Abstract: A porous sintered metal comprising voids at least partially communicating with each other, and pores provided in walls of the voids, the porous sintered metal having a BET surface area of 700 cm2/cm3 or more, and an average diameter of the pores being 1 &mgr;m or more when measured by a mercury press-in method. The porous sintered metal is produced by blending a metal powder, a binder and resin particles to prepare a mixture in which the resin particles are dispersed; molding the mixture to provide a green body; selectively extracting the resin particles from the green body with a solvent; debinding the extracted green body by heating; and sintering the debound green body.

Abstract: Channeled articles having very small diameter channels spaced very closely can be made by packing elongated cores in a fixture, clamping them, and then introducing matrix material around the cores. The matrix material is formed into a unitary body and solidified. The cores are pulled out, leaving open channels where they had been. Some core and matrix combinations will permit the cores to be pulled out. Others require a core release coating to be applied to the cores. The cores can be metal or ceramic or polymer, and the matrix can be metal or ceramic or polymer. The cores can be solid, or hollow. Rather than pulling the cores out, if they are polymer, they can be burned out. The matrix can be formed by liquid state, solid state, or hybrid liquid/solid state techniques. A related technique uses hollow cores, which are not pulled out, but which remain in the body after unification. For such tube-walled articles, the matrix can be formed similarly. Rather than insuring core release, core retention is required.

Abstract: A metal-based composite material is formed by impregnating a matrix metal of Al or Al alloy into ores of a porous preform of a hydrogenatable metal having a metal hydride in at least a part of its surface.

Abstract: The present invention relates to thermally conductive, elastomeric pads and methods for manufacturing such pads. The methods involve injection-molding a thermally conductive composition comprising about 30 to 60% by volume of an elastomer polymer matrix and about 25 to 60% by volume of a thermally conductive filler material. The resultant pads have heat transfer properties and can be used as a thermal interface to protect heat-generating electronic devices.

Abstract: An artificial paper having a porous aluminum foil as the substrate and a writable coating thereon, which includes aluminum trihydrate and other optional whitening agents to facilitate the writability of the substrate. The artificial paper has properties, such as writability, optical properties, mechanical properties, and durability equivalent to or superior to pulp-based paper.

Abstract: A porous prosthesis for delivering a medication to the site of implantation is disclosed.

Abstract: In a heat shield (1), in particular for combustion chambers and for thermal fluid flow machines, the heat shield consists of a feltlike material (3) composed of compressed and sintered intermetallic fibers. Advantageously, the intermetallic fibers consist of an iron based or nickel based intermetallic phase.

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

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

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

Abstract: An improved porous article and a method for forming such porous article are provided. A mixture of ceramic or metal particles and pliable organic hollow spheres is prepared in a liquid, typically as a suspension. The article is formed by pressing, slip casting, extruding or injection molding the mixture. The article is dried to remove the liquid, and then is fired so that the particles are bonded such as by sintering, and the organic spheres are eliminated, resulting in a strong porous article having uniformly spaced interconnected voids.

Abstract: The preparation of phenol-formaldehyde and melamine-formaldehyde resin-based binders extended with a cyclic urea-formaldehyde prepolymer and to products prepared using the binders. More particularly, the invention relates to a cyclic urea prepolymer comprising urea, formaldehyde, and ammonia or a primary amine which, when added to a phenol-formaldehyde or melamine-formaldehyde based resin, results in a useful binder for the manufacturer numerous articles.

Abstract: A sintered electrode of high-melting metal (for example tungsten) is produced from spherical metal powder having a well defined particle size. The mean particle size is from 5 to 70 &mgr;m. The particle size distribution covers a range from at most 20% below to at most 20% above the mean particle size.

Abstract: The present invention includes processes and resulting structures for producing a modified polymer having interconnecting channels. The interconnecting channels act as controlled transmission passages through the polymer. A hydrophilic agent is blended into the polymer so that it is distributed within the polymer. In one embodiment, an absorbing material is blended into the polymer so that the absorbing material is distributed within the product. The product is solidified so that the hydrophilic agent forms passages in the product through which a desired composition is communicable to the absorbing material that is entrained within the product. The solidified product may be used to form a desired shaped article such as plug type inserts and liners for closed containers, or it may be formed into a film, sheet, bead or pellet.

Abstract: A metallic porous product is produced by applying a slurry of a mixture of skeleton constituent metal particles and property modifying particles to an inflammable porous foam, burning the inflammable porous foam having open pores by heat to provide a metallic skeleton structure, and sintering the metallic skeleton structure.

Abstract: An apertured and porous metal article can find use, for example, in diaphragm or membrane electrolysis cells. The article may comprise a thin and flexible metal foam of small pores which, typically, has been perforated with large apertures. The article may also be provided with an electrocatalytic coating. It can be in substantial physical contact with a membrane or diaphragm separator used in the cell for separating anode and cathode members or compartments. There is also disclosed the preparation of the article and an electrolysis cell utilizing the resulting apertured and porous metal article.

Abstract: A masking tape for preventing the formation of coatings such as nickel aluminide on localized areas of a surface is formed from a tape comprising a first separating layer containing powdered metal oxide and a polytetrafluoroethylene binder; a second brazing alloy layer comprising a metal selected from the group consisting of brazing alloy, nickel, cobalt, iron, mixtures thereof, and alloys thereof in a fibrillated polytetrafluoroethylene binder; and an optional third layer comprising a powdered metal selected from the group consisting of nickel, cobalt, and iron in a fibrillated polytetrafluoroethylene binder.

Abstract: A method of making an article by joining together at least two porous components is described, the method comprising the steps of making at least two generally tubular PM components to be joined in the axial direction, each component having an axial length less than that of the tubular article; the at least two components both having interconnected porosity and each having at least one mutual mating face; assembling the at least two components together so that the at least one mutual mating faces are in proximity to each other; placing an infiltrant material in the bore of the assembled components; heating the assembled components to melt the infiltrant material and cause it to infiltrate the interconnected porosity at least in the region of the mutual mating faces so as to cause the components to become bonded together by the infiltrant material. Examples of the manufacture of valve guides are given.

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.

Abstract: A porous membrane produced by preparing a slurry made from at least one micropyretic substance and at least one liquid carrier. The slurry is dried into a green form having a desired geometric configuration. Combustion of the green form produces the porous membrane.

Abstract: A trapping plug with unique characteristics provides phase separators for cryogenic storage systems for space applications. The plug has a body of high-thermal conductivity metal such as OFHC copper and a multiplicity of holes of uniform, extremely small diameter and uniformly spaced extending through the body. The hole diameters and their uniformity in size and spacing enable precise design of an operating system using disclosed criteria. Hole diameters at the range of interest for systems for long-term storage of cryogenics such as liquid hydrogen, that is, 0.1 to 5.0 microns, may be provided in the plugs. Multiple plugs or clusters of plugs disposed in a plate may be used as required. A storage system making use of the trapping plugs also includes external vent lines and a flow regulator that controls flow of vapor through the vent lines.

Abstract: A method for preparing foamed aluminum alloy composites comprising the steps of: (a) placing a liquid hardness-reinforcement composition into a tank, the hardness-reinforcement composition containing about 54.about.64 wt. % of an inorganic powder, about 35.about.45 wt. % of a nonflammable curable resin, and about 1 wt. % of a curing agent; (b) placing a foamed aluminum alloy plate having an internal porous body into the tank containing the hardness-reinforcement composition, then applying a pressure of about 10.about.50 Kg/cm.sup.2 onto the foamed aluminum alloy plate for about one to two hours so as to allow the hardness-reinforcement composition to soak into the foamed aluminum alloy plate and form a coated layer on the surface of the porous body; (c) removing the foamed aluminum alloy plate that has been coated with a layer of the hardness-reinforcement composition from the tank; and (d) drying and curing the curable nonflammable resin so as to form the foamed aluminum alloy composite.

Abstract: A metallic coating on a part made from a ceramic composite is obtained from a powder obtained by mixing two powders: namely,a base powder A comprising 2 to 5% of a reactive element Ti or Zr, at least one melting element B or Si in proportions ensuring a liquidus temperature between 1000.degree. C. and 1300.degree. C. and additional metallic elements including at least 50% Ni or Ni+Co;a powder B in a weight ratio of 5 to 30%, the elements of which are chosen to impart to the part particularly desired surface properties such as anti-wear, anti-oxidation and/or anti-corrosion, and to ensure a liquidus temperature of powder B greater than that of powder A.

Abstract: An article coated with a thermal barrier coating system for high temperature use, has its thermal cyclic spallation life improved by the application of an aluminide to the outer portion of a bonding coating disposed on a substrate. The bond coating has a surface roughness in the range of about 200-600 microinches Ra prior to application of covering thermal barrier coating.

Abstract: Disclosed herein is a multilayered sliding member comprising a lubricating composition comprising polytetrafluoroethylene and, as filler, 1-25 wt % of fibrous magnesium oxysulfate, fan-shaped magnesium oxysulfate or a mixture thereof, and a porous sintered metal layer formed on a steel backing,the lubrication composition being impregnated in and coated on a porous sintered metal layer formed on the steel backing.

Abstract: In accordance with a method of producing metal sinter bodies, the bodies are provided with degassing openings which are made preferably before sintering of an initial press body part.

Abstract: A nonsacrifical laser hardened structure and method protects against incident high energy irradiation. A very thin outer face sheet with a reflective outer surface is laminated to a foam core which is further laminated to a support structure. The foam core includes liquid and vapor passages. A supply of liquid working fluid impregnates the foam core. A portion of incident irradiation energy is first reflected from the outer face sheet and substantially all the remaining irradiation energy conducted through the face sheet to be absorbed at the back of the face sheet into heat of vaporization of the liquid working fluid. Additional liquid working fluid is supplied to the back of the face sheet by capillary action through the foam core, and additional liquid working fluid is resupplied to the foam core through the liquid passages. Working fluid vapor is removed through the foam vapor passages.

Abstract: There is disclosed a method for making a self-supporting ceramic composite article having a porous core bearing a dense surface layer formed integrally with said core. A preform comprises a filler material and parent metal distributed therethrough, wherein the volume percent of parent metal is sufficient to form a volume of oxidation reaction product exceeding the total volume available within said preform. The parent metal is melted and reacted with an oxidant to form an oxidation reaction product filling the spatial volume and leaving voids. The reaction is continued to further transport molten parent metal through the oxidation reaction product to at least one surface of the preform to form oxidation reaction product on said surface substantially free of voids thereby forming a relatively dense surface layer.

Abstract: Perforated plates (10) having very small holes (14) with a uniform diameter throughout the plate thickness are prepared by a "wire drawing" process in which a billet of sacrificial metal is disposed in an extrusion can of the plate metal, and the can is extruded and restacked repeatedly, converting the billet to a wire of the desired hole diameter. At final size, the rod is then sliced into wafers, and the wires are removed by selective etching. This process is useful for plate metals of interest for high performance regenerator applications, in particular, copper, niobium, molybdenum, erbium, and other rare earth metals. Er.sub.3 Ni, which has uniquely favorable thermophysical properties for such applications, may be incorporated in regions of the plates by providing extrusion cans (20) containing erbium and nickel metals in a stacked array (53) with extrusion cans of the plate metal, which may be copper. The array is heated to convert the erbium and nickel metals to Er.sub.3 Ni.

Abstract: Ceramic bodies are bonded together via a layer of an oxidation reaction product of a molten metal, which metal is present in one or both of the ceramic bodies prior to bonding. At least one of the ceramic bodies comprises a ceramic product formed by the oxidation reaction of molten parent metal (e.g., alumina from molten aluminum) and grown as molten metal is transported through, and oxidized on the surface of, its own oxidation product. One or both of the ceramic bodies used in the bonding process contains surface-accessible channels of residual metal, i.e., metal channels which have resulted from molten-metal transport during the ceramic growth process. When the suitably assembled ceramic bodies are heated in the presence of an oxidant at a temperature above the melting point of the residual metal, molten metal at the surface of at least one of the ceramic bodies reacts with the oxidant to form a layer of oxidation reaction product, which may or may not incorporate at least one filler material.

Abstract: A fixing mechanism is provided including a heated roller. The heated roller includes a core made of a high thermally conductive metallic material, and a gudgeon for supporting such a core. The gudgeon is made from powder metal stainless steel material that has an interconnected porosity of 20%.

Abstract: A coating for a heat engine part, particularly a turbo-machine part made of superalloy, comprises an electrophoretically deposited metallic structure of cellular form with uniformly disposed cells of predetermined size, the structure preferably being composed of M, Cr, Al, and Y, where M denotes Ni, Co, Fe and mixtures thereof. The cellular metallic structure is consolidated by a sintering treatment, which may be reactive, or metallization, preferably in the vapor phase, and the coating is completed by a ceramic material applied by plasma spraying.

Abstract: A dental material of a metal composition for reinforcing the metal framework of a dental restoration comprising an aggregate combination of metal particles including a first high fusing temperature precious metal component and a second low fusing temperature component which form a porous sponge-like structure upon heat treatment.

Abstract: The method and material of the present inventioin includes a combination of a high-fusing temperature metal component and a low-fusing temperature metal component which are adapted to be heat treated at a temperature above the melting temperature of the low-fusing temperature metal component, such that a porous, sponge-like structure is formed with a total void volume of 20-80%.

Abstract: A frameless and coreless porous endosseous implant comprising a porous sintered metal layer (2) having a range of relatively large pores and porous sintered metal layers having a range of relatively small pores and laminated into one body by sintering integrally with the layer on either side thereof, or a porous singered metal layer having a range of relatively small pores and porous sintered metal layers having a range of relatively large pores and laminated into one body by sintering integrally with the layer on either side thereof, whereby the three layers each permit the ingrowth and penetration out of two or more kinds out of fibrous tissue, osteoid tissue and bone tissue in the pores thereof.

Abstract: There is disclosed a method for making a self-supporting ceramic composite article having a porous core bearing a dense surface layer formed integrally with said core. A preform comprises a filler material and parent metal distributed therethrough, wherein the volume percent of parent metal is sufficient to form a volume of oxidation reaction product exceeding the total volume available within said preform. The parent metal is melted and reacted with an oxidant to form an oxidation reaction product filling the spatial volume and leaving voids. The reaction is continued to further transport molten parent metal through the oxidation reaction product to at least one surface of the preform to form oxidation reaction product on said surface substantially free of voids thereby forming a relatively dense surface layer.

Abstract: Porous coating for substrates especially metal substrates. The pores are created by the removal of a fugitive material. The coatings have useful numerous applications also for heat exchange, optical coating and non-slip. Products formed from the coating and a method of forming such products are also disclosed.

Abstract: A method of producing self-supporting ceramic or ceramic composite bodies having a polymer component, which includes first providing a self-supporting ceramic or ceramic composite body comprising (i) a polycrystalline oxidation reaction product formed upon oxidation of a molten parent metal with an oxidant, and (ii) interconnected porosity at least partially accessible from one or more surfaces of said ceramic body. The polymer is disposed or formed within the interconnected porosity. The polymer is situated so as to alter, modify or contribute to the properties of the ceramic or ceramic composite body originally formed.

Abstract: The invention relates to a method of manufacturing permeable mineral membranes.The method of the invention is characterized in that a thin layer of gel of peptised hydroxide of at least aluminum is deposited on a permeable perous substrate and the resulting membrane is dried and fired at a temperature between 500.degree. and 1100.degree. C.The resulting membranes can be used for isotopic separation of gases or for filtration and ultrafiltration.

Abstract: A method for making seamless, porous metal articles comprising:(a) rotating a mold containing a stabilized suspension of a metal particulate at a rate and for a time such that the particulate is separated from the suspension and distributed on the interior wall of the mold, thereby forming a structure conforming to the interior wall of the mold, the rate of rotation being sufficiently high that at least about 100 Gs of centrifugal acceleration is achieved at the interior wall of the structure,(b) drying the formed structure to provide a structure having green or unsintered strength, and(c) sintering the dried structure to remove volatile material and fuse the individual particles of the particulate to each other to form the seamless, porous metal article.Metal articles in accordance with the invention have substantially uniform diameters, thicknesses and pore structures, have Bubble Point ratios of 1.5 or less, and find particular use as filters.

Abstract: This invention discloses a compact of hydrogen adsorption alloy principally composed of a metal hydride in which all surfaces of fine particles of hydrogen adsorption alloy are completely coated with a dissimilar metal by plating, without effecting reactivity and a porous material of high thermal conductivity is infiltrated with the fine particles of alloy to be formed into a compact by compression molding.By this construction, it is possible to improve decline in the thermal conductivity or dropping of the fine particles out of cells of the porous material caused by micronization as a result of repeated uses of the hydrogen adsorption alloy are avoided.

Abstract: Porous metallic bodies having a substantially uniform pore size of less than about 200 microns and a density of less than about 25 percent theoretical, as well as the method for making them, are disclosed. Group IIA, IIIB, IVB, VB, and rare earth metal hydrides are heated in a confining container at a controlled rate to a temperature of about greater than the temperature at which the hydride decomposes. Hydrogen is removed from the container and the remaining metal is heated during a second stage to a temperature greater than the temperature at which it was previously heated but not greater than the temperature of 1/2 to 2/3 the temperature at which the metal melts at a controlled rate. The resulting porous metallic body produced has a density less than about 25 percent theoretical and a pore size of less than about 200 microns. The metallic particles of the present invention have high inner surface area and possess minimum resistance to gas flow.

Abstract: New porous semiconductor dopant carriers are disclosed together with a method for the diffusion doping of semiconductors by the vapor phase transport of an n or p type dopant, such as phosphorus, arsenic, antimony, boron, gallium, aluminum, zinc, silicon, tellurium, tin and cadmium to the semiconductor host substrate; wherein the dopant source comprises a dopant containing porous, inert, rigid dimensionally stable and thermal shock resistant carrier comprised of SiC, elemental silicon or mixtures thereof.

Abstract: A porous sintered body, preferably a filter or filter material, with good corrosion resistance and with a pore volume which can be predicted within specified comparatively narrow limits, is made by loose sintering of a preferably gas-atomized spherical powder a ferritic-austenitic stainless steel.

Abstract: A porous body, for a solid electrolytic capacitor, is made from a combination of titanium and aluminum in order to reduce dependence upon tatalum, a material which is now in extremely short supply. First, the titanium hydride and aluminum are milled into an extremely fine micro-powder. Then, the powders are mixed with the aluminum content in the range of 45%-65%, compressed into the desired body shape, and given a three-step heat treatment. In the first step, the body is heated at a temperature of 400.degree. to 500.degree. C. for a dehydrogenation. In the second step, the dehydrogenated body is heated to an alloying temperature which is higher than 500.degree. C., but lower than the melting point of aluminum. In the third step, the alloyed body is heated to a temperature which is higher than the melting point of aluminum (about 1000.degree. C.).

Abstract: A foraminous body formed of a tin-containing atomized, compacted and sintered austenitic stainless steel powder, and process including the steps of sintering and cooling in a dissociated ammonia atmosphere.

Abstract: A composition of material for use as a friction lining with a cast iron mating surface. The friction lining has an iron powder base that reacts with tin to alloy and hold substantially equal weight percentages of graphite and coke in a fixed position. The friction lining has a substantially constant wear rate up to 300.degree. C. and a linear wear rate between 300.degree.-500.degree. C.

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: A composite formed from large pieces of aggregate formed from (1) metal hydride (or hydride-former) powder and (2) either metal powder or plastic powder or both is prepared. The composite has large macroscopic interconnected pores (much larger than the sizes of the powders which are used) and will have a very fast heat transfer rate and low windage loss. It will be useful, for example, in heat engines, hydrogen storage devices, and refrigerator components which depend for their utility upon both a fast rate of hydriding and dehydriding. Additionally, a method of preparing the composite and a method of increasing the rates of hydriding and dehydriding of metal hydrides are also given.

Abstract: A dental material of a metal composition for reinforcing the metal framework of a dental restoration comprising an aggregate combination of metal particles including a first high fusing temperature precious metal component and a second low fusing temperature component which form a porous sponge-like structure upon heat treatment.