Consolidated Metal Powder Compositions Patents (Class 75/228)
  • Patent number: 10632538
    Abstract: The invention relates to a method for producing a green compact composite comprising at least a first partial green compact and a second partial green compact, wherein, within one pressing cycle, a powder is introduced into a filling chamber and then separated into a first partial quantity and into a second partial quantity, and, within the same pressing cycle, the respective partial quantities are pressed to form a first partial green compact and a second partial green compact and the partial green compacts are amalgamated after the pressing, wherein the amalgamation forms a press fit between the first partial green compact and the second partial green compact and produces a predetermined breaking point in the green compact composite. Furthermore, the invention proposes a green compact composite, a sintered component and also a press, each of which can be based on the proposed method.
    Type: Grant
    Filed: June 10, 2015
    Date of Patent: April 28, 2020
    Assignee: GKN Sinter Metals Engineering GmbH
    Inventors: Alexander Hüllen, Rainer Schmitt, Eberhard Ernst
  • Patent number: 10465062
    Abstract: Processes for producing melamine octamolybdates having high thermal stability include a step of reacting molybdenum trioxide and melamine in an acidic aqueous system at a pH of less than or equal to about 4 to form a slurry of the melamine octamolybdate. The resulting melamine octamolybdate can be characterized by a decomposition onset temperature (or a temperature at a weight loss of 1%, or a temperature at a weight loss of 2%) on a thermogravimetric analysis curve of greater than 300° C., and is useful in polymer compositions as a smoke suppressant.
    Type: Grant
    Filed: December 7, 2017
    Date of Patent: November 5, 2019
    Assignee: J.M. Huber Corporation
    Inventors: Yue Liu, Aleksey Isarov, David Dwayne Temples, David Stanley Reece, Mitchell Lee Pierce
  • Patent number: 9988699
    Abstract: Hard particles are incorporated as a starting material in a sintered alloy. The hard particles may contain 20 to 60 mass % Mo, 3 to 15 mass % Mn, and more than 0.01 to 0.5 mass % C, the balance being Fe and unavoidable impurities.
    Type: Grant
    Filed: December 29, 2017
    Date of Patent: June 5, 2018
    Inventors: Kimihiko Ando, Nobuyuki Shinohara
  • Patent number: 9885240
    Abstract: A repaired article includes a body extending between a first side and a second side. The body has a repair section with an associated thickness between the first side and the second side. The repair section includes regions of plastic deformation distributed through the thickness. A gas turbine engine including the body is also disclosed.
    Type: Grant
    Filed: August 22, 2013
    Date of Patent: February 6, 2018
    Inventors: Edward R. Szela, Michael A. Joy, Daniel A. Bales, Bradford A. Cowles, David A. Rutz
  • Patent number: 9796020
    Abstract: A method for the manufacture of a metal part, the method including the steps: a) compacting agglomerated spherical metal powder to a preform, b) debinding and sintering the preform to a part at a temperature not exceeding 1275° C., c) performing one of the following steps: i) compacting the part to a density of more than 95% of the theoretical density, or ii) compacting the part to a density of less than 95% of the theoretical density and sintering the part at a temperature not exceeding 1275° C. to a density of more than 95% of the theoretical density, and d) subjecting the part to hot isostatic pressing at a temperature not exceeding 1200° C. The method provides an industrial process to produce fully dense parts from alloys which normally cannot be produced and still give good impact properties, which is vital for many applications where there alloys are used.
    Type: Grant
    Filed: January 8, 2010
    Date of Patent: October 24, 2017
    Assignee: Metec Powder Metal AB
    Inventor: Christer Åslund
  • Patent number: 9761422
    Abstract: A magnetic material sputtering target characterized in that, in a plane for observing the oxide in the target, oxide grains in the target have an average diameter of 1.5 ?m or less, and that 60% or more of the oxide grains in the observing plane of the target have a difference between a maximum diameter and a minimum diameter of 0.4 ?m or less, where the maximum diameter is a maximum distance between arbitrary two points on the periphery of an oxide grain, and the minimum diameter is a minimum distance between two parallel lines across the oxide grain. A non-magnetic grain dispersion-type magnetic material sputtering target that can inhibit abnormal discharge due to an oxide causing occurrence of particles during sputtering is obtained.
    Type: Grant
    Filed: February 15, 2013
    Date of Patent: September 12, 2017
    Assignee: JX Nippon Mining & Metals Corporation
    Inventors: Atsutoshi Arakawa, Hideo Takami, Yuichiro Nakamura
  • Patent number: 9633796
    Abstract: Tantalum powders produced using a tantalum fiber precursor are described. The tantalum fiber precursor is chopped or cut into short lengths having a uniform fiber thickness and favorable aspect ratio. The chopped fibers are formed into a primary powder having a controlled size and shape, narrow/tight particle size distribution, and low impurity level. The primary powder is then agglomerated into an agglomerated powder displaying suitable flowability and pressability such that pellets with good structural integrity and uniform pellet porosity are manufacturable. The pellet is sintered and anodized to a desired formation voltage. The thusly created capacitor anode has a dual morphology or dual porosity provided by a primary porosity of the individual tantalum fibers making up the primary powder and a larger secondary porosity formed between the primary powders agglomerated into the agglomerated powder.
    Type: Grant
    Filed: April 11, 2016
    Date of Patent: April 25, 2017
    Assignee: Greatbatch Ltd.
    Inventors: Yanming Liu, Barry C. Muffoletto, Jason T. Hahl
  • Patent number: 9630251
    Abstract: A titanium base alloy powder is formed by subsurface reduction of a chloride vapor with a molten alkali metal or molten alkaline earth metal to form reaction products comprising pre-alloy particles and a salt of the alkali metal or the alkaline earth metal. A majority of the pre-alloy particles have a composition of at least 50% by weight of titanium, about 5.38% to 6.95% by weight of aluminum, and about 3% to 5% by weight of vanadium. The pre-alloy particles are recovered from the reaction products to produce a titanium base alloy powder containing less than about 200 ppm alkali or alkaline earth metal.
    Type: Grant
    Filed: October 23, 2014
    Date of Patent: April 25, 2017
    Assignee: Cristal Metals Inc.
    Inventors: Lance E. Jacobsen, Adam Benish
  • Patent number: 9607743
    Abstract: The present invention provides a permanent magnet with excellent adhesion strength with plated layer and without significant decrease in magnetic properties, compared to the conventional R-T-B based magnet. By means that the R-T-B based magnet as the raw material is applied to heating treatment for a long time, the major phase grains will form core-shell like structures in the R-T-B based magnet in which R1 and Ce are included as an essential of R. When the mass concentration of R1 and Ce in the core portion is set as ?R1 and ?Ce respectively and that of R1 and Ce in the shell portion is set as ?R1 and ?Ce respectively, the ratio (B/A) between the mass concentration ratio of R1 to Ce in the shell portion (?R1/?Ce=B) and that of R1 to Ce in the core portion (?R1/?Ce=A) is 1.1 or more.
    Type: Grant
    Filed: April 22, 2014
    Date of Patent: March 28, 2017
    Inventors: Yasushi Enokido, Kyung-Ku Choi, Kenichi Suzuki, Daisuke Tanaka
  • Patent number: 9583271
    Abstract: An electrolytic capacitor comprising an anode comprised of cryogenically milled anode material is described. The cryogenic milling process prepares the active anode material for anode fabrication. The capacitor further comprises a casing of first and second casing members secured to each other to provide an enclosure. A feedthrough electrically insulated from the casing and from the casing and extending there from through a glass-to-metal seal, at least one anode electrically connected within the casing, a cathode, and an electrolyte. The cathode is of a cathode active material deposited on planar faces of the first and second casing members.
    Type: Grant
    Filed: July 1, 2013
    Date of Patent: February 28, 2017
    Assignee: Greatbach Ltd.
    Inventors: Donald F. Kaiser, William C. Thiebolt, Jason T. Hahl
  • Patent number: 9580790
    Abstract: A process of converting an outer layer of an object made of a refractory metal, such as titanium, into a carbide of the refractory metal. A molten metal, such as molten lithium, is placed adjacent the outer surface of the object. The lithium does not react with the titanium, nor is it soluble within the titanium to any significant extent at the temperatures involved. The molten lithium contains elemental carbon, that is, free carbon atoms. At high temperature, the carbon diffuses into the titanium, and reacts with titanium atoms to form titanium carbide in an outer layer. Significantly, no other atoms are present, such as hydrogen or oxygen, which can cause problems, because they are blocked by the molten lithium.
    Type: Grant
    Filed: December 20, 2007
    Date of Patent: February 28, 2017
    Assignee: IAP Research, Inc.
    Inventors: Julius John Bonini, Bhanumathi Chelluri, Edward Arlen Knoth
  • Patent number: 9347119
    Abstract: A selectively corrodible powder compact that may be used to make the components of a selectively corrodible perforating system is disclosed. The selectively corrodible powder compact includes a cellular nanomatrix comprising a nanomatrix material. The selectively corrodible powder compact also includes a plurality of dispersed particles comprising a particle core material having a density of about 7.5 g/cm3 or more, dispersed in the cellular nanomatrix. The selectively corrodible powder compact further includes a bond layer extending throughout the cellular nanomatrix between the dispersed particles.
    Type: Grant
    Filed: September 3, 2011
    Date of Patent: May 24, 2016
    Inventor: Zhiyue Xu
  • Patent number: 9309780
    Abstract: Coatings as may be used in a gas turbine are provided. A nickel based coating may include 15 to 40 wt % cobalt, 10 to 25 wt % chromium, 5 to 15 wt % aluminum, 0.05 to 1 wt % yttrium and/or at least one of elements from lanthanum series, 0.05 to 8 wt % ruthenium or iron, 0 to 1 wt % iridium, 0.05 to 5 wt % molybdenum, 0 to 3 wt % silicon, 0 to 5 wt % tantalum, 0 to 2 wt % hafnium, unavoidable impurities, and a balance of nickel. A cobalt based coating may include 15 to 40 wt % nickel, 15 to 28 wt % chromium, 5 to 15 wt % aluminum, 0.05 to 1 wt % yttrium and/or at least one of elements from lanthanum series, 0.05 to 5 wt % ruthenium and/or molybdenum, 0 to 2 wt % iridium, 0 to 3 wt % silicon, 0 to 5 wt % tantalum, hafnium, unavoidable impurities, and a balance of cobalt.
    Type: Grant
    Filed: September 18, 2012
    Date of Patent: April 12, 2016
    Inventor: Xin-Hai Li
  • Publication number: 20150147217
    Abstract: An article having a nanocomposite magnetic component and method of forming a nanocomposite magnetic component are disclosed. The article includes a plurality of nanocrystalline flake particles bonded along their prior particle boundaries. The nanocrystalline flake particles have a median grain size less than about 30 nanometers and include a first set of grains comprising predominantly permanent magnet phase and a second set of grains comprising predominantly soft magnet phase.
    Type: Application
    Filed: November 27, 2013
    Publication date: May 28, 2015
    Applicant: General Electric Company
    Inventors: Francis Johnson, Wanming Zhang, Min Zou, Christina Hongbing Chen
  • Publication number: 20150143952
    Abstract: In one embodiment, a permanent magnet includes a sintered compact having a composition represented by the composition formula: RpFeqMrCusCo100-p-q-r-s (where R is at least one element selected from rare earth elements, M is at least one element selected from Zr, Ti, and Hf, p is 10.5 atomic % or more and 12.5 atomic % or less, q is 24 atomic % or more and 40 atomic % or less, r is 0.88 atomic % or more and 4.5 atomic % or less, and s is 3.5 atomic % or more and 10.7 atomic % or less. The sintered compact has a structure having crystal grains constituted of a main phase including a Th2Zn17 crystal phase, and a crystal grain boundary. In the structure of the sintered compact, an average grain diameter of the crystal grains is 25 micrometer or more, and a volume fraction of the crystal grain boundary is 14% or less.
    Type: Application
    Filed: February 2, 2015
    Publication date: May 28, 2015
    Inventors: Yosuke Horiuchi, Shinya Sakurada, Keiko Okamoto, Masaya Hagiwara, Tsuyoshi Kobayashi, Masaki Endo, Tadahiko Kobayashi, Kazuomi Yoshima
  • Publication number: 20150147590
    Abstract: A new Enhanced High Pressure Sintering (EHPS) method for making three-dimensional fully dense nanostructures and nano-heterostructures formed from nanoparticle powders, and three-dimensional fully dense nanostructures and nano-heterostructures formed using that method. A nanoparticle powder is placed into a reaction chamber and is treated at an elevated temperature under a gas flow to produce a cleaned powder. The cleaned powder is formed into a low density green compact which is then sintered at a temperature below conventional sintering temperatures to produce a fully dense bulk material having a retained nanostructure or nano-heterostructure corresponding to the nanostructure of the constituent nanoparticles. All steps are performed without exposing the nanoparticle powder to the ambient.
    Type: Application
    Filed: November 14, 2014
    Publication date: May 28, 2015
    Applicant: The Government of the United States of America, as represented by the Secretary of the Navy
    Inventors: Boris N. Feigelson, James A. Wollmershauser
  • Publication number: 20150141234
    Abstract: A manufacturing method for reinforced structural elements includes providing a reinforcement structure including a first material, and embedding the reinforcement structure in an encasing matrix comprising a second material using additive layer manufacturing, ALM. A manufacturing tool for reinforced structural elements includes a positioning component including a jig for clamping a reinforcement structure including a first material and an ALM robot configured to embed a reinforcement structure clamped in the jig in an encasing matrix including a second material.
    Type: Application
    Filed: November 10, 2014
    Publication date: May 21, 2015
    Applicant: Airbus Operations GmbH
    Inventors: Peter Sander, Matthias Hegenbart, Carlos Weinbuch, Helene-Hedwig Koenig
  • Publication number: 20150122302
    Abstract: According to an embodiment, a thermoelectric conversion material is made of a polycrystalline material which is represented by a composition formula (1) shown below and has a MgAgAs type crystal structure. The polycrystalline material includes a MgAgAs type crystal grain having regions of different Ti concentrations. (AaTib)cDdXe??Composition formula (1) wherein 0.2?a?0.7, 0.3?b?0.8, a+b=1, 0.93?c?1.08, and 0.93?e?1.08 hold when d=1; A is at least one element selected from the group consisting of Zr and Hf, D is at least one element selected from the group consisting of Ni, Co, and Fe, and X is at least one element selected from the group consisting of Sn and Sb.
    Type: Application
    Filed: January 15, 2015
    Publication date: May 7, 2015
    Inventor: Takao SAWA
  • Patent number: 9017762
    Abstract: The invention relates to sputter targets and methods for depositing a layer from a sputter target. The method preferably includes the steps of: placing a sputter target in a vacuum chamber; placing a substrate having a substrate surface in the vacuum chamber; reducing the pressure in the vacuum chamber to about 100 Torr or less; removing atoms from the surface of the sputter target while the sputter target is in the vacuum chamber (e.g., using a magnetic field and/or an electric field). The deposited layer preferably is a molybdenum containing alloy including about 50 atomic percent or more molybdenum, 0.5 to 45 atomic percent of a second metal element selected from the group consisting of niobium and vanadium; and 0.5 to 45 atomic percent of a third metal element selected from the group consisting of tantalum, chromium, vanadium, niobium, and titanium.
    Type: Grant
    Filed: April 4, 2013
    Date of Patent: April 28, 2015
    Assignee: H.C. Starck, Inc.
    Inventors: Gary Alan Rozak, Mark E. Gaydos, Patrick Alan Hogan, Shuwei Sun
  • Patent number: 9017598
    Abstract: A metal-bonded graphite foam composite includes a ductile metal continuous phase and a dispersed phase that includes graphite foam particles.
    Type: Grant
    Filed: June 21, 2012
    Date of Patent: April 28, 2015
    Assignee: UT-Battelle, LLC
    Inventors: Paul A. Menchhofer, James W. Klett
  • Publication number: 20150098855
    Abstract: The present invention relates to a method of surface hardening a plurality of sintered bodies having a hard phase and a binder phase. The method includes the steps of placing the bodies in a container, and forming a system including the container and the bodies therein, and causing the bodies to move and collide with each other and with inside walls of the container. The container is vibrating utilizing a mechanical resonance frequency of the system.
    Type: Application
    Filed: March 7, 2013
    Publication date: April 9, 2015
    Inventors: Michael Carpenter, Sarah Geoghegan, Eugene Keown, Jane Smith
  • Publication number: 20150099104
    Abstract: In at least one embodiment, a single sintered magnet is provided having a concentration profile of heavy rare-earth (HRE) elements within a continuously sintered rare-earth (RE) magnet bulk. The concentration profile may include at least one local maximum of HRE element concentration within the bulk such that a coercivity profile of the magnet has at least one local maximum within the bulk. The magnet may be formed by introducing alternating layers of an HRE containing material and a magnetic powder into a mold, pressing the layers into a green compact, and sintering the green compact to form a single, unitary magnet.
    Type: Application
    Filed: October 9, 2013
    Publication date: April 9, 2015
    Inventors: Feng Liang, C Bing Rong, Michael W. Degner
  • Patent number: 8999514
    Abstract: Provided is bond coating powder and method of making. The method includes providing a powder including a plurality of parent particles. The method includes providing a plurality of dispersoids. The method includes mechanically alloying the powder and the plurality of dispersoids at ambient temperature. The mechanical alloying operable to provide a selective occupation of the plurality of dispersoids in a grain boundary area of the plurality of parent particles providing the bond coating powder. The plurality of dispersoids occupy about 18 percent to about 30 percent of the grain boundary area of the bond coating powder.
    Type: Grant
    Filed: February 3, 2012
    Date of Patent: April 7, 2015
    Assignee: General Electric Company
    Inventors: Arunkumar Shamrao Watwe, Yuk-Chiu Lau
  • Patent number: 8999229
    Abstract: Disclosed herein is a sintered composition comprising iron; about 0.05 to about 1 wt % molybdenum; about 3 to about 4.5 wt % silicon; about 0.05 to about 0.5 wt % chromium; about 0.011 to about 0.015 wt % magnesium; all weight percents being based on the total weight of the composition; the composition being devoid of carbon except for trace amounts; and wherein the composition is sintered. Disclosed herein too is a method comprising blending a powdered composition that comprises iron; about 0.05 to about 1 wt % molybdenum; about 3 to about 4.5 wt % silicon; about 0.05 to about 0.5 wt % chromium; about 0.011 to about 0.015 wt % magnesium; all weight percents being based on the total weight of the composition; the composition being devoid of carbon except for trace amounts; compacting and sintering the composition.
    Type: Grant
    Filed: November 11, 2011
    Date of Patent: April 7, 2015
    Assignee: Alpha Sintered Metals, Inc.
    Inventors: Thomas J. Cornelio, Leonid I. Frayman, Thomas E. Haberberger
  • Patent number: 8999230
    Abstract: New net shape strength retaining high temperature alloy parts are formed from fine metallurgical powders by mechanically blending the powders and placing them in die, placing a piston in the die, extending the piston into a driving chamber, filling the chamber with CH4 and air and compressing the powders with the filling pressure. Igniting gas in the chamber drives the piston into the cavity, producing pressures of about 85 to 150 tsi, compacting the powders into a near net shape alloy part, ready for sintering at 2300° C. without shrinking. The alloy parts are Re, Mo—Re, W—Re, Re—Hf—HfC, Re—Ta—Hf—HfC, Re—Mo—Hf—HfC, Mo—Re—Ta, Mo—Re-f-HfC, W—Re—Hf—HfC, W—Re—Ta—Hf—HfC or W—Re—Mo—Hf alloys.
    Type: Grant
    Filed: March 30, 2009
    Date of Patent: April 7, 2015
    Assignee: Utron Kinetics, LLC
    Inventors: Karthik Nagarathnam, Donald Trostle, Dennis Massey
  • Publication number: 20150093589
    Abstract: A composite particle comprises a core, a shielding layer deposited on the core, and further comprises an interlayer region formed at an interface of the shielding layer and the core, the interlayer region having a reactivity less than that of the core, and the shielding layer having a reactivity less than that of the interlayer region, a metallic layer not identical to the shielding layer and deposited on the shielding layer, the metallic layer having a reactivity less than that of the core, and optionally, an adhesion metal layer deposited on the metallic layer, wherein the composite particles have a corrosion rate of about 0.1 to about 450 mg/cm2/hour using an aqueous 3 wt % KCl solution at 200° F. An article comprises composite particles, wherein has a corrosion rates of about 0.1 to about 450 mg/cm2/hour using an aqueous 3 wt % KCl solution at 200° F.
    Type: Application
    Filed: October 21, 2014
    Publication date: April 2, 2015
    Inventors: Oleg A. Mazyar, Michael H. Johnson, Randall V. Guest, Nicholas Carrejo, Wayne R. Furlan, Sean L. Gaudette
  • Publication number: 20150093721
    Abstract: A dental blank is provided for yielding a metal frame having a desired shape according to a dental CAD/CAM system and a machining process. The dental blank is formed from a metal powder sintered body and contains Co as a main component, Cr in a proportion of 26% by mass or more and 35% by mass or less, Mo in a proportion of 5% by mass or more and 12% by mass or less, and Si in a proportion of 0.5% by mass or more and 1.0% by mass or less. Further, part of the Si is silicon oxide, and the ratio of the silicon oxide to the total amount of Si is preferably 10% by mass or more and 90% by mass or less.
    Type: Application
    Filed: September 26, 2014
    Publication date: April 2, 2015
    Inventors: Hidefumi NAKAMURA, Yukihiko SHIOHARA
  • Publication number: 20150075327
    Abstract: Disclosed is process for producing a wear-resistant coating on a component. The process comprises providing an electrolyte which contains Co and/or Ni, dispersing first particles comprising hard material particles and/or slip material particles in the electrolyte, dispersing second particles comprising metal alloy particles in which the metal alloy comprises chromium and aluminum in the electrolyte, providing a component to be coated in a bath of the electrolyte which has first and second particles dispersed therein, and electrodepositing a matrix of Co and/or Ni with incorporated first and second particles on the component. A correspondingly produced wear-resistant coating is also disclosed.
    Type: Application
    Filed: September 12, 2014
    Publication date: March 19, 2015
    Inventors: André WERNER, Josef LINSKA
  • Patent number: 8961646
    Abstract: There is provided a nickel alloy having an excellent creep strength as well as high-temperature oxidation resistance. The nickel alloy of the present invention comprises, by mass percent, Cr in a range of 11.5 to 11.9%, Co in a range of 25 to 29%, Mo in a range of 3.4 to 3.7%, W in a range of 1.9 to 2.1%, Ti in a range of 3.9 to 4.4%, Al in a range of 2.9 to 3.2%, C in a range of 0.02 to 0.03%, B in a range of 0.01 to 0.03%, Zr in a range of 0.04 to 0.06%, Ta in a range of 2.1 to 2.2%, Hf in a range of 0.3 to 0.4%, and Nb in a range of 0.5 to 0.8%, the balance being Ni and unavoidable impurities, and contains carbides and borides precipitating in crystal grains and at grain boundaries.
    Type: Grant
    Filed: November 9, 2011
    Date of Patent: February 24, 2015
    Assignees: Honda Motor Co., Ltd., National Institute for Materials Science
    Inventors: Yuefeng Gu, Tadaharu Yokokawa, Toshiharu Kobayashi, Toshio Osada, Junzo Fujioka, Hiroshi Harada, Daisuke Nagahama, Yusuke Kikuchi
  • Publication number: 20150044462
    Abstract: Material processing systems are disclosed. Some systems include methods of eliminating or reducing defects in elongate workpieces that can undergo large deformations during processing. Some systems include apparatus configured to facilitate such large deformations while maintaining internal stresses (e.g., tensile stresses) below a threshold stress. Some disclosed systems pertain to powder extrusion techniques. Continuous and batch processing systems are disclosed.
    Type: Application
    Filed: September 19, 2014
    Publication date: February 12, 2015
    Inventors: Mark W. Broadley, James Alan Sago, John Eckert, Jeffrey M. Farina
  • Publication number: 20150030494
    Abstract: Methods and apparatus for producing an object, the method comprising: performing an Additive Manufacturing process to produce an intermediate object from provided metal or alloy, whereby the intermediate object comprises regions having a contaminant concentration level above a threshold level; based upon one or more parameters, determining a temperature and a duration; and performing, on the intermediate object, a contaminant dispersion process by, for a duration that is greater than or equal to the determined duration, heating the intermediate object to a temperature that is greater than or equal to the determined temperature and less than the melting point of the metal or alloy, the contaminant dispersion process being performed so as to disperse, within the intermediate object, a contaminant from regions of high contaminant concentration to regions of low contaminant concentration until the intermediate object comprises no regions having a contaminant concentration level above the threshold level.
    Type: Application
    Filed: February 20, 2013
    Publication date: January 29, 2015
    Inventor: Charles Malcolm WARD-CLOSE
  • Publication number: 20150024233
    Abstract: Methods and apparatuses to fabricate additive manufactured parts with in-process monitoring are described. As parts are formed layer-by-layer, a 3D measurement of each layer or layer group may be acquired. The acquisition of dimensional data may be performed at least partially in parallel with the formation of layers. The dimensional data may be accumulated until the part is fully formed, resulting in a part that was completely inspected as it was built. The as-built measurement data may be compared to the input geometrical description of the desired part shape. Where the part fails to meet tolerance, it may be amended during the build process or rejected.
    Type: Application
    Filed: July 19, 2013
    Publication date: January 22, 2015
    Applicant: The Boeing Company
    Inventor: Steven Matthew GUNTHER
  • Patent number: 8911528
    Abstract: Molybdenum titanium sputter targets are provided. In one aspect, the targets are substantially free of the ?(Ti, Mo) alloy phase. In another aspect, the targets are substantially comprised of single phase ?(Ti, Mo) alloy. In both aspects, particulate emission during sputtering is reduced. Methods of preparing the targets, methods of bonding targets together to produce large area sputter targets, and films produced by the targets, are also provided.
    Type: Grant
    Filed: November 2, 2010
    Date of Patent: December 16, 2014
    Assignee: H.C. Starck Inc.
    Inventors: Mark E. Gaydos, Prabhat Kumar, Steve Miller, Norman C. Mills, Gary Rozak, Rong-Chein Richard Wu
  • Publication number: 20140335442
    Abstract: Provided is a method for preparing nickel-aluminum alloy powder at low temperature, which is simple and economical and is capable of solving the reactor corrosion problem. The method for preparing nickel-aluminum alloy powder at low temperature includes: preparing a powder mixture by mixing nickel powder and aluminum powder in a reactor and adding aluminum chloride into the reactor (S1); vacuumizing the inside of the reactor and sealing the reactor (S2); and preparing nickel-aluminum alloy powder by heat-treating the powder mixture in the sealed reactor at low temperature (S3).
    Type: Application
    Filed: October 1, 2013
    Publication date: November 13, 2014
    Inventors: Hyung Chul HAM, Shin Ae Song, Seong Cheol Jang, Yong Min Kim, Jonghee Han, Hyoung-Juhn Kim, Tae Hoon Lim, Suk Woo Nam, Sung Pil Yoon, Chang Won Yoon, Yeong Cheon Kim
  • Patent number: 8882975
    Abstract: Provided is an Sb—Te base alloy sinter sputtering target having Sb and Te as its primary component and comprising a structure in which Sb—Te base alloy particles are surrounded by fine carbon or boron particles; wherein, if the mean diameter of the Sb—Te base alloy particles is X and the particle size of carbon or boron is Y, Y/X is within the range of 1/10 to 1/10000. The present invention seeks to improve the Sb—Te base alloy sputtering target structure, inhibit the generation of cracks in the sintered target, and prevent the generation of arcing during the sputtering process.
    Type: Grant
    Filed: October 5, 2007
    Date of Patent: November 11, 2014
    Assignee: JX Nippon Mining & Metals Corporation
    Inventors: Masataka Yahagi, Hideyuki Takahashi, Hirohisa Ajima
  • Patent number: 8883309
    Abstract: A blue light-emitting silicate phosphor favorably employable as a blue light-emitting source of a light-emitting apparatus which gives emission of a visible light upon irradiation of ultraviolet rays having a wavelength of 254 nm, such as ultraviolet rays emitted by a fluorescent lamp is produced by a method comprising calcining a powdery mixture comprising a magnesium oxide powder, an MeO source powder, a EuO source powder and a SiO2 source powder, said magnesium oxide powder having a purity of 99.9 wt. % or higher and a BET specific surface area in the range of 3 to 60 m2/g and having been prepared by bringing a metallic magnesium vapor into contact with oxygen whereby oxidizing the metallic magnesium vapor.
    Type: Grant
    Filed: April 14, 2011
    Date of Patent: November 11, 2014
    Assignee: Ube Material Industries, Ltd.
    Inventors: Toru Inagaki, Masato Yamauchi, Seiji Noguchi, Kouichi Fukuda, Akira Ueki
  • Patent number: 8883047
    Abstract: Compositions related to skutterudite-based thermoelectric materials are disclosed. Such compositions can result in materials that have enhanced ZT values relative to one or more bulk materials from which the compositions are derived. Thermoelectric materials such as n-type and p-type skutterudites with high thermoelectric figures-of-merit can include materials with filler atoms and/or materials formed by compacting particles (e.g., nanoparticles) into a material with a plurality of grains each having a portion having a skutterudite-based structure. Methods of forming thermoelectric skutterudites, which can include the use of hot press processes to consolidate particles, are also disclosed. The particles to be consolidated can be derived from (e.g., grinded from), skutterudite-based bulk materials, elemental materials, other non-Skutterudite-based materials, or combinations of such materials.
    Type: Grant
    Filed: April 30, 2009
    Date of Patent: November 11, 2014
    Assignees: Massachusetts Institute of Technology, Trustees of Boston College
    Inventors: Zhifeng Ren, Jian Yang, Xiao Yan, Qinyu He, Gang Chen, Qing Hao
  • Patent number: 8845956
    Abstract: The disclosure relates to a method for production of a component, such as a contact piece, for a switchgear assembly. To introduce a slot and apply a contact outer contour directly during the powder-metallurgical production process of the contact material, contouring in the form of a slot or slots is introduced into the powder-metal material, which is located in a mold, essentially in a direction parallel to a normal to a surface of the component, to form the component with a slot.
    Type: Grant
    Filed: November 30, 2009
    Date of Patent: September 30, 2014
    Assignee: ABB Technology AG
    Inventors: Dietmar Gentsch, Guenter Pilsinger
  • Publication number: 20140286818
    Abstract: An embodiment in accordance with the present invention provides a method for creating and consolidating fragments and a useable structure formed from said consolidated fragments. The method includes swaging a metal powder into a first consolidated structure. The consolidated structure is ground to form particles and the particles are sifted to select those with a predetermined diameter. The particles having the predetermined diameter can then be swaged into a second consolidated structure. The resultant second consolidated structure is therefore configured to fragment controllably. The second consolidated structure can also be formed from reactive metal laminates such that the structure also has chemical energy.
    Type: Application
    Filed: May 17, 2013
    Publication date: September 25, 2014
    Inventors: David Michael Lunking, Timothy P. Weihs
  • Publication number: 20140286814
    Abstract: A composite magnetic material includes metal magnetic powder and thermosetting resin. The metal magnetic powder includes first metal magnetic powder and second metal magnetic powder. The first metal magnetic powder includes iron and a first element with oxygen affinity higher than that of iron. The second metal magnetic powder includes at least iron. The second metal magnetic powder also includes the first element for an amount smaller than the first element contained in the first metal magnetic powder, or not include the first element. A mean particle diameter of the first metal magnetic powder is greater than a mean particle diameter of the second metal magnetic powder. The second metal magnetic powder is 10 weight % to 30 weight % of the total amount of the metal magnetic powder. This composite magnetic material can secure high magnetic permeability and also improve withstand voltage.
    Type: Application
    Filed: November 14, 2012
    Publication date: September 25, 2014
    Inventors: Junichi Kotani, Nobuya Matsutani
  • Publication number: 20140262327
    Abstract: A disintegrable powder compact includes a matrix; a plurality of dispersed particles including a particle core material dispersed in the matrix; a ferrous alloy including carbon disposed in one of the matrix or particle core material; and a secondary element disposed in the other of the matrix or particle core material, the matrix and the plurality of dispersed particles having different standard electrode potentials. A process for preparing a disintegrable powder compact includes combining a primary particle including a ferrous alloy that includes carbon and a secondary particle to form a composition; compacting the composition to form a preform; and sintering the preform by forming a matrix, wherein the dispersed particles are dispersed in the matrix, the disintegrable powder compact is configured to disintegrate in response to contact with a disintegration fluid, and the primary particle and secondary particle have different standard electrode potentials.
    Type: Application
    Filed: March 12, 2013
    Publication date: September 18, 2014
    Applicant: Baker Hughes Incorporated
    Inventors: Zhiyue Xu, Zhihui Zhang, Yingqing Xu
  • Publication number: 20140271329
    Abstract: The present invention is directed to methods of preparing a bonded metallurgical powder composition comprising melting a binding agent and blending the melted binding agent with a metallurgical powder mixture, in the substantial absence of solvent, for a time sufficient to form the bonded metallurgical powder composition. Bonded metallurgical powder compositions prepared using these methods are also described, as well as compacted powder metallurgical parts prepared using them.
    Type: Application
    Filed: March 11, 2014
    Publication date: September 18, 2014
    Applicant: Hoeganaes Corporation
    Inventors: Kalathur S. Narasimhan, Christopher T. Schade
  • Publication number: 20140271325
    Abstract: Provided in one embodiment is a method, comprising: sintering a plurality of nanocrystalline particulates to form a nanocrystalline alloy, wherein at least some of the nanocrystalline particulates may include a non-equilibrium phase comprising a first metal material and a second metal material, and the first metal material may be soluble in the second metal material. The sintered nanocrystalline alloy may comprise a bulk nanocrystalline alloy.
    Type: Application
    Filed: March 14, 2014
    Publication date: September 18, 2014
    Inventors: Christopher A. Schuh, Mansoo Park
  • Patent number: 8834747
    Abstract: Compositions containing tin nanoparticles and electrically conductive particles are described herein. The tin nanoparticles can have a size below about 25 nm so as to make the compositions fusable at temperatures below that of bulk tin (m.p.=232° C.). Particularly, when the tin nanoparticles are less than about 10 nm in size, the compositions can have a fusion temperature of less than about 200° C. The compositions can contain a whisker suppressant to inhibit or substantially minimize the formation of tin whiskers after tin nanoparticle fusion. In some embodiments, the compositions contain tin nanoparticles, electrically conductive particles comprising copper particles, and a whisker suppressant comprising nickel particles. Methods for using the present compositions are also described herein. The present compositions can be used as a lead solder replacement that allows rework to be performed.
    Type: Grant
    Filed: March 3, 2011
    Date of Patent: September 16, 2014
    Assignee: Lockheed Martin Corporation
    Inventor: Alfred A. Zinn
  • Publication number: 20140241929
    Abstract: There are provided a rare-earth permanent magnet and a manufacturing method of the rare-earth permanent magnet with improved magnetic performance which is achieved through milling-ability-improved fine wet-milling step. In the method, coarsely milled magnet material is finely wet-milled in an organic solvent together with an organometallic compound expressed with a structural formula of M-(OR)x (M including at least one of Nd, Al, Cu, Ag, Dy, Tb, V, Mo, Zr, Ta, Ti, W, and Nb, R representing a substituent group consisting of a straight-chain or branched-chain hydrocarbon with carbon chain length of 2-16, and x representing an arbitrary integer) to obtain magnet powder and to make the organometallic compound adhere to particle surfaces of the magnet powder. Subsequently, the magnet powder having adhesion of the organometallic compound to particle surfaces thereof is formed into a formed body and sintered so as to obtain a permanent magnet 1.
    Type: Application
    Filed: September 25, 2012
    Publication date: August 28, 2014
    Inventors: Takashi Ozaki, Katsuya Kume, Toshiaki Okuno, Izumi Ozeki, Tomohiro Omure, Keisuke Taihaku, Takashi Yamamoto
  • Publication number: 20140234152
    Abstract: Provided is a sintered bearing that is capable of reducing cost through reduction in usage amount of copper, excellent in initial running-in characteristics and quietness, and is high in durability. Raw material powders including iron powder, flat copper powder, low-melting point metal powder, and graphite are loaded into a mold, and a green compact is formed under a state in which the flat copper powder is caused to adhere onto a molding surface. Subsequently, sintering is carried out without causing iron in the green compact to react with carbon so that an iron structure is formed of a ferrite phase. In this manner, a sintered bearing (1) including a base part (S2) including copper at a uniform content, and a surface layer (S1) covering a surface of the base part (S2) and including copper at a larger content than the base part (S2) can be obtained.
    Type: Application
    Filed: September 18, 2012
    Publication date: August 21, 2014
    Applicant: NTN CORPORATION
    Inventors: Yoshinori Ito, Sunao Shimizu, Eiichirou Shimazu, Takahiro Okuno
  • Publication number: 20140218144
    Abstract: The present invention relates to an elliptical unit block for preparing a core using soft magnetic metal powder and a core with excellent high current DC bias characteristics using the same, and more specifically, to an elliptical unit block for preparing a core using soft magnetic metal powder used in an inductor for an automotive electronic sub-assembly using a high current buck or boost inductor or a three phase line reactor or fuel cell system for power factor correction (PFC), and a powered magnetic core prepared using the same.
    Type: Application
    Filed: September 5, 2012
    Publication date: August 7, 2014
    Applicant: CHANG SUNG CO.
    Inventors: Jae-Yeol Park, Dal-Joong Kim, Bong-Gi Yoo, Gu-Hyun Kim, Kwang-Yong Yoo
  • Publication number: 20140212685
    Abstract: Disclosed herein is an engine 52, in particular a combustion engine or a jet-power unit, or an engine part 54, 56 made from metal, and in particular Al or Mg, or an alloy comprising one or more thereof.
    Type: Application
    Filed: March 31, 2014
    Publication date: July 31, 2014
    Applicant: Bayer International SA
    Inventors: Henning Zoz, Michael Dvorak, Horst Adams
  • Patent number: 8784729
    Abstract: The present invention is directed to a process for producing high density, refractory metal products via a press/sintering process. The invention is also directed to a process for producing a sputtering target and to the sputtering target so produced.
    Type: Grant
    Filed: January 16, 2007
    Date of Patent: July 22, 2014
    Assignee: H.C. Starck Inc.
    Inventors: Prabhat Kumar, Charles Wood, Gary Rozak, Steven A. Miller, Glen Zeman, Rong-Chein Richard Wu
  • Publication number: 20140154126
    Abstract: A multiphase composite system is made by binding hard particles, such as TiC particles, of various sizes with a mixture of titanium powder and aluminum, nickel, and titanium in a master alloy or as elemental materials to produce a composite system that has advantageous energy absorbing characteristics. The multiple phases of this composite system include an aggregate phase of hard particles bound with a matrix phase. The matrix phase has at least two phases with varying amounts of aluminum, nickel, and titanium. The matrix phase forms a bond with the hard particles and has varying degrees of hard and ductile phases. The composite system may be used alone or bonded to other materials such as bodies of titanium or ceramic in the manufacture of ballistic armor tiles.
    Type: Application
    Filed: November 18, 2013
    Publication date: June 5, 2014
    Inventor: Robert G. Lee