Nonparticulate Metal Component Patents (Class 428/553)
  • Patent number: 5145733
    Abstract: An electro-deposition coated member has a metal substrate or a non-metal substrate having been subjected to metal plating, a chemically colored film provided on said substrate, and a conductive electro-deposition coating film formed on said chemically colored film.
    Type: Grant
    Filed: March 15, 1991
    Date of Patent: September 8, 1992
    Assignee: Canon Kabushiki Kaisha
    Inventor: Susumu Kadokura
  • Patent number: 5130206
    Abstract: Extra loss is introduced in coupled cavity and klystron RF circuits by applying a surface coating to selected parts of circuit elements used in the circuits. The coating is applied in the form of a slurry, which is then sintered. The slurry comprises a mixture of an iron-base powder (such as a stainless steel) and a dielectric glass ceramic, suspended in a binder dissolved in a solvent. Circuits with the loss coating are easier to match than by other prior art techniques. The loss coating of the invention reduces the fabrication cost of coupled-cavity traveling wave tubes, while improving the performance by minimizing the gain ripple. Higher average power operation is possible, due to elimination of loss buttons previously employed in the prior art.
    Type: Grant
    Filed: July 29, 1991
    Date of Patent: July 14, 1992
    Assignee: Hughes Aircraft Company
    Inventors: Sunder S. Rajan, Ivo Tammaru, Steve L. Bosma, John W. Eldridge
  • Patent number: 5128213
    Abstract: A sliding material of a single substance made by extruding powder comprises aluminum as a main constituent, and at least one metal compound of 0.5 to 30 wt. % in total selected from the group consisting of metal nitride, metal carbide, metal phosphide, and metal boride, each of which has a hardness not less than 200 in Vicker's hardness, the metal compound being uniformly and finely dispersed in aluminum.
    Type: Grant
    Filed: September 20, 1991
    Date of Patent: July 7, 1992
    Assignee: Daido Metal Company Limited
    Inventors: Tadashi Tanaka, Masaaki Sakamoto, Koichi Yamamoto, Yoshiaki Sato
  • Patent number: 5126212
    Abstract: Disclosed herein is a (1) A multi-layered sintered sliding member comprising a back metal composed of a steel plate having (i) a plurality of independent protrusions formed at a surface thereof or (ii) a continuous protrusion and a plurality of independent recesses defined with said protrusions at the surface thereof and a sintered alloy layer formed integrally by securing on the surface of said back metal covering the surface of said protrusions, in which said sintered alloy layer is composed of a low density alloy region and a high density alloy region.
    Type: Grant
    Filed: June 27, 1991
    Date of Patent: June 30, 1992
    Assignee: Oiles Corporation
    Inventors: Shinji Yamada, Hideo Ozawa, Mitsuaki Andoh, Yasuhiro Shirasaka, Hideyuki Morioka
  • Patent number: 5114797
    Abstract: A metal structure component is provided with a protective coating including three layers. A first layer on the surface of the metal structural component is a bond improving metallic base layer on which an intermediate heat insulating oxidic layer is applied, followed by a titanium fire inhibiting metallic cover layer. Due to this arrangement of three layers, it is possible for the advantageous characteristics of the individual layers to cooperate to provide a good bonding and heat insulating protection of the intermediate layer in combination with the titanium fire inhibiting protection of the outer layer, whereby the structural component achieves a prolonged operational life without a substantial weight increase as compared to conventional protection layers provided only for heat insulation purposes. This layer structure also minimizes any adverse influence on the structural strength of the metal structural component.
    Type: Grant
    Filed: April 30, 1991
    Date of Patent: May 19, 1992
    Assignee: MTU Motoren- und Turbinen-Union Muenchen GmbH
    Inventors: Thomas Uihlen, Klaus Schweitzer
  • Patent number: 5087529
    Abstract: In a laminate material or a laminate workpiece with a functional layer affixed to one surface of a solid backing layer, the functional layer consisting of components which are not soluble in one another, thus normally forming a heterogeneous structure, a finely dispersed distribution of the undissolved components in a matrix of the functional layer is created, due to the fact that the components forming the functional layer are affixed to the backing layer as a fine powder material in the form of a powder mixture or agglomerated powder or predispersed powder formed through air plasma spraying. Thereby the backing layer itself contains a partial layer to be coated having a heterogeneous structure or a crystalline structure, for instance a lead bronze layer or a lead tin bronze layer. This partial layer is created in a surface region by the action of the plasma flame in a strictly defined zone down to a certain depth, for instance 20 to 200 .mu.
    Type: Grant
    Filed: December 20, 1989
    Date of Patent: February 11, 1992
    Assignee: Glyco Aktiengesellschaft
    Inventors: Ulrich Engel, Karl-Heinz Wegner
  • Patent number: 5069937
    Abstract: A method of preparing a roughened substrate surface for subsequent coating with a fluorocarbon polymer in a liquid medium. The surface of the substrate is thermally sprayed with a stainless steel alloy containing from 25 to 35 percent by weight of chromium. A metal-coated substrate produced by this method and an article having thereon a fluorocarbon surface coated by this method are also described.
    Type: Grant
    Filed: February 26, 1990
    Date of Patent: December 3, 1991
    Assignee: Whitford Plastics Limited
    Inventor: Nicholas J. Wall
  • Patent number: 5041339
    Abstract: A multilayered sliding material of lead bronze containing graphite in the form of a bimetal, comprising a steel plate or a steel plate having a copper plating coating and a sintered copper alloy bonded to the steel plate, the sintered copper alloy having a composition consisting of 5 to 16 wt % Sn, 2 to 20 wt % Pb, 0.03 to 1 wt % P, 0.5 to 3.9 wt % graphite, and the balance Cu, wherein hardness of the alloy exceeds Hv 100.
    Type: Grant
    Filed: August 21, 1989
    Date of Patent: August 20, 1991
    Assignee: Daido Metal Company
    Inventors: Sanae Mori, Masaaki Sakamoto, Koichi Yamamoto, Kenji Sakai
  • Patent number: 5037704
    Abstract: A sintered diamond compact or high pressure form boron nitride compact with an improved brazability, suitable for use for wear resisting tools, cutting tools, drill bits, dressers and wire-drawing dies is provided. This compact comprises a compact part containing at least 20% by volume of diamond and/or high pressure form boron nitride and a cemented carbide substrate bonded directly or through an interlayer to the compact part, characterized in that the surface of the compact is coated, at least partly, with a thin film consisting essentially of at least one member selected from the group consisting of carbides, carbonitrides and nitrides and mixtures or solid solutions thereof of at least one element selected from the group consisting of silicon and Group IVa, Va and VIa of Periodic Table, and having a thickness of 1 to 20 .mu.m.
    Type: Grant
    Filed: November 19, 1986
    Date of Patent: August 6, 1991
    Assignee: Sumitomo Electric Industries, Ltd.
    Inventors: Tetsuo Nakai, Akio Hara, Mitsuhiro Goto
  • Patent number: 5035958
    Abstract: There is provided by the present invention an alloy which is mechanically and chemically compatible with advanced nickel-base superalloys and nickel-base eutectic superalloys and which possesses excellent resistance to high temperature oxidation. The alloy of the invention is, therefore, particularly useful as a protective environmental coating for the external surfaces of hot-stage aircraft gas turbine engine components, e.g., rotating blades and stationary vanes, made from such advanced superalloys.
    Type: Grant
    Filed: October 11, 1989
    Date of Patent: July 30, 1991
    Assignee: General Electric Company
    Inventors: Melvin R. Jackson, Mark L. Prugar, Swe-Wong Yang, John R. Rairden, III, Michael F. X. Gigliotti, Jr.
  • Patent number: 5034186
    Abstract: A titanium or titanium alloy composite having a porous surface layer, which comprises a titanium or titanium alloy substrate and a porous titanium or titanium alloy layer that adheres strongly to said substrate, said porous layer being formed by first providing said substrate with a firmly adhering sinter of a mixture of a titanium or titanium alloy powder and a magnesium powder, and then removing magnesium from the sinter. A process for producing a titanium or titanium alloy composite having a porous surface layer, comprising: providing a coating composition comprising a binder added to a mixture of a titanium or titanium alloy powder and a magnesium powder; applying said composition to the surface of a titanium or titanium alloy substrate; heating the substrate at a temperature of from 650.degree. to 800.degree. C. in vacuo or an inert atmosphere so as to form a sinter of the powders of titanium or titanium alloy and magnesium which firmly adheres to said substrate; and removing magnesium from said sinter.
    Type: Grant
    Filed: November 20, 1986
    Date of Patent: July 23, 1991
    Assignee: Permelec Electrode Ltd.
    Inventors: Takayuki Shimamune, Hideo Sato, Masashi Hosonuma
  • Patent number: 5030517
    Abstract: A rapidly solidified aluminum base alloy is formed into a powder and plasma sprayed onto a substrate to provide a uniform and contiguous coating. Deposition and retention of the alloy onto the substrate are effected in a single process step. The coating exhibits improved mechanical and physical properties including excellent corrosion and oxidation resistance and improved elevated temperature strength and thermal stability.
    Type: Grant
    Filed: January 18, 1990
    Date of Patent: July 9, 1991
    Assignee: Allied-Signal, Inc.
    Inventors: Paul S. Gilman, Michael S. Zedalis, Santosh K. Das
  • Patent number: 5026599
    Abstract: An array of densely packed discrete metal microspheres which may be deformable and electrically conductive may be formed on a substrate by a method including the steps of providing a substrate having a depositing surface in the chamber forming a metal vapor in the chamber and depositing the metal vapor on the depositing surface, the depositing surface having a temperature at or above the melting point of the metal.
    Type: Grant
    Filed: March 27, 1990
    Date of Patent: June 25, 1991
    Assignee: Minnesota Mining & Manufacturing
    Inventor: David C. Koskenmaki
  • Patent number: 5024899
    Abstract: The improved friction facing has a porous, resilient fused metallic matrix with a second metal having a lower boiling point being infused into and alloyed with the matrix.
    Type: Grant
    Filed: October 22, 1990
    Date of Patent: June 18, 1991
    Inventor: Richard D. Lang
  • Patent number: 5011655
    Abstract: The invention provides a method of manufacturing a thin metallic body composite structure. First, an inner layer of a first metal is cleaned to remove oxides and promote metallurgical bonding. The inner layer has a plurality of penetrating holes piercing the thickness of the inner layer. The penetrating holes are filled with metal powder of a second metal. Two outer layers of the second metal are placed on opposite sides of the cleaned and filled inner layer to form a sandwich structure. The sandwich structure is heated to a temperature at which recrystallization will occur in a non-oxidizing atmosphere. The sandwich structure is then hot worked to reduce thickness of the sandwich structure forming the thin metallic body composite structure.
    Type: Grant
    Filed: December 22, 1989
    Date of Patent: April 30, 1991
    Assignee: INCO Alloys International, Inc.
    Inventor: William L. Mankins
  • Patent number: 5002834
    Abstract: Discloses a composite metal body having an oxide-dispersion-strengthened substrate made by mechanical alloying and a high chromium-aluminum nickel- or cobalt-base coating on the substrate. The substrate is characterized by containing an amount of aluminum effective to react with oxygen and nitrogen within the body of the substrate to prevent migration of these gases to the interface of substrate and coating and to thereby inhibit spalling of the coating.
    Type: Grant
    Filed: April 1, 1988
    Date of Patent: March 26, 1991
    Assignee: Inco Alloys International, Inc.
    Inventors: Gaylord D. Smith, Raymond C. Benn
  • Patent number: 4999255
    Abstract: A tungsten chromium carbide-nickel coated article and process for producing it in which the coating contains chromium-rich particles having at least 3 times more chromium than tungsten and wherein said chromium-rich particles comprise at least about 4.5 volume percent of the coating.
    Type: Grant
    Filed: November 27, 1989
    Date of Patent: March 12, 1991
    Assignee: Union Carbide Coatings Service Technology Corporation
    Inventors: John E. Jackson, Lynn M. McCaslin, Anthony J. Stavros, Robert C. Tucker, Jr.
  • Patent number: 4977035
    Abstract: A strip getter structure comprising getter powder pressed into and onto an open reticulated network carrier strip. The getter powder particles form an agglomeration with strength derived both from interlocking of said getter particles and from support of the getter agglomeration by the network. The getter strip structure is manufactured by continuous rolling of getter powder into and onto the network carrier strip by means of a gravity powder feed and a cylindrical rolling mill.
    Type: Grant
    Filed: March 3, 1989
    Date of Patent: December 11, 1990
    Assignee: Ergenics, Inc.
    Inventors: Jonathan A. Travis, Winfred L. Woodard, III
  • Patent number: 4977036
    Abstract: Workpieces are very rapidly diffusion coated by heating the packed workpieces at a rate that brings the workpieces to diffusion-coating temperature and then completing the diffusion coating, all in less than 50 minutes, then cooling. Workpiece can have top coating layer of aluminum flake covered by a layer of extremely fine alumina or silica in a magnesium chromate binder, to provide surface having roughness at least about 10 micro-inches smoother than before the top coating. Used aluminized jet engine hot section members can be reconditioned by a fluoridizing treatment that deoxidizes and also removes residual aluminizing, so that the members can then be repaired if necessary and re-aluminized.
    Type: Grant
    Filed: November 21, 1989
    Date of Patent: December 11, 1990
    Assignee: Alloy Surfaces Company, Inc.
    Inventor: Alfonso L. Baldi
  • Patent number: 4966818
    Abstract: This invention relates to a method to consolidate a metal powder body to a completely dense body, in which a plate capsule consisting of a cylindrical wall and in one end thereof an end plate is charged with said powder so that the powder completely or essentially completely will fill the capsule, whereafter the air optionally is evacuated from the capsule and optionally replaced with a non-oxidizing protective gas, said capsule thereafter being closed also in the opposite end by an end plaate, whereafter the capsule with its content is heated to a forging temperature suitable for the metal powder and is forged so that the powder is consolidated to a completely dense body.
    Type: Grant
    Filed: April 11, 1989
    Date of Patent: October 30, 1990
    Assignee: Uddeholm Tooling Aktiebolag
    Inventors: Bertil Johansson, Per Hasselstrom
  • Patent number: 4959273
    Abstract: A corrosion-resistant R-Fe-B type sintered permanent magnet exhibiting deterioration of not more than 5 % from the initial magnetic properties after being tested for 500 hours under the conditions of a temperature of 80.degree. C. and a relative humidity of 90 % is produced by:causing at least one colloidal noble metal selected from the group consisting of Pd, Ag, Pt and Au to be adsorbed in a colloidal state or forming a thin layer thereof through vapor deposition on the surface of the sintered body; applying at least one base metal selected from the group consisting of Ni, Cu, Sn and Co containing P and/or B by electroless plating; and further applying at least one base metal selected from the same group.The noble metal layer is 1-10 nm thick. The electroless plating layer is no more than 10 .mu.m and the electrolytic plating layer 5-60 .mu.m thick.
    Type: Grant
    Filed: September 18, 1989
    Date of Patent: September 25, 1990
    Assignees: Sumitomo Special Metals Co., Ltd., Toda Kogyo Corp.
    Inventors: Atsushi Hamamura, Takaki Hamada, Kouki Tokuhara, Yukimitsu Miyao, Tomoyuki Imai, Nanao Horiishi
  • Patent number: 4939038
    Abstract: A light metallic composite material containing therein fine granular additives dispersed in a matrix of a light metallic material, which composite material has a light weight, high mechanical strength, and excellent characteristics such as high damping ability. The additives each have a density less than that of the matrix and heat resistance enough to withstand a heating temperature at which they are composited with the matrix. Preferably, the additives are each formed with a coating which increases mechanical strength and provides an electromagnetic characteristic different from that of the matrix. Preferably, the composite material is produced by heating a mixture of matrix powders and additives up to a temperature where only part of the mixture including no microspheres is softened but the mixture is adequately composited, an amount of additives being equal to 10% to 70% by volume of the matrix, and by forming the composited mixture into a desired shape and solidifying same.
    Type: Grant
    Filed: November 30, 1987
    Date of Patent: July 3, 1990
    Assignee: Inabata Techno Loop Corporation
    Inventor: Tadao Inabata
  • Patent number: 4923762
    Abstract: A precoated steel sheet for a two-piece can, which comprises: a steel sheet; a precoating film formed on one surface of the steel sheet, which is to be the outer surface of a two-piece can, by applying a precoating composition onto the one surface of the steel sheet and curing same; and another precoating film formed on the other surface of the steel sheet, which is to be the inner surface of the two-piece can, by applying another precoating composition onto the other surface of the steel sheet and curing same. The above-mentioned precoating composition comprises a thermosetting coating material and an internal lubricant having a content ratio within the range of from 0.1 to 30 weight parts relative to 100 weight parts of a resin as a solid content in the thermosetting coating material.
    Type: Grant
    Filed: July 19, 1989
    Date of Patent: May 8, 1990
    Assignees: NKK Corporation, Toyo Ink Mfg. Co., Ltd.
    Inventors: Hiroshi Ishikawa, Naoki Gunji, Yoshinori Hoshino, Taro Ohyama
  • Patent number: 4906529
    Abstract: A method is provided for producing an erosion-resistant layer or coating on the surface of a metallic workpiece. The method includes providing a thermally sprayable alloy of Ni-Cr-Fe-B-Si and thermally spraying the alloy on the workpiece to a specified thickness, following which the sprayed-on layer is heated in vacuum to a temperature between 250.degree. C. to 400.degree. C. for a time at the stated temperature of about 5 to 30 minutes sufficient to effect degassing of the layer. The temperature of the layer is thereafter raised to a range of about 800.degree. C. to 950.degree. C. and maintained at that temperature in vacuum for between 5 to 30 minutes. The temperature at the layer is then raised to between 900.degree. C. and 1100.degree. C. under a protctive atmoshpere at a pressure of between 200 to 600 mm Hg to effect fursion of the layer at above its melting point, following which the coated metallic workpiece is finally cooled to room temperature under the protective atmosphere.
    Type: Grant
    Filed: February 4, 1987
    Date of Patent: March 6, 1990
    Assignee: Castolin S.A.
    Inventors: Niels Brundbjerg, Wolfgang Simm
  • Patent number: 4895609
    Abstract: Metals are made pyrophoric by diffusing aluminum or zinc into them and then leaching it out, or by reacting with aluminum and then leaching aluminum out. Powdered aluminum and powdered nickel, iron or cobalt, can thus be carried on an elongated support web and reacted by heating for a few seconds to a few minutes, after which leaching will provide elongated pyrophoric foil suitable for decoying heat-seeking missile.
    Type: Grant
    Filed: June 10, 1988
    Date of Patent: January 23, 1990
    Assignee: Alloy Surfaces Company, Inc.
    Inventor: Alfonso L. Baldi
  • Patent number: 4889772
    Abstract: For some applications of slide layers, for example in connecting rod bearings of internal combustion engines, for individual sites of a formed piece, high load bearing capability are required while for other places of the same formed piece good embedding abilities are demanded. A composite material with a slide layer applied by cathode sputtering of a tightly cohesive matrix and an insoluble component distributed statistically in it, is adapted to these opposite demands in that the diameter of the particle of the insoluble material has gradients at predetermined sites, which extend parallel to the surface of the slide layer, and to which slide layer hardness gradients correspond. These gradients are generated during the cathode sputtering process in the substrate to be coated to form a growing slide layer having temperature gradients which are maintained and which extend parallel to the substrate surface.
    Type: Grant
    Filed: December 22, 1987
    Date of Patent: December 26, 1989
    Assignee: Balzers Aktiengesellschaft
    Inventors: Erich Bergmann, Jurgen Braus
  • Patent number: 4889773
    Abstract: A coating for improved resistance welding of galvanized steel parts or sheets comprises a binder, and a metal phosphide pigment, preferably a ferrophosphorus pigment, having a particle size of from about 0.1 to about 30 microns. The pigment can also include up to about 40% by weight of an additional metal such as tin, aluminum or lead, which can be combined with the metal phosphide in pigment form or deposited onto the surface of the particles. The coating can be applied to either the faying or non-faying surfaces of the galvanized steel, or to the resistance welding electrode, and may be removed, if desired, after the welding operation.The advantages of the present invention include a significant reduction in welding current and an increase in the weldability lobe width, a restoration of the dynamic resistance beta peak, and an increase in electrode life.
    Type: Grant
    Filed: November 7, 1988
    Date of Patent: December 26, 1989
    Assignee: Occidental Chemical Corporation
    Inventors: Donald H. Campbell, Gerald L. Evarts
  • Patent number: 4871621
    Abstract: An improved method for encasing objects in metal is disclosed as are the novel encased objects so prepared. An object is wrapped with a sheet comprising sinterable particulate or powdered metal and an organic binder, and is the fired to volatilize the binder and to sinter the particulate metal into a unitary metal structure. In the preferred embodiment of this invention, the object to be encased is a green sinterable particulate object which undergoes sintering simultaneously with the particulate metal casing during the firing step.
    Type: Grant
    Filed: December 16, 1987
    Date of Patent: October 3, 1989
    Assignee: Corning Incorporated
    Inventors: Rodney D. Bagley, Raja R. Wusirika
  • Patent number: 4851188
    Abstract: An abrasive, wear resistant layer is applied to the tip surface of a superalloy gas turbine blade by high temperature sintering operation which produces a high strength bond between the layer and the blade, minimizes gamma prime phase growth, and prevents recrystallization in the blade. Important features of the invention include removing plastic strain damage from the tip surface prior to the sintering operation, using induction heating techniques to sinter a layer of metal powder particles and ceramic particulates to the blade tip surface, and shielding the airfoil and root portion of the blade from the radiant heating source during the sintering operation while at the same time, conductively removing heat from the blade.
    Type: Grant
    Filed: December 21, 1987
    Date of Patent: July 25, 1989
    Assignee: United Technologies Corporation
    Inventors: Robert P. Schaefer, Walter F. Gustafson, David A. Rutz, Kenneth E. Taylor
  • Patent number: 4847044
    Abstract: A softer metal such as aluminum, or a metal forming a metal aluminide, or an alloy containing these metals is added to a metal aluminide composite during fabrication to promote easy consolidation of the metal aluminide matrix with the reinforcing phase. The metal aluminide may be titanium aluminide, nickel aluminide, or iron aluminide. The softer metal, the metal aluminide matrix, and the reinforcing phase are pressed together at a temperature above the softening temperature of the softer metal. The softened metal promotes flow and consolidation of the matrix and the reinforcement at relatively low temperatures. The composite is held at an elevated temperature to diffuse and convert the soft metal phase into the metal aluminide matrix. By consolidating at a lower temperature, cracking tendencies due to thermal expansion differences between the matrix and reinforcement is reduced. By consolidating at a lower pressure, mechanical damage to the fibers is avoided.
    Type: Grant
    Filed: April 18, 1988
    Date of Patent: July 11, 1989
    Assignee: Rockwell International Corporation
    Inventor: Amit K. Ghosh
  • Patent number: 4842953
    Abstract: A mixture of two powdered alloys of the M, Cr, Al type, M being Co and/or Ni, is disclosed, in one form, for use in providing an abradable surface of an article and is characterized by the substantial absence of B. The first alloy has substantially no Si and has a higher melting range than that of the second alloy. The second alloy has substantially no Y and consists essentially of, by weight, 8-12% Si, 1.5-4% Al, 10-30% Cr, with the balance M and incidiental impurities. The total mixture composition consists essentially of, by weight, 10-35% Cr, 4-10% Al, from a small but effective amount up to about 0.09% Y, 2-6% Si, with the balance M and incidental impurities.
    Type: Grant
    Filed: November 28, 1986
    Date of Patent: June 27, 1989
    Assignee: General Electric Company
    Inventors: Roger J. Perkins, Murray S. Smith, Jr.
  • Patent number: 4818628
    Abstract: A process for making a composite bearing material comprising a steel backed, prealloyed, lead-bronze sintered powder metal matrix whereby the first sinter step includes induction heating the prealloyed powder and steel backing to above 650.degree. C. and thereafter sintering the same at temperatures of about 850.degree. C. in a second sintering furnace. A composite bearing material made by the same process and comprising a lead particle size averaging less than about 8 microns and having no lead islands larger than about 44 microns.
    Type: Grant
    Filed: August 31, 1987
    Date of Patent: April 4, 1989
    Assignee: Federal-Mogul Corporation
    Inventors: Robert G. Alexander, George C. Pratt
  • Patent number: 4798770
    Abstract: Light alloy articles comprising a body of light alloy having a composite fiber/light alloy layer, a sprayed heat-resistant alloy layer, and a sprayed ceramic base layer formed on the body in this sequence exhibit improved heat resistance and insulation and are very useful in the manufacture of internal combustion engine pistons. A method for producing such a coated light alloy article by spraying is also provided.
    Type: Grant
    Filed: November 6, 1987
    Date of Patent: January 17, 1989
    Assignee: Toyota Jidosha Kabushiki Kaisha
    Inventors: Tadashi Donomoto, Mototsugu Koyama, Masaaki Nagaoka
  • Patent number: 4798771
    Abstract: A bearing or other support member containing intercalated graphite exhibits many of the properties of a metal (ie: conductivity, luster, ductility) while enhancing the lubricating properties of pure graphite. The bearings are made by pressing an intercalated graphite powder either alone or mixed with metal powders, organic polymers or ceramic powders into the desired shape. This results in a bearing that has low friction properties, improved load bearing characteristics, higher operating temperatures and a reduced cost of manufacture.
    Type: Grant
    Filed: August 27, 1985
    Date of Patent: January 17, 1989
    Assignee: Intercal Company
    Inventor: Ferdinand L. Vogel
  • Patent number: 4741973
    Abstract: Ceramic particles useful as abrasives in a metal matrix layer are described. The particles are coated with an oxide monolayer and a metal duplex layer. Preferably, the particles are silicon carbide; the oxide monolayer is aluminum oxide, and the metal duplex layer is a nickel-boron alloy over pure nickel.
    Type: Grant
    Filed: December 15, 1986
    Date of Patent: May 3, 1988
    Assignee: United Technologies Corporation
    Inventors: David A. Condit, Harry E. Eaton
  • Patent number: 4732818
    Abstract: The present invention relates to a composite bearing material comprising three layers: (1) a metal backing, (2) a porous metal interlayer bonded to the metal backing which includes bronze or other copper alloy particles from two distinct particle size ranges and (3) a PTFE based composition intermixed with and overlying the porous metal interlayer. In accordance with the method of the present invention, the porous metal interlayer substantially comprises a relatively non-homogeneous mixture of particles from the two distinct particle size ranges, wherein a substantial portion of the relatively fine powder is segregated adjacent the metal backing. The present invention includes a significant thickness of the PTFE based composition applied to and remaining above the surface of the porous metal backing.
    Type: Grant
    Filed: September 29, 1986
    Date of Patent: March 22, 1988
    Assignee: Federal-Mogul Corporation
    Inventors: George C. Pratt, Michael C. Montpetit, Michael D. Lytwynec
  • Patent number: 4731297
    Abstract: Laminated components of the open magnetic circuit type including, or incorporating, inductors of the same type are manufactured by alternately superposing a plurality of green magnetic layers and a plurality of fragmentary, green conductor strips, each strip constituting about half a turn of coil in coil-forming conductor patterns, in such a manner that the ends of the conductor strips overlap the ends of adjacent strips whereas the remainders of the adjacent strips are separated by each interposing magnetic layer, the conductor strips being arranged so that they are vertically superposed along the same spiraling loci, sintering the resulting laminate to a solid sintered body, and, before or after the sintering, sectioning the laminate along the spiraling loci into individual components.
    Type: Grant
    Filed: August 20, 1985
    Date of Patent: March 15, 1988
    Assignee: TDK Corporation
    Inventor: Minoru Takaya
  • Patent number: 4705726
    Abstract: A weldable steel plate plated with zinc, a zinc base alloy or zinc composite and coated on the plating with a coating material comprising a mixture of at least one type of ferrous alloy powder with an oxygen concentration of 1.0% by weight or less and zinc dust, is provided, and the weldable coated steel plate also has good workability, coherence, weldability and corrosion resistance.
    Type: Grant
    Filed: February 2, 1987
    Date of Patent: November 10, 1987
    Assignee: Nippon Steel Corporation
    Inventors: Yoshio Shindou, Joji Oka, Taketoshi Taira, Yujiro Miyauchi, Fumio Yamazaki
  • Patent number: 4681817
    Abstract: This piston ring has a composite plated layer at least on its outwardly facing sliding surface. The composite plated layer includes a quantity of hard particles of a granular dispersion material dispersed in a matrix of matrix metal consisting essentially of nickel-cobalt-phosphorous alloy containing about 10% to about 40% by weight of cobalt, about 2% to about 15% by weight of phosphorous, and remainder substantially nickel. It may also further include a quantity of lubricating particles having average particle diameter of from about 0.5 microns to about 20 microns and having a content of from about 5% to about 3% by volume. Yet further, the composite plated layer may include a quantity of short fibrous dispersion material dispersed in the matrix of matrix metal. Thereby, the wear on the piston ring, and also the wear on the cylinder bore in which it slides, are reduced.
    Type: Grant
    Filed: December 23, 1985
    Date of Patent: July 21, 1987
    Assignee: Kabushiki Kaisha Riken
    Inventor: Manabu Shinada
  • Patent number: 4678717
    Abstract: Coatings of a powdered protective metallic material or refractory material and mixtures thereof are formed on a ferrous metal strip as a wet film dispersion in a resin binder composition of a synthetic organic resin and a volatile organic solvent compatible with said resin, and the coated strip is heated to effect curing said resin binder and forming a flexible non-tacky dry film. The metal strip having the cured dry film containing powdered protective metallic material can be subjected to varying heat treatments to provide a wide range of protective coatings having improved surface properties, including iron-protective metal diffusion alloy coatings, such as iron-aluminum diffusion alloy coatings having a surface concentration of aluminum between about 8 and 10 wt. percent aluminum, which have improved high temperature oxidation resistance after being severely strained during fabrication at room temperature.
    Type: Grant
    Filed: September 17, 1985
    Date of Patent: July 7, 1987
    Assignee: Inland Steel Company
    Inventors: Richard A. Nickola, Brian A. Sok, Shashi B. Agarwal
  • Patent number: 4670215
    Abstract: There is disclosed a process for forming a wear-resistant, sintered layer on a metallic substrate. The process comprises steps of adhesively attaching to a surface of metallic substrate an alloy particle sheet containing 94 to 99 weight % of ternary eutectic alloy particles and 6 to 1 weight % of acryl binder, heating in a non-oxidating atmosphere to a temperature of 150.degree. to 380.degree. C. and holding at the temperature for at least 5 minutes, and heating a sintering temperature of the alloy particles.
    Type: Grant
    Filed: February 19, 1985
    Date of Patent: June 2, 1987
    Inventors: Tsuyoshi Morishita, Sigemi Osaki, Noriyuki Sakai, Yukio Shimizu, Toshiharu Konishi, Takahumi Sakuramoto
  • Patent number: 4663243
    Abstract: A porous boiling surface and method of making, which surface comprises a flame-sprayed matrix of ferrous alloy powder on a metal substrate, the matrix being characterized by having irregularly spaced, angled macropores which extend partly through the thickness of the matrix and which improve the boiling perfrmance of the surface.
    Type: Grant
    Filed: October 28, 1982
    Date of Patent: May 5, 1987
    Assignee: Union Carbide Corporation
    Inventors: Alfred M. Czikk, James W. Kern
  • Patent number: 4640814
    Abstract: A powder-metallurgy method for producing tubular product having at least one surface and preferably an internal surface thereof clad with an alloy different from and preferably more resistant to destructive media than the material from which the remainder of the tubing is constructed. An assembly is constructed of a metal tubing having an internal surface to be clad and a tubular insert mounted generally axially within the tubing in spaced-apart relation to the internal surface thereof, which provides a generally annular cavity between the internal surface of the tubing and the tubular insert. This cavity is filled with metal particles of a composition to be clad on the tubing internal surface. The cavity is sealed and the assembly is heated to an elevated temperature at which it is forged to compact the metal particles introduced to the cavity to substantially full density and metallurgically bond the particles to the internal surface of the tubing to provide a desired destructive-media resistant cladding.
    Type: Grant
    Filed: October 17, 1985
    Date of Patent: February 3, 1987
    Assignee: Crucible Materials Corporation
    Inventors: Walter T. Haswell, Jr., Karl S. Brosius, Scott B. Justus, David A. Salvatora
  • Patent number: 4640815
    Abstract: A powder-metallurgy method and assembly for producing tubular product having at least one surface and preferably an interior surface thereof clad with an alloy different from and preferably more resistant to destructive media than the material from which the remainder of the tubing is constructed. An assembly is constructed of a metal tubing having an internal surface to be clad and a tubular insert mounted generally axially within the tubing in spaced-apart relation to the internal surface thereof, which provides a generally annular cavity between the internal surface of the tubing and the tubular insert. This cavity is filled with metal particles of a composition to be clad on the tubing internal surface. The cavity is sealed and the assembly is heated to an elevated temperature at which it is extruded to compact metal particles introduced to the cavity to substantially full density and metallurgically bonded the particles to the internal surface to provide a desired destructive-media resistant cladding.
    Type: Grant
    Filed: October 17, 1985
    Date of Patent: February 3, 1987
    Assignee: Crucible Materials Corporation
    Inventors: Karl S. Brosius, Scott B. Justus, David A. Salvatora
  • Patent number: 4632074
    Abstract: A wear-resistant member and method for producing the same which member may form a movable member in an internal combustion engine which is subjected to high pressure such as a rocker arm, tappet, cam, valve or valve seat. The member is formed as a combination of a ferrous sintered body and a ferrous base body having a common surface. The sintered body is formed from a compressed powder body disposed in contact with the ferrous base body. The powder body, in a preferred embodiment, consists of 0.5 to 7.0% by weight carbon, 0.1 to 5.0% phosphorus, the balance being iron, and having a porosity of 12 to 20% by volume at least 40% of which is pores having a pore size of not more than 300.mu.. The combined powder body and ferrous base body are heated to a temperature higher than the liquid-phase temperature of the powder body but lower than the melting point of the ferrous body to sinter the powder body.
    Type: Grant
    Filed: September 30, 1985
    Date of Patent: December 30, 1986
    Assignee: Nippon Piston Ring Co.
    Inventors: Kentaro Takahashi, Takeshi Hiraoka, Yoshikatsu Nakamura, Masajiro Takeshita
  • Patent number: 4623595
    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; anda bearing layer, consolidated with the base by fusion and formed by applying on said base a powder coating having a thickness of 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.
    Type: Grant
    Filed: February 3, 1983
    Date of Patent: November 18, 1986
    Assignee: Taiho Kogyo Co., Ltd.
    Inventors: Kenichiro Futamura, Eiji Asada, Tatsuhiko Fukuoka
  • Patent number: 4612256
    Abstract: Wear-resistant coating on a machine part which is subject to friction wear, the coating being applied by a flame spray process and being composed of a plurality of superposed sprayed-on layers each differing in structure or composition from each layer adjacent thereto.
    Type: Grant
    Filed: April 27, 1984
    Date of Patent: September 16, 1986
    Assignee: Goetze AG
    Inventors: Hans J. Neuhauser, Ulrich Buran, Manfred Fischer
  • Patent number: 4608318
    Abstract: This invention relates to a double composite structure comprising cemented carbides embedded in an austenitic stainless steel matrix forming a wear, impact, drill and corrosion resistant shape by powder metallurgy techniques. Molten metal is then cast around the composite structure forming the body of a tool, lock or parts which are particularly useful for earthmoving and security applications.
    Type: Grant
    Filed: April 17, 1984
    Date of Patent: August 26, 1986
    Assignee: Kennametal Inc.
    Inventors: Nicholas Makrides, Earle W. Stephenson
  • Patent number: 4606977
    Abstract: The present invention is for a flat B containing amorphous powder based in Fe, Ni, Co or a combination thereof; a coating resulting from deposition of the powder; and a method for depositing the powder.The composition of the powder and the resulting coating consists essentially of the formulation: (Fe,Ni,Co).sub.bal Cr.sub.0-20 (Mn,Mo,W).sub.0-35 (B,Si,C).sub.5-25 (Al,Ti).sub.0-10 where the subscripts are in atomic percent and with the proviso that 4.ltoreq.B.ltoreq.15, and that the balance will exceed 50%.
    Type: Grant
    Filed: October 22, 1984
    Date of Patent: August 19, 1986
    Assignee: Allied Corporation
    Inventors: James Dickson, Louis F. Nienart, David W. Roth
  • Patent number: 4606883
    Abstract: Method of manufacturing a metallic composite article, with which the surface area of a base member, which surface area consists of a metallic base material, is bonded to a plating material over the entire surface. The base member is to be plated with a layer which is as far as possible homogeneous and thin and the composition of which is freely selectable. For this purpose, the plating material is placed in a sheet-metal cap which is adapted to the surface area to be plated as well as to the adjacent area of the base member surrounding this surface area and overlaps this adjacent area. Once the plating material and sheet-metal cap have been pressed against the base member the sheet-metal cap is evacuated and welded by electron beam, under vacuum, to the base member, whereupon base member, plating material and sheet-metal cap are hot-isostatically pressed. The sheet-metal cap is then removed, leaving the desired, plated base member.
    Type: Grant
    Filed: October 1, 1984
    Date of Patent: August 19, 1986
    Assignee: J. Wizemann GmbH & Co.
    Inventors: Kurt Wizemann, Hans Weisskopf, Peter Peppler