With Nonmetal Constituent - Silicon(si) Considered A Metal (e.g., Cermet, Etc.) Patents (Class 75/230)
  • Publication number: 20100180514
    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.
    Type: Application
    Filed: January 12, 2010
    Publication date: July 22, 2010
    Inventor: Shaiw-Rong Scott Liu
  • Publication number: 20100180725
    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.
    Type: Application
    Filed: March 26, 2010
    Publication date: July 22, 2010
    Applicants: Mitsubishi Denki Kabushiki Kaisha, Ishikawajima-Harima Heavy Industries Co., Ltd.
    Inventors: Akihiro GOTO, Masao AKIYOSHI, Katsuhiro MATSUO, Hiroyuki OCHIAI, Mitsutoshi WATANABE, Takashi FURUKAWA
  • Publication number: 20100154587
    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.
    Type: Application
    Filed: December 22, 2008
    Publication date: June 24, 2010
    Inventor: Jimmy W. Eason
  • Patent number: 7722726
    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.
    Type: Grant
    Filed: March 31, 2005
    Date of Patent: May 25, 2010
    Assignee: Santoku Corporation
    Inventors: Kazumasa Shintani, Ryo Murakami, Kazuhiko Yamamoto
  • Publication number: 20100124514
    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.
    Type: Application
    Filed: September 14, 2006
    Publication date: May 20, 2010
    Applicants: THE TIMKEN COMPANY, IAP RESEARCH, INC.
    Inventors: Bhanumathi Chelluri, Edward Arlen Knoth, Edward John Schumaker, Ryan D. Evans, James. L. Maloney, III
  • Publication number: 20100098574
    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.
    Type: Application
    Filed: August 13, 2009
    Publication date: April 22, 2010
    Inventors: Hengda D. Liu, Bryan Smith, Richard King
  • Patent number: 7695542
    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.
    Type: Grant
    Filed: November 30, 2007
    Date of Patent: April 13, 2010
    Assignee: Longyear TM, Inc.
    Inventors: Kristian S. Drivdahl, Michael D. Rupp
  • Publication number: 20100075160
    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.
    Type: Application
    Filed: September 15, 2009
    Publication date: March 25, 2010
    Inventors: Valerie CHAUMAT, Jean-François Henne
  • Patent number: 7682557
    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.
    Type: Grant
    Filed: December 15, 2006
    Date of Patent: March 23, 2010
    Assignee: Smith International, Inc.
    Inventors: Zhou Yong, Sike Xia, Sharath Kolachalam
  • Publication number: 20100008812
    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.
    Type: Application
    Filed: June 30, 2009
    Publication date: January 14, 2010
    Applicant: HITACHI POWDERED METALS CO., LTD.
    Inventor: Hideaki Kawata
  • Publication number: 20100003157
    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.
    Type: Application
    Filed: July 9, 2007
    Publication date: January 7, 2010
    Applicant: H.C. Starck GmbH
    Inventors: Roland Scholl, Ulf Waag, Aloys Eiling
  • Publication number: 20100003155
    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.
    Type: Application
    Filed: September 11, 2009
    Publication date: January 7, 2010
    Applicant: Biomet Manufacturing Corp.
    Inventors: Ned M. Hamman, J. Fleming, Elizabeth A. Schlueter, Isaac Janson, Jason D. Meridew, Mukesh Kumar
  • Publication number: 20090293672
    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.
    Type: Application
    Filed: June 2, 2009
    Publication date: December 3, 2009
    Applicant: TDY Industries, Inc.
    Inventors: Prakash K. Mirchandani, Morris E. Chandler, Eric W. Olsen
  • Patent number: 7622011
    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.
    Type: Grant
    Filed: December 24, 2003
    Date of Patent: November 24, 2009
    Assignee: Japan Science and Technology Agency
    Inventors: Akihisa Inoue, Baolong Shen
  • Patent number: 7622153
    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.
    Type: Grant
    Filed: August 3, 2005
    Date of Patent: November 24, 2009
    Assignee: M&G USA Corporation
    Inventor: Kevin L. Rollick
  • Publication number: 20090277415
    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.
    Type: Application
    Filed: May 11, 2009
    Publication date: November 12, 2009
    Inventors: Herbert Moeding, Stephan Beer, Manfred Laudenklos
  • Patent number: 7578892
    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.
    Type: Grant
    Filed: March 30, 2006
    Date of Patent: August 25, 2009
    Assignee: Hitachi Metals, Ltd.
    Inventors: Satoshi Hirosawa, Hiroyuki Tomizawa, Ryosuke Kogure
  • Patent number: 7575619
    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.
    Type: Grant
    Filed: March 24, 2006
    Date of Patent: August 18, 2009
    Assignee: Hitachi Powdered Metals Co., Ltd.
    Inventors: Hideaki Kawata, Hiroki Fujitsuka
  • Publication number: 20090183598
    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.
    Type: Application
    Filed: May 31, 2007
    Publication date: July 23, 2009
    Applicant: KYOCERA CORPORATION
    Inventors: Takehiro Oonishi, Takanori Nishihara
  • Patent number: 7517375
    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).
    Type: Grant
    Filed: January 4, 2006
    Date of Patent: April 14, 2009
    Assignee: Iowa State University Research Foundation, Inc.
    Inventors: Bruce Allan Cook, Joel Lee Harringa, Alan Mark Russell, Justin S. Peters, Atiq Ahmed
  • Publication number: 20090071290
    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.
    Type: Application
    Filed: November 14, 2005
    Publication date: March 19, 2009
    Inventors: Teruo Shimizu, Tsuneo Maruyama
  • Publication number: 20090007724
    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.
    Type: Application
    Filed: November 2, 2004
    Publication date: January 8, 2009
    Inventor: Jianxin Liu
  • Publication number: 20080314199
    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.
    Type: Application
    Filed: May 19, 2008
    Publication date: December 25, 2008
    Inventors: Leslie Wade Niemi, Gregory P. Marzec
  • Publication number: 20080280166
    Abstract: Solid oxide fuel cell wherein the anode has a cermet, including a metallic portion and an electrolyte ceramic material portion substantially uniformly interdispersed.
    Type: Application
    Filed: December 30, 2003
    Publication date: November 13, 2008
    Applicant: PERELLI & C.S.P.A.
    Inventors: Boris L. Kuzin, Sergey M. Beresnev, Nina M. Bogdanovich, Edhem Kh. Kurumchine, Ana Berta Lopes Correia Tavares, Antonio Zaopo, Yuri A. Dubitsky
  • Publication number: 20080166255
    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.
    Type: Application
    Filed: January 3, 2008
    Publication date: July 10, 2008
    Applicant: HERAEUS INC.
    Inventors: Fenglin YANG, Carl Derrington, Bernd Kunkel
  • Patent number: 7384448
    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.
    Type: Grant
    Filed: February 16, 2004
    Date of Patent: June 10, 2008
    Assignee: Climax Engineered Materials, LLC
    Inventor: Loyal M. Johnson, Jr.
  • Publication number: 20080056929
    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.
    Type: Application
    Filed: November 24, 2004
    Publication date: March 6, 2008
    Applicant: MITSUBISHI MATERIALS PMG CORPORATION
    Inventors: Takashi Nakai, Kinya Kawase
  • Patent number: 7090730
    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.
    Type: Grant
    Filed: November 13, 2003
    Date of Patent: August 15, 2006
    Assignee: Shin-Etsu Chemical Co., Ltd.
    Inventors: Tadao Nomura, Takehisa Minowa
  • Patent number: 7083859
    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.
    Type: Grant
    Filed: July 7, 2004
    Date of Patent: August 1, 2006
    Assignee: Hitachi Chemical Co., Ltd.
    Inventor: Hideji Kuwajima
  • Patent number: 7008462
    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.
    Type: Grant
    Filed: December 16, 2004
    Date of Patent: March 7, 2006
    Assignee: Sulzer Metco (Canada) Inc.
    Inventors: Petr Fiala, Anthony Peter Chilkowich, Karel Hajmrle
  • Patent number: 6978533
    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.
    Type: Grant
    Filed: August 7, 2000
    Date of Patent: December 27, 2005
    Assignee: Matsushita Electric Industrial Co., Ltd.
    Inventors: Fumitoshi Yamashita, Yuichiro Sasaki
  • Patent number: 6960319
    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.
    Type: Grant
    Filed: October 27, 1995
    Date of Patent: November 1, 2005
    Assignee: The United States of America as represented by the Secretary of the Army
    Inventor: Deepak Kapoor
  • Patent number: 6921422
    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.
    Type: Grant
    Filed: September 23, 2003
    Date of Patent: July 26, 2005
    Assignee: Iowa State University Research Foundation, Inc.
    Inventors: Bruce A. Cook, Alan Russell, Joel Harringa
  • Patent number: 6916355
    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.
    Type: Grant
    Filed: November 19, 2002
    Date of Patent: July 12, 2005
    Assignee: NGK Insulators, Ltd.
    Inventors: Masahiro Kida, Takahiro Ishikawa, Masayuki Shinkai, Takatoshi Ikematsu
  • Patent number: 6852174
    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.
    Type: Grant
    Filed: August 12, 2002
    Date of Patent: February 8, 2005
    Assignee: Daido Tokushuko Kabushiki Kaisha
    Inventors: Satoshi Takemoto, Takanobu Saito
  • Patent number: 6833018
    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.
    Type: Grant
    Filed: May 13, 2002
    Date of Patent: December 21, 2004
    Assignee: Keystone Investment Corporation
    Inventor: John C. Kosco
  • Patent number: 6830637
    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.
    Type: Grant
    Filed: May 31, 2002
    Date of Patent: December 14, 2004
    Assignee: Osram Sylvania Inc.
    Inventors: Ricky D. Morgan, Thomas J. Dixon, Harry D. Martin, III
  • Patent number: 6821312
    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.
    Type: Grant
    Filed: April 1, 2002
    Date of Patent: November 23, 2004
    Assignee: Alcoa Inc.
    Inventors: Siba P. Ray, Xinghua Liu, Frankie E. Phelps, Joseph M. Dynys, Douglas A. Weirauch, Jr.
  • Publication number: 20040211290
    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.
    Type: Application
    Filed: March 10, 2004
    Publication date: October 28, 2004
    Applicant: Mitsubishi Materials Corporation
    Inventors: Teruo Shimizu, Tsuneo Maruyama
  • Publication number: 20040206203
    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.
    Type: Application
    Filed: December 1, 2003
    Publication date: October 21, 2004
    Applicant: SECO TOOLS AB
    Inventors: Olof Kruse, Johnny Bruhn
  • Publication number: 20040170552
    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.
    Type: Application
    Filed: December 10, 2003
    Publication date: September 2, 2004
    Inventors: Shuichi Irumata, Ryo Suzuki
  • Patent number: 6746507
    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.
    Type: Grant
    Filed: March 25, 2002
    Date of Patent: June 8, 2004
    Assignee: NGK Insulators, Ltd.
    Inventors: Masayuki Shinkai, Masahiro Kida, Takahiro Ishikawa, Toshimasa Ochiai
  • Patent number: 6733562
    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.
    Type: Grant
    Filed: November 22, 2002
    Date of Patent: May 11, 2004
    Assignee: Ceratizit Austria GmbH
    Inventors: Gerhard Knünz, Helmut Beirer, Andreas Lackner, Wolfgang Glätzle, Erwin Hartlmayr
  • Publication number: 20040079188
    Abstract: A sintered copper alloy material product is provided on which a skin (particularly, a skin of a solid lubricant with low adhesion, such as PTFE or molybdenum disulfide) is securely formed on the surface thereof and has good sliding properties and good seizure resistance under unlubricating environments or under corrosive environments. A sintered copper alloy material is processed using a selective chemical etching solution containing a compound of one kind or more selected from the group of consisting of peroxide, peroxocompound, chromic acid and permanganic acid and a compound of one kind or more selected from the group of consisting of phosphoric acid, sulfuric acid, nitric acid, hydrochloric acid, hydrofluoric acid, zirconic hydrofluoric acid, titanic hydrofluoric acid, titanic acid, molybdic acid, tungstic acid, vanadic acid, niobic acid, and organic chelating agent. Thereafter, a lubricating skin is on the surface of the processed material.
    Type: Application
    Filed: July 31, 2003
    Publication date: April 29, 2004
    Applicant: NIHON PARKERIZING CO., LTD.,MITSUBISHI MATERIALS CORPORATION
    Inventors: Kazuhiko Mori, Sinnosuke Nakano, Tokunori Kodama, Teruo Shimizu, Tsuneo Maruyama
  • Publication number: 20040081573
    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.
    Type: Application
    Filed: October 23, 2002
    Publication date: April 29, 2004
    Applicant: 3D SYSTEMS, INC.
    Inventor: Kenneth J. Newell
  • Patent number: 6723387
    Abstract: A thermal spray method for the fabrication of ceramic/metal and ceramic/ceramic hardcoating for wear applications. The method makes use of feedstock powder, composed of micron-scale aggregates of hard phase material particles that are either mixed or coated with a readily fusible nano-scale binder phase material. Thus, during thermal spraying, the nanostructured material undergoes rapid melting while the aggregated material is heated but not necessarily melted. A dense coating is formed when the molten nano-material fills the available pore spaces between the heated and softened aggregates, providing a strong and tough matrix for the consolidated material. Optimal wear properties are achieved when the volume fraction of aggregated particles is high, typically in the range of 0.5-0.9. Aggregated material may be composed of one, two or more particles of difference sizes and/or compositions, with particle size distribution that gives high packing density for the hard phase.
    Type: Grant
    Filed: September 19, 2002
    Date of Patent: April 20, 2004
    Assignee: Rutgers University
    Inventors: Bernard H. Kear, Ganesh Skandan
  • Patent number: 6709739
    Abstract: A plurality of closed metal cells is provided. Each cell encapulates a fluid or a fluid-like filler with a metal skin or cell wall. The closed cells are joined into an aggregate arrangement to form a composite material in which the bonded cell walls form a continuous metal matrix. The cell walls and the encapulated cell filler fluid or fluid-like filler provide controllable stiffness and strength as well as vibration-damping and shock-absorbing characteristics to the material. The resulting closed cell metal composite finds many advantages uses including use as a prosthetic device, a casting, or an automotive component. The component material is elastically compliant or stiff, depending on the design, as well as lightweight and resistant to buckling and crushing. The material provides desirable physical properties such as heat-capacity, thermal and electrical conductivity, vibration-damping capacity, and shock-absorbing characteristics.
    Type: Grant
    Filed: June 24, 2002
    Date of Patent: March 23, 2004
    Assignee: Case Western Reserve University
    Inventors: Robert L. Mullen, Mehmet Ozgur, Gerhard E. Welsch
  • Patent number: 6692548
    Abstract: A copper-based sliding material produced by sintering, comprising at least two phases of copper and/or copper alloys which phases have hardness levels different form each other, and hard particles with an average particle size of 0.1 to 10 &mgr;m which are dispersed in at least one phase with the exception of a softest phase in an amount of 0.1 to 10 vol. % of the whole copper-based sliding material, said sliding material satisfying (H2/H1)≧1.2 in which H1 is the Vickers hardness of the softest phase and in which H2 is the Vickers hardness of a phase hardest in hardness including said hard particles.
    Type: Grant
    Filed: June 25, 2001
    Date of Patent: February 17, 2004
    Assignee: Daido Metal Company Ltd.
    Inventors: Kenji Sakai, Naohisa Kawakami, Satoru Kurimoto, Takashi Inaba, Koichi Yamamoto, Takayuki Shibayama
  • Patent number: 6676894
    Abstract: A method for forming a copper-infiltrated iron powder metal article comprises compacting and sintering a predominately iron powder to form an iron-base matrix that contains between about 1 and 7 weight percent nickel and about 0.1 and 1.2 weight percent phosphorus. A copper metal is infiltrated into pores within the iron-base matrix. The product article comprises between about 2.0 and 23 weight percent copper infiltrant. Preferably, infiltration is carried out concurrently with sintering of the iron powder compact. The resulting product exhibits a particularly useful combination of mechanical properties, including high tensile strength and elongation.
    Type: Grant
    Filed: May 29, 2002
    Date of Patent: January 13, 2004
    Assignee: NTN Corporation
    Inventor: William Victor Alcini
  • Patent number: 6660056
    Abstract: A valve seat is provided in which wear resistance can be ensured by optimizing the matrix structure without dispersing of expensive hard particles, and therefore the machinability can be improved and the holding down of cost can be achieved. The valve seat exhibits a metallographic structure consisting of only bainite single phase or only a mixed phase of bainite and martensite, has an area ratio of bainite and martensite in cross section of 100:0 to 50:50, and has a matrix hardness of 250 to 850 Hv.
    Type: Grant
    Filed: May 1, 2001
    Date of Patent: December 9, 2003
    Assignee: Hitachi Powdered Metals Co., Ltd.
    Inventors: Koichiro Hayashi, Hideaki Kawata, Toru Tsuboi