Abstract: In a process for sintering a metal member bonded to a substrate during which the metal member undergoes densification at a temperature which is different from the curing temperature of the substrate, an improvement is provided which comprises causing the densification temperature of the metal member to be closer to or identical with the curing temperature of the substrate by adding to said metal member prior to sintering an amount of organometallic compound which undergoes decomposition before the densification temperature of the metal member has been reached to provide under the sintering conditions employed a densification temperature-modifying amount of a metal or metal oxide which can be the same as or different from the metal of the aforesaid metal member.The improved sintering process of the present invention is particularly adapted for use in the fabrication of multilayer ceramic substrates which serve as circuit modules for seminconductor chips.

Abstract: A process is disclosed for producing a composite in the form of a sheet which involves forming a slurry of a brazing alloy powder and a vehicle, applying the slurry as a pattern or as a layer to a structural substrate, removing the vehicle from the slurry, and melting the alloy uniformly into a homogeneous mass without melting the substrate, and thereafter cooling the same to solidify it into a self supporting sheet.

Abstract: To produce a sintered metal type brake friction element which beds-in quickly and which has a "feel" similar to a resin-based element, powdered metallic friction material is subjected to a resistance sintering or furnace sintering operation, so as to produce a sintered substrate and an unsintered or partly sintered surface layer which has less wear resistance than the substrate but friction properties which are not substantially less than the substrate. The surface layer may be formed of the same or different material as the substrate layer depending upon the sintering technique chosen.

Abstract: A base powder mixture consisting of diamond material and solid support is inserted into the recess of a mold block for the manufacture of cutting elements for, in particular, deep drill bits, the mold block is then externally hermetically enclosed and hot isostatically pressed. The base powder mixture is, first of all, inserted directly into the recess, the mold block is then enclosed as a whole in a capsule and placed in a high pressure furnace in which pressure is applied to the mold block by a liquid or gaseous pressure medium and, finally, after cooling and lowering of the pressure, the capsule is removed and the finished cutting elements are taken out of the recess.

Abstract: An assembly and method for hot consolidating powder metal by heat and pressure in a container. The container is a mass of material substantially fully dense and incompressible with at least a portion which is capable of plastic flow at pressing temperatures and forming a closed cavity of a predetermined shape and volume for receiving a quantity of powder metal with the interior walls being movable to reduce the volume of the cavity for compacting powder metal into an article. A shaping insert is disposed in the cavity for defining a void in the article as the powder metal is compacted against the shaping insert. A force-responsive means allows relative movement between the shaping insert and at least a portion of the interior walls of the cavity as powder metal is compacted in response to a force reducing the volume of the cavity.

Abstract: A process for forming a substantially planar porous metal coating on a substrate which comprises thermal spraying of the metal on the substrate to form a porous metal coating on the substrate, rolling the sprayed coating to render it substantially planar and in the process close the pores, and then removing part of the surface to improve planarity and to reopen the surface-connected pores of the surface. The metal to be sprayed may be in the form of a wire, powder or molten metal mass and be selected from the group consisting of aluminum, zinc, tin, copper, nickel, or their alloys. Preferably, the substrate is selected from the group consisting of steel, aluminum, aluminized or galvanized steel, tin plate, and plastic. The spraying is preferably conducted in a non-oxidizing or reducing atmosphere. Preferably, the coating on the substrate is subjected to cold rolling. Most preferably, the rolling is conducted so as to reduce the coating thickness to approximately half of its original thickness.

Abstract: Metal/ceramic abradable seals of the type used in jet aircraft are improved by using a substrate which is able to deform during cooling from the brazing temperature and then rendering the substrate rigid after the cool down.

Abstract: A thick film conductor material comprising metal particles containing both gold and at least one additional element prealloyed into a single particle. The additional element may preferably be Pd and the prealloying may preferably be accomplished by coprecipitation. The conductor material, when bonded with Al wire, impedes the growth of intermetallic compounds and subsequent Kirkendall voids, even at elevated temperatures.

Abstract: Disclosed are coatings which are improved by a special peening process. Uniform sized spherical steel shot, in the range 1-2.5 mm is impacted at uniform low velocities onto a coated workpiece. Peening intensities are in the range 0.30-0.60 mm N. MCrAlY high temperature coatings are particularly improved, with densities of the order of 99 percent. Physical vapor desposited coatings have surface finishes of the order of 30.times.10.sup.-6 inch AA (Arithmetic Average) and plasma sprayed coatings have finishes of the order of 100.times.10.sup.-6 inch AA compared to unpeened finishes of 50-60.times.10.sup.-6 inch AA and 200-300.times.10.sup.-6 AA respectively.

Abstract: In a continuous friction-actuated process for the extrusion of copper, a passageway 3 is formed between an arcuate first member and a second member in the form of a wheel 1 having a circumferential groove 2 formed in its peripheral surface into which groove the first member projects. The wheel is rotated and metal is fed into the passageway at one end and extrudes from the passageway through at least one die orifice 6 located in or adjacent to an abutment member 5 extending across the passageway at the other end thereof. The abutment member is of substantially smaller cross-section than the passageway so as to leave a substantial gap between the abutment member and the groove.

Abstract: A sliding member highly improved with lubricating performance, wear resistant property and strength has a thin steel sheet or plate and sintered metal layer deposited on the steel sheet, wherein the sintered metal layer, comprises copper as a main component incorporated with a certain amount of tin, nickel, phosphorus, graphite and, optionally, with iron, and a sliding member exhibiting excellent lubricating performance, wear resistant property and strength even under impact and heavy loads includes a thick steel sheet or plate with which thin steel sheet of the above-mentioned sliding member is integrally joined.

Abstract: Metal ceramics composites having high bonding strength wherein a metal body and a ceramics body are bonded through a bonding layer are produced bycoating on the ceramic body a metallizing layer-forming composition, which forms through heat treatment with the ceramic body a metallizing layer consisting essentially of70-90% by weight of at least one of molybdenum metal and tungsten metal, 0.5-15% by weight of manganese oxide, 0.1-10% by weight of yttrium oxide, 0.1-15% by weight of aluminum oxide and 0.1-15% by weight of silicon dioxide,heating the ceramic body and the coated metallizing layer-forming composition to form and adhere the metallizing layer on the ceramic body,applying metal plating on either or both of the metallizing layer surface to be bonded and the metal body surface to be bonded, andbonding the thus obtained ceramic body and metal body by using a brazing metal.

Abstract: The present invention relates to the production of metal parts whose core and surface must have different characteristics.

Abstract: A composite contact material for light-duty electrical contacts is formed by combining, typically by powder-metallurgical techniques, a matrix metal and particles of a conductive material that is typically harder and more corrosion resistant than the matrix metal, and by removing, in a differential material removal step, some of the matrix metal from a surface of the composite, thereby producing a "sandpaper" surface with a substantial number of the particles projecting by a substantial amount above the matrix metal surface. Typical matrix metals are copper, copper alloys, or nickel, and typical particle materials are metals such as Ru, Re, Os, and intermetallics, oxides, borides, nitrides, carbides, silicides, and phosphides of such metals as Al, Ti, Ni, Nb, Mo, Ru, Ta, W, Re, or Os. Particle size is typically between about 0.1 .mu.m and 100 .mu.m, preferably less than 10 .mu.m, and the particle volume fraction is typically between about 1% and 50%, preferably between 5% and 30%.

Abstract: The object of the invention is a process of manufacturing a sintered compact of sinterable pulverulent material, in which the powder is moulded against a moulding surface and sintered in contact with the moulding surface and in which the pores in at least local areas of the compact are sealed by infiltration with an infiltration material which during a stage of the infiltration process is in liquid form and which by temperature decrease is caused to solidify in the pores, and the characteristic features of the invention are that the moulding takes place on the moulding surface in such a way that the moulding surface is covered with relatively fine-grained sinterable powder which by its own adhesion or by adhesion intensified by additives is caused to form an at least temporarily retained fine powder layer (3) on the moulding surface, and that at least one layer (5) of sinterable coarse powder is applied to the fine powder layer, and that both layers are sintered and infiltration is effected such that the infi

Abstract: Methods for improving microstructures of line-of-sight deposited films are described. Columnar growth defects ordinarily produced by geometrical shadowing during deposition of such films are eliminated without resorting to post-deposition thermal or mechanical treatments. The native, as-deposited coating qualities, including homogeneity, fine grain size, and high coating-to-substrate adherence, can thus be retained. The preferred method includes the steps of emitting material from a source toward a substrate to deposit a coating non-uniformly on the substrate surface, removing a portion of the coating uniformly over the surface, again depositing material onto the surface, but from a different direction, and repeating the foregoing steps. The quality of line-of-sight deposited films such as those produced by sputtering, progressively deteriorates as the angle of incidence between the flux and the surface becomes increasingly acute.

Abstract: The compound tool is made from a powder-metallurgically-prepared portion, establishing the wear-resisting zones onto which a carrier body is cast from steel.

Abstract: Article produced in a mould for a plastics moulding tool having a mould surface defining the contours of the article, with the article comprising a body formed from a composition comprising a sinterable material having a sintering temperature which material, before sintering, is shapable into a desired shape and which during sintering forms a porous body having pores, the sinterable material being at least partially sintered in the mould, and also comprising a matrix having a lower melting point than the sintering temperature of the sinterable material, with the matrix comprising a matrix metal which is infiltrated in the porous body to substantially fill the pores.

Abstract: A railcar for transporting coal includes steel sheets metallized with an aluminum coating on the interior surfaces thereof normally engaged by coal lading. A coating thickness of substantially 0.006-0.009 inch significantly extends the service life of the railcar by inhibiting corrosion and abrasion of the steel sheets by the coal. The method includes the steps of cleaning all interior surfaces of the railcar sheets prior to a metallizing operation and followed by application of a seal coat.

Abstract: A method for making a drill bit and product resulting therefrom in which carbide elements are coated with carbide and nitride materials such as those of titanium as by chemical vapor deposition after which the elements are cast in molten steel.

Abstract: A surface-coated blade member for cutting tools comprises a metal substrate of a super hard alloy and a coating on at least one surface of said substrate, said coating being composed of a layer of vapor deposited titanium on the surface of said metal substrate and at least one layer of vapor deposited titanium compound on said layer of titanium, and said layer of titanium compound being selected from the group consisting of titanium carbide, titanium nitride, titanium carbo-nitride, titanium oxy-carbide and titanium oxy-carbo-nitride, said layer of titanium being no larger than 2 .mu.m thick and said layer of titanium compound being 0.5 to 10 .mu.m thick.

Abstract: The cavity of a hollow turbine has its bottom equipped with a temporary means of obturation and is filled with a mixture of metal chips and a powder consisting of low melting metals, said mixture being subjected to a heating operation in order to join the chips with each other and with the walls of the blade by means of diffusion brazing of said fusible metal.

Abstract: The present invention aims to provide a sliding member: to be operated under a high load and high sliding speed; having high impact resistance and high break-in property; to be highly resistant and stable under boundary lubricating conditions, and; to be engaged with the swash plate made of iron or aluminum in a swash plate type compressor. The sliding member of the present invention comprises:a base comprising an iron-based alloy, and;a bearing layer, consolidated to said base and formed by applying on said base a powder coating having a thickness not more than 0.5 mm, and then baking said coating, said powder consisting of an iron family element and an additive component which includes from 3 to 30% by weight of boron.

Abstract: Pyrophorically activated surfaces of metal foil or screen, prepared by diffusing into surface a selectably removable second metal that is then selectively removed as by leaching, can be covered with reactive or inert materials. Reactive materials such as easily ignited metals or carbon or decomposable chemicals increase the heat generated by pyrophoric action. Inert materials slow down or prevent pyrophoric action. Pressure-sensitive adhesive tape in which the adhesive is of the non-transfer or transfer types can be adhered to pyrophorically activated surfaces to slow down action or to adhere material that reduces or increases severity of pyrophoric action. Pyrophoric Ni can be preserved for many months in alkaline solutions such as aqueous KOH, NaOH and triethanolamine. Pyrophoric Fe is prepared and preserved in aqueous alkaline stannite. Even better preservation is obtained for Ni and Fe with glycerine, ethylene glycol, triethanolamine and propylene oxide.

Abstract: A method of forming a clinically unbreakable composite structure between a noble based metal and a ceramic comprising depositing a thin layer of a bonding material including finely divided particles of a noble metal halide alone or in combination with particles of a noble metal; sintering the layer at a predetermined temperature between 1775.degree. F. and 1975.degree. F. and firing a ceramic over the sintered coating.

Abstract: A nickel-base welding electrode is provided comprising a nickel core and a metallic powder-laden flux coating bonded thereto, the total composition of the electrode comprising about 40% to 50% by weight of the nickel core and about 60% to 50% by weight of the coating. The coating contains as fluxes about 18% to 30% titanium dioxide, about 8% to 16% calcium fluoride, about 1% to 3% iron carbonate, about 1.5% to 4% calcium carbonate, about 2% to 6% calcium-magnesium carbonate, and contains as the powdered metals about 20% to 30% chromium, about 3% to 8% manganese, about 1% to 4% molybdenum, about 1% to 5% niobium, about 8% to 18% iron, 0% to about 6% nickel, up to 1% graphite, and as extrusion aids about 1% to 4% clay and about 1% to 5% organic extrusion aid material.

Abstract: A sliding member for use in an internal combustion engine having an improved wear resistance. The sliding member has a sliding surface composed of a mixture of 50 to 97% by weight of high carbon ferrochromium and 3 to 50% by weight of ferrous alloy applied thereto by spraying. In a preferred embodiment, the ferrous alloy is high carbon iron containing at least 0.6% by weight of carbon.

Abstract: A roto-gravure printing base cylinder is made by providing a cylindrical body (1), for example of steel, and applying thereover a cover layer (2) by thermal spraying, for example plasma-spraying, or arc-spraying. The cover layer is made of a material which is inert with respect to electrolytes used in applying a further copper layer over the cover layer to form a finished roto-gravure cylinder for optical engraving, for example an electrochemical valve metal, preferably tantalum, niobium or, most desirably, titanium oxide, forming a matrix in which, before application of the material as a layer on the steel cylinder, electrochemically active materials are applied made of a metal, preferably of the platinum group or other noble metal, and uniformly distributed over the surface, settled on the matrix material.

Abstract: A composite article having particular utility as a welding stud and a process for producing the article. The article is comprised of a pin and an enclosing member formed from a dissimilar material. The pin is comprised of a head and a shank. The pin is formed from a metal. The cross-section of the head is larger than that of the shank in a direction normal to the length of the pin. The enclosing member fits over and is adhered to the shank. The enclosing member is formed from material in powder form. It is placed upon the shank and sintered thereon. The enclosing member fits up against the head so that the article is substantially devoid of a gap therebetween. The absence of a gap is attributable to the shape of the shank. The cross-section of the shank is larger, in a direction normal to the length of the pin, adjacent the head than over other parts thereof.

Abstract: The present invention relates to a slide member which has excellent wear, seizing, and scuffing resistances, and excellent adherence property, and which can be used even under high-temperature conditions, and which is suited for being applied to slide surfaces of piston rings, cylinder liners and slide surfaces of the air compressors for internal combustion engines. For this purpose, according to the present invention, the slide surface has a layer which is formed by plasma spray-coating of a powdery mixture consisting of 5 to 80% by weight of an Fe/Ni alloy and 95 to 20% by weight of an Fe/high-Cr alloy.

Abstract: An article of improved wear characteristics and composed of a relatively low wear resistant base metal coated by a particulate refractory metal having a melting point of at least 1490.degree. C. deposited within the near-surface region thereof comprising a base metal or alloy of relatively low wear resistance, a refractory metal deposited within said near-surface region, said refractory metal being selectively deposited in the form of discrete particles, and the particles being idiomorphic or blocky or equiaxial or spheroidal or acicular or dendritic and a plurality of these particles having dimensions of less than 10 micrometers, a plurality of the particles being contiguous to form clusters of the particles that are spaced from each other. The clusters of particles may form microscopic regions of refractory metal which in turn may produce macroscopic regions of refractory metal having the appearance of a continuous coating.

Abstract: Bearing material including aluminum as its main ingredient and at least one lubricant additive, produced by compacting a powder material including aluminum as its main ingredient and at least one lubricant additive into a desired shape, subjecting the compacted and shaped powder material to heat treatment, extruding the heat-treated material and then subjecting the extruded material to heat treatment.The bearing material thus formed has a structure in which the lubricant additives are uniformly distributed as fine particles of small size, and also has a high percentage of elongation.

Abstract: The present invention relates to a sintered porous metal plate which comprises metal particles directly and integrally bonded together by sintering under pressure, said plate being of a porous structure and having a density gradient in the direction of thickness. The present invention is also directed to a method of making such a sintered porous plate.

Abstract: A composite and a method for bonding the composite. The composite includes a ceramic portion of silicon nitride, a refractory metal portion and a layer of MoSi.sub.2 indirectly bonding the composite together. The method includes contacting the layer of MoSi.sub.2 with a surface of the silicon nitride and with a surface of the metal; heating the layer to a temperature below 1400.degree. C.; and, simultaneously with the heating, compressing the layer such that the contacting is with a pressure of at least 30 MPa. This composite overcomes useful life problems in the fabrication of parts for a helical expander for use in power generation.

Abstract: The present invention relates to powder metal articles that can be successfully welded to ferrous base materials. A formed part having an initial part density of at least 5.8 grams per cubic centimeter subsequently compressed is to at least ninety-two per cent (92%) of theoretical full density at a controlled area, including a contact area at which the part is adapted to be welded to the other material and at least a 0.025 inch wide margin of the surface laterally contiguous the contact area to a subsurface depth of at least 0.025 inch while retaining the initial part density throughout the balance of the article. Such increased densification is accomplished by applying inwardly directed, localized surface pressure against the controlled area of a formed powder metal part.

Abstract: A sintered powdered aluminum core for an inductor used in the tuning stages of high frequency equipment is disclosed. Such cores have threads ground on them having sharp thread profiles, as opposed to the flat thread profiles produced by screw machines, and plating the cores produces superior eletrical properties.

Abstract: A composite metal sintered article combining a metal shell which has been electroformed and/or electroless plated and/or vapor deposited, positioned inside or outside of a metal sintered compact. A method of making the composite metal sintered article using both a powder metallurgy process and a surface treating process. This composite metal sintered article has excellent surface properties and high dimensional accuracy and is favorably used for many kinds of forming molds, dies and structural members, especially for press molds in making glassware.

Abstract: In one embodiment, a compact for tools, such as cutting, drilling and shaping tools, consists essentially of self-bonded abrasive particles. The bonded particles define a substantially continuous interconnected network of pores, dispersed throughout the compact. The method for making such a compact comprises the steps of bonding a mass of abrasive particles, aided by a sintering aid material, under high temperatures and pressures (HP/HT) to form an abrasive body comprised of said particles in a self-bonded form and said material infiltrated throughout the body. The body is then treated to remove substantially all infiltrated material, thereby to produce a compact consisting essentially of the self-bonded abrasive particles. In another embodiment, a composite compact which is made in a similar manner to the first embodiment consists essentially of a layer of self-bonded abrasive particle and a substrate layer (preferably of cemented carbide) bonded to the abrasive particle layer.

Abstract: An oxide-coated cathode for electron tubes which comprises a base metal plate made of an alloy comprising nickel as a main component and 2% by weight or more of at least one high-melting point metal, an oxide layer coated on the base metal plate comprising at least one oxide of a reducing element, a carbon coating layer coated on the oxide layer, and an alkaline earth oxide layer capable of emitting electrons coated on the carbon coating layer can maintain electron emitting life for a long period of time due to the prevention of interfacial reaction between the base metal plate and the alkaline earth oxide layer by the oxide layer and the carbon coating layer.

Abstract: A sintered powdered aluminum core for an inductor used in the tuning stages of high frequency equipment is disclosed. Such cores have threads ground on them having sharp thread profiles, as opposed to the flat thread profiles produced by screw machines, and plating the cores produces superior electrical properties.

Abstract: A stainless steel pipe having a surface layer with excellent resistance against vanadium pentoxide attack experienced upon boiler heating tubes for power generation, corrosion by sulfates, corrosion by chlorides experienced upon boiler heating tubes for various burning furnace and high-temperature gas corrosion experienced upon tubes for heating furnaces in the chemical industry, and also relates to methods for forming the surface layer.

Abstract: Method for hard-facing substrates is disclosed using a hard facing material consisting essentially of combined vanadium and carbon and minor amount of uncombined carbon with up to 15% by weight cobalt.

Abstract: A gas generator for an inflatable vehicle safety bag comprises three concentric chambers defined between a diffuser cup and a centrally recessed base member adapted to fit over a steering wheel hub, including an inner chamber for holding an electric ignition squib, an intermediate chamber for holding a canister of gas generating agent, and an outer chamber filled with stacked and coiled wire mesh, and a sintered metallic fiber body. The squib flashes through openings in the inner chamber to ignite the gas generating agent, and the gas produced thereby (primarily N.sub.2) passes through openings in a partition ring, obliquely through the wire mesh where the heat and chemical residues from the reaction are absorbed, and out openings in the diffuser cup through the sintered fiber filter. A diverter ring in the outer chamber serves to channel the gas flow obliquely or diagonally through the wire mesh.

Abstract: A metallic material, particularly useful for electrical contacts, comprises a matrix metal, for example silver or copper, with additives embedded therein in powder form. However, while being in powder form the additives are arranged in elongate fiber like lengths preferably parallel fiber like lengths. A method of producing such a distribution is to fill a tube of the matrix metal with the powder and draw it out to wire thickness, bundle a number of such wires together and fuse the outer coverings to form a continuous matrix with embedded fiber like lengths of powder.

Abstract: This invention concerns getters for controlled atmosphere and vacuum processes, and in particular, for processes carried out in an atmosphere having a very low oxygen content. The invention has been particularly developed for the vacuum brazing of parts, such as gas turbine components, but has a wide variety of other applications, including argon purged retort brazing and diffusion bonding.

Abstract: An x-ray tube anode has a body or substrate comprised of molybdenum or an alloy thereof and a surface layer on which an electron beam impinges to generate x-rays, comprising an alloy of tungsten, rhenium and molybdenum. A method of making the anode is also disclosed.

Abstract: A flame sprayed high energy milled powder coated article comprising a superalloy substrate and a coating consisting of chromium and at least one element selected from iron, cobalt or nickel. Optionally the coating can contain other elements, e.g., aluminum, carbon, yttrium or the rare earth elements.

Abstract: Plasma deposition welding powder for the production of a wear-resistant coating on machine parts subject to friction consists essentially of a mixture of two components A and B, of which component A is present at 70 to 99.5 weight percent of the total of A and B. Component A comprises at least one metal selected from the group consisting of molybdenum and tungsten. Component B is present at 0.5 to 30 weight percent of the total of A and B and consists essentially of at least one alloy or compound of at least one of the metals selected from the group consisting of cobalt, chromium, iron, nickel, copper and manganese, with at least one of the elements selected from the group consisting of phosphorus, boron and silicon.

Abstract: Disclosed is a flywheel assembly for recording and or reproducing devices which is produced by molding and sintering a mixture consisting principally of iron and graphite powders and, if necessary, a sulfur powder.

Abstract: A coating of zirconium is bonded to niobium by applying to the niobium a paint of Mo and Zr powder which is fired above 1520.degree. C but below the zirconium-niobium liquidus temperature of 1740.degree. C. Such coating is used in making an improved seal by juxtaposing the metal body to the ceramic body, applying a powdered alumina sealing glass or frit and firing to the melting temperature of the frit.