Abstract: A method for selectively and rapidly extracting/removing a plasticizer from a compact such as a green laminate that is produced at a certain point in the process of manufacturing a multilayer ceramic capacitor. Carbon dioxide is introduced into a pressure chamber in which the green laminate has been placed, and the temperature and the pressure of the pressure chamber are set to 40° C. and 10 MPa, respectively, so that the pressure chamber is filled with a supercritical carbon dioxide. The plasticizer is extracted/removed from the green laminate by using the supercritical carbon dioxide. Then, a de-binder step and a baking step are performed in an ordinary manner. By performing the de-plasticizer process of selectively extracting/removing the plasticizer before the de-binder step, it is possible to suppress the formation of a graphite-like substance even if the temperature is increased rapidly in the subsequent de-binder step and the baking step.

Abstract: The invention includes methods of forming physical vapor deposition targets, and includes targets and target assemblies. The methods of forming the targets comprise hot-pressing or die forging of suitable materials to form a target blank. The target blank has a pair of opposing surfaces, with one of the opposing surfaces having a topography that is substantially an inverse of an expected wear profile. The target blank can be bonded to a backing plate to form a target assembly or can be utilized as a monolithic target.

Abstract: A method of manufacturing a separator for a polymer electrolyte fuel cell in which the specific resistance is small, and the coefficient of thermal conductivity and the gas shielding property are high and have high strength. The sintering material comprises a phenol resin coated to the surface of a powder of carbon, and the plate is a metallic plate having plating on both surfaces. After the metallic plate is arranged in a mold provided with grooves, the sintering material is filled to both sides of the metallic plate, and then they are heated and sintered. The separator for a fuel cell becomes homogeneous, and, as a result, the gas shielding property rises with high strength, because phenol resin has been uniformly distributed in the sintering material. Moreover, because oxides are not generated on the surfaces of the separator by sintering, the specific resistance will be relatively small.

Abstract: The presently claimed invention relates to a method of making a PcBN cutting tool insert. The method includes the following steps: mixing raw material powders, (e.g., cBN, hBN, TiC, TiN, Ti(C,N), WC, W, C, Co, Co2Al9, Al AlN, Al2O3) with a liquid (e.g., ethanol) and an agent (e.g., polyethylene glycol, PEG) to form a homogeneous slurry with the desired composition; forming spherical powder agglomerates, typically 100 &mgr;m in diameter, preferably by spray drying; pressing said agglomerates to form a body of desired dimensions and density using conventional tool pressing technology; removing the agent from the powder at a suitable temperature and atmosphere; raising the temperature to 1000-1350° C. in vacuum; solid state sintering the body at 1000-1350° C. in vacuum, for 1-90 minutes to form a body with 35-55 vol % porosity; optionally, adding 0.

Abstract: An armature segment of an electrical machine includes a coil and a core section. A method of producing such a segment comprises the steps of tightly winding the coil, providing a compaction die having a cavity for shaping the tightly wound coil, introducing the tightly wound coil into the compaction die and compacting the coil therein so as to reduce the volume occupied by the coil, providing a compression-moulding die having a moulding cavity, positioning the compacted coil in the moulding cavity of the compression die, filling the moulding cavity with insulated ferromagnetic particles, and compressing the insulated ferromagnetic particles in the moulding cavity so as to form the armature segment as a single-piece unit including the core section and the compacted coil.

Abstract: The invention aims to provide a method for preparing a composite substrate which has minimized surface asperities on a dielectric layer, which are otherwise developed under the influence of an electrode layer, unevenness upon printing, and surface roughness inherent to thick-film dielectrics, which eliminates a need for a polishing step, which is easy to manufacture, and which is applicable to the fabrication of a thin-film light-emitting device of high display quality, as well as the resulting composite substrate and a thin-film EL device using the same.

Abstract: 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.

Abstract: A method for producing an improved anisotropic magnet through an extrusion process wherein the container involved in the extrusion process is first coated, on its internal surface, with a material to prevent the bonding of the interior surface to the particle charge to be extruded and, thereby, to prevent cracking due to tensile stresses. In addition, an improved anisotropic extrusion product, with enhanced magnetic properties, can be obtained by holding the temperature of the extrusion product at temperatures between 1000° F. and 1750° F. for between 1 and 10 hours.

Abstract: 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.

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

Abstract: A method for forming a metallic coating on a substrate comprising an intermetallic compound, and the coatings made by this method are disclosed. The method broadly comprises forming an alloyed agglomerate from a precursor comprising at least two metals suitable for forming an intermetallic compound and depositing a coating of the partially converted agglomerate onto a roughened surface of a substrate.

Abstract: Bodies for heating, for example electric sealing jaws, are produced according to the present invention by a method which includes compaction and densification or consolidation of pulverulent, metallic material in a mould. The mould (6) is first supplied with the pulverulent material (10) which is compacted, as well as treated with an impregnating solution (12). Thereafter, the body (2) is heated to dry the solution and to sinter the pulverulent material. The method gives a dense body possessing superior thermal conductivity.

Abstract: A method of regenerating a phase-change sputtering target for optical storage media. First, a used powder-metallurgy sputtering target composed of a target material, an adhesion material, and a backing plate is recycled. Then, the target material is separated from the backing plate. Then, the target adhesion material is scraped from the recycled target material Thereafter, the surface of the recycled target material is processed. Finally, the backing plate, a new adhesion material, the recycled target material, and new powders are placed in a vacuum thermal-pressure furnace in sequence to perform a thermal-pressure sintering process.

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

Abstract: Disclosed is a method of making a composite diamond having a cutting edge comprising a diamond compact bonded to a cemented carbide substrate, the diamond compact having a working surface, an edge of which provides the cutting edge, wherein the diamond compact comprises a first phase containing a polycrystalline mass of diamond particles and a second phase containing a diamond catalyst/solvent and ruthenium, which method includes the steps of providing a cemented carbide substrate, providing a layer of diamond particles on a surface of the substrate, providing a source of diamond catalyst/solvent and ruthenium, wherein the source of the diamond catalyst/solvent and ruthenium is the cemented carbide substrate.

Abstract: The invention relates to a method for connecting a metallic support element to at least one body consisting of a powder metallurgical sintered material. The method is characterised in that said body is brought into contact with the support element in the form of a green body which is compacted from a sintered powder, in that a thin, flat copper body is brought into contact with the green body respectively and in that the entire resulting arrangement is heated to the temperature required to sinter the green body before being cooled again once the sintering process is complete.

Abstract: A method and apparatus for directly making rapid prototype tooling from a computer model having a free-form shape. The method steps comprise essentially: (a) machining a soft metal tooling base so as to contour at least one free-form surface in conformity with the computer model; (b) cold-gas dynamic spraying the contoured surface to form superimposed impact welded metal particle layers, the layers consisting of at least one thermal management under-layer comprising primarily copper, and at least an outer wear resistant layer comprising primarily tool steel.

Abstract: According to the inventive method for producing a composite part (4), a support body (1) is produced from a powder with a ferrous alloy base using powder metallurgy. A magnet body (2) which is based on an alloy that is rich in rare earths is applied to the support body (1) and both are then sintered in a furnace (1), whereby a solid joint is formed between the support body (1) and the magnet body (2).

Abstract: Lightweight metal matrix composites containing a skeleton structure of titanium, titanium aluminide, or Ti-based alloy are manufactured by low temperature infiltration with molten Mg-based alloy or Mg—Al alloy at 450-750° C., with molten In, Pb, or Sn at 300-450° C., or with molten Ag and Cu at 900-1100° C. The skeleton structure with a density of 25-35% is produced by loose sintering of Ti or Ti-based alloy powders. A primary deformation of the Ti skeleton structure before the infiltration is carried out by cold or hot rolling or forging to obtain a porous flat or shaped preform with a porosity <50% and pores drawn out in one direction such as the direction of future rolling of the composite plate.

Abstract: A process for forming a shaped metallic article, including the steps of combining the starting materials, forming the starting materials into a shape to produce a nonmetallic metal precuror article of a certain geometry, and converting the nonmetallic article to a metallic article by reduction or decomposition, while substantially retaining the geometry of the nonmetallic article. The forming step in which the starting materials are fabricated into a shape can include extrusion, dry pressing, or slurry casting. Further, another embodiment is a metallic article produced by converting a nonmetallic article with a certain geometry, including a plurality of open-ended channels, substantially to the same geometry as the nonmetallic article from which it was converted.

Abstract: A gas blowing plug and a manufacturing method therefor wherein the gas blowing plug includes a slit-shaped gas passage (22) ranging from the bottom to the top of the plug. The gas passage (22) is continuous or discontinuous in a horizontal cross section of the plug. The slit-shaped gas passage (22) is also continuous from the bottom to the top of the plug and slit-shaped gas passage (26) is discontinuous in a vertical cross section of the plug. In one example, the cross-sectional shape of the slit-shaped gas passage (22) is a pointed star.

Abstract: These forged articles are useful as connecting rods. The bushing is assembled during the forging operation of the powder metal connecting rod. This reduces the number of manufacturing operations required to process a powder metal article. The main components of this article are a sintered powder metal perform and preferably a bronze bushing. The bronze bushing is inserted in the bore of the sintered perform of a connecting rod and thereafter forged in during forging then heated to provide bonding between the bushing and connecting rod.

Abstract: A sputter target produced from an alloy powder, the individual particles of which are composed of an Si—Al alloy. It is found that a high degree of homogeneity of the sputter target can be achieved in this way.

Abstract: A rotary cone bit, having a functionally-engineered surface of this invention, comprises a bit body having at least one leg extending therefrom, and a cone that is rotatably disposed on the leg. The cone typically comprises a plurality of cutting elements that project outwardly therefrom. The cutting elements comprises a cermet material selected from the group consisting of refractory metal carbides, nitrides, borides, carbonitrides and mixtures thereof. A functionally-engineered material is disposed over a surface portion of at least one of the cutting elements to form a wear resistant surface thereon. The wear resistant surface has a hardness that is different than that of the underlying cutting element. The wear resistant surface is provided by forming a conformable material mixture by combining one or more powders selected from the group consisting of cermets, carbides, borides, nitrides, carbonitrides, refractory metals, Co, Fe, Ni, and combinations thereof, with an applying agent.

Abstract: An exhaust manifold (10) of the present invention comprises a liner (12) that includes inner surface (14) defining manifold passages and an outlet surface (16). The exhaust manifold (10) includes a shell (18) of a homogeneous and continuous material disposed over the outer surface (16) of the liner (12). The shell (18) and liner (12) of the exhaust manifold (10) include first (60) and second (72) composition formed from ferrous and non-ferrous metal powders (62), ceramic powder (64), and a binder (74) added thereto to form the manifold (10). The invention discloses a method of making the exhaust manifold (80) that comprises the steps of forming the liner (12) and molding the shell (18) of a homogeneous and continuous material completely encapsulating the outer surface (16) of the liner (12). Accordingly, the exhaust manifold (10) of the subject invention has a reduced weight and dissipates heat energy contained in the exhaust thereby increasing the efficiency of the catalytic converter (42).

Abstract: Disclosed are a method for manufacturing cutting blades with a shortened manufacturing process and an apparatus for manufacturing cutting blades with a single manufacturing facility, as well as a cutting blade having cutting segments in which diamond particles are uniformly distributed.

Abstract: Formation of sintered metal fiber porous mats used as burner faces and filters comprises dispersing metal fibers in a viscous aqueous solution of one or more cellulose ethers, vacuum molding the dispersed metal fibers on a foraminous support, eliminating residual aqueous cellulose ether from the vacuum molded metal fiber porous mat, and sintering the mat. Water solutions of methylcellulose and/or hydroxypropyl methylcellulose having a viscosity of at least about 1500 centipoises are often used pursuant to this invention.

Abstract: Spent sputtering targets are refurbished by filling the depleted region of the target with new sputter material using a hot isostatic pressing or HIP'ing technique.

Abstract: An iron-based powder including a heat-resistant insulate coating and a powder core are suggested. A paint containing silicone resin and pigment is added to a raw material powder primarily containing a ferromagnetic metal, especially, iron, agitation and mixing are performed and, thereafter, a drying treatment is performed so as to form a coating containing silicone resin and pigment on the surface of the iron-based powder. The ratio of the silicone resin content to the pigment content in the coating is preferably 0.01 or more, but less than 4.0 on a mass basis. The pigment is preferably at least one selected from the group consisting of metal oxides, metal nitrides, metal carbides, minerals, and glass. The paint may be sprayed to the iron-based powder in a fluidized state. A coating containing at least one of Si compounds, Ti compounds, Zr compounds, P compounds, and Cr compounds may be formed as a lower layer of the aforementioned coating.

Abstract: A suspension application apparatus for applying a suspension containing powder particles of an oxide dispersed in a liquid to a plate for magnet sintering, the oxide having a specific gravity greater than the liquid. The apparatus includes: a container for storing the suspension; a stirrer for stirring the suspension stored in the container; a transport path through which the suspension is transported from the container to the plate; and a homogenizer for homogenizing the suspension by applying a mechanical force to at least part of the suspension flowing through the transport path.

Abstract: A method for producing an anisotropic magnet with high energy product through extrusion and, more specifically, by placing a particle charge of a composition from the which magnet is to be produced in a noncircular container, heating the container and particle charge and extruding the container and particle charge through a noncircular extrusion die in such a manner that one of the cross-sectional axes or dimension of the container and particle charge is held substantially constant during the extrusion to compact the particle charge to substantially full density by mechanical deformation produced during the extrusion to achieve a magnet with anisotropic magnetic properties along the axes or dimension thereof and, more specifically, a high energy product along the transverse of the smallest cross-sectional dimension of the extruded magnet.

Abstract: There is provided a sintered material of which dimensional accuracy has been increased by improving the sinterability of Cu—Al based sintered material. More specifically, there are provided a sintered material and a composite sintered contact component, which are excellent in strength, wear resistance, seizure resistance and corrosion resistance. The sintered material is a Cu—Al based sintered material containing at least 1 to 12 wt % Sn and 2 to 14 wt % Al, and the composite sintered contact component is formed by sinter-bonding this sintered material to a metal baking.

Abstract: A method for forming dresser of chemical mechanical polishing pad, firstly to make a stainless steel bottom seat. Then preparing metal welding powder and organic glue, mixing the aforesaid metal welding powder, organic glue and adequate ratio of water to welding thick liquid and uniformly distributing or pasting it on the aforesaid dresser bottom seat to form the sintering layer. The aforesaid metal welding material includes the active metal with diamond can form metal carbonate. Then using the computer visual inspection system to proceed the diamond powder distribution, uniformly distributing them for 60 to 2500 grains per square centimeter. Proceeding the sintering process to make the friction layer of chemical mechanical polishing pad dresser.

Abstract: A powder compact is produced by disposing a foil or film-like mold member packed with a powder in a cavity of a rubber mold which is loaded in a die. The rubber mold, the foil or film-like type mold member and the powder packed in the foil or film-like mold member are compressed by a punch to obtain a powder compact. The powder compact with the foil or film-like mold member being attached thereto is removed, by pressure, from the rubber mold. Since the powder to be compressed into a compact is not packed directly in the cavity of the rubber mold, but is packed in the mold member, no part of the rubber mold is caught in the space formed by the powder that is in contact with the rubber mold. Accordingly, cracks and chips in the powder compact can be prevented even when the rubber mold is restored to its initial shape and many shape and size variations of the powder compact can be realized.

Abstract: The present invention relates generally to a new metal/ceramic laminate magnet and process thereof. More particularly, the invention encompasses a new process for fabrication of a large area laminate magnet with a significant number of holes, integrated metal plate(s) and electrodes for electron and electron beam control. The present invention also relates to a magnetic matrix display and electron beam source and methods of manufacture thereof.

Abstract: A method for the rapid fabrication of mold inserts for molds and molds c is disclosed; wherein high machinability rates and time and cost savings along with increased tool life and material savings are obtained through the use of blank die inserts formulated from material commonly used in the metal injection molding process of complex shaped parts. The method involves first the creation of cutting path programs developed from CAD files of the part; direct machining of the cavity and core inserts as described to predetermined sizes; processing the cavity and core inserts to convert the soft material—initially consisting of fine metal powders in a matrix of binder compounds—into a dense, fully hardenable material comparable to the material used in conventional toolmaking; and performing any necessary finishing and fitting operations to fit the resulting dies into a base that can be used as part of an injection molding tool.

Abstract: A lead-free plain bearing is formed by dispersing an alloy powder formed from 7-13 mass percent of Sn, 0.1-5 mass percent of Ag, and Cu on a backing, such as a steel plate, and sintering. The alloy powder may further include one or more of 0.05-0.5 mass percent of molybdenum disulfide powder and 0.1-2 mass percent of graphite powder. The bearing surface may be rough finished by machining to a roughness of 0.3-1 &mgr;m Ra and then fine finished by polishing to a roughness of at most 0.1 &mgr;Ra.

Abstract: A method of making a tire mold segment with a porous metal tread surface for a tire mold wherein an annular segmental tire model of refractory material is formed with tire model segments which are used to shape and form each tire mold segment from powdered metal by applying heat and pressure to sinter the powdered metal as it is shaped by the tire model segment. Blades may be mounted in the tire model segments for transfer to the tire mold segments for molding slits a tire tread.

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

Abstract: The use of liquid phase sintering for weighting of a golf club head is disclosed herein. The preferred weighting material is a multiple component material that includes a high-density component, a binding component and an anti-oxidizing component. A preferred multiple component material includes tungsten, copper and chromium. The liquid phase sintering process is performed in an open air environment at standard atmospheric conditions.

Abstract: A plating material mainly consisting of nickel-titanium is hot pressed onto a surface.

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

Abstract: High energy flux infrared heaters are used to treat an object having a surface section and a base section such that a desired characteristic of the surface section is physically, chemically, or phasically changed while the base section remains unchanged.

Abstract: An improved X-ray tube target comprises a refractory metal target substrate and a refractory metal focal track applied to the target substrate by a tape casting process. The X-ray tube target comprises a refractory metal target substrate and a refractory metal focal track formed on the target substrate to form a focal track/target substrate interface plane that varies less than about ±0.13 mm.

Abstract: A high strength spongy sintered metal composite sheet comprising a porous spongy sintered metal layer having continuous holes, and a high strength sintered, dense metal reinforcing layer having a porosity smaller than the porosity of the spongy sintered metal layer, laminated thereon, wherein the sintered, dense metal reinforcing layer has a thickness of 0.5-30% thickness with respect to the entire high strength spongy sintered metal composite sheet.

Abstract: The present invention relates to an abrasive dressing tool used for mechanical and chemical planarization abrasion of the surface of the work pieces as can be used for semiconductor wafers or the like which require precise, planar and micro polishing, and a method for manufacturing the same dressing tool. Specifically, ultimately macro- and micro-scratches on wafers can be drastically reduced, the rate of inferior finished products or wafers can be decreased and abrasive life time of the tool can be prolonged, by sintering and brazing abrasive particles with a nickel based brazing metal on the abrasive tool, and then filling or covering the non-sintered parts and re-crystallized parts of sintered and brazed layers, apt to crack or fall-out from the surface, through electroplating process.

Abstract: A base metal repair tape includes a first layer formed braze alloy bonded together with fibrillated polytetrafluoroethylene, a second layer formed from powdered base metal bonded together by fibrillated polytetrafluoroethylene and a third layer comprising a brazing alloy bonded together by fibrillated polytetrafluoroethylene. This is used to repair base metal by placing the first layer on the base metal and brazing the base metal powder so that the brazing alloy melts and diffuses into the base metal powder bonding it to the surface of the article. This permits the braze powder to be bonded to the base metal surface with minimal distance between the base powder particles. The number of alternating layers of base metal and braze alloy can be increased to increase the thickness of the repair. This can also be used to form small intricate parts.

Abstract: The invention relates to a method for connecting a metallic support element to at least one body (4) consisting of a powder metallurgical sintered material. The method is characterised in that said body (4) is brought into contact with the support element (3) in the form of a green body (4.1) which is compacted from a sintered powder, in that a thin, flat copper body is brought into contact with the green body (4.1) respectively and in that the entire resulting arrangement is heated to the temperature required to sinter the green body (4.1) before being cooled again once the sintering process is complete.

Abstract: The invention relates to a composite material, manufactured by dynamic densification of an amount of granular or powdered relatively brittle material or a mixture of one or more of such materials, wherein a continuous porous product is obtained, whereafter, by infiltration thereof with a second material, the brittle material particles are embedded in a continuous network of the second material. The invention further relates to a composite comprising ceramic particles embedded in a continuous matrix of a second material, obtainable by a method according to the invention, and to products manufactured from such composite.

Abstract: A method for preparing an aluminum alloy-containing coating composition is described. A slurry containing a selected amount of aluminum is combined with at least one additional slurry containing a selected amount of a second metal which forms an alloy with aluminum. The resulting slurry mixture is applied to a metal substrate, and then heated to form a substantially devolatilized coating. The coating then receives a secondary heat treatment. Related compositions and articles are also described, as are processes for repairing a damaged or worn coating, utilizing the slurry.