Powder Next To Powder Patents (Class 419/6)
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Publication number: 20140170012Abstract: The invention relates to an additive manufacturing apparatus and method. According to the invention, an additive manufacturing apparatus includes a material supply system. The material supply system delivers layers of partially sintered pulverant material to an additive manufacturing device.Type: ApplicationFiled: December 18, 2012Publication date: June 19, 2014Applicant: United Technologies CorporationInventors: Robert P. Delisle, Christopher F. O'Neill, Paul R. Faughnan, Jesse R. Boyer
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Patent number: 8748006Abstract: The invention relates to a slide bearing composite material having at least one carrier layer and a sintered bearing metal layer. The sintered bearing metal layer is designed in at least one layer region as a gradient layer.Type: GrantFiled: March 10, 2010Date of Patent: June 10, 2014Assignee: Federal-Mogul Wiesbaden GmbHInventors: Holger Schmitt, Thomas Enghof, Daniel Meister
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Publication number: 20140153687Abstract: The invention relates to a fuel component and a method for manufacturing of a fuel component. The fuel component is adapted to be used in fission reactors. The fuel component comprises a core consisting of a first material, and a layer consisting of a second material. The layer encloses at least partly the core. The first material comprises a fissile substance. The fuel component comprises an intermediate layer between the core and the layer. The intermediate layer has a material gradient that comprises a decrease of the concentration of the first material from the core to the layer and an increase of the concentration of the second material from the core to the layer.Type: ApplicationFiled: February 23, 2011Publication date: June 5, 2014Applicant: WESTINGHOUSE ELECTRIC SWEDEN ABInventors: Lars Hallstadius, Karin Backman, Björn Rebensdorff, Hans Widegren
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Publication number: 20140154126Abstract: A multiphase composite system is made by binding hard particles, such as TiC particles, of various sizes with a mixture of titanium powder and aluminum, nickel, and titanium in a master alloy or as elemental materials to produce a composite system that has advantageous energy absorbing characteristics. The multiple phases of this composite system include an aggregate phase of hard particles bound with a matrix phase. The matrix phase has at least two phases with varying amounts of aluminum, nickel, and titanium. The matrix phase forms a bond with the hard particles and has varying degrees of hard and ductile phases. The composite system may be used alone or bonded to other materials such as bodies of titanium or ceramic in the manufacture of ballistic armor tiles.Type: ApplicationFiled: November 18, 2013Publication date: June 5, 2014Inventor: Robert G. Lee
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Patent number: 8728388Abstract: A method is provided that includes depositing metal powder over a seed crystal having a predetermined primary orientation, scanning an initial pattern into the metal powder to melt or sinter the deposited metal powder, and re-scanning the initial pattern to re-melt the scanned metal powder and form an initial layer having the predetermined primary orientation. The method further includes depositing additional metal powder over the initial layer, scanning an additional pattern into the additional metal powder to melt or sinter at least a portion of the additional metal powder, re-scanning the additional pattern to re-melt a portion of the initial layer and the scanned deposited additional metal powder to form a successive layer having the predetermined primary orientation, and repeating the steps of depositing additional metal powder, scanning the additional pattern, and re-scanning the additional pattern, until a final shape of the component is achieved.Type: GrantFiled: December 4, 2009Date of Patent: May 20, 2014Assignee: Honeywell International Inc.Inventors: Mark C. Morris, Tom Strangman, Yiping Hu
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Publication number: 20140131050Abstract: A method of making a composite downhole article is disclosed. The method include forming at least one removable core member comprising a first metallic material that is removable in a wellbore fluid at a first removal rate; and disposing at least one outer member on the core member, the outer member comprising a second material that is removable in the wellbore fluid at a second removal rate, wherein the removable core member has a composition gradient or a density gradient, or a combination thereof, and wherein the first removal rate is substantially greater than the second removal rate. A method of using a composite downhole article is also disclosed. The method includes forming a composite downhole article as described above; using the article to perform a first wellbore operation; exposing the article to the wellbore fluid; and selectively removing the second removable member.Type: ApplicationFiled: January 17, 2014Publication date: May 15, 2014Applicant: BAKER HUGHES INCORPORATEDInventors: Zhiyue Xu, Michael Johnson
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Patent number: 8703045Abstract: The present invention relates to a method of manufacturing a multiple composition component 10, comprising: arranging first, second and third constituent parts 40, 30, 42 having first, second and third compositions respectively A, B, C so that the first constituent part 40 shares a first boundary with the second constituent part 30 and the second constituent part 30 shares a second boundary with the third constituent part 40. The first, second and third constituent parts 40, 30, 42 are each either a powder or a solid so that the first and second boundaries are each a solid adjacent to a powder. The arrangement is then processed so as to form a single solid component having first, second and third regions 16, 18, 20 having first, second and third compositions A, B, C respectively.Type: GrantFiled: November 15, 2010Date of Patent: April 22, 2014Assignee: Rolls-Royce PLCInventors: Robert J. Mitchell, Catherine M. F. Rae, Mark C. Hardy, Shaun R. Holmes
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Patent number: 8697258Abstract: An article includes a working portion including cemented carbide, and a heat sink portion in thermal communication with the working portion. The heat sink portion includes a heat sink material having a thermal conductivity greater than a thermal conductivity of the cemented carbide. Also disclosed are methods of making an article including a working portion comprising cemented carbide, and a heat sink portion in thermal communication with the working portion and including a heat sink material having a thermal conductivity that is greater than a thermal conductivity of the cemented carbide. The heat sink portion conducts heat from the working portion.Type: GrantFiled: July 14, 2011Date of Patent: April 15, 2014Assignee: Kennametal Inc.Inventors: Prakash K. Mirchandani, Alfred J. Mosco, Eric W. Olsen, Steven G. Caldwell
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Patent number: 8694142Abstract: This invention has provided a direct manufacturing methodology of customized lingual orthodontic brackets by selective laser melting. The procedure is as follows. First of all, measure the dentition data and construct the 3D CAD model of the teeth through reverse engineering. Then a single soleplate of the lingual bracket contacting the tooth surface, as well as the ideal slot position is designed based on the teeth features. The designed models are later imported into the SLM machine and used to produce the brackets with desired materials directly. This method can actualize customized manufacture with highly accuracy, producing highly matched brackets all at once. The invention not only saves time and cost, but also has wide adaptation range and is able to adopt various raw materials. Different raw materials can be utilized in one step to accommodate specific capacity requirement of different parts of the brackets.Type: GrantFiled: May 19, 2008Date of Patent: April 8, 2014Assignee: South China University of TechnologyInventors: Yongqiang Yang, Shufan Wang
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Publication number: 20140086781Abstract: A plurality of first cup-shaped members and a plurality of second cup-shaped members are placed alternately in repetition to form a pipe having an inner through-hole. At this point, neither the first cup-shaped members nor the second cup-shaped members are sintered yet. Then, the resultant pipe is sintered to obtain a pipe-shaped thermal power generation device. While the pipe is sintered, a pressure is applied to the pipe along a longitudinal direction of the pipe in a direction in which the pipe is compressed.Type: ApplicationFiled: November 27, 2013Publication date: March 27, 2014Applicant: Panasonic CorporationInventors: Akihiro SAKAI, Tsutomu KANNO, Kohei TAKAHASHI, Hiromasa TAMAKI, Yuka YAMADA
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Publication number: 20140072468Abstract: The object of the invention is to provide a hard tip where the nose side has wear resistance and the bonding side has toughness. The chemical composition of sintered hard alloy constituting the hard tip is such that a compounding ratio of WC to Co is substantially the same from the nose side to the bonding side, and a first bonding metal or a second bonding metal has a gradient chemical composition wherein the content of the first bonding metal or the second bonding metal is increased from the nose side to the bonding side, the first bonding metal does not form the eutectic texture with WC, and the second bonding metal has the eutectic temperature with WC over the eutectic temperature of WC—Co sintered hard alloy and the melting point over the liquid phase sintering temperature of WC—Co sintered hard alloy.Type: ApplicationFiled: November 15, 2013Publication date: March 13, 2014Applicant: KABUSHIKI KAISHA MIYANAGAInventor: Masaaki Miyanaga
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Patent number: 8663359Abstract: Methods of forming larger sintered compacts of PCD and other sintered ultrahard materials are disclosed. Improved solvent metal compositions and layering of the un-sintered construct allow for sintering of thicker and larger high quality sintered compacts. Jewelry may also be made from sintered ultrahard materials including diamond, carbides, and boron nitrides. Increased biocompatibility is achieved through use of a sintering metal containing tin. Methods of sintering perform shapes are provided.Type: GrantFiled: June 25, 2010Date of Patent: March 4, 2014Assignee: Dimicron, Inc.Inventors: David P. Harding, Mark E. Richards, Richard H. Dixon, Victoriano Carvajal, Bao-Khang Ngoc Nguyen, German A. Loesener, A. Ben Curnow, Troy J. Medford, Trenton T. Walker, Jeffery K. Taylor, Bill J. Pope
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Patent number: 8654502Abstract: An apparatus, a method, a planar insulating substrate and a chipset have been presented, comprising at least one module configured to establish a predefined pattern on a planar insulating substrate so that conductive particles can gather according to the predefined pattern. At least one another module is configured to transfer the conductive particles to the planar insulating substrate, wherein the conductive particles are arranged to gather according to the predefined pattern. A sintering module is configured to fuse the conductive particles on the planar insulating substrate, wherein the conductive particles are arranged to fuse according to the predefined pattern to establish a conductive plane on the planar insulating substrate. Embodiment of the invention relate to printable or printing electronics on a fibrous web.Type: GrantFiled: May 9, 2008Date of Patent: February 18, 2014Assignee: Stora Enso OyjInventors: Juha Maijala, Petri Sirviö
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Patent number: 8647561Abstract: Embodiments of the present invention include methods of producing a composite article. A method comprises introducing a first powdered metal grade from a feed shoe into a first portion of a cavity in a die and a second powdered metal grade from the feed shoe into a second portion of the cavity, wherein the first powder metal grade differs from the second powdered metal grade in chemical composition or particle size. Further methods are also provided. Embodiments of the present invention also comprise composite inserts for material removal operations. The composite inserts may comprise a first region and a second region, wherein the first region comprises a first composite material and the second region comprises a second composite material.Type: GrantFiled: July 25, 2008Date of Patent: February 11, 2014Assignee: Kennametal Inc.Inventors: X. Daniel Fang, David J. Wills, Prakash K. Mirchandani
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Publication number: 20130299347Abstract: A sputtering target that includes at least two consolidated blocks, each block including an alloy including a first metal (e.g., a refractory metal such as molybdenum in an amount greater than about 30 percent by weight) and at least one additional alloying ingredient; and a joint between the at least two consolidated blocks, the joint being prepared free of any microstructure derived from a diffusion bond of an added loose powder. A process for making the target includes hot isostatically pressing (e.g., below a temperature of 1080° C.), consolidated preform blocks that, prior to pressing, have interposed between the consolidated powder metal blocks at least one continuous solid interface portion. The at least one continuous solid interface portion may include a cold spray body, which may be a mass of cold spray deposited powders on a surface a block, a sintered preform, a compacted powder body (e.g., a tile), or any combination thereof.Type: ApplicationFiled: March 11, 2013Publication date: November 14, 2013Applicant: H.C. STARCK, INC.Inventors: Gary Alan Rozak, Mark A. Gaydos, Christopher Michaluk
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Patent number: 8579994Abstract: A method for producing a solid-state cell which makes it possible to produce a highly reliable solid-state cell that suppresses a decrease in the thickness of the solid electrolyte layer and a short circuit between the positive and negative electrodes, and which is highly flexible in the size and shape of the solid electrolyte layer and electrodes. The method comprising: a structure preparing step for preparing a first structure, a second structure, or a third structure, a solid electrolyte material powder layer, and a positive electrode material powder layer are stacked, in this sequence; an insulating member disposing step for disposing a heat-resistant insulating member which is in contact with an outer periphery of the structure in the stacking direction of the structure and surrounds the outer periphery; and a heat-compressing step for heat-compressing the structure and heat-resistant insulating member, in the stacking direction of the structure.Type: GrantFiled: May 11, 2009Date of Patent: November 12, 2013Assignee: Toyota Jidosha Kabushiki KaishaInventors: Hirokazu Kawaoka, Hiroyasu Kado
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Publication number: 20130259732Abstract: The present invention relates to a method for manufacturing thermally stressed engine components having a geometrically complex structure by metal injection moulding of metal powder mixed with a binder, by which method individual parts of the engine component are produced as separately moulded green compact sections and then as debindered brown compact sections which are joined together to form a two-part or multi-part brown compact and sintered in the assembled state, with the brown compact sections having differing shrinkage properties in the sintering process, depending on the type and size of the metal powder used, with at least one more heavily shrinking first brown compact section being automatically pressed against at least one second brown compact section during sintering of the assembled brown compact.Type: ApplicationFiled: November 25, 2011Publication date: October 3, 2013Applicant: Rolls-Royce Deutschland Ltd. & Co KGInventors: Alexander Schult, Dan Roth-Fagaraseanu
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Publication number: 20130216420Abstract: A manufacturing method of a multilayer shell-core composite structural component comprises the following procedures: (1) respectively preparing feeding material for injection forming of a core layer, a buffer layer and a shell layer, wherein the powders of feeding material of the core layer and the shell layer are selected from one or more of metallic powder, ceramic powder or toughening ceramic powder, and are different from each other, and the powder of feeding material of the buffer layer is gradient composite material powder; (2) layer by layer producing the blank of multilayer shell-core composite structural component by powder injection molding; (3) degreasing the blank; (4) sintering the blank to obtain the multilayer shell-core composite structural component. The multilayer shell-core composite structural component has the advantages of high surface hardness, abrasion resistance, uniform thickness of the shell layer, stable and persistent performance.Type: ApplicationFiled: June 29, 2011Publication date: August 22, 2013Inventors: Yadong Li, Yajun Li
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Publication number: 20130218281Abstract: A method of pressure forming a brown part from metal and/or ceramic particle feedstocks includes: introducing into a mold cavity or extruder a first feedstock and one or more additional feedstocks or a green or brown state insert made from a feedstock, wherein the different feedstocks correspond to the different portions of the part; pressurizing the mold cavity or extruder to produce a preform having a plurality of portions corresponding to the first and one or more additional feedstocks, and debinding the preform. Micro voids and interstitial paths from the interior of the preform part to the exterior allow the escape of decomposing or subliming backbone component substantially without creating macro voids due to internal pressure. The large brown preform may then be sintered and subsequently thermomechanically processed to produce a net wrought microstructure and properties that are substantially free the interstitial spaces.Type: ApplicationFiled: April 30, 2010Publication date: August 22, 2013Applicant: ACCELLENT INC.Inventors: Mark W. Broadley, James Alan Sago, Hao Chen, Edward J. Schweitzer, John Eckert, Jeffrey M. Farina
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Publication number: 20130209815Abstract: A one-piece component includes a first subregion made of a base material, and a second subregion made of the base material as binder with intercalated hard material particles, the second subregion being injection-molded onto the first subregion by means of MIM injection molding, so that an integral connection is formed between the first subregion and the second subregion. Furthermore, a method for producing the one-piece component by means of MIM injection molding is described.Type: ApplicationFiled: February 6, 2013Publication date: August 15, 2013Applicant: Robert Bosch GmbHInventors: Tilla HAUBOLD, Matthias SCHUMACHER
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Publication number: 20130177468Abstract: A dental implant for preventing elution of metal when applied within an oral cavity and preventing the occurrence of mismatching (bumpy occlusion or the like) when fixed in place, and its manufacturing method are provided. The abutment is manufactured through steps including molding a titanium molded body composition to obtain a titanium molded body, molding a ceramic molded body composition to obtain a ceramic molded body, assembling the titanium molded body and the ceramic molded body together to obtain an assembled body, degreasing the assembled body so that the titanium molded body becomes a titanium degreased body and the ceramic molded body becomes a ceramic degreased body, and sintering the assembled body to transform the titanium degreased body into a titanium member and to transform the ceramic degreased body into a ceramic member so that the titanium member and the ceramic member are firmly fixed and joined together.Type: ApplicationFiled: March 4, 2013Publication date: July 11, 2013Applicant: SEIKO EPSON CORPORATIONInventor: Seiko Epson Corporation
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Publication number: 20130156626Abstract: A method for manufacturing a part includes metal injection molding of metal powder mixed with a binder to produce individual components of the part as separately molded green compact sections which are then debindered to form brown compact sections. At least one of the brown compact sections is subjected to a pre-sintering process to undergo a first shrinkage. The pre-sintered brown compact section and a further brown compact section are joined together to form a multi-part brown compact which is subsequently subjected to a main sintering process, where the pre-sintered brown compact section undergoes less shrinkage than the further brown compact section to draw together and firmly connect the pre-sintered brown compact section and the further brown compact section.Type: ApplicationFiled: December 19, 2012Publication date: June 20, 2013Applicant: ROLLS-ROYCE DEUTSCHLAND LTD & CO KGInventor: ROLLS-ROYCE DEUTSCHLAND LTD & CO KG
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Publication number: 20130133209Abstract: Disclosed herein is a diamond-containing blade, including: a blade body having at proximal end a connection part to be fitted into a gripper; and an edge longitudinally formed along one side of the blade body, wherein the blade is manufactured by a process in which a power mixture for constituting the edge, including 20 wt % or less of diamond particles coated with Ti and having a particle size of 20 ?m or less and residual Ti powder or Ti alloy powder, is charged in a space of a mold corresponding to the edge, Ti powder or Ti alloy powder for constituting the blade body is charged in another space of the mold corresponding to the blade body, the charged powders are pressed to obtain a molded product, the molded product is sintered to obtain a sintered body, and then an edge of the sintered body is sharpened.Type: ApplicationFiled: September 10, 2012Publication date: May 30, 2013Applicant: Forever Co., Ltd.Inventor: Kimiko Sueda
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Publication number: 20130135078Abstract: According to one embodiment, a monolithic cassette with graded electrical resistivity is presented. The monolithic cassette has a continuous grain structure between a first end and a second end; wherein electrical resistivity of the monolithic cassette is graded such that the resistance varies continuously from the first end to the second end. Methods and compositions for forming the monolithic cassette are also presented.Type: ApplicationFiled: November 26, 2012Publication date: May 30, 2013Applicant: General Electric CompanyInventor: General Electric Company
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Publication number: 20130121868Abstract: A method of manufacturing a weld-free apparatus for use in the connection of dissimilar metals includes the steps of providing a mold designed to replicate a reverse of the apparatus, introducing a low alloy, ferritic steel composition atomized powder into a first portion of the mold, introducing a series of atomized powders incrementally into a second portion of the mold to form a transition region between the ferritic steel composition and an austenitic stainless steel composition, and introducing an austenitic stainless steel composition atomized powder into a third portion of the mold. The method further includes the step of consolidating and melting the atomized powders in a high temperature, high pressure inert gas atmosphere to form the apparatus.Type: ApplicationFiled: May 3, 2012Publication date: May 16, 2013Applicant: ELECTRIC POWER RESEARCH INSTITUTE, INC.Inventors: David W. Gandy, Kent K. Coleman, John Shingledecker
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Publication number: 20130115125Abstract: A sintering method with uniaxial pressing includes: a powder filling step of disposing a spent target in an inner space of a frame jig having the inner space piercing in a uniaxial direction, and filling the inner space with a raw material powder for a target to cover an erosion part side of the spent target with the raw material powder for a target, a cushioning-material disposition step of disposing a deformable cushioning material so that the raw material powder for a target with which the inner space has been filled in the powder filling step is sandwiched between the spent target and the deformable cushioning material; and a sintering step of pressing the raw material powder for a target with which the inner space has been filled and the spent target in the uniaxial direction through the cushioning material and sintering them.Type: ApplicationFiled: December 26, 2012Publication date: May 9, 2013Applicant: TANAKA HOLDINGS CO., LTD.Inventor: TANAKA HOLDINGS CO., LTD.
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Publication number: 20130093551Abstract: An R—Fe—B based magnet having gradient electric resistance and a method for producing the same are provided. The magnet includes an exterior layer (G) and a main body layer (H). The exterior layer (G) is connected with the main body layer (H) via a sintered layer (I). The oxygen content in the exterior layer (G) is higher than the oxygen content in the main body layer (H), so the electrical resistivity of the exterior layer (G) is not lower than the electrical resistivity of the main body layer (H). The R—Fe—B based magnet having gradient electric resistance is capable of maintaining high resistance and excellent magnetic performance simultaneously.Type: ApplicationFiled: December 24, 2010Publication date: April 18, 2013Inventors: Buzhuang Peng, Juntao Zhao, Guangjun Li
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Publication number: 20130089384Abstract: A drill includes a drill bit, an intermediate part, and a shaft. The drill bit is made from a sintered carbon-containing hard metal. The intermediate part is made from steel and arranged along an axis between the drill bit and the shaft. An activity of carbon in the steel of the intermediate part is greater at a temperature ranging from 1100° C. to 1450° C. than an activity of carbon in the sintered hard metal at the temperature.Type: ApplicationFiled: August 31, 2012Publication date: April 11, 2013Inventors: Arno Glaser, Steven Moseley
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Publication number: 20130078132Abstract: An integral forming method for a composite metal includes: a preparation step including preparing powders of at least two metals or alloys; a formation step including producing a single blank from the powders of one of the at least two metals or alloys by pressing molding or metal injection molding, and then producing a composite metal blank from the single blank and the powders of a remainder of the at least two metals or alloys; and a sintering step including sintering the composite metal blank into a composite metal product. The processing procedures are simplified, and the production is easier. Limitation to the choices of materials is small. The bonding strength of the composite metal is enhanced.Type: ApplicationFiled: September 21, 2012Publication date: March 28, 2013Applicant: Fusheng Precision Co., LTD.Inventors: Bao-Bin Li, Guo-Jie Weng
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Publication number: 20130079187Abstract: A cam member for a vehicle differential includes a cam surface made of a high-durability alloy and a clutch surface made of a high-density magnetic alloy. The cam surface and the clutch surface can either be formed into a single component or as separate components that are mechanically coupled together. In one aspect, both the high-durability alloy and the high-density magnetic alloy are powdered metal alloys. As a result, the cam member has different surfaces with optimized characteristics that would ordinarily be difficult to incorporate into a single component.Type: ApplicationFiled: September 28, 2011Publication date: March 28, 2013Inventor: Andrew N. Edler
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Patent number: 8355815Abstract: Methods include one or more of robotically positioning a cutting element on an earth-boring tool, using a power-driven device to move a cutting element on an earth-boring tool, and robotically applying a bonding material for attaching a cutting element to an earth-boring tool. Robotic systems are used to robotically position a cutting element on an earth-boring tool. Systems for orienting a cutting element relative to a tool body include a power-driven device for moving a cutting element on or adjacent the tool body. Systems for positioning and orienting a cutting element on an earth-boring tool include such a power-driven device and a robot for carrying a cutting element. Systems for attaching a cutting element to an earth-boring tool include a robot carrying a torch for heating at least one of a cutting element, a tool body, and a bonding material.Type: GrantFiled: February 12, 2009Date of Patent: January 15, 2013Assignee: Baker Hughes IncorporatedInventors: David Keith Luce, Sean W. Wirth, Alan J. Massey, Crystal A. Parrott
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Publication number: 20120321498Abstract: Composite articles, including composite rotary cutting tools and composite rotary cutting tool blanks, and methods of making the articles are disclosed. The composite article includes an elongate portion. The elongate portion includes a first region composed of a first cemented carbide, and a second region autogenously bonded to the first region and composed of a second cemented carbide. At least one of the first cemented carbide and the second cemented carbide is a hybrid cemented carbide that includes a cemented carbide dispersed phase and a cemented carbide continuous phase. At least one of the cemented carbide dispersed phase and the cemented carbide continuous phase includes at least 0.5 percent by weight of cubic carbide based on the weight of the phase including the cubic carbide.Type: ApplicationFiled: August 22, 2012Publication date: December 20, 2012Applicant: TDY INDUSTRIES, LLCInventor: Prakash K. Mirchandani
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Patent number: 8333922Abstract: A method of producing three-dimensional bodies which wholly or for selected parts consists of a composite of crystalline or nanocrystalline metal particles in a matrix of amorphous metal. A metal powder layer (4) is applied onto a heat-conducting base (1, 13) and limited areas of the layer is melted successively by means of a radiation gun and cooled so that they can be made to solidify into amorphous metal. In connection with the melting of one or several of the limited areas, the radiation gun is regulated so that the melted area is cooled in accordance with a stipulated time-temperature curve in order to form a composite of crystalline or nanocrystalline metal particles in a matrix of amorphous metal. The method is repeated until a continuous layer, which contains composite metal to a desired extent, is formed. A new powder layer (4) is applied and the method is repeated, the new layer being fused to the underlying layer for successive construction of the three-dimensional body.Type: GrantFiled: August 31, 2009Date of Patent: December 18, 2012Assignee: Exmet ABInventors: Peter Skoglund, Abraham Langlet
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Patent number: 8329091Abstract: In one aspect, there are provided methods for producing porous metallic structures, wherein the methods involve the use of collagen fibrils on the nanometer scale as a “sacrificial” scaffold upon which metal particles are deposited. Also disclosed are structures comprising a porous metallic matrix having favorable strength, porosity, and density characteristics. Structures produced in accordance with the present disclosure are useful for, inter alia, the fabrication of devices such as filters, heat exchangers, sound absorbers, electrochemical cathodes, fuel cells, catalyst supports, fluid treatment units, lightweight structures and biomaterials.Type: GrantFiled: January 29, 2010Date of Patent: December 11, 2012Assignee: Widener UniversityInventor: Gennaro J. Maffia
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Publication number: 20120306308Abstract: An R—Fe—B based porous magnet according to the present invention has an aggregate structure of Nd2Fe14B type crystalline phases with an average grain size of 0.1 ?m to 1 ?m. At least a portion of the magnet is porous and has micropores with a major axis of 1 ?m to 20 ?m.Type: ApplicationFiled: August 16, 2012Publication date: December 6, 2012Applicant: HITACHI METALS, LTD.Inventors: Takeshi NISHIUCHI, Noriyuki NOZAWA, Satoshi HIROSAWA, Tomohito MAKI, Katsunori BEKKI
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Publication number: 20120297911Abstract: A forged composite powder metal part, such as a CVJ inner race or bevel gear, and method of making the same are disclosed. The forged composite powder metal part includes a outer section concentrated with a first powder metal material, a inner section concentrated with a second powder metal material and a variable boundary profile between the materials of the two sections. For example, in a forged CVJ inner race, the different materials can provide improved wear resistance in the ball tracks and improved spline performance. As another example, in a forged bevel gear, the different materials can be used to create a continuous variable boundary profile that defines the depth of a harder layer over the teeth.Type: ApplicationFiled: June 15, 2012Publication date: November 29, 2012Applicant: GKN SINTER METALS, LLCInventor: Timothy E. Geiman
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Publication number: 20120285826Abstract: A sputtering target that includes at least two consolidated blocks, each block including an alloy including molybdenum in an amount greater than about 30 percent by weight and at least one additional alloying ingredient; and a joint between the at least two consolidated blocks, the joint being free of any microstructure due to an added bonding agent (e.g., powder, foil or otherwise), and being essentially free of any visible joint line the target that is greater than about 200 ?m width (e.g., less than about 50 ?m width). A process for making the target includes hot isostatically pressing, below a temperature of 1080° C., consolidated perform blocks that may be surface prepared (e.g., roughened to a predetermined roughness value) prior to pressing.Type: ApplicationFiled: May 9, 2012Publication date: November 15, 2012Applicant: H.C. STARCK, INC.Inventors: Gary Alan Rozak, Mark E. Gaydos
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Patent number: 8309018Abstract: Methods of forming bit bodies for earth-boring bits include assembling green components, brown components, or fully sintered components, and sintering the assembled components. Other methods include isostatically pressing a powder to form a green body substantially composed of a particle-matrix composite material, and sintering the green body to provide a bit body having a desired final density. Methods of forming earth-boring bits include providing a bit body substantially formed of a particle-matrix composite material and attaching a shank to the body. The body is provided by pressing a powder to form a green body and sintering the green body. Earth-boring bits include a unitary structure substantially formed of a particle-matrix composite material. The unitary structure includes a first region configured to carry cutters and a second region that includes a threaded pin. Earth-boring bits include a shank attached directly to a body substantially formed of a particle-matrix composite material.Type: GrantFiled: June 30, 2010Date of Patent: November 13, 2012Assignee: Baker Hughes IncorporatedInventors: Redd H. Smith, John H. Stevens, James L. Duggan, Nicholas J. Lyons, Jimmy W. Eason, Jared D. Gladney, James A. Oxford, Benjamin J. Chrest
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Publication number: 20120282501Abstract: A flow battery electrode assembly including a first impermeable, substantially metal electrode consisting essentially of a metal and a second permeable electrode. The assembly also includes at least one electrically conductive spacer connecting the first impermeable, substantially metal electrode and the second permeable electrode such that the first impermeable, substantially metal electrode and the second permeable electrode are spaced apart from each other by an electrolyte flow path. At least one electrically conductive spacer includes a plurality of electrically conductive spacers which mechanically and electrically connect adjacent first impermeable, substantially metal and second permeable electrodes.Type: ApplicationFiled: May 14, 2012Publication date: November 8, 2012Applicant: Primus Power CorporationInventors: Kyle Haynes, Paul Kreiner, Jonathan L. Hall, Brad Kell, Rick Winter
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Publication number: 20120237386Abstract: A method of making a composite sintered powder metal article includes providing a first powder comprising hard particles and a powdered binder in a first region of a mold. Providing a second powder comprising a metal or metal alloy powder in a second region of the mold, wherein the second powder contacts the first powder and comprises at least one of a metal powder and a metallic alloy powder. The first powder and the second powder are consolidated in the mold to provide a green compact. The green compact is sintered to provide a composite sintered powder metal article comprising a cemented hard particle region formed from the first powder and metallurgically bonded to a metallic second region formed from the second powder.Type: ApplicationFiled: June 4, 2012Publication date: September 20, 2012Applicant: TDY INDUSTRIES, LLCInventors: Prakash K. Mirchandani, Morris E. Chandler, Eric W. Olsen
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Patent number: 8268452Abstract: Methods for forming earth-boring tools include providing a metal or metal alloy bonding agent at an interface between a first element and a second element and sintering the first element, the second element, and the boding agent to form a bond between the first element and the second element at the interface. The methods may be used, for example, to bond together portions of a body of an earth-boring tool (which may facilitate, for example, the formation of cutting element pockets) or to bond cutting elements to a body of an earth-boring tool (e.g., a bit body of a fixed-cutter earth-boring drill bit or a cone of a roller cone earth-boring drill bit). At least partially formed earth-boring tools include a metal or metal alloy bonding agent at an interface between two or more elements, at least one of which may comprise a green or brown structure.Type: GrantFiled: July 31, 2007Date of Patent: September 18, 2012Assignee: Baker Hughes IncorporatedInventors: Nicholas J. Lyons, Jimmy W. Eason, Redd H. Smith, John H. Stevens
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Publication number: 20120228361Abstract: An ultrasonic welding tool fabricated of powder metal material includes a body and a welding tip extending axially from the body to a working end. The powder metal material can be ferrous-based and admixed with additives, such as alumina, carbide, ferro-molybdenum, ferro-nickel, chrome or tribaloy. An exposed surface of the welding tip can comprise Fe3O4 oxides. The tool is compacted to the desired shape and sintered. The body can include a different second material compacted separately from the welding tip and then joined to the tip and sintered.Type: ApplicationFiled: May 21, 2012Publication date: September 13, 2012Inventor: Denis CHRISTOPHERSON, JR.
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Publication number: 20120231262Abstract: The present invention provides an electrode material for aluminum electrolytic capacitors and a production method thereof. The electrode material of the present invention is formed of a sintered body of at least one of aluminum or aluminum alloys, and does not require an etching process. The electrode material of the present invention ensures a high capacitance even when the aluminum or aluminum alloy powder has a small particle diameter and the sintered body has a large thickness. Specifically, the present invention provides an electrode material for aluminum electrolytic capacitors, comprising a sintered body of at least one of an aluminum powder and aluminum alloy powders, wherein: the powder has an average particle diameter d50 of 1 to 10 ?m, and the sintered body comprises two or more sintered layers in which average particle diameters d50 of powders contained in adjacent sintered layers have a difference of at least 0.5 ?m.Type: ApplicationFiled: November 25, 2010Publication date: September 13, 2012Applicant: TOYO ALUMINIUM KABUSHIKI KAISHAInventors: Shinya Sone, Toshifumi Taira, Masashi Mehata
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Patent number: 8246902Abstract: A method for manufacturing a plate-type heat pipe includes providing a mold including a first cavity and a plurality of second cavities and depositing cores into the mold. Each core has a first portion in the first cavity and a second portion in a corresponding second cavity. First and second metal powder are filled into the mold. The cores are then removed from the mold to form a green piece by the first and second metal powder, which has first and second chambers therein. The green piece is sintered, whereby the first metal powder forms an outer wall of the heat pipe and the second metal powder forms a wick structure. The heat pipe has a heat absorbing portion having the first chambers and fins having the second chambers communicating with the first chambers.Type: GrantFiled: August 31, 2009Date of Patent: August 21, 2012Assignee: Foxconn Technology Co., Ltd.Inventor: Chuen-Shu Hou
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Publication number: 20120197327Abstract: One aspect relates to an electrical bushing for use in a housing of an implantable medical device. The electrical bushing includes at least one electrically insulating base body and at least one electrical conducting element. The electrical bushing includes a holding element to hold the electrical bushing in or on the housing. The conducting element is set-up to establish, through the base body, at least one electrically conductive connection between an internal space of the housing and an external space. The conducting element is hermetically sealed with respect to the base body. The at least one conducting element includes at least one cermet. The holding element is made, to at least 80% by weight with respect to the holding element, from a material selected from the group consisting of a metal from any of the subgroups IV, V, VI, VIII, IX, and X of the periodic system.Type: ApplicationFiled: January 30, 2012Publication date: August 2, 2012Applicant: HERAEUS PRECIOUS METALS GMBH & CO. KGInventor: Heiko Specht
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Patent number: 8230762Abstract: Methods of manufacturing rotary drill bits for drilling subterranean formations include forming a plurality of boron carbide particles into a body having a shape corresponding to at least a portion of a bit body of a rotary drill bit, infiltrating the plurality of boron carbide particles with a molten aluminum or aluminum-based material, and cooling the molten aluminum or aluminum-based material to form a solid matrix material surrounding the boron carbide particles. In additional methods, a green powder component is provided that includes a plurality of particles each comprising boron carbide and a plurality of particles each comprising aluminum or an aluminum-based alloy material. The green powder component is at least partially sintered to provide a bit body, and a shank is attached to the bit body.Type: GrantFiled: February 7, 2011Date of Patent: July 31, 2012Assignee: Baker Hughes IncorporatedInventors: Heeman Choe, John H. Stevens, James C. Westhoff, Jimmy W. Eason, James L. Overstreet
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Publication number: 20120169183Abstract: There are provided a ceramic composition for a piezoelectric actuator allowing for low-temperature sintering and a method of manufacturing the same, and a piezoelectric actuator. A Cuo powder and an MnO powder as an sintring additive are added to a PZT-PZN piezoelectric ceramic powder to allow low-temperature sintering at a temperature of 950° C. or lower, and the usage of high-priced palladium (Pd) used as materials for high-temperature inner electrodes is decreased due to lowering of the sintering temperature, and thereby to achieve cost reduction.Type: ApplicationFiled: December 22, 2011Publication date: July 5, 2012Inventors: Boum Seock Kim, Seung Gyo Jeong, Eun Tae Park
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Publication number: 20120136400Abstract: A method comprising molding a first component from a first feedstock comprising a first material powder and a first binder, molding a second component from a second feedstock comprising a second material powder and a second binder, placing the first component and the second component in physical communication with each other in order to form an assembled component, removing the first binder and the second binder from the assembled component and performing a sintering operation on the assembled component so as to bond the first component and the second component together.Type: ApplicationFiled: April 29, 2010Publication date: May 31, 2012Applicant: MAETTA SCIENCES, INC.Inventors: Benoit Julien, Mathieu Boisclair, Alexei Mourski
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Patent number: 8182739Abstract: A concentric-circular-gradient functional material for biogenic use is produced using first, second, third and forth cylindrical partitions, and a cylindrical dice which are concentrically stood on a supporting stand. Ti powder (A) fills the first cylindrical partition. A first mixed powder including Ti powder (A) and biogenic material powder (B) fills between the first and second cylindrical partitions. A second mixed powder including a smaller amount of Ti powder (A) than the first mixed powder fills between the second and third cylindrical partitions. A third mixed powder including a smaller amount of Ti powder (A) than the second mixed powder fills between the third and fourth cylindrical partitions. The biogenic material powder (B) fills between the fourth cylindrical partition and the dice. The first to fourth partitions are pulled out. The dice is capped using a punch. The powders are sintered using a discharge plasma sintering machine.Type: GrantFiled: June 13, 2008Date of Patent: May 22, 2012Assignee: Nihon UniversityInventors: Michiharu Okano, Hiroshi Izui
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Patent number: 8178212Abstract: Method for chemical bonding of fiberglass fibers to steel surfaces to prepare the steel for bonding with carbon composite material. This fiber-bonding step greatly increases the strength of the subsequent metal-composite bond. The fiberglass fibers which are chemically bonded to the steel provide a high surface area interface to entangle with carbon fibers in the composite component, and thereby inhibit crack formation on the boundary surface between the steel and composite components when they are bonded together.Type: GrantFiled: October 24, 2008Date of Patent: May 15, 2012Assignees: Honeywell International Inc., The University of Notre Dame du LacInventors: Allen H. Simpson, Mark L. La Forest, Alexander Mukasyan