Abstract: A method of making a shaped article involves forming an aqueous mixture comprising inorganic powder material, supercritical fluid, organic binder component a portion of which is essentially insoluble in water, and aqueous vehicle, and extruding the mixture into a shaped article.

Abstract: An improvement in a method of extruding a plasticized inorganic powder mixture having a plasticizing organic binder carried in an aqueous vehicle, by passing the mixture through an extruder and then through a die to produce an extrudate. The improvement involves homogeneously blending in the extruder as part of the mixture, carbon dioxide in the supercritical and/or liquid form, to lower the viscosity of the mixture and produce an extrudate that is stiffer in a shorter time than it would be, absent the carbon dioxide, without increasing the extrusion pressure.

Abstract: Composite materials are disclosed comprising a continuous matrix with composite reinforcements therein. The composite materials may include a continuous metal, metal alloy or intermetallic matrix with intermetallic matrix composite reinforcements dispersed therein. Suitable metals for the continuous matrix include Al, Ti, Cu and Fe, and alloys and intermetallics thereof. The composite reinforcements comprise ceramic particles dispersed in a continuous intermetallic matrix. Suitable intermetallics include alumnides of Ti, Cu, Ni, Mg and Fe, while suitable ceramics include refractory metal borides, carbides, nitrides, sulicides and sulfides. In one embodiment, the ceramic particles are formed in-situ within the intermetallic matrix of the composite reinforcements. The composite materials are produced by powder metallurgical techniques wherein powders of the continuous matrix component and powders of the composite reinforcement are blended and consolidated.

Abstract: A nickel-based superalloy possessing good mechanical properties when hot regarding traction, creep and cracking resistance has a chemical composition which comprises, in percentages by weight: Co 14.5 to 15.5 ; Cr 12 to 15 ; Mo 2 to 4.5 : Al 2.5 to 4; Ti 4 to 6; Hf not more than 0.5 ; C 100 to 300 ppm; B 100 to 500 ppm; Zr 200 to 700 ppm; possibly W up to 4.5; and nickel as the remainder. Components made from these alloys have an excellent microstructural stability when operating at temperatures up to 800.degree. C.

Abstract: An improvement in a method of extruding a plasticized powder mixture having a thermally gellable binder carried in an aqueous vehicle, by passing the mixture through an extruder and then through a die to produce an extrudate, the improvement being the additional step of contacting the extrudate directly after it leaves the die with an agent for simultaneously lowering the gel point of the binder and dehydrating the extrudate. The result is a stiffening of the extrudate in a shorter time than it would be, absent the additional step.

Abstract: A method for forming nickel base superalloy articles of manufacture by a combination of hot die forging, isothermal forging and heat treatment below and above the solvus.

Abstract: Electrochemical heat sources, materials used to make electrochemical heat sources and methods of forming electrochemical heat sources are disclosed. The electrochemical heat sources includes at least two metallic agents capable of interacting electrochemical with one another, such as magnesium and iron or nickel. The metallic agents may be provided in a variety of forms, including a frozen melt, a bimetallic foil, wire of a first metal wrapped around strands of a different metal, and a mechanical alloy. The metallic agents may be in the form of a powder filling a straw, or small particles extruded with a binder or pressed to form a rod. The powder filled straw or rod may be placed in a heat chamber surrounded by tobacco in a smoking article. An electrolyte solution contacts the metallic agents in the heat chamber to initiate the electrochemical interaction, generating heat which in turn may be used to volatilize nicotine and flavor materials in the tobacco.

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

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

Abstract: An improved method is disclosed for encasing an object in a shell or layer of outer material. The encased object and the outer material are formed from sinterable metal or ceramic particulate material. Both the object to be encased and the shell or encasement are formed by extrusion. Novel methods are disclosed by which the object and the outer material can be simultaneously formed by co-extruding the sinterable particulate materials, or by extruding the outer layer onto a formed object using the die assembly of the invention.

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

Abstract: A method is provided for obtaining uniform grain growth within .gamma.' precipitation strengthened nickel-base superalloys. The method includes forming a billet having a very fine grain size in order to achieve optimum superplasticity of the superalloy during forging. The article is then heated to a pre-working hold temperature in a manner which prevents coarsening of the microstructure and a loss of superplasticity. The article is then worked, such as by forging, at a temperature below the .gamma.' solvus temperature of the alloy, so as to maintain local strain rates within the article below a critical strain rate for random grain growth, and so as to maintain the strain rate gradient throughout the article below a critical upper limit. After working, the article is subjected to annealing at a temperature which is less than the .gamma.' solvus temperature of the alloy, and for a duration which is sufficient to remove accumulated metallurgical strain in the article.

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

Abstract: A soft magnetic bulky alloy according to the present invention is obtained by forming under pressure a powder and granule material mainly made of a Fe-M-B based amorphous alloy containing Fe, B and M where M is at least one element selected from a group consisting of Ti, Zr, Hf, V, Nb, Ta, Mo and W. In the soft magnetic bulky alloy, an amorphous alloy phase and a bcc phase with fine grain sizes of 30 nm or below are present in a mixed state, or the bcc phase with fine grain sizes of 30 nm or below is mainly present. The present invention also discloses a method of manufacturing such a soft magnetic bulky alloy.

Abstract: A metal matrix composite reinforced with shape memory alloy is disclosed ch is formed by blending metal particles and shape memory alloy particles to form a homogeneous powder blend, and consolidating the powder blend to form a unitary mass. The unitary mass is then plastically deformed such as by extrusion in the presence of heat so as to cause an elongation thereof, whereby the metal particles form a matrix and the shape memory alloy partices align in the direction of elongation of the unitary mass. The composite can be used in structural applications and will exhibit shape memory characteristics.

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

Abstract: A method for producing Li(Al) alloy anode comprises the steps of alloying Li and Al, grinding the formed alloy, pressing the powder around a current conductive thread and enclosing the anode element in a microporous separator material.

Abstract: A method for manufacturing tubes filled with powdery and/or granular substances comprising the steps of forming a metal strip into a tube, feeding powdery and/or granular substances into the tube being formed as a core, joining together the edges of the tube filled with the core of the powdery and/or granular substances by high-frequency welding, and reducing the diameter of the welded tube filled with the core of the powdery and/or granular substances. At least the top layer of the core in the tube is composed of powdery and/or granular substances having low enough magnetic susceptibility to remain unattracted to the magnetized tube edges that is determined based on the welding heat input.

Abstract: Thick-skinned extruded metal honeycomb structures, and a method and apparatus for making them, are disclosed wherein a plasticized powder metal extrusion batch is extruded though a die assembly comprising a die and annular mask, the mask having a central outlet for extrusion of the skin and honeycomb core and an extrudate reservoir adjacent the central outlet, the die and mask cooperating to form a skinforming gap fed by the die and by the extrudate reservoir, such that batch material supplied from the reservoir and directly from the die combines to form a thickened outer skin which is integral with, and resistant to separation from, the honeycomb core.

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

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

Abstract: A method for producing an anisotropic rare earth magnet is improved by extruding using a compacted material formed in a shape having difference in level between the center part to be in contact with the end face of a punch and the outer peripheral part to be faced with a molding cavity formed between the punch and a cylindrical die of a mold.

Abstract: Billets are produced from powdery alloys by a process which comprises densely packing in a can a powdery metal or alloy easy of plastic working and a powdery alloy difficult of plastic working in that order, sealing hermetically the can and thereafter degassing the same; or a process which comprises densely packing a powdery alloy difficult of plastic working in a can and, then, densely packing a powdery metal or powdery alloy easy of plastic working in the can to make the powdery metal or alloy into a lid of the can, wherein the powdery alloy easy of plastic working is coarse powder, while the powdery alloy difficult of plastic working is fine powder, and the powdery alloy is a rapidly solidified powdery alloy comprising an Al-base, Mg-base, Ni-base, Ti-base or Fe-base alloy.

Abstract: A high strength structural member formed in a forming process using a starting powder of a light alloy. The starting powder is a mixture of a crystalline phase main powder component and at least 5% by volume of an additional powder component which includes between 5% and 100% by volume of an amorphous phase of the light alloy powder and the balance of a crystalline phase.

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

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

Abstract: Discrete powder particles of copper 14 and INVAR 12 are mixed together in a container 16 and packed into a powder metal article. This article is hot vacuum degassed and vacuum sealed and then heated to temperature well below the sintering temperature of copper or INVAR. Immediately after heating the article, it is subjected to a high pressure, high strain force such as extrusion through a die thereby yielding a fully dense, strong composite material 10 with excellent combined thermal expansion and conductivity properties.

Abstract: A method and die apparatus for manufacturing a honeycomb body of triangular cell cross-section and high cell density, the die having a combination of (i) feedholes feeding slot intersections and (ii) feedholes feeding slot segments not supplied from slot intersections, whereby a reduction in feedhole count is achieved while still retaining good extrusion efficiency and extrudate uniformity.

Abstract: A method and die apparatus for manufacturing a honeycomb body of rhombic cell cross-section by extrusion through an extrusion die of triangular cell discharge slot configuration, the die incorporating feedholes at selected slot intersections only, such that slot segments communicating directly with the feedholes discharge web material and slot segments not so connected do not discharge web material, whereby a rhombic cell cross-section in the extruded body is provided.

Abstract: A rapidly solidified, low density aluminum base alloy consists essentially of the formula Al.sub.bal Li.sub.a Cu.sub.b Mg.sub.c Zr.sub.d wherein "a" ranges from about 2.2 to 2.5 wt %, "b" ranges from about 0.8 to 1.2 wt %, "c" ranges from about 0.4 to 0.6 wt % and "d" ranges from about 0.4 to 0.8 wt %, the balance being aluminum plus incidental impurities. The alloy is especially suited to be consolidated to produce a strong, tough, low density aircraft landing wheel.

Abstract: A compacted and consolidated aluminum-based alloy material is obtained by compacting and consolidating a rapidly-solidified material having a composition represented by the general formula: Al.sub.a Ni.sub.b X.sub.c M.sub.d or Al.sub.a' Ni.sub.b X.sub.c M.sub.d Q.sub.e, where X is one or two elements selected from La and Ce or an Mm; M is Zr or Ti; Q is one or more elements selected from Mg, Si, Cu and Zn, and a, a', b, c, d and e are, in atomic percentages, 84.ltoreq.a.ltoreq.94.8, 82.ltoreq.a'.ltoreq.94.6, 5.ltoreq.b .ltoreq.10, 0.1.ltoreq.c.ltoreq.3, 0.1.ltoreq.d.ltoreq.3, and 0.2.ltoreq.e.ltoreq.2. According to the production process of the invention, powder or flakes obtained by rapidly solidifying are compacted, followed by compressing, forming and consolidating by conventional plastic working operations. The consolidated material has an elongation sufficient to withstand secondary working operations. Moreover, the material retains the excellent properties of its raw material as they are.

Abstract: A method of forming or reforming a composite material comprises relatively rotating a pair of members (2,3) while urging them together under pressure so as to mix or remix together the materials (1) making up the composite. The urging direction is substantially parallel with the axis of relative rotation. The composite is then extruded (7).

Abstract: Particle reinforced composite material produced by mixing granules of a composite material formed by rapidly solidifying a melt comprising a based light metal matrix and particles of a non-metallic reinforced material with granules of unreinforced host metal matrix, compacting the mixture and applying a shear deformation on said mixture.

Abstract: An improvement in a method and apparatus is provided in extruding a powder material to form an article, in which the material is passed through an extruder and then through a die, wherein the material is provided in the form of a mixture which includes a vehicle, the improvement comprising having one or more gear pumps in succession between the extruder and the die, so that the powder material passes through the gear pump(s) after it leaves the extruder and before it enters the die. The gear pump(s) can have one or more pair of gears which are arranged sequentially with respect to the flow of the material.

Abstract: A cylindrical, iron-based sintered slug comprising an iron-based sintered alloy having a surface hardness represented by an HRB of 40-90 is formed such that its interior porosity is 5% or less but greater than 0%, the porosities of both its surface layer regions lying at most 1 mm below its outer and inner surfaces are fixed at at least 3% or less but greater than 0% and the distribution of pores in each of the surface layers is decreased gradually toward the surface.

Abstract: A method of manufacturing a superconducting wire consisting essentially of mixing superconducting ceramic powders selected from a group selected from a group consisting of Y-Sr-Cu-O, Y-Ba-Cu-O, La-Sr-Cu-O, La-Ba-Cu-O and Bi-Sr-Ca-Cu-O with metal powder, filling the mixture in a metal pipe and forming the mixture into wire by at least one of extrusion, drawing and swaging. The resulting wire would have superconductivity which is not reduced upon distortion by external stress.

Abstract: Improvement of Nb-alloys, which are known as heat-resistant alloys, by giving anti-oxidation property thereto and increasing the high temperature strength thereof. In addition to a determined amount of Al, one of (1) suitable amounts of Ti, Cr and V, and (2) suitable amounts of Cr and Co, are added to Nb-matrix, and a high melting temperature metal oxide such as Y.sub.2 O.sub.3 or Al.sub.2 O.sub.3 is dispersed in the matrix. Preferable method of preparing the alloys is combination of mechanical alloying and subsequent hot processing.

Abstract: A heat-resisting aluminum alloy contains manganese ranging from 6 to 8% by weight, iron ranging from 0.5 to 2% by weight, zirconium ranging from 0.03 to 0.5% by weight, and copper ranging from 2 to 5% by weight, the balance being essentially aluminum. The aluminum alloy has been confirmed to be high in mechanical strength both at ordinary temperatures and at high temperatures while to be suitable for producing an article by using so-called atomization process.

Abstract: A rivet is formed from a friction-actuated extrustion. The extrusion is produced by a process that utilizes a comminuted rapidly solidified aluminum alloy ribbon as the in-feed for a continuous friction-actuated extruder. Gumming and flow problems are eliminated. The extruded product is devoid of surface blistering. The extrusion is converted into a rivet that has improved ambient and elevated temperature mechanical properties.

Abstract: The process of the invention relates to forming MA iron-base ODS alloys. A billet of iron-base ODS alloy is provided. The billet is consolidated at a temperature within a predetermined range of sufficient temperature for formation of coarse and/or fine grain sizes during a final heat treatment. The consolidated billet is worked into final form. The object is annealed to recrystallize grains to a size determined by the temperature of the consolidation and the working of the extruded billet.

Abstract: Magnesium base metal alloy sheet is produced by rolling the rolling stock extruded or forged from a billet at a temperature ranging from 200.degree. C. to 300.degree. C. The billet is consolidated from rapidly solidified magnesium based alloy powder that consists essentially of the formula Mg.sub.bal Al.sub.a Zn.sub.b X.sub.c, wherein X is at least one element selected from the group consisting of manganese, cerium, neodymium, praseodymium, and yttrium, "a" ranges from about 0 to 15 atom percent, "b" ranges from about 0 to 4 atom percent, "c" ranges from about 0.2 to 3 atom percent, the balance being magnesium and incidental impurities, with the proviso that the sum of aluminum and zinc present ranges from about 2 to 15 atom percent. The alloy has a uniform microstructure comprised of fine grain size ranging from 0.2-1.0 .mu.m together with precipitates of magnesium and aluminum containing intermetallic phases of a size less than 0.1 .mu.m.

Abstract: The invention relates to an extrusion process and an extrusion tool for the production of cylindrical metallic or ceramic blanks having one or more internal twisted longitudinal bores. A plasticized, pulverulent starting material, deformable by means of extrusion, is forced through a space formed by a die and a mandrel. One or more twisted central pins of a rigid material are fastened to the mandrel which ends before the inner space of the die. The central pins form the longitudinal bores in the blank. The positioning of the longitudinal bores is extremely symmetrical within the blank and uniformly achieved in the various individual blanks extruded using the same production batch.

Abstract: A rolling bearing comprise a bearing ring having inner and outer rings, and rolling elements. At least one of the inner and outer rings and the rolling elements is formed of a sintered alloy steel and has pores and carbides present therein. The largest one of the pores has a diameter equal to or smaller than 3 .mu.m in terms of a diameter assued if the largest pore were converted to a spherical shape. The largest one of the carbides has a diameter equal to or smaller than 12 .mu.m in terms of a diameter assumed if the largest carbide were converted to a spherical shape. The at least one of the inner and outer rings and the rolling elements has hardness higher than 64 and lower than 69 in terms of HRC.

Abstract: An aluminum alloy is prepared from an aluminum alloy powder having a composition of:lubricating componentPb: 3 to 15 Wt %;hardening componentSi: 1 to 12 Wt %;rainforcement componentone or more selected among Cu, Cr, Mg, Mn, NiZn, Fe and: 0.2 to 5.0 Wt %;and remainder of aluminum as principal material or matrix.To the aluminum alloy powder set forth above, powder state Pb in 3 to 12 Wt % is added. With the mixture of the aluminium alloy powder and Pb powder, a billet is formed. For the billet, extrustion process is performed in a extrusion ratio greater than or equal to 40. In the extruded block, Si particle dispersed in the aluminum matrix is in a grain size smaller than or equal to 12 .mu.m. Furthermore, at least of half of added Pb power particle is dispersed to have greater than or equal to 0.74 of circularity coefficient.

Abstract: A process for the production of, in particular, ceramic parts having a cavity by press molding or pressing sealed sheaths.The core used for defining the cavity and preventing subsequent machining operations is initially more voluminous than the desired cavity and has an adequate ductility to allow partial extrusion during pressing. This avoids often excessive mechanical stresses, which can lead to a bursting or shattering of the densified part when the sheath is removed. This process has, application to the hot isostatic pressing of fragile materials.

Abstract: A complex part composed of rapidly solidified magnesium base metal alloy is produced by superplastic forming at a temperature ranging from 160.degree. C. to 275.degree. C. and at a rate ranging from 0.00021 m/sec to 0.00001 mm/sec, to improve the formability thereof and allow forming to be conducted at lower temperature. The rapidly solidified magnesium based alloy has a composition consisting essentially of the formula Mg.sub.bal Al.sub.a Zn.sub.b X.sub.c, wherein X is at least one element selected from the group consisting of manganese, cerium, neodymium, praseodymium and yttrium, "a" ranges from 0 to about 15 atom percent, "b" ranges from 0 to about 4 atom percent and "c" ranges from about 0.2 to 3 atom percent, the balance being magnesium and incidental impurities, with the proviso that the sum of aluminum and zinc present ranges from about 2 to 15 atom percent. Such an alloy contains fine grain size and finely dispersed magnesium-, aluminum- rare earth intermetallic phases.

Abstract: A metal extrusion process and apparatus in wich a semisolid material is fed into a passageway formed between first and second members, with one of the members being moved toward a die such that the moveable member draws the semisolid material through the passageway and through the die means.

Abstract: A metal extrusion process and apparatus in which a semisolid material is fed into a passageway formed between first and second members, with one of the members being moved toward a die such that the semisolid material is drawn through the passageway and solidifies before passing through the die means.

Abstract: A process of making anisotropic permanent magnets by extruding a rare earth magnetic alloy below the melting temperature of the alloy at an extrusion ratio of from 10:1 to 26:1.

Abstract: In production of a composite material such as an elongated Ti-base composite material advantageously used for eyeglass frames, a crude composite material formed by application of at least one surface layer of a component material to a base block by means of spraying processing is subsequently subjected to pressure application preferably with heat. A multi-layer construction can be easily obtained even starting from a base block of an intricate surface configuration thanks to employment of the spraying process, and the final pressure application assures strong diffusion bonding between the core block and the surface layers. The base block may be given in the form of a mold to be ultimately removed from the product.