Powder Next To Powder Patents (Class 419/6)
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Publication number: 20090026026Abstract: Vehicular brake rotor formed by powder metallurgy including metals such as titanium powder.Type: ApplicationFiled: July 23, 2007Publication date: January 29, 2009Inventor: Gerald Martino
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Publication number: 20090026027Abstract: Diffusion bonded brake rotor and hub formed by powder metallurgy including metals such as titanium powder.Type: ApplicationFiled: December 26, 2007Publication date: January 29, 2009Inventor: Gerald Martino
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Patent number: 7452500Abstract: The invention relates to a method for making metallic and/or non-metallic products 2, in particular dental products, by freeform sintering and/or melting, in which the products 2 are fabricated layer by layer from a material 5 that is applied layer by layer by means of a computer-controlled high-energy beam 7, in particular a laser or electron beam. In order to reduce production times, beam 7 irradiates predetermined positions P1 to P6 of a layer of a material 5 a plurality of time, namely m times, where m is a whole integer greater than 1. Each of said positions P1 to P6 is initially heated during the first irradiation to a temperature below the melting point Tmelt of the material 5, and during the mth irradiation to a temperature above said melting point and is completely melted over the entire thickness of the layer in such a way that the material (5) fuses at said position to the layer thereunder. The invention also relates to an apparatus for performing said method.Type: GrantFiled: February 24, 2005Date of Patent: November 18, 2008Assignee: BEGO Medical GmbHInventor: Ingo Uckelmann
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Patent number: 7454262Abstract: Arrangement for producing a three-dimensional product, which arrangement comprises a work table on which said three-dimensional product is to be built up, a powder dispenser which is arranged so as to distribute a thin layer of powder on the work table for forming a powder bed, a radiation gun for delivering energy to the powder, fusing together of the powder then taking place, means for guiding the beam emitted by the radiation gun over said powder bed for forming a cross section of said three-dimensional product by fusing together parts of said powder bed, and a control computer in which information about successive cross sections of the three-dimensional product is stored, which cross sections build up the three-dimensional product, where the control computer is intended to control said means for guiding the radiation gun over the powder bed according to an operating scheme forming a cross section of said three-dimensional body, said three-dimensional product being formed by successive fusing together of sType: GrantFiled: December 12, 2003Date of Patent: November 18, 2008Assignee: Arcam ABInventor: Morgan Larsson
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Publication number: 20080279710Abstract: A method of producing an electrically conductive composite composition, which is particularly useful for fuel cell bipolar plate applications.Type: ApplicationFiled: May 8, 2007Publication date: November 13, 2008Inventors: Aruna Zhamu, Jinjun Shi, Jiusheng Guo, Bor Z. Jang
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Publication number: 20080274371Abstract: A composite substrate for superconductors and methods for making the same are described. The composite substrate of the present invention includes at least a core layer having and a sheath layer having a cube texture on at least a portion its surface. In certain embodiments, the core layer can include a nickel-tungsten-molybdenum alloy having about 2-10 atomic percent tungsten and 2-15 atomic percent molybdenum. In some embodiments, the sheath layer can include nickel or a nickel-tungsten alloy having about 0 to 6 atomic percent tungsten. Generally, the core layer is stronger than the sheath layer and an interdiffusion zone can exist between the core layer and the sheath layer.Type: ApplicationFiled: April 2, 2008Publication date: November 6, 2008Applicant: AMERICAN SUPERCONDUCTOR CORPORATIONInventors: Cornelis Leo Hans THIEME, Elliott D. THOMPSON
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Publication number: 20080237403Abstract: A method of producing an airfoil including the steps of providing a first preform having a metallic powder of a first alloy, the first preform defining an airfoil body having curved pressure and suction sides. A tip cap is disposed between the pressure and suction sides of the airfoil at a radially outer end of the airfoil body. A partial height squealer tip extends radially outwards from the tip cap to provide a second preform that is a metallic powder of a second alloy different from the first alloy. The tip cap is formed in the shape of an extension of the squealer tip. The first and second preforms are sintered to consolidate the metal powders. An airfoil according to the method is also disclosed.Type: ApplicationFiled: March 26, 2007Publication date: October 2, 2008Applicant: GENERAL ELECTRIC COMPANYInventors: Thomas Joseph Kelly, Mark Kevin Meyer, Melissa Jane Parks, Stephen Joseph Ferrigno
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Patent number: 7428777Abstract: A method and device for thermal conduction is provided. Methods of forming heatsinks are provided that include advantages such as the ability to produce intricate detailed features that other manufacturing methods are not capable of. Other advantages provided include a reduction in process time and cost due to the absence of a need to machine components after initial fabrication. Embodiments of heatsinks that are formed using methods provided include features such as sub-fins and other detailed features that cannot be formed using other manufacturing processes. Further embodiments of heatsinks that are formed using methods provided include materials that cannot be formed using other manufacturing processes.Type: GrantFiled: June 28, 2005Date of Patent: September 30, 2008Assignee: Intel CorporationInventors: Kai Yong Cheng, Chew Keat Lim, Teik Hua Ng
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Publication number: 20080199716Abstract: Electrical contact device, in particular for low-voltage switches and contactors, comprising a contact element produced in one piece. Said contact element comprises in particular a first conducting area and a second contact area, said first area and said second area being produced with materials of different types. The device according to the invention is suitably produced through a sintering process of at least two powders of conductive material of different types, in order to define in said contact element a first conducting area produced with a first of said powders, and a second contact area produced with a second of said powders.Type: ApplicationFiled: May 3, 2006Publication date: August 21, 2008Applicant: ABB SERVICE S.R.L.Inventors: Romano Elidi, Massimo Maura
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Publication number: 20080199343Abstract: Method for forming a unitary component from a plurality of powder metallurgy compacts. The method in some embodiments includes fluidizing first and second surfaces, wherein a first powder metallurgy compact defines the first surface and a second powder metallurgy compact defines the second surface. The method also includes joining the fluidizing first and second surfaces to form a bonded structure and thermally treating the bonded structure to fuse the first and second compacts into a unitary component.Type: ApplicationFiled: June 29, 2007Publication date: August 21, 2008Inventors: Jedidiah David Rust, Michael Charles Watt, Laxmappa Hosamani, Jason Joseph Schmertman
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Publication number: 20080181810Abstract: A magnetic film of an oxide-containing cobalt base alloy has a smaller coercivity difference than conventional magnetic films. A target material and a sputtering target of the invention are capable of forming the magnetic film. A manufacturing method of the target material is also disclosed. The magnetic film of an oxide-containing cobalt base alloy and the oxide-containing cobalt base alloy target material each have a Fe content of 100 ppm or less. The sputtering target includes the target material bonded to a backing plate. The manufacturing method of the oxide-containing cobalt base alloy target material includes preparing a Co—Cr alloy by melting Cr ingot and at least one Co source selected from Co ingot and Co powder, preparing Co—Cr alloy powder by atomizing the Co—Cr alloy, preparing a mixed powder by mixing the Co—Cr alloy powder, Pt powder and oxide powder, and sintering the mixed powder after forming or simultaneously with forming.Type: ApplicationFiled: September 18, 2007Publication date: July 31, 2008Applicant: MITSUI MINING & SMELTING CO., LTD.Inventor: Kazuteru Kato
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Publication number: 20080145686Abstract: 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: ApplicationFiled: October 25, 2007Publication date: June 19, 2008Inventors: Prakash K. Mirchandani, Alfred J. Mosco, Eric W. Olsen, Steven G. Caldwell
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Publication number: 20080112834Abstract: In a process for manufacturing composite sintered machine components, the composite sintered machine component has an approximately cylindrical inner member and an approximately disk-shaped outer member, the inner member has pillars arranged in a circumferential direction at equal intervals and a center shaft hole surrounded by the pillars, and the outer member has holes corresponding to the pillars of the inner member and a center shaft hole corresponding to the center shaft hole of the inner member and connected to the holes. The process comprises compacting the inner member and the outer member individually using an iron-based alloy powder or an iron-based mixed powder so as to obtain compacts of the inner member and the outer member, tightly fitting the pillars of the inner member into the holes of the outer member, and sintering the inner member and the outer member while maintaining the above condition so as to bond them together.Type: ApplicationFiled: November 1, 2007Publication date: May 15, 2008Applicant: HITACHI POWDERED METALS CO., LTD.Inventors: Hiromasa Imazato, Koichiro Yokoyama
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Patent number: 7368079Abstract: A method for forming an ultra hard material layer is provided. The method includes disposing a metallic liner inside the periphery of a refractory metal enclosure, introducing ultra hard material feed stock into the enclosure, and sintering using HPHT processing and cooling to form the ultra hard material layer, substantially free of peripheral cracking, chipping and fracturing.Type: GrantFiled: December 9, 2003Date of Patent: May 6, 2008Assignee: Smith International, Inc.Inventors: Xian Yao, David DenBoer, Scott Horman
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Patent number: 7361300Abstract: Methods are provided for making a porous filter that is useful in polymer melt spinning. The methods include pressing particles, such as a metal powder, to form a filter having a filter body integrally formed with a top cap and a bottom cap. The filter body and caps are formed as a single component or, alternatively, are formed as two or three separate parts that are fitted and pressed together to form a single component having blind inlet and outlet cavities. After pressing, the component is sintered to form the porous filter. The particles are pressed and cohere to form the caps and filter body without the use of a polymeric binder, and the inlet and outlet cavities are formed substantially without machining.Type: GrantFiled: August 12, 2003Date of Patent: April 22, 2008Assignee: MOTT CorporationInventors: William R. Kelly, Larry Moore
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Publication number: 20080091267Abstract: Medical devices, such as endoprostheses, and methods of making the devices are disclosed. The endoprostheses comprise a tubular member capable of maintaining patency of a bodily vessel. The tubular member includes a mixture of at least two compositions, where the presence of the second composition gives the mixture a greater hardness than that of the first composition alone. The first composition includes less than about 25 weight percent chromium, less than about 7 weight percent molybdenum, from about 10 to about 35 weight percent nickel, and iron. The second composition is different from the first and is present from about 0.1 weight percent to about 5 weight percent of the mixture.Type: ApplicationFiled: March 29, 2007Publication date: April 17, 2008Inventors: Jonathan S. Stinson, Matthew Cambronne, Richard B. Frank, Richard A. Gleixner, James E. Heilmann
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Publication number: 20080075618Abstract: A method for manufacturing a downhole tool includes obtaining a three-dimensional model of the downhole tool; converting the three-dimensional model of the downhole tool into a model having a plurality of two-dimensional layers; and building the downhole tool, layer-by-layer, by melting a metal powder or an alloy powder using an electron beam based on the model having a plurality of two-dimensional layers. A downhole tool manufactured by a process includes obtaining a three-dimensional model of the downhole tool; converting the three-dimensional model of the downhole tool into a model having a plurality of two-dimensional layers; and building the downhole tool, layer-by-layer, by melting a metal powder or an alloy powder using an electron beam based on the model having a plurality of two-dimensional layers.Type: ApplicationFiled: July 27, 2007Publication date: March 27, 2008Applicant: SCHLUMBERGER TECHNOLOGY CORPORATIONInventors: Gary A. Martin, David J. Belliveau, Daniel B. Theriault
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Patent number: 7347968Abstract: The invention shows how powder injection molding may be used to form a continuous body having multiple parts, each of which has different functional properties such as corrosion resistance or hardness, there being no connective materials such as solder or glue between the parts. This is accomplished through careful control of the relative shrinkage rates of these various parts. Although there is no limit to how many parts with different functional properties can make up an object, special attention is paid to certain pairs of functional properties that are difficult and/or expensive to combine in a single object when other manufacturing means are used.Type: GrantFiled: October 1, 2003Date of Patent: March 25, 2008Assignee: Advanced Materials Technology Pte. Ltd.Inventors: Kay Leong Lim, Lye-King Tan, Eng-Seng Tan, Robin Baumgartner
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Publication number: 20080054216Abstract: There is disclosed a piezoelectric/electrostrictive body in which a polarization direction of a domain indicates reversible conversion in an electric field and a strain ratio increases, a manufacturing method of the same, and a piezoelectric/electrostrictive element. The piezoelectric/electrostrictive body includes a matrix phase represented by a composition formula ABO3, and an additional, material phase included in the matrix phase, having at least a crystal structure of tetragonal system, represented by a composition formula ABO3 and having a composition different from that of the matrix phase. For example, an alkali-niobate-based material of the tetragonal system, BaTiO3, PZT, PbTiO3, or (Bi0.5, Na0.5)TiO3 is added as an additional material forming the additional material phase to an alkali-niobate-based matrix material forming the matrix phase to form the piezoelectric/electrostrictive body.Type: ApplicationFiled: August 24, 2007Publication date: March 6, 2008Applicant: NGK Insulators, Ltd.Inventors: Hirofumi Yamaguchi, Shuichi Ozawa
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Publication number: 20070272724Abstract: A friction stir tool has an axis of rotation and a welding tip that is made of powdered metal material.Type: ApplicationFiled: March 22, 2007Publication date: November 29, 2007Inventor: Denis Christopherson
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Publication number: 20070269329Abstract: A composite article that can be used as a substrate for coated conductors is disclosed. The composite substrate has at least three layers in which one or more inner layers of Ni—W alloys with 9 at. %-13 at. % W and two outer layers of Ni—W alloys with 3 at. %-9 at. % W. The content of W element gradually decreases from the inner layers to the outer layers. The composite substrate can be prepared using a process of designing and sintering composite ingot, rolling composite ingot and then annealing composite substrate. The composite substrate have a dominant cube texture on the outer layer of the whole substrate which have a weaker magnetism and higher strength than that of a single Ni-5 at. % W alloy substrate.Type: ApplicationFiled: December 7, 2006Publication date: November 22, 2007Inventors: Meiling Zhou, Hongli Suo, Min Liu, Yue Zhao, Dong He, Yingxiao Zhang, Lin Ma, Yaming Li, Jie Zhou, Yonghua Zhu, Shuai Ye, Lingji Ma, Zili Zhang, Tieyong Zuo
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Patent number: 7241416Abstract: A rotor shaft assembly (101) of a type used in a turbocharger, manufactured by mounting a powder compact of a titanium aluminide rotor (203) to a powder compact of a steel shaft (207), with a metal powder admixed with a binder (211) interposed between the rotor and shaft, and debinding and sintering the mounted compact combination. Sintering produces a strong metallurgical bond between the shaft and rotor, providing a near-net rotor shaft assembly (101) and also an inexpensive and efficient method for the manufacture of an assembly capable of withstanding the high forces and temperatures within a turbocharger.Type: GrantFiled: August 12, 2003Date of Patent: July 10, 2007Assignee: Borg Warner Inc.Inventor: Patrick Sweetland
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Patent number: 7241415Abstract: A selective inhibition of sintering (SIS) technique may be used to fabricate a three-dimensional (3-D) dense metal object from a binderless metal powder. Layers of metal powder are provided on a build tank. For each layer, regions of the layer are sinter-inhibited, e.g., by depositing a sinter-inhibiting material such as a ceramic slurry, a metal salt, or oxidizing metal particles in the powder using chemicals or a concentrated heat source. Each layer may be compacted before the next layer is provided. A final compact may then be sintered. Unwanted sintered sections may be removed from the compact at boundaries formed by the sinter-inhibited (unsintered) regions, and the object extracted.Type: GrantFiled: June 30, 2003Date of Patent: July 10, 2007Assignee: University of Southern CaliforniaInventor: Behrokh Khoshnevis
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System and method for fabricating a three-dimensional metal object using solid free-form fabrication
Patent number: 7220380Abstract: A method for solid free-form fabrication of a three-dimensional metal object includes depositing a particulate blend in a defined region, the particulate blend including a number of metal or metal alloy particulates and a peroxide, and selectively ink-jetting a binder system onto a predetermined area of the particulate blend to form a green part, wherein the liquid phase binder includes a water soluble monofunctional acrylate-based monomer, a water soluble difunctional acrylate-based monomer, an amine, and water.Type: GrantFiled: October 14, 2003Date of Patent: May 22, 2007Assignee: Hewlett-Packard Development Company, L.P.Inventors: Isaac Farr, Terry M. Lambright, Daniel A. Kearl -
Patent number: 7172724Abstract: In order for a surface of a three-dimensional sintered object to be smoothly finished by removing unwanted portions and an excessively sintered growth formed during sintering to form sintered layers, the three-dimensional sintered object is formed by repeating successive processes of dispensing a powdery material and directing an optical sintering beam to the powdery material to form the sintered layer, until a required number of integral laminated bodies are formed. During the formation of the integral laminated bodies, trimming is applied to a first zone different from a second zone in which each laminated body is formed, to remove unwanted portions of the respective laminated body.Type: GrantFiled: November 27, 2002Date of Patent: February 6, 2007Assignee: Matsushita Electric Works, Ltd.Inventors: Satoshi Abe, Yoshikazu Higashi, Hirohiko Togeyama, Norio Yoshida, Isao Fuwa, Shushi Uenaga, Seizo Machida, Masataka Takenami
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Patent number: 7146708Abstract: A method of making composite electric machine rotor assembly of a desired magnetic pattern. Magnetic segments and non-magnetic segments are separately formed to green strength, and then arranged adjacent to each other in a desired magnetic pattern. A small amount of powder material is added in-between the segments, and the whole assembly is then sintered to form a sinterbonded composite component of high structural integrity.Type: GrantFiled: September 9, 2004Date of Patent: December 12, 2006Assignee: Delphi Technologies, Inc.Inventors: Frederick B. Reiter, Jr., Tom L. Stuart
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Patent number: 7108829Abstract: A method of manufacturing a sliding part includes the steps of forming a green member by injection molding integrally and unmixedly two powdery metallic materials of different compositions, sintering the green member and subjecting the green member to at least one heat treatment.Type: GrantFiled: March 8, 2004Date of Patent: September 19, 2006Assignee: Matsushita Electric Industrial Co., Ltd.Inventors: Hiroyuki Fukuhara, Hidenobu Shintaku
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Patent number: 7070734Abstract: A green article comprising an A-B powder mixture and methods of manufacturing such green articles and corresponding sintered articles are disclosed. The A-B powder mixture consists of a minor volume fraction of a relatively fine powder A and a complementary major volume fraction of a relatively coarse prealloyed powder B wherein the A-B powder mean particle size ratio is at least about 1:5. Metal powder A consists of one or more elemental metals or alloys which has a melting or solidus temperature above the highest sintering temperature at which the A-B powder mixture may be sintered without slumping. Prealloyed metal powder B consists of one or more alloys which are amenable to supersolidus liquid phase sintering. Green articles made from the A-B powder have a wider sintering temperature window than do articles made from prealloyed metal powder B alone.Type: GrantFiled: March 16, 2004Date of Patent: July 4, 2006Assignee: The Ex One CompanyInventors: Jianxin Liu, Michael L. Ryneson
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Patent number: 6984270Abstract: 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.Type: GrantFiled: October 31, 2002Date of Patent: January 10, 2006Assignee: Shin-Etsu Chemical Co., Ltd.Inventors: Koji Sato, Mitsuo Kawabata, Takehisa Minowa
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Patent number: 6973723Abstract: A piston includes a piston structure being unitarily formed in a powder metallurgy process, the piston structure having a crown assembly and a skirt assembly, at least a partial combustion chamber being formed intersecting a piston crown surface during the powder metallurgy process, the skirt assembly depending from the crown assembly and having two spaced apart pin bosses, each pin boss having a pin bore defined therein, a pair of opposed semi-circular skirt members, each skirt member extending outwardly from and being integrally joined to both of the pin bosses. The piston may be formed by executing a powder metallurgy process on at least two different metallic constituents to define a non-homogenous piston structure. A method of forming a piston is further included.Type: GrantFiled: January 8, 2003Date of Patent: December 13, 2005Assignee: International Engine Intellectual Property Company, LLCInventors: John L. Cagney, Valeri B. Petrov
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Patent number: 6939508Abstract: A method for manufacturing a net-shaped bimetallic part that includes the steps of: providing a tool that defines a cavity and a tooling surface; depositing a layer of an environmental metal material onto the tooling surface; filling the cavity in the tool with a powdered metal material; and simultaneously heating the tool and subjecting the tool to a pressurized gas to consolidate the powdered metal material and diffusion bond the environmental metal material to the consolidated powdered metal material to form a bimetallic part.Type: GrantFiled: October 24, 2002Date of Patent: September 6, 2005Assignee: The Boeing CompanyInventors: Clifford C. Bampton, Victor Samarov
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Patent number: 6926777Abstract: The invention relates to a method for producing rod-shaped permanent magnets according to which pressed parts (2) are produced that are then assembled to a rod-shaped green product. Said green product is subsequently sintered, whereby a rod-shaped single-piece permanent magnet (1) is produced.Type: GrantFiled: December 19, 2000Date of Patent: August 9, 2005Assignee: Vacuumschmelze GmbH & Co. KGInventors: Georg Werner Reppel, Volker Zellmann
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Patent number: 6926969Abstract: The invention relates to a process for the production of sintered porous bodies, to porous bodies produced correspondingly using the process, and to their use. With the solution according to the invention, sintered bodies which achieve improved properties, such as an increased surface area, deformability of the structures at room temperature or modification of the initial pore volume, are to be produced. To this end, at least one sintering-active powder which forms at least one intermetallic phase or mixed crystals is applied to the surface of a porous basic body. Heat treatment is to be carried out subsequently, in which intermetallic phases or mixed crystals which increase the specific surface area can be formed.Type: GrantFiled: October 4, 2002Date of Patent: August 9, 2005Assignees: Inco Limited, Fraunhofer-Gesellschaft zur Forderung der angewandten Forschung e. V.Inventors: Alexander Bohm, Hartmut Gohler, Dirk Naumann
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Patent number: 6908588Abstract: The invention relates to a process for manufacturing an evaporation source for physical vapor deposition. The evaporation source is formed of the actual sputtering target with an aluminum component and one or more further components as well as of a backing plate made from a material having better thermal conductivity than the target. The backing plate made of a powdery starting material is pressed, together with the powdery components of the sputtering target, into sandwiched powder fractions and then formed.Type: GrantFiled: June 12, 2002Date of Patent: June 21, 2005Assignee: Plansee AktiengesellschaftInventors: Peter Wilhartitz, Stefan Schönauer, Peter Polcik
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Patent number: 6889419Abstract: A method of making composite electric machine components. Magnetic segments and non-magnetic segments are separately formed to green strength, and then arranged adjacent to each other in a desired magnetic pattern. A small amount of powder material is added in-between the segments, and the whole assembly is then sintered to form a sinterbonded composite component of high structural integrity.Type: GrantFiled: April 16, 2002Date of Patent: May 10, 2005Assignee: Delphi Technologies, Inc.Inventors: Frederick B. Reiter, Jr., Tom L. Stuart
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Patent number: 6881376Abstract: The present invention relates to a nuclear fuel body comprising tungsten network and a method for manufacturing the same, more particularly, a nuclear fuel body in which tungsten network is continuously formed over the entire or some parts of a sintered body and a method for manufacturing the same. The sintered body in the nuclear fuel body of the present invention contains tungsten network having excellent heat conductivity, leading to the enhancement of heat conductivity of the nuclear fuel sintered body itself with decreasing the temperature of the nuclear fuel, so that it can contribute to the improvement in safety and performance of nuclear fuel.Type: GrantFiled: October 2, 2003Date of Patent: April 19, 2005Assignees: Korea Atomic Energy Research Institute, Korea Hydro & Nuclear Power, Co., Ltd.Inventors: Kun Woo Song, Jae Ho Yang, Keon Sik Kim, Ki Won Kang, Jong Hun Kim, Youn Ho Jung
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Patent number: 6872356Abstract: The residual stresses that are experienced in polycrystalline diamond cutters, which lead to cutter failure, can be effectively modified by selectively thinning the carbide substrate subsequent to high temperature, high pressure (sinter) processing, by selectively varying the material constituents of the carbide substrate, by subjecting the PDC cutter to an annealing process during sintering, by subjecting the formed PDC cutter to a post-process stress relief anneal, or a combination of those means.Type: GrantFiled: November 15, 2002Date of Patent: March 29, 2005Assignee: Baker Hughes IncorporatedInventors: Trent N. Butcher, Ralph M. Horton, Stephen R. Jurewicz, Danny E. Scott, Redd H. Smith
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Patent number: 6843960Abstract: A method for preparing compositionally graded metallic plates and compositionally graded metallic plates suitable for use as interconnects for solid oxide fuel cells are provided. The method of the invention, utilizing powder metallurgy, enables making metallic plates of generally any desired composition to meet the corrosion requirements of fuel cells and other applications, and enables making metallic plates of graded composition from one surface of the plate to the other. A powder of the desired alloy composition is obtained, then solvents, dispersants, a plasticizer and an organic binder are added to form a slip. The slip is then formed into a layer on a desired substrate that can be flat or textured. Once dried, the layer is removed from the substrate and the binder is burned out. The layer is sintered in a reducing atmosphere at a set temperature for a predefined duration specific to the materials used and the desired final properties.Type: GrantFiled: June 12, 2002Date of Patent: January 18, 2005Assignee: The University of ChicagoInventors: Michael Krumpelt, Terry Alan Cruse, John David Carter, Jules L. Routbort, Romesh Kumar
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Publication number: 20040228754Abstract: To make a three-dimensional object, an optical beam is first irradiated on a predetermined portion of a powder layer to form a sintered layer, which is then covered with a new powder layer. The optical beam is again irradiated on a predetermined portion of the new powder layer to form another sintered layer that has been united with the underlying sintered layer. These processes are repeatedly carried out to form a plurality of sintered layers united together. When the second lower density layer is formed on the first higher density layer, a powder material layer for the lower density layer is formed at a predetermined thickness so as to have a thickness suitable for sintering condition and then the powder material layer is sintered to form the lower density layer.Type: ApplicationFiled: September 29, 2003Publication date: November 18, 2004Applicant: Matsushita Electric Works, Ltd.Inventors: Satoshi Abe, Isao Fuwa, Hirohiko Togeyama, Norio Yoshida, Masataka Takenami, Shuushi Uenaga
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Publication number: 20040166012Abstract: A magnetic armature, having an outer ring formed of a first powdered metal, the outer ring having magnetic qualities and the first powdered metal of the outer ring includes metals having poor welding characteristics; an inner ring formed of a second powdered metal and being disposed within the outer ring, the inner ring being an iron metal having good welding characteristics and the inner ring defines an inner opening for receiving a shaft for rotating the magnetic armature; wherein said outer ring and said inner ring are joined together by a sintering process and the shaft is welded to the inner ring.Type: ApplicationFiled: February 21, 2003Publication date: August 26, 2004Inventor: David Earl Gay
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Patent number: 6773824Abstract: 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.Type: GrantFiled: June 10, 2003Date of Patent: August 10, 2004Assignee: Crucible Materials Corp.Inventors: Frank J. Rizzo, Brian A. Hann, Joseph F. Perez
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Patent number: 6756010Abstract: 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.Type: GrantFiled: June 11, 2002Date of Patent: June 29, 2004Assignee: Sumitomo Special Metals Co., Ltd.Inventors: Tsutomu Harada, Hitoshi Morimoto, Atsuo Tanaka
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Publication number: 20040105999Abstract: A composite article and a method for making it are described. A clad structure composed of Zr and Ti is produced by cladding zirconium to a titanium surface. The surface can be either commercially pure titanium or a titanium alloy, such as Ti-6Al-4V, and may be manufactured by powder metallurgy techniques into barstock material or a shaped perform, which may be subsequently forged, extruded, or rolled.Type: ApplicationFiled: August 12, 2003Publication date: June 3, 2004Inventors: Stanley Abkowitz, Susan M. Abkowitz
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Patent number: 6730263Abstract: The invention relates to a method for producing a sintered part comprised of a powdery material, especially comprised of a sintered metallurgical powder. According to the inventive method, a green compact which forms an elementary shape of the part is firstly compression molded from the powder. The desired final shape of the part is produced by subjecting partial areas of the elementary shape on the green compact to a successive non-cutting shaping. Afterwards, said final shape is finished by sintering.Type: GrantFiled: May 2, 2001Date of Patent: May 4, 2004Assignee: GKN Sinter Metals GmbHInventors: Eberhard Ernst, Bernhard Brust, Berthold Morber, Wolfgang Schiemenz
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Patent number: 6723278Abstract: This invention presents the process of direct laser casting of copper alloys: Cu—X (where X=Ni, Fe, W;) and their composites Cu—Y and Cu—X—Y (Y=WC, TiC, Ti+C) from powders prepared using mechanical mixing and ball milling processes. Since the metallic powder is combined with a low melting point Cu metal, which has good thermal and electrical conductivity, the combination allows the powder mixture to be melted by CO2 laser and re-solidified into a part with good mechanical properties and conductivity. The laser casting process for the Cu-based in-situ formation and the material systems formed using the said method have been developed. The process can be used to fabricate complex three-dimensional objects by multi-layer overlapping and the material systems can be used to build rapid tooling due to the properties of good thermal conductivity and low wear rate.Type: GrantFiled: January 31, 2002Date of Patent: April 20, 2004Assignees: The National University of Singapore, The Singapore Institute of Manufacturing TechnologyInventors: Li Lu, Jerry Ying Fuh, Yoke San Wong, Zhenda Chen, Gnian Cher Lim
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Patent number: 6716388Abstract: A rotary chip-removing tool includes a rotary tool body and a tool tip fastened on a front end thereof. The tool tip is formed of an injection molded body which has an integral cutting edge at its front end, and a coupling structure at its rear end. The coupling structure can be in the form of a threaded hole, or a rearward projection, for coupling the tool tip against the tool body. The tool tip is formed of first and second materials. The first material forms at least part of the cutting edge, and the second material forms the coupling structure. The first material is more brittle than the second material, and the second material is tougher than the first material.Type: GrantFiled: February 4, 2003Date of Patent: April 6, 2004Assignee: Seco Tools ABInventors: Johnny Bruhn, Mattias Puide, Mikael Gronkvist
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Patent number: 6685880Abstract: A cemented carbide insert of a first grade has at least one cutting point consisting of a cemented carbide of a second grade with different composition and/or grain size with an uneven transition zone between the first and second grade.Type: GrantFiled: November 9, 2001Date of Patent: February 3, 2004Assignee: Sandvik AktiebolagInventors: Lars-Åke Engström, Hélène Ouchterlony
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Publication number: 20040018107Abstract: A selective inhibition of sintering (SIS) technique may be used to fabricate a three-dimensional (3-D) dense metal object from a binderless metal powder. A number of layers of metal powder are provided on a build tank. For each layer, regions of the layer are sinter-inhibited, e.g., by depositing a sinter-inhibiting material such as a ceramic slurry, a metal salt, or oxidizing metal particles in the powder using chemicals or a concentrated heat source. Each layer may be compacted before the next layer is provided. A final compact may then be sintered. Unwanted sintered sections may be removed from the compact at boundaries formed by the sinter-inhibited (unsintered) regions, and the object extracted.Type: ApplicationFiled: June 30, 2003Publication date: January 29, 2004Inventor: Behrokh Khoshnevis
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Patent number: 6660225Abstract: The invention shows how powder injection molding may be used to form a continuous body having multiple parts, each of which has different functional properties such as corrosion resistance or hardness, there being no connective materials such as solder or glue between the parts. This is accomplished through careful control of the relative shrinkage rates of these various parts. Although there is no limit to how many parts with different functional properties can make up an object, special attention is paid to certain pairs of functional properties that are difficult and/or expensive to combine in a single object when other manufacturing means are used.Type: GrantFiled: September 24, 2001Date of Patent: December 9, 2003Assignee: Advanced Materials Technologies Pte, Ltd.Inventors: Kay Leong Lim, Lye-King Tan, Eng-Seng Tan, Robin Baumgartner
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Patent number: 6643913Abstract: A method of manufacturing a laminated ferrite chip inductor array, including the steps of printing on individual ferrite sheets having electrically communicating through holes U-shaped conductor patterns disposed 180° to one another, piling the ferrite sheets together, and sintering the piled ferrite sheets to form the inductor array.Type: GrantFiled: May 11, 2001Date of Patent: November 11, 2003Assignee: TDK CorporationInventors: Fumio Uchikoba, Toshiyuki Anbo