Abstract: A hard sintered compact for tools is a sintered compact obtained by super-high pressure sintering of 45-75% by vol. of cubic boron nitride powder and the remaining proportion of binder powder. The binder includes 5-25% by wt. of Al and the remaining proportion of at least one species of compounds represented by (Hf.sub.1-z M.sub.z) C, where M denotes elements of IVa, Va and VIa groups in a periodic table except for Hf, and 0.ltoreq.z.ltoreq.0.3 is satisfied. Because of this composition, improvements are made in strength, wear resistance and heat resisting property of the binder, and a hard sintered compact for tools having excellent strength and excellent wear resistance can be obtained.

Abstract: An improved temperature stable synthetic polycrystalline diamond (PCD) product includes at least one temperature stable PCD integrally and chemically bonded to a matrix carrier support through a carbide forming layer which is of a thickness of at least about 1 micron, the layer on at least one surface of the PCD is in turn bonded to the matrix carrier. A wide variety of shapes, sizes and configurations of such products is achieved through relatively low temperature and relatively low pressure processing. Various products of various geometries are described as well as the details of the processing to achieve chemical bonding of the PCD elements in a variety of support matrix carrier materials to form a unitary structure having a temperature stability up to about 1,200 degrees C.

Abstract: The invention relates to high speed tool steels produced by powder metallurgy; to parts subject to heavy wear which are fabricated from such steel; and to a method of such fabrication. According to the invention, the part subject to heavy wear contains Nb in the amount of 2-15 wt. % and V in the amount of 1-4 wt. %, and further contains metal carbides in the amount of 10-30 vol. %; and that the lower limit of the carbon content is given by the formulaC.sub.min =0.45+0.1(%Nb)+0.20(%V),and the upper limit of the carbon content is given by the formulaC.sub.max =1.0+0.15(%Nb)+0.24(%V).In manufacturing the steel the melt of the alloying components is subjected to atomization in an overheated state (substantially above the liquidus temperature), to produce a powder.

Abstract: A self-sustaining combustion synthesis process for producing hard, tough, lightweight, low exothermic potential product (LEPP)/high exothermic potential product (HEPP) composites is based on the thermodynamic dependence of adiabatic temperature and product composition on the stoichiometry of the LEPP and HEPP reactants. For lightweight products the composition must be relatively rich in the LEPP component. LEPP rich composites are obtained by varying the initial temperature of the reactants. The product is hard, porous material whose toughness can be enhanced by filling the pores with aluminum or other metal phases using a liquid metal infiltration process. The process can be extended to the formation of other composites having a low exothermic component.

Abstract: There are disclosed a high strength nitrogen-containing cermet which comprises 7 to 20% by weight of a binder phase composed mainly of Co and/or Ni, with the balance being a hard phase composed mainly of TiC, TiN and/or Ti(C,N) and inevitable impurities, wherein the hard phase comprises 35 to 59% by weight of Ti, 9 to 29% by weight of W, 0.4 to 3.5% by weight of Mo, 4 to 24% by weight of at least one of Ta, Nb, V and Zr, 5.5 to 9.5% by weight of N and 4.5 to 12% by weight of C; and a process for preparing the same which comprises via the formulating, mixing, drying, molding and sintering steps of Co and/or Ni powder, at least one powder of TiC, Ti(C,N) and TiN, WC powder, Mo and/or Mo.sub.2 C, and at least one powder of carbides of Ta, Nb, V and Zr, wherein the sintering step is carried out by elevating the temperature up to 1350.degree. C. in vacuum, with the nitrogen atmosphere being made 1 torr at 1350.degree. C.

Abstract: The present invention relates to a method of preparing an alloy for use as a cutting tool material comprising hard principles and binder phase by which a uniform distribution of the hard principles in the binder phase is obtained, and the resulting product.

Abstract: A composite material is disclosed along with the method of making the same. The material comprises a tough grade of cemented carbide granule dispersed with a hard brittle grade of cemented carbide granules to form a matrix. The quantity of hard, brittle cemented carbide granules is between 20% to 60% of the total composition. Such material functions to improve wear resistance without sacrificing toughness.

Abstract: The present invention relates to a method of sintering ceramics and ceramics obtained by said method. According to the present invention, the synthesis and sintering of ceramics can be simultaneously carried out by utilizing the reaction heat generated when at least one metallic element selected from metallic elements of IIb, IVb, Vb and VIb groups of the Periodic Table is combined with at least one nonmetallic element such as B, C N and Si without heat or by preliminarily heating the ceramics at temperatures remarkably lower than the usual sintering temperature ceramics thus-produced are superior in abrasion resistance and corrosion resistance.

Abstract: An improved temperature stable synthetic polycrystalline diamond (PCD) product includes at least one temperature stable PCD integrally and chemically bonded to a matrix carrier support through a carbide forming layer which is of a thickness of at least about 1 micron, the layer on at least one surface of the PCD is in turn bonded to the matrix carrier. A wide variety of shapes, sizes and configurations of such products is achieved through relatively low temperature and relatively low pressure processing. Various products of various geometries are described as well as the details of the processing to achieve chemical bonding of the PCD elements in a variety of support matrix carrier materials to form a unitary structure having a temperature stability up to about 1,200 degrees C.

Abstract: The invention relates to a cold work steel having a very high resistance to wear and good impact strength made powder-metallurgically through the consolidation of metal powder to a dense body. The powder has the following chemical composition expressed in weight-%: 0.5-2.5 C, 0.1-2 Si, 0.1-2 Mn, 0.5-1.5 N, max 15 Cr, preferably 6.5-111 Cr, max 4 Mo, max 1 W, 3-15 V, wherein up to half the amount of vanadium can be replaced by 1.5 times as much niobium, and part of the vanadium can be replaced by titanium at a content up to four times the content of nitrogen and the double amount of zirconium at a content up to eight times the content of nitrogen, and wherein the ratio V/(C+N) shall amount to not less than 2.5 and not more than 3.8, balance essentially only iron, impurities and accessory elements in normal quantities. The invention also relates to a method of manufacturing the steel. First there is made a steel powder having a composition as above with the exception of the nitrogen content.

Abstract: A mechanical seal is, at a sliding surface and at its vicinity, formed of a pore-dispersed cemented carbide, so that the lubricating characteristics can be improved and the strength maintained by strictly stipulating the magnitude, shape, and volumetric ratio of the pores, such that pores are contained in an amount of 0.5 to 20 volume %, formed in at least one shape selected from the group of a substantially spherical shape and a substantially cylindrical shape, the pores in the substantially spherical shape having an average diameter of 3 to 20 .mu.m, the pores in the substantially cylindrical shape having an average diameter of 3 to 20 .mu.m and an average length in the range from the average diameter up to 300 .mu.m, and that the pores are prevented from linking to each other to give a length greater than 2 mm.

Abstract: Cobalt-bound tungsten carbide metal matrix composites having a unique microstructure are produced by consolidating partially sintered greenware under high pressures, e.g., 120,000 psi, at temperatures less than those used for conventional liquid phase sintering in a relatively short time, e.g., from less than one minute to less than about one hour. The composites have a binder phase which contains less than about 80 weight percent of the tungsten found in a composite prepared from the same or similar compositions via liquid phase sintering. These composites provide cutting tools with both toughness and wear resistance which exceed that of cutting tools made from the same or similar compositions via liquid phase sintering.

Abstract: The present invention relates to a cemented carbonitride alloy in which the toughness has been improved by the incorporation in the structure of whiskers of nitrides, carbides and/or carbonitrides of titanium, zirconium and/or hafnium.

Abstract: Dense, finely grained composite materials comprising one or more ceramic phase or phase and one or more metallic and/or intermetallic phase or phases are produced by combustion synthesis. Spherical ceramic grains are homogeneously dispersed within the matrix. Methods are provided, which include the step of applying mechanical pressure during or immediately after ignition, by which the microstructures in the resulting composites can be controllably selected.

Abstract: The present invention relates to a method of sintering ceramics and ceramics obtained by said method. According to the present invention, the synthesis and sintering of ceramics can be simultaneously carried out by utilizing the reaction heat generated when at least one metallic element selected from metallic elements of IIIb, IVa, Vb and VIb groups of the Periodic Table is combined with at least one nonmetallic element such as B, C, N and Si without heat or by preliminarily heating the ceramics at temperatures remarkably lower than the usual sintering temperature ceramics, thus-produced are superior in abrasion resistance and corrosion resistance.

Abstract: Compositions for the production of rare earth-ferromagnetic-metal permanent magnets comprise mixtures of rear earth-ferromagnetic metal alloy powder and a lesser amount of a powdered second-phase sintering aid, wherein there is added up to about 2 percent by weight of a particulate refractory oxide, carbide, or nitride additive. Permanent magnets are prepared by mixing the components, aligning the mixture in a magnetic field, pressing and sintering. The refractory material inhibits grain growth in the second phase during sintering, improving the magnetic properties of the major phase.

Abstract: A super hard high-speed tool steel having a composition satisfying the condition of 0.ltoreq.C-Ceq.ltoreq.0.6 (where Ceq=0.06Cr+0.033 W+0.063 Mo+0.2 V within the range of 1.7.ltoreq.C.ltoreq.4.1%, the composition containing 3 to 10% of Cr, 1 to 20% of W, 1 to 15% of Mo (where 18.ltoreq.W+2Mo.ltoreq.40), 1 to 15% of V, not greater than 15% of Co, not greater than 2% of Si, not greater than 1% of Mn, and the balance substantially Fe and inevitable impurities, the steel further containing in uniformly dispersed state 2 to 12% in total of one, two or more selected from a group consisting of nitrides, carbides and carbonitrides of Ti, V, Zr, Nb, Hf and Ta in the composition. This tool steel exhibits a distinguished hardness of HRC 71 or higher, as well as toughness.

Abstract: The invention relates to a tool steel intended for cold working operations and having very high impact strength and good resistance to wear, said steel being made powder-metallurgically by consolidation of metal powder to a dense body. The steel has the following chemical composition expessed in weight-% 1-2.5% C, 0.1-2% Si, max 0.3% N, 0.1-2% Mn, 6.5-11% Cr, max 4% Mo, max 1% W and 3-7% V, wherein up to half the amount of vanadium can be replaced by 1.5 times as much niobium, and wherein the ratio V/C shall amount to between 2.5 and 3.7, balance essentially only iron and impurities and accessory elements in normal amounts.

Abstract: Amorphous metal-ceramic and microcrystalline metal-ceramic composites are synthesized by solid state reaction-formation methods. These metal-ceramic composites are characterized by a composition that ranges from about 75 to about 99.9 percent ceramic in about 0.1 to about 25 percent amorphous or microcrystalline metal binder phase.

Abstract: The invention provides a flexible, deformable sintered abrasive material made of a bronze alloy with particulate abrasive grain. The alloy consists essentially of3 to 30 wt. % of Ag,0 to 1 wt. % of Si,0.05 to 3 wt. % of Ge, Sn, Pb, Zn and/or Cd,the remainder being copper. The sintered abrasive material is best suited for abrasive material carriers with concave or convex surfaces or for winding around grinding drums.

Abstract: Sputter targets and a process for producing sputter targets are provided, comprised of carbides and/or nitrides and/or borides of refractory metals. In a first step, a dense composite body is produced comprised of one or more carbides and/or nitrides and/or borides of the metals of Groups IV A-VI A of the periodic table and a metallic binding agent comprised of one or more metals of the iron group of the periodic table. This composite body in the form of a shaped blank is machined, if necessary, and the binding agent is removed by chemical or electrochemical treatment. The sputter target as so produced has excellent mechanical strength and high thermal shock resistance. Levels of contaminating elements and the residual metallic binding agent are extremely low, meeting the requirements typically placed on sputter targets.

Abstract: There is disclosed a sintered alloy for decoration comprising2 to 30% by weight of a binding phase comprising one or more elements selected from the group consisting of Fe, Ni, Co, Cr, Mo and W;0 to 10% by weight of a strengthening phase comprising one or more material selected from the group consisting of a metal, an alloy, a metal oxide, a metal nitride and a metal carbide;the balance of a hard phase represented by the formula:(Tia, Mb) (Nw, Cx, Oy)z(wherein M, A, b, w, x, y and z are defined in the specification); andinevitable impurities.The sintered alloy for decoration according to this invention possesses both a decorativeness suitable for decorative members as well as excellent corrosion resistance and mechanical properties.

Abstract: A diamond sintered body for tools contains a diamond content in excess of 93 percent and not more than 99 percent by volume and a residue including at least one of a metal or a carbide selected from groups IVa, Va and VIa of the periodic table and an iron group metal of 0.1 to 3 percent by volume in total and pores at least 0.5 percent and not more than 7 percent by volume.

Abstract: Aluminum-base alloys and a method of preparing aluminum-base alloys by mechanical alloying in the presence of a carbidiferous processing aid wherein a strong carbide former such as titanium is included so as to produce carbides in the final alloy more thermally stable at temperatures in excess of 100.degree. C. than Al.sub.4 C.sub.3.

Abstract: A process for producing composite materials which comprises subjecting particles of a malleable matrix material, i.e., a metal or alloy or the components of a matrix alloy and particles of a reinforcing material such as a carbide or an oxide or an intermetallic to energetic mechanical milling under circumstances to insure the pulverulent nature of the mill charge so as to enfold matrix material around each of said reinforcing particles to provide a bond between the matrix material and the surface of the reinforcing particle. The process is exemplified by the use of aluminum alloy as the matrix material and silicon carbide as the reinforcing particles. Reinforcing particles are present in an amount of about 0.2 to about 30 volume percent of total matrix and reinforcing particles. The invention is also directed to the product of the process.

Abstract: The present invention provides a method for controlling the carbon content of dewaxed carbide preforms in a carbon containing furnace. The method includes the steps of placing the preforms in a carbon containing furnace and then heating the furnace to a predetermined temperature range between 800 and 1100 degrees Centigrade. At that temperature, a mixture of methane and hydrogen is introduced into the furnace chamber such that the amount of methane is between 10 and 90 percent of the amount of methane present at equilibrium for the reaction C.sub.solid +2H.sub.2 .revreaction.CH.sub.4. The furnace chamber is maintained at its temperature for a first time period sufficient for the chemical reaction XC+2H2.revreaction.X+CH.sub.4 (where X is selected from the group of W, Ti, Ta, Hf and No) substantially reaches equilibrium but shorter than the a second time period in which the reaction C.sub.solid +2H2.revreaction.CH.sub.

Abstract: Fully dense consolidated powder alloys of iron, cobalt and/or nickel characterized by having an ultrafine microstructure exhibiting a substantially uniformly dispersed harding phase of particle size essentially less than 3 microns, are produced from prealloyed powders by rapidly quenching an atomized molten alloy charge and subjecting the solidified alloy powder particles to the step of hot consolidation to produce substantially fully dense metal stock directly from prealloyed powder.

Abstract: A titanium nitride base cermet with high toughness comprises, by weight, 42 to 95% of TiN, 2 to 20% of one or more of Mo, W and the carbides thereof, 2.85 to 30% of an Ni, Co or a mixture thereof, and 0.15 to 8.0% of Al.sub.4 C.sub.3, with the balance being inevitable impurities, wherein half or less of TiN may be replaced with one or more of the carbides and/or carbonitrides of metals from the Groups IVa and Va of the periodic table, with the proviso that the amount of TiN is no less than 30% in the cermet.

Abstract: A hard alloy including at least one hard phase and a binary or multicomponent binder metal alloy, in which the hard substance comprises a finely dispersed, homogeneous distribution in the binder metal. The hard phase comprises a carbide of a Group IVb, Vb or VIb transition metal, and the binder metal alloy comprises a solid alloy of a Group IVb, Vb or VIb transition metal, with Re, Ru, Rh, Pd, Os, Ir, or Pt.

Abstract: The present invention relates to a method for producing golden sintered alloys for ornamental purposes and suitable for use in watches. They are mainly composed of 10-40 percent by weight of titanium nitride, 10-30 percent by weight of nickel and valanced niobium carbide. Less than 40 percent by weight of the nickel may be substituted by at least one member from the group of chromium, molybdenum, tungsten and titanium. The alloys have a high degree of hardness (Rockwell A scale), excellent corrosion resistance and a beautiful gold color.

Abstract: An aluminum coated carbon article or composite, and process therefor having aluminum chemically bonded to carbon via an interface of a metal monocarbide formed in situ when an intermetallic phase comprising aluminum and a metal capable of reacting with carbon to form a metal carbide is reduced by carbon to aluminum and a metal carbide, the metal selected from the group consisting of tantalum, titanium and hafnium.

Abstract: An abrasion resistant sintered alloy for use in internal combustion engines which comprises 0.5 to 4.0% by weight of carbon, 5.0 to 30.0% by weight of Cr, 1.5 to 16.0% by weight of Nb, 0.1 to 4.0% by weight of Mo, 0.1 to 10.0% by weight of Ni and 0.1 to 5.0% by weight of P, which permits liquid-phase sintering at temperatures not higher than 1,250.degree. C., and have 0.2 to 10% by volume of sintering pores at least 40% of which consist of pores having a pore size of not larger than 150 .mu.m, is disclosed.

Abstract: An aluminum coated carbon article or composite, and process therefor having aluminum chemically bonded to carbon via an interface of a metal monocarbide formed in situ when an intermetallic phase comprising aluminum and a metal capable of reacting with carbon to form a metal carbide is reduced by carbon to aluminum and a metal carbide, the metal selected from the group consisting of tantalum, titanium and hafnium.

Abstract: An improved sintered compact for use in a cutting tool is proposed which comprises 80 to 95 volume % of high pressure form boron nitride, a binder material which is a carbide, a nitride and/or a carbonitride of a IVb and Vb transition metal in the periodic table, and aluminum compounds. It may further include copper and/or iron group metal or metals. The sintered compact obtained has high hardness even though the sintering pressure and temperature are relatively low.

Abstract: A sintered compact for use in a machining tool comprising 80 to 10 volume % of a high pressure form of boron nitride, and the balance a matrix of at least one binder compound material selected from the group consisting of a carbide, nitride, carbonitride, boride or silicide of IVa and Va transition metal of the periodic table, their mixtures as well as the solid solution of these compounds; the matrix forming a continuous bonding structure in the sintered body.A method of producing the compact comprises preparing a mix of 80 to 10 volume % of a high pressure form of a boron nitride powder with 20 to 90 volume % of at least one powdered binder compound selected from the group consisting of a carbide, a nitride, a carbonitride, a boride and a silicide of a IVa, or a Va metal, mixtures thereof or solid solutions of these compounds, and sintering the mix under pressures more than 20 Kb at temperatures higher than 700.degree. C. for more than 3 minutes.

Abstract: Method for hard-facing substrates is disclosed using a hard facing material consisting essentially of at least one vanadium carbide. In a particular embodiment of the invention tungsten is present in the hard facing material in solid solution with vanadium carbide.

Abstract: P/M products are provided having improved resistance to wear and abrasion by adding controlled amounts of pre-alloyed refractory carbide material to metal powders selected from the group consisting of iron-base, nickel-base, aluminum-base, copper-base and beryllium-base powders following which the mixed powders are compacted and sintered to the desired shape.

Abstract: This invention concerns production by extrusion of hollow cylindrical bodies starting with granulated alloys of aluminum containing silicon. It consists of preparing the composition of the alloy in a liquid form, producing granules by centrifugal pulverization or atomization, introducing the granulated material into an extrusion press to obtain the hollow profile by extrusion and extruding the granular material within to form a cylindrical body. This invention is applicable to form hollow bodies and particularly sleeves of motors of high content silicon aluminum alloy through which size and distribution of primary silicon is improved over traditional casting methods.

Abstract: Method for hard-facing substrates is disclosed using a hard facing material consisting essentially of combined vanadium and carbon and minor amount of uncombined carbon with up to 15% by weight cobalt.

Abstract: Ceramic tantalum carbide artifacts having high thermal shock and mechanical erosion resistance are provided by incorporating tungsten-rhenium and carbon particles in a tantalum carbide matrix. The mix is sintered by hot pressing to form the ceramic article which has a high fracture strength relative to its elastic modulus and thus has an improved thermal shock and mechanical erosion resistance. The tantalum carbide is preferable less than minus 100 mesh, the carbon particles are preferable less than minus 100 mesh, and the tungsten-rhenium particles are preferable elongate, having a length to thickness ratio of at least 2/1. Tungsten-rhenium wire pieces are suitable as well as graphite particles.