Nonparticulate Metal Component Patents (Class 428/553)
  • Patent number: 5907761
    Abstract: The present invention is a brazing composition for brazing a tube made of aluminum or aluminum alloy and a fin made of aluminum or aluminum alloy when manufacturing a heat exchanger such as evaporators, condensers, radiators, etc., comprising a powder of Al--Si--Zn alloy and binder, wherein the content of Zn in the powder of Al--Si--Zn alloy is in a range of 10 to 55 wt %.
    Type: Grant
    Filed: December 18, 1997
    Date of Patent: May 25, 1999
    Assignee: Mitsubishi Aluminum Co., Ltd.
    Inventors: Ken Tohma, Hitoshi Saito, Hiroto Momosaki
  • Patent number: 5904966
    Abstract: A laminated structure is obtained by hot isostatic pressing. The structure comprises a first metallic outer layer (produced by powder metallurgy) on one side, a second metallic outer layer on the other side which can form a brittle intermetallic phase and/or a brittle ordered phase with the first side, and a ductile metallic intermediate layer, the layers possessing mutually different coefficients of thermal expansion, whereby the intermediate layer acts as a diffusion barrier against the formation of the aforementioned brittle intermetallic phases or ordered phases. The invention also concerns a manufacturing method for the structure and an application of same as a cathode in a plasma sputtering unit.
    Type: Grant
    Filed: March 22, 1996
    Date of Patent: May 18, 1999
    Assignee: Innovative Sputtering Technology N.V. (I.S.T.)
    Inventor: Paul Lippens
  • Patent number: 5894053
    Abstract: In a process for applying a metallic adhesion layer for thermally sprayed ceramic thermal barrier coatings to metallic components, the surface which is to be coated being cleaned in a first process step, so that the metallic surface is free of grease and oxide, a binder is applied to the metallic surface of the base material in a second process step. Metallic adhesive powder is applied uniformly to the binder in a third process step and solder powder, which has a smaller particle size than the adhesive powder, is applied uniformly to the binder in a fourth process step. After drying the binder, a heat treatment is carried out for the purpose of soldering. The adhesion layers produced in this way are rough and provide a considerable positive lock for the ceramic thermal barrier coatings which are to be sprayed thereon.
    Type: Grant
    Filed: November 5, 1996
    Date of Patent: April 13, 1999
    Assignee: ABB Research Ltd.
    Inventor: Reinhard Fried
  • Patent number: 5891584
    Abstract: Articles for hot hydrocarbon fluid wherein the surface for contacting the fluid is a diffusion barrier material or a catalytic material coated on a metal substrate. The material is either catalytically-inactive tantalum oxide which inhibits the formation of coke in the fluid or catalytically-active zirconium oxide which promotes the formation of a loosely adherent coke in the fluid while inhibiting the formation of gum in the fluid. The coating materials, i.e., the diffusion barrier coating material and the catalytic coating material, are deposited by chemical vapor deposition (CVD), e.g., by effusive chemical vapor deposition of an organometallic compound on the surface without the use of carrier gas, without pre-oxidation of the surface and without thermal decomposition of the diffusion barrier material or the catalytic coating material.
    Type: Grant
    Filed: March 17, 1997
    Date of Patent: April 6, 1999
    Assignee: General Electric Company
    Inventor: George A. Coffinberry
  • Patent number: 5875830
    Abstract: Metallic articles having heat transfer channels are produced by solidification of molten metallic material about pre-formed channel defining members such that a solidified metallic deposit having heat transfer channels is formed. The channel defining members may be in the form of either solid elements (which are subsequently removed to leave the channels), or conduit elements (which may remain permanently embedded in the article). Moulds, dies, cores and other tools for use in moulding or casting of plastics and metals are particularly suitably formed by the process, the heat transfer channels being used for cooling of the respective articles during use. The molten metallic material is preferably deposited by spray forming utilizing one or more sprays of molten metallic material.
    Type: Grant
    Filed: July 8, 1996
    Date of Patent: March 2, 1999
    Assignee: Sprayforming Developments Limited
    Inventors: Alfred Richard Eric Singer, Richard Michael Jordan, Allen Dennis Roche
  • Patent number: 5864745
    Abstract: In order to enhance the seizure resistance of a swash plate, which is the sliding part of a swash-plate type compressor, copper alloy is flame-sprayed on the swash plate. Depending upon the necessity, the following control of structure/composition: (a) a mixed structure is provided such that atomized bronze powder, which is melted during flame spraying, and an unmelted atomized structure are mixed; (b) Pb is not contained or contained slightly in the melted structure: (c) Sn, P, Al, Ag, Si, Mn, Cr, Ni, Zn, Pb and/or Bi is added to the copper; (d) hard matters are added to copper alloy; and, (e) an intermediate layer of Ni or the like is formed between the flame-sprayed layer and the substrate, is carried out.
    Type: Grant
    Filed: November 16, 1995
    Date of Patent: January 26, 1999
    Assignees: Taiho Kogyo Co., Ltd., Kabushiki Kaisha Toyoda Jidoshokki Seisakusho
    Inventors: Kimio Kawagoe, Soo-Myung Hon, Kenji Takenaka, Manabu Sugiura, Eiji Tokunaga
  • Patent number: 5850591
    Abstract: A method of manufacturing a porous metal sheet having pores forming a pattern, comprising the steps of supplying metal powders to a peripheral surface, of at least one pattern roller of a pair of rollers, on which a pattern including a large number of concaves is formed; dropping metal powders to the concaves and accumulating metal powders on the peripheral surface of the pattern roller except the concaves; and rolling directly the metal powders accumulated on the peripheral surface of the pattern roller by rotating a pair of the rollers. It is preferable to laminate porous metal sheets or solid metal sheets manufactured by a method other than the above-described method on the metal sheet manufactured by the above-described method.
    Type: Grant
    Filed: April 18, 1997
    Date of Patent: December 15, 1998
    Assignee: Katayama Special Industries, Ltd.
    Inventor: Hirofumi Sugikawa
  • Patent number: 5848351
    Abstract: The porous metallic material of the present invention has an overall porosity of 80 to 99%, and a skeleton in a three dimensional network structure which is entirely composed of a sintered metal powder having a porosity of 10 to 60%. The specific surface area is very high, for example, 300 to 11000 cm.sup.2 /cm.sup.3. The porous metallic material can be reinforced by a reinforcing plate. The porous metallic material is also suitable for an electrode of an alkaline secondary battery and enables achievement of increases in the life and the amount of the active material contained therein. The porous metallic material can be produced by preparing a foamable slurry containing a metal powder, forming the foamable slurry, drying the formed product, preferably after foaming, and finally burning the dry formed product.
    Type: Grant
    Filed: March 10, 1997
    Date of Patent: December 8, 1998
    Assignee: Mitsubishi Materials Corporation
    Inventors: Kouji Hoshino, Yoshitaka Mayuzumi, Tohru Kohno, Norikazu Komada
  • Patent number: 5832360
    Abstract: A bond for a single layer metal bond abrasive tool can be easily chemically and electrochemically stripped from the metal core of a recovered used tool to facilitate reuse of the core. Relative to conventionally bonded tools, the speed of stripping the novel bond is quick, and the stripped core has a smooth, clean surface which needs only minimal mechanical repair prior to reuse. In one aspect, the novel bond consists essentially of a ternary bond composition of copper, tin and titanium, in which the copper and tin are pre-alloyed and the pre-alloy and titanium component are incorporated in the bond composition as fine particle size powders. In another aspect, the bond is a quaternary bond composition consisting essentially of copper, tin, titanium and silver. The powder components can be used dry or mixed with a fugitive liquid binder as a paste. The novel bond can be brazed at lower temperature than copper/tin/titanium bonds prepared otherwise.
    Type: Grant
    Filed: August 28, 1997
    Date of Patent: November 3, 1998
    Assignee: Norton Company
    Inventors: Richard M. Andrews, Bradley J. Miller, Marcus R. Skeem, Ren-Kae Shiue
  • Patent number: 5812926
    Abstract: A hard facing alloy is applied to a surface of a substrate by making a mixture of at least two constituents whose net composition is the desired hard facing alloy composition. The constituents have different solidus temperatures, at least one of which is above a processing temperature of the substrate and another of which is below the processing temperature of the substrate. In one preferred approach, the mixture is prepared by pressing and lightly sintering the constituents in the form of powders, so that the mixture retains its shape and can be attached to the substrate surface. Then the substrate is heated to the processing temperature and maintained for a time sufficient to permit interdiffusion of the several different phases toward a homogeneous hard facing alloy composition uniformly through a major portion of the volume.
    Type: Grant
    Filed: September 3, 1991
    Date of Patent: September 22, 1998
    Assignee: General Electric Company
    Inventors: Joseph Carl Wukusick, Roger Johnson Perkins, deceased, Murray Sawyer Smith, Jr.
  • Patent number: 5805973
    Abstract: Articles for hot hydrocarbon fluid wherein the surface for contacting the fluid is a metal oxide, amorphous glass or metal fluoride diffusion barrier material coated on a metal substrate. The metal oxide, amorphous glass or metal fluoride is deposited by chemical vapor deposition (CVD), e.g., by effusive CVD of an organometallic compound on the surface without the use of carrier gas, without pre-oxidation of the surface and without thermal decomposition of the diffusion barrier coating material. Examples of coating materials deposited by effusive CVD are SiO.sub.2, TiO.sub.2, spinel and Al.sub.2 O.sub.3. The articles having the coated surfaces find utility in components subjected to high temperatures wherein the components are in contact with hydrocarbon fluids without additives, without special attention to quality control and without the need for special processing.
    Type: Grant
    Filed: March 12, 1997
    Date of Patent: September 8, 1998
    Assignee: General Electric Company
    Inventors: George A. Coffinberry, John F. Ackerman
  • Patent number: 5780164
    Abstract: A hard drive disk substrate is formed of a multi-phase ceramic-based material having at least two phases with amorphous phases being present in an amount less than about 1 volume percent based on the volume of the ceramic-based material or at least one phase being free metal. A process for producing the ceramic-based disk substrate is produced by forming a flat disk of a porous ceramic and then infiltrating the porous ceramic with a metal whereby a multi-phase ceramic-based computer hard drive disk is produced. Additionally, a step of passivating the porous ceramic by elevating it to a temperature of about 1300.degree. to about 1800.degree. C. before the infiltrating step may be performed, such that the surfaces are passivated and the reaction kinetics can be controlled during the infiltrating step. A preferred composite material is made of a multi-phase boron carbide composite material including grains having peaks with an average roughness value, Ra, of between about 1 to about 200 .ANG.
    Type: Grant
    Filed: June 29, 1995
    Date of Patent: July 14, 1998
    Assignee: The Dow Chemical Company
    Inventors: Aleksander J. Pyzik, Uday V. Deshmukh, Chan Han, Kevin J. Nilsen, Donald J. Perettie, Arthur R. Prunier, Jr.
  • Patent number: 5763106
    Abstract: The present invention provides a ceramic based composite powder and a method for applying the composite powder using a H.V.O.F. gun to form a self-lubricating coating for metal parts. The composite powder and coating are comprised of a ceramic powder, a metal powder, and a solid lubricant powder.
    Type: Grant
    Filed: January 19, 1996
    Date of Patent: June 9, 1998
    Assignee: Hino Motors, Ltd.
    Inventors: Cheryl Renee Blanchard, Richard Allen Page
  • Patent number: 5759707
    Abstract: Metal structures, e.g. coolers or heat exchangers, can be produced by placing together metal components coated with solder, dipping them into a slurry of a flux, and soldering them by heating. Alternatively, components coated with solder can also be coated with flux, then placed together to form the metal structure and soldered by heating. In this case, however, the flux must be applied so as to adhere securely, and to this end in the prior art the flux has been "glued on" to the metal surface by organic or other binders, which when burned out during the soldering process can produce undesirable exhaust gases or emissions. The present invention discloses a metal component which is provided with a sintered flux coating which adheres without binder. The coating can optionally also contain solder metal or other auxiliaries dispersed therein.
    Type: Grant
    Filed: October 4, 1996
    Date of Patent: June 2, 1998
    Assignee: Solvay Fluor und Derivate GmbH
    Inventors: Heinz-Joachim Belt, Ruediger Sander, Werner Rudolph
  • Patent number: 5740516
    Abstract: A firearm bolt prepared from an alloy of tungsten, nickel and iron having a density of about from 14.1 g/cc to 18.0 g/cc. The alloy preferably also contains at least one of molybdenum, cobalt, rhenium, tantalum and gold. The alloy is preferably manufactured by standard powder metallurgical techniques followed by a liquid phase sinter and vacuum anneal. The bolt can also be manufactured using solid state sintering. The bolt can also be manufactured by mechanically working the material after sintering, after annealing, or after both sintering and annealing.
    Type: Grant
    Filed: December 31, 1996
    Date of Patent: April 14, 1998
    Assignee: Remington Arms Company, Inc.
    Inventors: Marlin R. Jiranek, II, Michael D. Keeney
  • Patent number: 5740515
    Abstract: An article of manufacture which is subject to erosive and corrosive attack in a high-temperature environment is formed of a substrate of nickel or cobalt-based superalloy, and a protective silicide coating disposed on the substrate. A thermal barrier layer of ceramic may be disposed between the superalloy and the silicide layer, and an MCrAlY layer may be disposed between the ceramic and the superalloy substrate. The silicide coating is preferably MoSi.sub.2.
    Type: Grant
    Filed: April 6, 1995
    Date of Patent: April 14, 1998
    Assignee: Siemens Aktiengesellschaft
    Inventor: Wolfram Beele
  • Patent number: 5736261
    Abstract: A conductive paste in which cracks do not occur even at boundaries between areas of different film thicknesses comprises spherical and flake-form silver powders, a low softening point glass frit, organic rhodium material and an organic vehicle; the proportion of the flake-form silver powder with respect to the total amount of silver powder is in the range 15 to 80 wt % and the proportion of the rhodium contained in the organic rhodium material with respect to the total amount of silver powder is 0.0001 wt % or less.
    Type: Grant
    Filed: November 22, 1995
    Date of Patent: April 7, 1998
    Assignee: Murata Manufacturing Co., Ltd.
    Inventor: Haruhiko Kano
  • Patent number: 5732322
    Abstract: The disclosure describes a resin composition for a sliding member, comprising 1 to 25 wt % of component A selected from the group consisting of phosphates and barium sulfate, 1 to 15 wt % of component B selected from the group consisting of magnesium silicate and mica, and 5 to 50 wt % of component C selected from the group consisting of lead, tin, lead-tin alloy and mixtures thereof, the balance of polytetrafluoroethylene.
    Type: Grant
    Filed: May 22, 1995
    Date of Patent: March 24, 1998
    Assignee: Oiles Corporation
    Inventors: Takashi Nakamaru, Sumihide Yanase, Akihiko Okimura
  • Patent number: 5705281
    Abstract: A nickel-base superalloy article has a coating having a composition, in weight percent, of from about 10 to about 20 percent cobalt, from about 14 to about 25 percent chromium, from about 2 to about 12 percent aluminum, from 0 to about 0.2 percent yttrium, from about 0.001 to about 3 percent boron, from about 1 to about 10 percent silicon, balance nickel and incidental impurities. The coating is preferably applied by mixing together two powders, one with a higher solidus temperature and one with a lower solidus temperature, whose net composition is that of the coating. The powder mixture is compacted with a binder, applied to a surface of the article, and heated to a temperature above the lower solidus temperature.
    Type: Grant
    Filed: November 22, 1995
    Date of Patent: January 6, 1998
    Assignee: General Electric Company
    Inventors: Jim D. Reeves, David E. Budinger, Robert A. Anderson
  • Patent number: 5682596
    Abstract: A metal alloy article is provided with an improved fretting wear resistant coating combination for use in the temperature range of about 650.degree.-1100.degree. F. on an article contact surface shaped to cooperate with an abutting member. An example is a gas turbine engine blade base carried by an abutting support slot. The coating combination includes an inner portion of a Ni base alloy having a room temperature annealed yield strength of greater than about 30 ksi to less than about 57 ksi and densely deposited from a powder, for example by the high velocity oxygen--fuel thermal spray process rather than by other processes such as air plasma spray. Cured on the inner portion is an outer portion of graphite particles mixed in an inorganic binder capable of stable use in the range of about 650.degree.-1100.degree. F., for example silicates or phosphates, such as of aluminum.
    Type: Grant
    Filed: November 28, 1995
    Date of Patent: October 28, 1997
    Assignee: General Electric Company
    Inventors: Kevin P. Taylor, Jerry D. Schell
  • Patent number: 5672435
    Abstract: Hard disk drive components, such as, sliders, load beams, support arms, actuators, actuator bearings, spacers, clamps, spindles, ball bearings, thrust bearings, journal bearings, base plates, housings, and covers, formed of a multi-phase ceramic-based material. One method of making the hard disk drive components includes (a) forming a porous body of ceramic; (b) infiltrating a liquid into the pores of the ceramic body; (c) solidifying the infiltrated liquid; and (d) machining the metal-infiltrated ceramic body to form the hard disk drive component.
    Type: Grant
    Filed: June 29, 1995
    Date of Patent: September 30, 1997
    Assignee: The Dow Chemical Company
    Inventors: David W. Born, Uday V. Deshmukh, Timothy G. Fawcett, Richard T. Fox, Kevin J. Nilsen, Aleksander J. Pyzik
  • Patent number: 5665480
    Abstract: A copper-lead alloy bearing having a high corrosion resistance, especially a high corrosion resistance to sulfur, comprising a back metal and a copper-lead-based bearing alloy bonded thereto. The copper-lead-based bearing alloy consists of more than 10 but not more than 20% Ni, 0.5 to 8% Sn, 8 to 30% Pb, not less an 0.005 but not more than 0.2% P, and the balance of Cu and incidental impurities.
    Type: Grant
    Filed: March 12, 1996
    Date of Patent: September 9, 1997
    Assignee: Daido Metal Company Ltd.
    Inventors: Tadashi Tanaka, Masaaki Sakamoto, Koichi Yamamoto, Tsukimitsu Higuchi
  • Patent number: 5666644
    Abstract: An end bearing used in an automatic transmission gear having a one-way clutch mechanism having multi-layers comprising a back metal, a copper alloy layer, a tin layer having a thickness of 0.5 to 4 .mu.m and a Cu-Sn intermetallic compound layer having a thickness of 0.5 to 4 .mu.m and having a Microvickers hardness of from 400 to 700, which intermetallic compound layer is positioned just under the tin layer and which intermetalic compound layer is are formed on the copper alloy of such an end bearing. According to the present invention, it is possible to improve anti-seizure characteristics of an end bearing even under a condition of a decrease in the amount of oil supply which decrease occurs in higher engine speed, thus enabling the provision of an end bearing having superior anti-seizure characteristics.
    Type: Grant
    Filed: November 23, 1994
    Date of Patent: September 9, 1997
    Assignee: Daido Metal Company Ltd.
    Inventors: Tadashi Tanaka, Masaaki Sakamoto, Koichi Yamamoto, Tsukimitsu Higuchi, Kouki Ozaki
  • Patent number: 5652877
    Abstract: The present invention relates to alloys in which the essential constituent is aluminum, metal deposits produced from these alloys, substrates coated with these alloys and the applications of these alloys. The alloys of the present invention are characterized in thatthey have the following atomic composition (I):Al.sub.a Cu.sub.b Co.sub.b' (B,C).sub.c M.sub.d N.sub.e I.sub.f(I)a+b+b'+c+d+e+f=100, expressed as number of atoms, a.gtoreq.50, 0.ltoreq.b<14, 0.ltoreq.b'.ltoreq.22, 0<b+b'.ltoreq.30, 0.ltoreq.c.ltoreq.5, 8.ltoreq.d.ltoreq.30, 0.ltoreq.e.ltoreq.4, f.ltoreq.2, where M represents one or more elements chosen from Fe, Cr, Mn, Ni, Ru, Os, Mo, V, Mg, Zn and Pd; N represents one or more elements chosen from W, Ti, Zr, Hf, Rh, Nb, Ta, Y, Si, Ge and the rare earths; I represents the inevitable production impurities;and they contain at least 30% by mass of one or more quasicrystalline phases.
    Type: Grant
    Filed: April 5, 1995
    Date of Patent: July 29, 1997
    Assignee: Centre National de la Recherche
    Inventors: Jean-Marie Dubois, Antoine Pianelli
  • Patent number: 5643683
    Abstract: A wet type sliding apparatus in which a multilayer sliding member is used in the presence of a lubricating oil, characterized in that the multilayer sliding member is composed of (1) a backing metal layer, (2) a porous, sintered layer provided thereon and (3) a surface layer consisting essentially of polyetheretherketone formed by impregnating and coating the porous, sintered layer with a sliding resin consisting essentially of polyetheretherketone. The above sliding member has a small friction coefficient and excellent wear resistance. In particular, the sliding noise can be more effectively inhibited by adjusting the face roughness of the surface layer of the sliding member to 2 .mu.m or less.
    Type: Grant
    Filed: January 24, 1996
    Date of Patent: July 1, 1997
    Assignee: Daido Metal Company Ltd.
    Inventors: Tadashi Tanaka, Hidehiko Tamura, Takahiro Niwa, Izumi Maruyama, Yoshihiro Fukutani
  • Patent number: 5634189
    Abstract: A structural component is formed with an outer shell of sintered, solid, powder particles, and a porous core of sintered, hollow, bodies arranged in layers. The hollow bodies are of increased diameter in the layers in a direction from the outer periphery of the core towards the center of the core. The material of the outer shell and of the core is a metal or ceramic.
    Type: Grant
    Filed: November 14, 1994
    Date of Patent: May 27, 1997
    Assignee: Mtu Motoren-Und Turbinen Union Munchen GmbH
    Inventors: Axel Rossmann, Wilfried Smarsly
  • Patent number: 5594933
    Abstract: The invention relates to a magnetoresistance material, i.e. a conductive material that exhibits magnetoresistance, which is an inhomogeneous system consisting of a nonmagnetic matrix and ultrafine particles of a ferromagnetic material such as Co or Ni--Fe--Co dispersed in the nonmagnetic matrix. With the aim of reducing deterioration of the magnetoresistance effect, an alloy or mixture of at least two metal elements selected from Cu, Ag, Au and Pt is used as the material of the nonmagnetic matrix. Optionally, the nonmagnetic matrix may contain a limited quantity of a supplementary element selected from Al, Cr, In, Mn, Mo, Nb, Pd, Ta, Ti, W, V, Zr and Ir. A film of the magnetoresistance material can be formed on a substrate, and it is optional to interpose a buffer layer between the film and the substrate and/or cover the film with a protective layer.
    Type: Grant
    Filed: June 30, 1995
    Date of Patent: January 14, 1997
    Assignee: NEC Corporation
    Inventors: Kazuhiko Hayashi, Hidefumi Yamamoto, Junichi Fujikata, Kunihiko Ishihara
  • Patent number: 5581799
    Abstract: A brazeable aluminum material is composed of an aluminum core and a brazing agent layer consisting of a brazing agent thermally sprayed onto and covering a surface of the core. A number of unmolten minute particles of the brazing agent are present in the brazing agent layer, which contains at least an aluminum-silicon alloy and/or a mixture of aluminum and silicon. Characteristic features of a method of producing the brazeable aluminum material are the steps of: preparing a powder composed of minute particles; and thermally spraying the powder onto the aluminum core in such a state that only a surface of each minute particle is molten, with a pith of the particle remaining unmolten. The powder is an Al-Si alloy and/or a mixture of Al powder and Si powder.
    Type: Grant
    Filed: May 15, 1995
    Date of Patent: December 3, 1996
    Assignee: Showa Aluminum Corporation
    Inventors: Takashi Terada, Masahiro Kojima, Taizo Morita, Katsuyuki Arakawa, Ichiro Iwai, Masakazu Furuta
  • Patent number: 5579534
    Abstract: A heat-resistant member is constructed by having a ceramic coating layer deposited on the surface of a metallic substrate through the medium of a metallic bonding layer. The metallic bonding layer is composed of at least two layers, i.e. a layer of an aggregate of minute particles disposed on the metallic substrate side and a layer of an aggregate of coarse particles disposed on the ceramic coating layer side. Otherwise, the metallic bonding layer is composed of at least three layers, i.e. two layers of an aggregate of coarse particles disposed one each on the metallic substrate side and the ceramic coating layer side and one layer of an aggregate of minute particles interposed between these two layers of an aggregate of coarse particles. These layers are obtained by the low pressure ambient plasma thermal spraying using a fine powder or a coarse powder of an alloy resistant to corrosion and oxidation.
    Type: Grant
    Filed: May 19, 1995
    Date of Patent: November 26, 1996
    Assignee: Kabushiki Kaisha Toshiba
    Inventors: Masayuki Itoh, Kazuhiro Yasuda, Kunihiko Wada, Seiichi Suenaga, Shinji Arai
  • Patent number: 5573859
    Abstract: A soldering composition is self melting and is auto-regulating. The solder composition (100) has a central core (102) made from a non-magnetic metal. A coating (105) of a magnetic material surrounds most or all of the central core. A solder layer (108) overlies the coating of magnetic material, and the solder layer has a melting temperature that is lower than the Curie temperature of the magnetic material. The auto-regulating temperature substantially corresponds to the Curie temperature. When the solder composition is placed in a field of alternating current, the magnetic material heats up and melts the solder coating. When the Curie temperature is reached, the magnetic material stops heating, thus controlling the maximum temperature of the soldering composition. As the temperature of the composition drops below the Curie temperature, the magnetic material again heats up, thus keeping the temperature of the solder constant.
    Type: Grant
    Filed: September 5, 1995
    Date of Patent: November 12, 1996
    Assignee: Motorola, Inc.
    Inventor: Anthony B. Suppelsa
  • Patent number: 5569543
    Abstract: A method and composition for coating an automotive brake rotor to render it corrosion resistant without impeding the braking function of the rotor, includes cleaning the rotor and thereafter applying a coating composition thereto which composition includes an inorganic alkali metal-silicate binder and a finely divided metal admixed therewith.
    Type: Grant
    Filed: October 31, 1994
    Date of Patent: October 29, 1996
    Assignees: Inorganic Coatings, Inc., Ford Motor Company
    Inventors: Parke Schaffer, Jr., Thomas Laughin, David M. Mann
  • Patent number: 5549975
    Abstract: A coated tool consisting of a cermet body and a refining layer thereon. The refining layer is a wear resistant layer of (Ti, Me) N, wherein Me is at least one metal which forms a stable oxide at a temperature above 700.degree. C.
    Type: Grant
    Filed: July 20, 1994
    Date of Patent: August 27, 1996
    Assignee: Balzers Aktiengesellschaft
    Inventors: Hans Schulz, Josef Maushart
  • Patent number: 5543235
    Abstract: The present invention provides multiple grade, composite cemented carbide articles and a method of making such articles. The cemented carbide articles comprise carbides of different grades (or different compositions and/or microstructures) and, therefore, correspondingly different properties at different locations in the same article. The method of the present invention comprises filling different areas or portions of a die with metallurgical powders having different compositions and/or microstructures. The powder is then compressed as a single compact in the die cavity. The compressed compact is subsequently sintered to produce a multigrade cemented carbide article having composition and/or microstructural variations within the volume of the article.
    Type: Grant
    Filed: April 26, 1994
    Date of Patent: August 6, 1996
    Assignee: SinterMet
    Inventors: Prakash K. Mirchandani, Robert E. Thomas, Mark Cippel
  • Patent number: 5523183
    Abstract: A battery electrode is provided comprising a porous, pleated metal structure, preferably comprising nickel as its substrate.
    Type: Grant
    Filed: October 18, 1994
    Date of Patent: June 4, 1996
    Assignee: Pall Corporation
    Inventors: Paul C. Koehler, Stephen Geibel, Ralph B. Di Palma
  • Patent number: 5523170
    Abstract: An article with a high temperature superalloy body having a directionally oriented microsuucture and a structural discontinuity, such as a crack, or surface erosion or wear portion, is repaired, to provide a repaired article, using a mixture of Ni base ahoy powders. One powder includes a careful balance of the temperature depressants Si and B. In the one powder, Si is included in the range of about 0.05-2.2 wt. % to provide about 0.02-1.3 wt. % Si in a repaired portion as bonded with the article. In that same powder, B is include in the range of about 0.2-1.2 wt. % to provide about 0.08-0.7 wt. % in that repaired portion. In the repair method, the repaired portion can be provided, when shorter brazing times are used, with improved mechanical properties by diffusing the brazed alloy and aging the repaired structure in the range of about 1600.degree.-1700.degree. F. for a time in the range of about 1-16 hours.
    Type: Grant
    Filed: December 28, 1994
    Date of Patent: June 4, 1996
    Assignee: General Electric Company
    Inventors: David E. Budinger, Jim D. Reeves, Robert A. Anderson
  • Patent number: 5514479
    Abstract: Disclosed herein is process method and articles of plated coating having functions ranging from wear resistance, lubricity, corrosion resistance, and further incorporating therein particulate matter having light emitting properties. Having this codeposited light emitting particles within the functional layer provides a signal for the determination of the presence of the coating and its stage of deterioration.
    Type: Grant
    Filed: June 5, 1995
    Date of Patent: May 7, 1996
    Inventor: Nathan Feldstein
  • Patent number: 5514480
    Abstract: A metal-based composite includes a metal matrix including aluminum as a major component, discontinuous alumina fibers buried in the metal matrix, mullite particles buried therein, and solid lubricant particles buried therein. The solid lubricant particles can be either graphite particles with a nickel layer formed on a surface thereof, or boron nitride cermet particles. By thus including the specific solid lubricant particles, the wear resistance of the metal-based composite can be improved, the wear of its mating parts can be reduced, and the friction coefficient between the metal-based composite and the mating parts can be inhibited from fluctuating. Hence, the metal-based composite can appropriately make aluminum-based internal combustion engines.
    Type: Grant
    Filed: August 5, 1994
    Date of Patent: May 7, 1996
    Assignee: Aisin Seiki Kabushiki Kaisha
    Inventors: Katumi Takagi, Shuji Inoue
  • Patent number: 5510193
    Abstract: Metal carbide supported polycrystalline diamond (PCD) compacts having improved shear strength and impact resistance properties, and a method for making the same under high temperature/high pressure (HT/HP) processing conditions. A sintered polycrystalline cubic boron nitrite (PCBN) compact interlayer is provided to be bonded at a first interface to a sintered PCD compact layer, and at a second interface to a cemented metal carbide support layer comprising particles of a metal carbide in a binder metal. The supported compact is characterized as having a substantially uniform sweep through of the binder metal from the cemented metal carbide support layer, which sweep through bonds the sintered PCD compact layer to the sintered PCBN interlayer, and the sintered PCBN interlayer to the cemented metal carbide support layer.
    Type: Grant
    Filed: October 13, 1994
    Date of Patent: April 23, 1996
    Assignee: General Electric Company
    Inventors: David B. Cerutti, Henry S. Marek
  • Patent number: 5508114
    Abstract: A method of manufacturing a lead-provided porous metal sheet comprises the steps of: forming a porous metal material having a metal layer on a surface of a framework of a porous base material comprising a foamed sheet and the like, by plating the porous base material and/or applying fine metal powders thereto; passing the porous metal material through a pair of rolls having a plurality of projections formed thereon to compress the porous metal material against the projections and reduce or eliminate pores so as to form one or more recesses extending; and forming solid metal portions by applying fine metal powders to the entire recesses.
    Type: Grant
    Filed: December 9, 1994
    Date of Patent: April 16, 1996
    Assignee: Katayama Special Industries, Inc.
    Inventor: Hirofumi Sugikawa
  • Patent number: 5508115
    Abstract: A titanium alloy matrix fiber reinforced composite made from titanium alloy sheet processed to have ductility up to about 35%. Of particular usefulness is the composite having a Ti.sub.3 Al titanium aluminide having this level of ductility. The composites have good resistance to thermal cyclic fatigue.
    Type: Grant
    Filed: April 1, 1993
    Date of Patent: April 16, 1996
    Assignee: United Technologies Corporation
    Inventors: Gary D. Linsey, Otis X. Chen, Martin J. Blackburn
  • Patent number: 5496650
    Abstract: Process of imparting conductivity to a three-dimensional net-shaped porous sheet can be performed efficiently before carrying out electroplating process. Fine metallic powders are applied to the porous sheet made of a foamed sheet, a nonwoven sheet, a mesh sheet or a plurality of sheets layered one on the other, so that a conductive metallic layer is formed on the porous sheet. Then, an electroplated layer is formed on the surface of the conductive metallic layer. The conductive metallic layer remains when the porous sheet burned out. Consequently, a metallic layer of the conductive metallic layer and the electroplated layer forms the metallic framework of the metallic porous sheet.
    Type: Grant
    Filed: September 13, 1994
    Date of Patent: March 5, 1996
    Assignee: Katayama Special Industries, Ltd.
    Inventor: Hirofumi Sugikawa
  • Patent number: 5489487
    Abstract: A multi-layer bearing consists of a backing steel plate, a layer of Cu--Pb bearing alloy comprising, by weight, 1 to 20% of Ni and containing Pb-phase grains dispersed in the matrix, and an overlay of Pb alloy containing In. In in the overlay is diffused into the Pb-phase grains in the bearing alloy layer and forms a diffusion layer of high corrosion resistance in which In coexists with the Pb-phase grains, in an area of 30 to 200 .mu.m from the interface to the overlay. Even if the overlay is worn and the Cu--Pb bearing alloy layer is exposed, high corrosion resistance will be maintained.
    Type: Grant
    Filed: October 5, 1994
    Date of Patent: February 6, 1996
    Assignee: Daido Metal Company Ltd.
    Inventors: Tadashi Tanaka, Masaaki Sakamoto, Koichi Yamamoto, Tsukimitsu Higuchi
  • Patent number: 5484662
    Abstract: A solid lubricant coating system for use with a metal interface subject to high temperatures and wet lubrication, comprising agglomerates of particles of (i) solid lubricant particles selected from the group consisting of graphite, boron nitride, molybdenum disulfide, lithium fluoride, NaF, WS.sub.2, and calcium fluoride; and (ii) steel particles fused together and bounding said solid lubricant particles at least at certain intersections, certain portions of said steel particles being air-hardened to a high hardness upon exposure of the coating to the interface at high temperatures.
    Type: Grant
    Filed: May 6, 1994
    Date of Patent: January 16, 1996
    Assignee: Ford Motor Company
    Inventor: V. Durga N. Rao
  • Patent number: 5482782
    Abstract: A sliding-contact material comprising a backing steel plate optionally plated with Cu, and a layer of sintered copper alloy formed on one of the surfaces of the backing steel plate, wherein the layer of sintered copper alloy consists essentially of 4 to 20 wt % Sn, 1 to 10 wt % Ni, 0.05 to 1 wt % B, and balance of Cu and incidented impurities, and does not practically include P, and the sintered copper alloy has a Vickers hardness not less than Hv 100.
    Type: Grant
    Filed: November 29, 1994
    Date of Patent: January 9, 1996
    Assignee: Daido Metal Company Ltd.
    Inventors: Tadashi Tanaka, Masaaki Sakamoto, Koichi Yamamoto, Tsukimitsu Higuchi, Kouki Ozaki
  • Patent number: 5482918
    Abstract: A method for producing microcomposite powders for use in superconducting and non-superconducting applications.
    Type: Grant
    Filed: February 7, 1994
    Date of Patent: January 9, 1996
    Assignee: The United States of America as represented by the Secretary of the Interior
    Inventors: Michael A. Maginnis, David A. Robinson
  • Patent number: 5480728
    Abstract: A conductive contact for use with metal oxide superconductors is described. The conductive contact comprises a metal contact which is attached by a diffusion bonding means to a superconductive metal oxide substrate. In a preferred embodiment, diffusion bonding means comprises a metal paint which includes metal particles and an organic binder which is heated to pyrolized the organic binder and form metallic diffusion bonds to the metal contact and metal oxide substrate. The invention also comprises a method for forming the conductive contact which includes selecting the superconducting metal oxide substrate, coating the substrate with a metal paint, placing the metal contact in touching contact with the metal paint and heating the combination of materials described above to pyrolized the organic binder and coalesce the metal particles.
    Type: Grant
    Filed: January 3, 1994
    Date of Patent: January 2, 1996
    Assignee: General Electric Company
    Inventor: John E. Tkaczyk
  • Patent number: 5472793
    Abstract: A composite spray coating comprises an iron base material, a spray coating film applied thereon and a diffusion layer of aluminum or aluminum-zinc alloy, and is used for hot-dip galvanization.
    Type: Grant
    Filed: December 12, 1994
    Date of Patent: December 5, 1995
    Assignee: Tocalo Co., Ltd.
    Inventors: Yoshio Harada, Kazumi Tani, Yoshihumi Kobayashi
  • Patent number: 5470821
    Abstract: Composite bulk superconducting materials having desirable physical, measured transport current density and high T.sub.c superconducting characteristics are provided which comprise a first matrix of superconducting ceramic oxide crystalline grains with a second matrix of elemental metal (gold, silver, palladium and tin) situated within the interstices between the crystalline grains. Preferably, each matrix is a continuous phase within the composite material, with the ceramic oxide preferably being present at a level of at least about 80% by weight, whereas the elemental metal is present at a level of up to about 20% by weight. In fabrication procedures, a precursor superconducting ceramic oxide is first prepared and reduced to a fine powder size; this is mixed with powdered elemental metal, and the mixture is compressed using high compaction pressures on the order of 14 tons/cm.sup.2 or greater to form a body, which is then sintered to yield the composite.
    Type: Grant
    Filed: February 15, 1995
    Date of Patent: November 28, 1995
    Assignees: The University of Kansas, Midwest Superconductivity, Inc.
    Inventors: Kai W. Wong, Xin Fei, Ying Xin, Yi-Han Kao
  • Patent number: 5464699
    Abstract: A pyrophoric coating formed by leaching aluminum from an aluminide coated web in which the aluminide coating was formed on or into the web by an exothermic and diffusion reaction of a powder containing aluminum and chromium with or without a transition metal selected from the group consisting of iron, nickel or cobalt and in which the weight ratio of chromium to aluminum is at least 1:50 but no more than about 1:4.
    Type: Grant
    Filed: November 15, 1993
    Date of Patent: November 7, 1995
    Assignee: Alloy Surfaces Co. Inc.
    Inventor: Alfonso L. Baldi
  • Patent number: 5455118
    Abstract: The present invention describes a plated component and plating method in which the plating adheres to the reinforcement particles on the surface of a composite component. This allows the component to be processed above 400.degree. C. without blistering. The plating method allows brazing, such as gold/tin and gold/germanium brazing, maintains hermeticity, and prevents corrosion over a sustained period of time. By utilizing an activator such as palladium, which can produce catalytic sites on which electroless nickel can be deposited, a component with a surface of exposed reinforcement particles can be plated to form a uniform surface without voids. It has been found that by using a combination of nickel-boron and a palladium activator, that Al/SiC composites can be plated with good adhesion when exposed to temperatures above 400.degree. C.
    Type: Grant
    Filed: February 1, 1994
    Date of Patent: October 3, 1995
    Assignee: PCC Composites, Inc.
    Inventor: Arnold J. Cook