposition of the green compacts to the support plate, the chipping of the green compacts and the like. In addition, the efficiency of operation of the press machine can be increased.

Abstract: The present invention provides a powder compacting apparatus including: a die having a through hole forming a cavity; a first punch and a second punch for pressing a rare-earth alloy magnetic powder filled in the cavity; and a magnetic field generator for applying an orientation magnetic field parallel to a pressing direction through the rare-earth alloy magnetic powder in the cavity, wherein at least one of the first and second punches and has a curved pressing surface, and the pressing surface is given a shape such as to suppress the movement of particles of the rare-earth alloy magnetic powder along the pressing surface during the pressing step.

Abstract: A method for compacting powder materials into articles comprises placing a powder material in a shaping cavity of a mold, the cavity being defined by active and passive shaping surfaces of one-piece or composite shaping members of the mold; mutually moving the shaping members of the mold along a pressing axis, with the pressing force transferred from the shaping members of the mold to the powder material through the active shaping surfaces. Surfaces of the powder article, parallel to the pressing axis, are formed by the passive shaping surfaces of the one-piece or composite shaping members of the mold. According to the invention, surfaces of the powder article, parallel to the pressing axis, are formed using parts of at least one passive shaping surface, located on the one-piece or composite shaping members split along the pressing axis.

Abstract: A radial anisotropic sintered magnet formed into a cylindrical shape includes a portion oriented in directions tilted at an angle of 30° or more from radial directions, the portion being contained in the magnet at a volume ratio in a range of 2% or more and 50% or less, and a portion oriented in radial directions or in directions tilted at an angle less than 30° from radial directions, the portion being the rest of the total volume of the magnet. The radial anisotropic sintered magnet has excellent magnet characteristics without occurrence of cracks in the steps of sintering and cooling for aging, even if the magnet has a shape of a small ratio between an inner diameter and an outer diameter.

Abstract: A process for the manufacture of compressed articles, particularly cemented-carbide cutting blade inserts, by compacting metallic powder and subsequently sintering the compact, particularly cemented-carbide reversible cutting blade inserts, which have a seating surface and at least one cutting edge extending approximately in parallel with the seating surface which is at a predetermined distance from the seating surface, by means of a press having a die-plate and a top ram and a bottom ram, comprising the steps of: Charging a predetermined volume of metallic powder into the die-plate bore with the bottom ram taking a predetermined charging position in the die-plate bore, Displacing the bottom ram and the top ram to predetermined first and second positions, Displacing the bottom ram and, if need be, the top ram more while simultaneously measuring the compressive force at least for the bottom ram with the shift of the bottom ram or top ram being effected along a predetermined curve desired for the compressive

Abstract: The present invention relates to a method for manufacturing a highly purified diamond. In the method, a copper powder having purity 99.8% or more and having an acid-insoluble impurity concentration at 50 ppm or less, and graphite are mixed at first. The mixture of the copper powder and graphite is loaded into a sample tube. The sample tube is placed in an explosive tube. Explosive is loaded in the surrounding of the sample tube. Graphite is shock-compressed by the detonation of the explosive to yield diamond.

Abstract: Tungsten powder is mixed with a second powder metal and a binder to be used as small arms projectiles and shot pellets for use in shot guns which is cost effective to produce and which can perform ballistically. Ballistic performance equal to or superior to that of lead would be offered by a material having a specific gravity equal to or greater than lead. The non-toxic projectiles are manufactured in a cost-effective process; yet still produces projectiles and shot pellets that can perform ballistically. This projectile composition can perform substantially as well as lead and lead alloys or better without the need to fabricate the composition from a high temperature molten state which requires large amounts of energy input. In one particular embodiment of the invention, the tungsten powder is blended with iron powder and Portland Cement for constructing projectiles. The tungsten, iron and Portland Cement (W/Fe Portland cement) shot provides a satisfactory substitute for lead shot.

Abstract: A coating composition produces a protective coating to a substrate, which coating has an improved surface smoothness. The coating composition comprises a mixture of at least a first type of particles and a second type of particles that are dispersed in a liquid medium. The particles form a total population of particles having a median ESD in a range from about 1 to about 7 micrometers. The different types of particles have different median ESDs. The first type of particles has a maximum ESD of about 40 micrometers, and the second type of particles has a maximum ESD of about 20 micrometers. A method for producing a coating having an improved surface smoothness comprises applying such a coating composition on a substrate and curing the coating composition to produce a protective coating. The coating may be further densified by a burnishing process or further improved by applying another coating comprising particles having ESDs less than about 4 micrometers.

Abstract: A method for forming composite parts of two or more dissimilar materials by injection molding. Two or more different metallic- or ceramic-based powder materials are used to form two or more different feedstocks, which are each melted and injected under heat and pressure into mold cavities and allowed to solidify to form a composite green compact. In an example of the present invention, two or more powder materials are each mixed with a binder system and granulated to form feedstocks, the feedstocks are melted and concurrently or sequentially injected into a mold and allowed to solidify, and the solidified composite green compact is then subjected to binder removal and sintering processes.

Abstract: A method of making sheet bar and other precursors of formed products to be made by extensive working. The method includes providing a powder metal, preferably under 100 PPM oxygen content of non-spherical particles, compacting the powder into a coherent precursor form of at least 100 pounds, whereby a precursor is provided enabling extended fabrication to a finished product form. The finished product is resistant to breakup in fabrication due to oxide inclusion effect and produces a low oxygen end product. The method can process multiple species of metals that include at least one higher melting metal and one lower melting metal to produce an alloy or micro-composite of the metals as worked, where one metal is preferably a refractory metal (Ta, Nb, W, Wo, Zr, Hf, V and Re). The process is controlled to cause powder of the higher melting metal to be extended into a fibrous form.

Abstract: A method of producing a high-density article is presented comprising selecting one or more primary tungsten-containing constituents with densities greater than 10.0 g/cc and one or more secondary constituents with densities less than 10.0 g/cc, co-milling the mixture of constituents in a high-energy mill to obtain mechanical alloying effects, then processing the resulting powder product by conventional powder metallurgy to produce an article with bulk density greater than 9.0 g/cc.

Abstract: Structure and method for producing very dense bodies of material from particulate materials. A particle material is placed within an electrically conductive container. A solenoid or coil 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 magnetic pressures are created upon the electrically conductive container, and the electrically conductive container is compressed, and the transverse dimension thereof is reduced. Thus, the particulate material within the electrically conductive container is firmly compacted, and a rigid body of material is provided. Any one of numerous types of particulate material may be employed. A method and system for selecting various parameters which enable the material to be densified to densities in excess of 90% of the material's maximum density is also illustrated in another embodiment of the invention.

Abstract: A method of forming dense articles from metal or metal alloy powders by friction forming. A self supporting shaped deposit of powder is formed on a substrate. Relative movement is established between the shaped deposit and a friction forming tool. The forming end of the friction tool is urged into compressive contact with the shaped deposit so as to generate an amount of heat sufficient to plasticize the deposit and thereby form a dense article. The steps may be repeated to built up the article to any pre-desired thickness. The substrate may be removed to establish a free standing coherent article, or the article may be left tightly bonded to the substrate. The article is very uniform in both thickness and composition, and enjoys substantially full density and a very fine microstructure.

Abstract: The invention concerns a method of preparing high density compacts for soft magnetic applications comprising the steps of subjecting an iron or iron-based soft magnetic powder the particles of which are electrically insulated to compaction in an uniaxial pressure operation with a ram speed of at least 2 m/s.

Abstract: A process for producing an iron-based powder composition for powder metallurgy having excellent flowability at room temperature and a warm compaction temperature, having improved compactibility enabling lowering ejection force in compaction, and to provide a process for producing a compact of a high density from the iron-based powder composition, wherein the iron-based powder composition comprises an iron-based powder, a lubricant, and an alloying powder, and at least one of the iron-based powder, the lubricant, and the alloying powder is coated with at least one surface treatment agent selected from the group of surface treatment agents of organoalkoxysilanes, organosilazanes, titanate coupling agents, fluorine-containing silicon silane coupling agents, and wherein the iron-based powder composition is compacted at a temperature not lower than the lowest melting point of the employed lubricants, but not higher than the highest melting point of the employed lubricants.

Abstract: A powder pressing apparatus comprises a die having a through hole, an upper punch and a lower punch. At least one of the upper and lower punches has a punching surface having an edge portion provided with a projection. The projection has a tip chamfered by a width not greater than 0.5 mm. The punching surface has a slope having a surface roughness Ra not greater than 1.0 &mgr;m. A rare-earth alloy powder is fed into a cavity formed in the through hole of the die. The rare-earth alloy powder in the cavity is oriented by magnetic field, and pressed by using the upper and lower punches. The upper punch and the lower punch are brought closest to each other at a minimum distance not smaller than 1.7 mm during the pressing. An obtained compact is used for manufacture of a sintered body and a voice coil motor.

Abstract: The invention concerns a method of preparing high density compacts for soft magnetic applications comprising the steps of subjecting an iron or iron-based soft magnetic powder the particles of which are electrically insulated to compaction in an uniaxial pressure operation with a ram speed of at least 2 m/s.

Abstract: An iron aluminide fuel injector component such as a nozzle, plunger or other part is manufactured from iron aluminide or includes an iron aluminide coating on at least a portion of a surface in contact with the fuel which passes through the fuel injector. The iron aluminide alloy can include 8 to 32 wt. % Al, up to 5 wt. % refractory metal, B and/or C in amounts sufficient to form borides and/or carbides. The fuel injector component can be formed from powders of the iron aluminide alloy by powder metallurgy techniques and the coating can be formed by a diffusional reaction process, cathodic plasma process, chemical vapor deposition or physical vapor deposition. The fuel injector component is corrosion, carburization, sulfidation and/or coking resistant.

Abstract: The invention concerns a process for the preparation of soft magnetic composite products comprising the steps of providing particles of an iron based soft magnetic material with an electrically insulating layer; optionally mixing the dry powder with a lubricant; compacting the powder and heating the obtained component at an elevated temperature in the presence of water vapour. The invention also comprises the iron powder compact subjected to this treatment.

Abstract: A device for regulating the flow of particulate material comprising a first, inlet conduit having an outlet end, and a second, outlet conduit aligned with the first conduit and having an inlet end sufficiently close to the outlet end of the first conduit as to receive at least a portion of a particulate material flow exiting the first conduit. The lateral relationship of the adjacent ends of the two conduits is adjusted to change the area of the inlet end exposed to material leaving the first conduit to adjust the flow of particulate material through the second conduit; material which does not enter the second conduit is recycled. The device is particularly useful for regulating the flow of small quantities of metal powder being fed to a laser consolidation process. The invention also includes the method of regulating by lateral adjustment of the adjacent conduit ends.

Abstract: A corrosion resistant, high strength austenitic stainless steel consisting of 1.0% or less of Si, 2.0% or less of Mn, 0.5% or less of O, 7 to 30% of Ni, 14 to 26% of Cr, 0.3% or less of combination of C and N, at least one element selected from the group consisting of 1.0% or less of Ti, 2.0% or less of Zr and 2.0% or less of Nb, and the balance consisting of Fe and unavoidable impurities, the percentage being given in weight basis; said steel containing carbonitride with a grain size of several to 100 nm dispersed therein; said steel having an average crystal grain size of 1 &mgr;m or less; and said steel containing 90% by volume or more of austenite phase; is excellent in strength and corrosion resistance.

Abstract: A green compact of a rare earth alloy magnetic powder is made by pressing the powder. The powder is pressed within an air environment that has a temperature controlled at 30° C. or less and a relative humidity controlled at 65% or less.

Abstract: The invention relates to a method for the manufacturing of a plate (2) of metal or of a ceramic material, the plate comprising one or more fields (3) which occupy the major part of the surface of the plate and which on at least one side of the plate is high relief patterned, more specifically patterned such that the plate on said at least one side within the area of said field or fields has reliefs with high projections and deep valleys (9) or recesses (8) alternatingly, and between the sides a thin web (10), said high relief patterned field or fields being at least partly bordered by broad edge portions (4) which have a thickness larger than the mean thickness of the plate within the region of said high relief patterned field or fields. In a preparatory step an intermediate product (1) is manufactured, comprising at least a first portion (11) which shall form said high relief patterned field(s), which however is/are not yet high relief patterned but contain(s) an adequate quantity of material.

Abstract: An iron-based powder composition is provided that is greatly flowable and compactible and less dependent on temperature with respect to flowability and compactibility at room temperature or during warming. The iron-based powder composition includes an iron-based powder, a lubricant melted and fixed to the iron-based powder, an alloying powder bonded to the iron-based powder with the aid of the lubricant, and a free lubricant. One or more constituent members are coated with an organosiloxane layer in a coating ratio of greater than about 80%. The organosiloxane has phenyl groups as a functional group. The lubricant melted and fixed to the iron-based powder is a composite melt composed of a calcium soap and a lithium soap, or a composite melt composed of a calcium soap and an amide lubricant. The free lubricant is a mixed powder composed of an amide lubricant and a methyl polymethacrylate powder, or a lithium soap powder. A process for producing the iron-based powder composition is also provided.

Abstract: An article having a hollow cavity formed therein and a method for forming the same. The article includes a hollow structure having an open end and a body portion that is surrounded by a powdered material. The article is processed in, for example, a hot isostatic pressing operation, to permit a pressurized fluid to consolidate the powdered material. The pressurized fluid is permitted to pass through the open end of the hollow structure and into the body portion to thereby prevent the body portion from collapsing while the powdered material is being consolidated.

Abstract: A sandwich component, which comprises at least two massive metallic sheet metal parts located opposite one another and a metal powder layer to be expanded, which is arranged between the sheet metal parts, is shown, in which the sandwich component has additional reinforcing elements in individual cross-sectional areas, and the said reinforcing elements are connected in a positive-locking manner to the expanded metal powder layer surrounding same, and the said metal powder layer is in turn connected to the outer, massive metallic sheet metal parts in such a way that it cannot be detached without destruction.

Abstract: A multiple-acting powder metal press is disclosed for making green form double helical gear compacts. The press has inner and outer lower punches, and an upper, outer punch. The upper and lower outer punches have left hand and right hand external helical profiles as chosen to produce a desired helical gear. The punches co-operate with left hand and right hand helical dies carried by the press about the punches. The helical faces require that the dies rotate relative to the punches during operation. A cam and roller mechanism may drive this rotation. The compact forming process commences with an open position in which powder is introduced to a vacant lower die cavity. The upper portions of the press advance downward to close the cavity. All parts of the press except the lower inner, or transfer, punch then move downward at the same speed to transfer powder to the extremities of the cavity. When transfer is complete both lower punches may be stopped, while the upper punches continue to advance.

Abstract: The present invention relates to a method of forming a powder rod core comprising injecting a powder mix material into a mold, moving the mold to a curing station, and injecting material into a second mold.

Abstract: This invention relates to a transformer and more particularly, to a system and method for making a transformer utilizing dynamic magnetic compaction. A coil is placed in a conductive container, and a conductive powder material, such as ferrite, is placed in the container and surrounds the coil and the turns of the coil. A power supply energizes a capacitor which subsequently provides a high energizing current to a second, energizing coil within which the container, material and inner coil are situated, thereby causing the container, powder materials and coil to be compacted to provide an electrical component, such as a transformer, motor, commutator, rotor or choke.

Abstract: A magnetic powder feeding method for feeding magnetic powder into a cavity of a pressing apparatus includes the steps of: providing magnetic powder outside of the cavity; forming a magnetic field in a space including the cavity; and moving the magnetic powder into the cavity using a force exerted on the magnetic powder by the magnetic field, while the magnetic powder is oriented in a direction of the magnetic field. In the method, the step of moving of the magnetic powder into the inside of the cavity is performed after the start of the application of the magnetic field.

Abstract: A method for producing a compact of rare earth alloy powder of the present invention includes: a powder-filling step of filling rare earth allow powder in a cavity formed by inserting a lower punch into a through hall of a die of a powder compacting machine; and a compression step of pressing the rare earth alloy powder while applying a magnetic field, the steps being repeated a plurality of times. When the (n+1)th (n is an integer equal to or more than 1) stage compression step is to be carried out, the top surface of a compact produced in the n-th stage compression step is placed at a position above the bottom surface of a magnetic portion of a die.

Abstract: A method for making a nickel/silicon sputter target, targets made thereby and sputtering processes using such targets. The method includes the step of blending molten nickel with sufficient molten silicon so that the blend may be cast to form an alloy containing no less than 4.5 wt .% silicon. Preferably, the cast ingot is then shaped by rolling it to form a plate having a desired thickness. Sputter targets so formed are capable of use in a conventional magnetron sputter process; that is, one can be positioned near a cathode in the presence of an electric potential difference and a magnetic field so as to induce sputtering of nickel ion form the sputter target onto the substrate.

Abstract: The electrode used in processing a surface of a mold is manufactured as follows. Material powder such as metal powder or metal compound powder is filled in a female mold of the mold. Then the material powder in the female mold is press-molded using a male mold. The surface of the mold is then treated using this electrode.

Abstract: An ingot is made from a used target of 30 weight % or more, and new metals of the same components, and recycled alloy powder is made by a gas atomizing process. Magnetic permeability is controlled not to exceed 2 by adjusting the content of rare earth metals in rare earth alloy powder to be at least 35 weight %. By blending the recycled alloy powder with other powder to produce alloy powder containing at least 50 weight % of rare earth alloy powder having a magnetic permeability not higher than 2 and containing at least 65 weight % of rare earth alloy powder. By sintering the alloy powder under pressure and thereafter cutting top, bottom and side surfaces of the sintered material, a target having a magnetic permeability not higher than 2 and having a thickness not less than 8 mm is fabricated.

Abstract: Method and device for production of powder metal bodies comprising: introducing powder material (4) in a compacting chamber (4) in a hollow die (1), compacting the material in mainly axial direction in the compacting chamber by urging a first punch (2), axially into said compacting chamber, advancing said first punch (2) further into compacting chamber for further compacting the powder material and imparting upon the die plate (1) a biasing tension, causing the edge portion of the die opening to move under increasing tension in the same direction as the first punch (2), thereby causing opening radial size reduction, causing axial compression also in a direction opposed to that by the first punch (2) by a second punch (3), arranged to move opposed relative the die (1) as compared to that of the first punch (2), and retracting the first punch (2) axially, thereby relieving the hollow die from its biasing and regaining initial form, thereby simultaneously expelling the compact thus formed.

Abstract: A method is provided for lubricating a die cavity that includes applying a lubricant composition containing a high melting point polymeric wax lubricant to the wall of a die cavity. Preferably, the lubricant is a polyamide lubricant that has a melting temperature greater than the temperature of the die wall during use. The present invention also provides a method of making a compacted metal part that includes applying the lubricant composition to an internal wall of a die cavity, introducing a metal-based powder composition into the die cavity; and compacting the powder composition at a pressure sufficient to form a compacted part from the metal powder composition.

Abstract: The present invention relates to a molding composition based on sinterable materials, comprising a) from 80 to 99.5% by weight of sinterable powder having a maximum particle size of 2000 &mgr;m, b) from 0.5 to 20% by weight of metallocene polyolefin wax, c) if desired, up to 19.5% by weight of a further dry lubricant, and to its use for producing shaped ceramic and powder metallurgical parts by pressing.

Abstract: An intermediary die 10 is provided with inner circumferential helical teeth r, a lower punch 7 is provided with outer circumferential helical teeth p, and an upper punch 8 is provided with outer circumferential helical teeth q, respectively. When the intermediary die 10, the lower punch 7 and the upper punch 8 all engage to manufacture helical gears by compacting powdered materials, lateral displacement (phase displacement) of a phase guide 11 which is adapted to engage with the upper outer punch 8a, is forcibly corrected to allow it to return to its original position, from the time when the load of the upper outer punch 8a is reduced to when the intermediary die 10 is released. There is also provided an escape surface on the pressing surface of the upper outer punch 8a. The escape surface is designed to reduce the slide contact force developed on a compacted product Ga when the upper outer punch 8a and the compacted product Ga are respectively displaced in a lateral direction.

Abstract: A method of making sheet bar and other precursors of formed products to be made by extensive working. The method includes providing a powder metal, preferably under 100 PPM oxygen content of non-spherical particles, compacting the powder into a coherent precursor form of at least 100 pounds, whereby a precursor is provided enabling extended fabrication to a finished product form. The finished product is resistant to breakup in fabrication due to oxide inclusion effect and produces a low oxygen end product. The method can process multiple species of metals that include at least one higher melting metal and one lower melting metal to produce an alloy or micro-composite of the metals as worked, where one metal is preferably a refractory metal (Ta, Nb, W, Wo, Zr, Hf, V and Re). The process is controlled to cause powder of the higher melting metal to be extended into a fibrous form.