Abstract: A cold cast mass element has solid metal particles of greater than 75% by volume and a binding agent of less than 25% by volume, with an outside surface. The binding agent is exposed on the outside surface and encapsulates the solid metal particles within the cold cast mass element. The may have an outside surface has a hardness of greater than durometer 70 Shore A and preferably has a hardness of above about 75 Shore A or above about 100 Shore D. The mass element has a binding agent which is an epoxy resin or thermosetting phenol formaldehyde resin. The metal particles can be grinded iron of preferably 85% to 96% by volume with a binding agent 4% to 12% by volume. The mass element preferably has solid metal particles of greater than 85% by weight; and a binding agent of less than 15% by weight.

Abstract: In one aspect, there are provided methods for producing porous metallic structures, wherein the methods involve the use of collagen fibrils on the nanometer scale as a “sacrificial” scaffold upon which metal particles are deposited. Also disclosed are structures comprising a porous metallic matrix having favorable strength, porosity, and density characteristics. Structures produced in accordance with the present disclosure are useful for, inter alia, the fabrication of devices such as filters, heat exchangers, sound absorbers, electrochemical cathodes, fuel cells, catalyst supports, fluid treatment units, lightweight structures and biomaterials.

Abstract: An efficient oxygen scavenging composition for use in film forming polymers is disclosed wherein the oxygen scavenging composition comprises an oxidizable metal particle, such as elemental iron; a water hydrolysable Lewis acid, such as aluminum chloride; and an acidifying electrolyte such as sodium or potassium bisulfate.

Abstract: This invention discloses a method of making an oxygen scavenging particle comprised of an activating component and an oxidizable component wherein one component is deposited upon the other component from a vapor phase and is particularly useful when the activating component is a protic solvent hydrolysable halogen compound and the oxygen scavenging particle is a reduced metal.

Abstract: Provided is a method of producing a sintered compact including the steps of mixing raw material powders respectively composed of a chalcogenide element and a Vb group element or raw material powders of an alloy of two or more elements including a chalcogenide element and a Vb group element, and hot pressing the mixed powder under conditions that satisfy the following formula: P(pressure)?{Pf/(Tf?T0)}×(T?T0)+P0(Pf: final pressure, Tf: final temperature, P0: atmospheric pressure, T: heating temperature, T0: room temperature, and temperatures in Celsius). This method is able to produce a high-density, high-strength and large-diameter sintered compact containing a chalcogenide element (A) and a Vb group element (B) or containing the element (A) and (B) and additionally a IVb group element (C) and/or an additive element (D) which is free from cracks even when it is assembled and used as a sputtering target-backing plate assembly.

Abstract: Wear protection sheets containing hard material particles having a metallic shell and solder material particles selected from the group consisting of soft solders, hard solders and high-temperature solders, the use of the wear protection sheets and a process for producing them by tape casting are described.

Abstract: An electrode is used to perform discharge surface treatment of a work piece. The electrode is made of a green compact obtained by compression-molding an electrode material including powder of any of a metal, a metallic compound, and ceramics. The discharge surface treatment includes generating an electric discharge between the electrode and the work piece in an atmosphere of a machining medium and forming a film consisting of a machining material on a surface of a work piece using energy produced by the electric discharge. The powder has an average particle diameter of 5 micrometer to 10 micrometers, and contains 40 volume percent or more of a component not forming or less easily forming carbide as a component for forming the film on the work piece. The electrode has a hardness in a range of B to 8B tested with a pencil scratch test for a coating film.

Abstract: Hardmetal compositions each including hard particles having a first material and a binder matrix having a second, different material comprising rhenium or a Ni-based superalloy. Tungsten may also be used a binder matrix material. A two-step sintering process may be used to fabricate such hardmetals at relatively low sintering temperatures in the solid-state phase to produce substantially fully-densified hardmetals. A hardmetal coating or structure may be formed on a surface by using a thermal spray method.

Abstract: Methods of fabricating bodies of earth-boring tools include mechanically injecting a powder mixture into a mold cavity, pressurizing the powder mixture within the mold cavity to form a green body, and sintering the green body to a desired final density to form at least a portion of a body of an earth-boring tool. For example, a green bit body may be injection molded, and the green bit body may be sintered to form at least a portion of a bit body of an earth-boring rotary drill bit. Intermediate structures formed during fabrication of an earth-boring tool include green bodies having a plurality of hard particles, a plurality of matrix particles comprising a metal matrix material, and an organic material that includes a long chain fatty acid derivative. Structures formed using the methods of fabrication are also disclosed.

Abstract: The invention provides a method for producing alloy flakes for rare earth sintered magnets, which makes uniform the intervals, size, orientation, and shape of the R-rich region and the dendrites of the 2-14-1 phase, which inhibits formation of chill, and which produces flakes that are pulverized into powder of a uniform particle size in the pulverization step in the production of a rare earth sintered magnet, and that are pulverized into powder compactable into a product with a controlled shrink ratio, and alloy flakes for a rare earth sintered magnet obtained by the method, and a rare earth sintered magnet having excellent magnetic properties.

Abstract: A method of uniformly dispersing a nano powder throughout a micron powder. Ordinary mixing or agitation does not succeed in attaining uniform dispersal: the nano powder agglomerates into microscopic masses. In one form of the invention, a charge of a micron powder, with fifty weight percent of charge of nanopowder is loaded into a ball mill. The mixture is ball milled for less than two hours, at room temperature in a dry condition, and produces a highly uniform distribution of the nano powder throughout the micron powder.

Abstract: Provided are methods comprising at least one metal powder with an extractable material and a composition comprising a polyol, a hydrophilic polymer, or both in order to form a mixture in which the metal powder and the extractable material assume respective positions. The composition functions as a homogenizing agent that allows the mixture to remain well-mixed for extended periods of time under ambient conditions. Also provided are green bodies and porous constructs, including implants, that are made in accordance with the disclosed methods. The green bodies and porous constructs have a substantially uniform porosity that is at least partially attributable to the ability of the composition to maintain the metal powder and the extractable material in their respective positions prior to sintering.

Abstract: Fibers for diamond-impregnated cutting tools and their associated methods for manufacture and use are described. The cutting tools contain a diamond-impregnated cutting portion that contains fibers made from carbon, glass, ceramic, polymer, and the like. The fibers can be in any form, including chopped and milled fibers. The fibers may also be coated with metal, ceramic, or other performance-enhancing coatings. The fibers may be used to both control the tensile strength control the erosion rate of the matrix to optimize the cutting performance of the tools. Additionally, the fibers may also weaken the structure and allow higher modulus binders to be used for the cutting tools at a lower cost, allowing the amount of fibers to be tailored to retain the diamonds in the cutting portion for the desired amount. And as the cutting portion erodes, the fibers may also increase the lubricity at the face of the cutting portion.

Abstract: Process for the assembly of at least two articles made of silicon carbide-based materials by moderately refractory non-reactive brazing, in which the articles are placed in contact with a non-reactive brazing composition, and the assembly formed by the articles and the brazing composition is heated to a brazing temperature that is sufficient to melt the brazing composition in order to form a refractory joint, in which the non-reactive brazing composition is a binary alloy formed, as mass percentages, from 56% to 70% silicon and 44% to 30% yttrium.

Abstract: A method for forming a carbide composite that includes providing a mixture of carbide particles and a metallic binder in a container; sintering the container contents at a first processing condition having a pressure of less than about 45,000 psi; and sintering the container contents at a second processing condition having a pressure of greater than about 100,000 psi is disclosed.

Abstract: A hard phase forming alloy powder, for forming a hard phase dispersed in a sintered alloy, consists of, by mass %, 15 to 35% of Mo, 1 to 10% of Si, 10 to 40% of Cr, and the balance of Co and inevitable impurities. A production method, for a wear resistant sintered alloy, includes preparing a matrix forming powder, the hard phase forming alloy powder, and a graphite powder. The production method further includes mixing 15 to 45% of the hard phase forming alloy powder and 0.5 to 1.5% of the graphite powder with the matrix forming powder into a raw powder. The production method further includes compacting the raw powder into a green compact having a predetermined shape and includes sintering the green compact. A wear resistant sintered alloy exhibits a metallic structure in which 15 to 45% of a hard phase is dispersed in a matrix. The hard phase consists of, by mass %, 15 to 35% of Mo, 1 to 10% of Si, 10 to 40% of Cr, and the balance of Co and inevitable impurities.

Abstract: The invention relates to mixtures of metal, alloy or composite powders which have a mean particle diameter D50 of not more than 75 ?m, preferably not more than 25 ?m, and are produced in a process in which a starting powder is firstly deformed to give platelet-like particles and these are then comminuted in the presence of milling aids together with further additives and also the use of these powder mixtures and shaped articles produced therefrom.

Abstract: A method for providing a porous metal implant. A mixture of a biocompatible metal, a spacing agent, and a binder is provided. The mixture is formed into a shaped the spacing agent is removed to form a plurality of pores in the implant. A shaped porous metal implant is also provided.

Abstract: A macroscopic composite sintered powder metal article including a first region including cemented hard particles, for example, cemented carbide. The article includes a second region including one of a metal and a metallic alloy selected from the group consisting of a steel, nickel, a nickel alloy, titanium, a titanium alloy, molybdenum, a molybdenum alloy, cobalt, a cobalt alloy, tungsten, and a tungsten alloy. The first region is metallurgically bonded to the second region, and the second region has a thickness of greater than 100 microns. A method of making a macroscopic composite sintered powder metal article is also disclosed, herein. The method includes co-press and sintering a first metal powder including hard particles and a powder binder and a second metal powder including the metal or metal alloy.

Abstract: This invention discloses a method of making an oxygen scavenging particle comprised of an activating component and an oxidizable component wherein one component is deposited upon the other component from a vapour phase and is particularly useful when the activating component is a protic solvent hydrolysable halogen compound and the oxygen scavenging particle is a reduced metal.

Abstract: Disclosed is a Fe—Ga—P—C—B—Si based metallic glass alloy particle prepared by a gas atomizing process, which has an approximately complete spherical shape, a relatively large particle size and a high crystallization temperature (Tx). The plurality of particles may be subjected to a spark plasma sintering process at the crystallization temperature or less under a compression pressure of 200 MPa or more, to provide a bulk Fe-based sintered metal soft magnetic material of metallic glass, which has a high density, a single phase structure of metallic glass in an as-sintered state, excellent soft magnetic characteristics applicable to a core of a magnetic head, a transformer or a motor, and a high specific resistance.

Abstract: A quasi-monolithic cylinder crankcase is provided that is cast in a metal permanent mold for an internal combustion engine having an infiltration body penetrating the cylinder crankcase, wherein the infiltration body is composed of an inductively welded, open-cell metal foam.

Abstract: A magnetic alloy material according to the present invention has a composition represented by Fe100-a-b-cREaAbCoc, where RE is a rare-earth element always including La, A is either Si or Al, 6 at %?a?11 at %, 8 at %?b?18 at %, and 0 at %?c?9 at %, and has either a two phase structure consisting essentially of an ?-Fe phase and an (RE, Fe, A) phase including 30 at % to 90 at % of RE or a three phase structure consisting essentially of the ?-Fe phase, the (RE, Fe, A) phase including 30 at % to 90 at % of RE and an RE(Fe, A)13 compound phase with an NaZn13-type crystal structure. The respective phases have an average minor-axis size of 40 nm to 2 ?m.

Abstract: A wear resistant sintered member comprising an Fe base alloy matrix and a hard phase dispersed in the Fe base alloy matrix and having an alloy matrix and hard particles precipitated and dispersed in the alloy matrix. Manganese sulfide particles having particle size of 10 ?m or less are uniformly dispersed in crystal grains of the overall Fe base alloy matrix, and manganese sulfide particles having particle size of 10 ?m or less are dispersed in the alloy matrix of the hard phase.

Abstract: It is an object to provide a composite material having a satisfactory sintering density and exhibiting excellent abrasion resistance and a method for manufacturing the same. The composite material contains a Ti alloy matrix containing Ti as a primary component and TiB and NiB dispersed in the Ti alloy matrix. The method for manufacturing the composite material includes the step of conducting sintering by using a mixed powder containing a Ti powder and/or a Ti alloy powder containing Ti as a primary component and a Ni—B alloy powder.

Abstract: A highly wear resistant sintered, hot pressed, or otherwise compacted ceramic composite material is described, consisting of two discrete phases of the form AlxMgyB14 where x and y ?1 or like hard, orthorhombic compounds, and TiB2 or like Group IVB transition metal di-borides, and with an unexpectedly high content of transition metal di-boride in the range from 40 to 90 percent (28 to 85 volume percent).

Abstract: A sliding part in which a surface coverage ratio of copper in the sliding part increases. A bearing which is the sliding part is formed by filling the raw powder into the filling portion of the forming mold, compacting the raw powder to form a powder compact, and sintering the powder compact. A copper-based raw powder is composed of a copper-based flat raw powder having an average diameter smaller than that of an iron-based raw powder and an aspect ratio larger than that of the iron-based raw powder, and a copper-based small-sized raw powder having the average diameter is smaller than that of the copper-based flat raw powder. The copper segregates at the surface of the sliding part. In the bearing in which the copper-based flat powder segregates at the surface, the surface is covered with the copper-based small-sized raw powder that has emerged on the surface, as well as the copper-based flat raw powder, thereby it is possible to increase the surface coverage ratio of copper.

Abstract: The structural integrity of a metal powder body during heat treatment is enhanced by the in situ formation of metal nanoparticles. The nanoparticles bond to one another and to the metal powder particles of the powder body during heat treatment to provide strength to the powder body prior to the operation of the physical phenomena which transform the powder body into a coherent article. The precursor or precursors from which the nanoparticles are derived are preferably metal salts which are added to the powder or powder body in the form of a solution. The use of conventional binders is optional.

Abstract: The present invention provides increased recovery in additive-enhanced or alloy-enhanced molten steel. This is accomplished by deoxidizing powders blended with the additive alloys. The deoxidizing powder reacts with the oxygen, thereby depleting the oxygen in this region. The alloy or additive region is enriched, thereby improving the recovery in the molten steel.

Abstract: Solid oxide fuel cell wherein the anode has a cermet, including a metallic portion and an electrolyte ceramic material portion substantially uniformly interdispersed.

Abstract: A method of making Re and Re-based materials comprises steps of: providing a Re powder starting material or a Re powder starting material and at least one additional powder material; subjecting at least the Re powder to a first degassing treatment for reducing the oxygen content thereof; increasing the density of the degassed Re powder or a mixture of the degassed Re powder and the at least one additional powder material to form a green billet; subjecting the billet to a second degassing treatment to further reduce the oxygen content; and consolidating the billet to form a consolidated material with greater than about 95% of theoretical density and low oxygen content below about 200 ppm for Re and below about 500 ppm for Re-based materials formed from the mixture, excluding oxygen from non-metallic compounds and ceramics. Materials so produced are useful in the manufacture of deposition sources such as sputtering targets.

Abstract: Apparatus for producing silver nano-particle material comprises a furnace and a crucible positioned within the furnace, the crucible containing a quantity of precursor material, the furnace heating the quantity of precursor material contained in the crucible to vaporize the precursor material. A process gas supply operatively associated with the furnace provides a process gas to an interior region of the furnace. A conduit is operatively associated with the furnace so that an inlet end of the conduit is open to the interior region of the furnace. A particle separator system is operatively associated with an outlet end of the conduit.

Abstract: A hydroxy fatty acid salt having an average particle diameter of from 5 ?m to 100 ?m with a composition of from 0.3 wt % to 2 wt %, and more preferably, from 0.5 wt % to 2 wt % is added to a raw material powder in powder metallurgy, and worm molding is performed. In addition, a hydroxy fatty acid salt having an average particle diameter of 50 ?m or less is attached on a mold in advance, and after that, the warm molding is performed. As a hydroxy fatty acid salt, 12-hydroxy lithium stearate is suitably used.

Abstract: An R—Fe—B base sintered magnet having a composition of 12–17 at % of R (wherein R stands for at least two of yttrium and rare earth elements and essentially contains Nd and Pr), 0.1–3 at % of Si, 5–5.9 at % of B, 0–10 at % of Co, and the balance of Fe, containing a R2(Fe,(Co),Si)14B intermetallic compound primary phase and at least 1% by volume of an R—Fe(Co)—Si grain boundary phase, and being free of a B-rich phase exhibits a coercive force of at least 10 kOe despite a reduced content of heavy rare earth.

Abstract: Disclosed are conductive powder having a packing density of 68% by volume or more with a relative value preferably comprising 60 to 92% by weight of roughly spherical and silver-plated copper powder part of the surface of which has been coated with 3 to 30% by weight of silver based on an amount of roughly spherical copper powder with exposing at least a surface of a portion of an alloy of copper with silver, and the surface of which is coated with 0.02 to 1.0% by weight of an aliphatic acid based on an amount of the roughly spherical and silver-plated copper powder, and 8 to 40% by weight of silver powder, and a method for preparing the same.

Abstract: A thermal spray composition and method of deposition for abradable seals for use in gas turbine engines, turbochargers and steam turbines. The thermal spray composition includes a solid lubricant and a ceramic preferably comprising 5 to 60 wt % total of the composition in a ratio of 1:7 to 20:1 of solid lubricant to ceramic, the balance a matrix-forming metal alloy selected from Ni, Co, Cu, Fe and Al and combinations and alloys thereof. The solid lubricant is at least one of hexagonal boron nitride, graphite, calcium fluoride, lithium fluoride, magnesium fluoride, barium fluoride, tungsten disulfide and molybdenum disulfide particles. The ceramic includes at least one of albite, illite, quartz and alumina-silica.

Abstract: A powder molded magnet manufactured by a method comprising the steps of: (1) forming a granular compound of diameter of not more than 250 ?m with a rare earth-iron rapid-quenched flake, which has not more than 150 ?m in diameter, being coarsely ground if necessary, and a binder, (2) dry-blending the granular compound with fatty acid metallic soap powder, (3) forming compressed powder from the granular compound dry-blended with the fatty acid metallic soap powder, by powder molding, and (4) heat-treating the compressed powder to a temperature higher than a thermally dissociating temperature of stabilized isocyanate.

Abstract: Disclosed is a flow-softening tungsten alloy having the general formula: W100-pAiBjCkDe wherein W is tungsten; A is one or more elements selected from the group consisting of nickel, iron, chromium and cobalt; B is in or more elements selected from the group consisting of molybdenum, niobium and tantalum; C is one or more of the elements selected from the groups consisting of titanium and aluminum; D is one or more elements selected from the group consisting of boron, carbon, and silicon; i is from about 5 to about 8 weight percent; j is from 0 to about 4 weight percent; k is from about 0.1 to about 4 weight percent; 1 is from 0 to about 0.1 weight percent; and p is greater than or equal to about 7 weight percent and less than or equal to about 20 weight percent. In this alloy p is approximately equal to the sum of i, j, k and 1. A method of preparing this alloy and a kinetic energy penetrator manufactured from it are also disclosed.

Abstract: This invention relates to a ductile binder phase for use with AlMgB14 and other hard materials. The ductile binder phase, a cobalt-manganese alloy, is used in appropriate quantities to tailor good hardness and reasonable fracture toughness for hard materials so they can be used suitably in industrial machining and grinding applications.

Abstract: A composite material 5 in which a dispersing material 7 is dispersed in a matrix 6 is provided. The composite material 5 is producible by steps of filling said mixed material in a space forming region to be defined by at least two container elements when said at least two container elements are integrated into one body, and then infiltrating said aluminum (Al) being molten due to heat generated by said self-combustion reaction into pores inside said mixed material through at least one hole formed in an upper part of a reaction container formed by combining said at least two container elements in which said mixed material is filled in said space forming region in a state being fixed to a predetermined shape, thereby an aluminide intermetallic compound is formed by self-combustion reaction between said metal powder and said aluminum (Al), and a dispersing material is dispersed into said matrix.

Abstract: There is disclosed a powder magnetic core in which a permeability does not easily drop even when an applied magnetic field intensifies, comprising: a bulk body containing a main component of a powder of an Fe-base alloy having a soft magnetic property, and the balance substantially including a heat-treated insulation binder and a void, wherein an aspect ratio of the powder is in a range of 1 to 1.5, and a volume ratio of the powder in the bulk body is in a range of 40 to 60 volume %, and an initial permeability (?0) has a value which satisfies 6??0?20, and a relation of ?/?0?0.5 is established between K and A, when the permeability is ? with an applied magnetic field of 24 kA/m.

Abstract: A method of forming a powder metal material includes molding a compact from a powder mix comprising an iron-containing powder and glass, and subsequently sintering the compact. Also disclosed is a sintered powder metal material including iron and glass.

Abstract: A large-diameter tungsten-lanthana rod having an elongated grain structure substantially parallel to the longitudinal axis of the rod is described. The large diameter rod is produced by rolling at a temperature greater than 1400° C. and less than 1700° C. to achieve at least about a 40% reduction in cross-sectional area. The high strength of the longitudinally elongated grain structure is desirable for applications such as rocket nozzles.

Abstract: A method of making cermet inert anodes for the electrolytic production of metals such as aluminum is disclosed. The method includes the step of spray drying a slurry comprising ceramic phase particles and metal phase particles. The resultant spray dried powder, which comprises agglomerates of both the ceramic phase and metal phase particles, may then be consolidated by techniques such as pressing and sintering to produce a cermet inert anode material. The ceramic phase may comprise oxides of Ni, Fe and at least one additional metal selected from Zn, Co, Al, Li, Cu, Ti, V, Cr, Zr, Nb, Ta, W, Mo, Hf and rare earths. The metal phase may comprise Cu, Ag, Pd, Pt, Au, Rh, Ru, Ir and/or Os. The consolidated cermet inert anode material exhibits improved properties such as reduced porosity. The cermet inert anodes may be used in electrolytic reduction cells for the production of commercial purity aluminum as well as other metals.

Abstract: A sintered alloy has prolonged life span in a state where it is in contact with pure water. A bearing 5 is made of a Cu-based sintered alloy 51 having excellent corrosion resistance against liquid including sulfur or its compounds. A tetrafluoroethylene resin layer 53 is provided at the external surface of the sintered alloy 51. The Cu-based sintered alloy 51 is covered with a tetrafluoroethylene resin layer 53 having corrosion resistance, so that it is possible to secure high corrosion resistance even when the sintered alloy 51 is in contact with ionized pure water. It is also possible to provide a sintered alloy having prolonged life span while it is in contact with pure water.

Abstract: Preparation, handling, and spray drying, in an economic and environmentally-friendly way, of slurries for the production of tungsten carbide based hard metal tools or components by the powder injection molding or extrusion route is disclosed. The slurry used is based on ethanol-water and contains metal carbide and metallic raw materials as well as stearic acid and a low concentration of polyethylenimine (PEI). The concentration of PEI is 0.01-1 wt % of the raw material weight. This combination results in low-viscous slurries, which require less use of ethanol, energy, manpower, and equipment time in their preparation, handling, and spray drying. The invention also relates to the powder obtained by using the method.

Abstract: The present invention relates to a hafnium silicide target for forming a gate oxide film composed of HfSi1.02-2.00. Obtained is a hafnium silicide target superior in workability and embrittlement resistance, and suitable for forming a HfSiO film and HfSiON film that may be used as a high dielectric gate insulation film in substitute for a SiO2 film, and to the manufacturing method thereof.

Abstract: There are disclosed a method for producing a composite material composed of a dispersing agent and a matrix, and a composite material produced by the method. The matrix is formed by the steps of coating a metal-coated dispersing agent to form a metal-coated layer on the surface of the dispersing agent, filling the metal-coated dispersing agent in a jig prepared in a fixed shape, and then causing the reaction of the metal-coated layer with a molten Al by impregnating the metal-coated dispersing agent with the molten Al filled in the jig.

Abstract: A hard metal grade powder is produced from hard material, metal binder, and non-water-soluble pressing aid components, by forming a slurry containing the components and pure water as a liquid phase and then drying the slurry. Here, the hard material and metal binder components are first milled in water, to form a slurry. Then the pressing aid components are added to the slurry in the form of an emulsion produced with the aid of an emulsifier with the addition of water.

Abstract: A method of fabricating an article, such as a prototype part or a tooling for injection molding, by way of selective laser sintering, using a composite powder system of a metal and/or ceramic powder with a polymer binder comprising thermoplastics and thermoset polymers, and a metal hydride powder to form a “green” article. After removal of unfused material from the green article it is placed in an oven or furnace in a non-reactive atmosphere such as, for example, nitrogen or argon, for subsequent heat treatment to decompose and drive off the binder and sinter the metal substrate particles prior to infiltration by a metal with a lower melting point. During the critical step of decomposing the binders, the metal hydride begins to decompose also and releases an in-situ concentration of hydrogen gas that creates the reducing conditions necessary to thoroughly decompose the polymer fragments so that the hydrocarbon fragments can escape the skeleton structure of the article.