Containing Boron(b) Or Nitrogen(n) Patents (Class 75/244)
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Patent number: 7531021Abstract: An article includes a microscale composite material having a matrix with more titanium than any other element, and a dispersion of titanium boride particles in the matrix. At least about 50 volume percent of the titanium boride particles have a maximum dimension of less than about 2 micrometers.Type: GrantFiled: May 27, 2005Date of Patent: May 12, 2009Assignee: General Electric CompanyInventors: Andrew Philip Woodfield, Eric Allen Ott, Clifford Earl Shamblen
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Patent number: 7531020Abstract: A heat sink that is particularly suitable for semiconductor components is made from a diamond-containing composite material. In addition to a diamond fraction amounting to 40-90% by volume, the composite material also contains 7 to 59% by volume copper or a copper-rich phase (with Cu>80 at. %) and 0.01 to 20% by volume boron or a boron-rich phase (with B>50 at. %). The bonding of copper to the diamond grains can be considerably improved by the addition of boron, with the result that a high thermal conductivity can be achieved. The heat sink component is preferably produced with an unpressurized and pressure-assisted infiltration technique.Type: GrantFiled: October 30, 2006Date of Patent: May 12, 2009Assignees: Plansee SE, Ecole Polytechnique Federale de LausanneInventor: Ludger Weber
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Patent number: 7501081Abstract: A nanostructured monolithic titanium boride (TiB) material and methods of forming such a material are disclosed and described. This material has a room-temperature four-point flexural strength about three times that of commercially available titanium diboride (TiB2). The achievement of nanostructured internal microstructural arrangement having a network of interconnected titanium monoboride whiskers affords a very high strength to this material above some of the best ceramic materials available in the market. The material contains a small amount of titanium and a densifier, but it is largely made of TiB phase with substantially no TiB2. The nanostructured monolithic titanium boride material can be formed by high temperature processing of a powder precursor having carefully selected weight and size distributions of titanium powder, titanium diboride powder, and densifier powder.Type: GrantFiled: January 25, 2007Date of Patent: March 10, 2009Assignee: University of Utah Research FoundationInventor: K. S. Ravi Chandran
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Publication number: 20090041609Abstract: The invention relates to manufacturing the flat or shaped titanium matrix composite articles having improved mechanical properties such as lightweight plates, sheets for aircraft and automotive applications, heat-sinking lightweight electronic substrates, armor plates, etc. High-strength discontinuously-reinforced titanium metal matrix composite (TMMC) comprises (a) titanium matrix or titanium alloy as a major component, (b) ceramic and/or ?50 vol. % intermetallic hard particles dispersed in matrix, (c) complex carbide- and/or boride particles at least partially soluble in matrix at sintering or forging temperatures such as ?50 vol. % AlV2C, AlTi2Si3, AlTi6Si3, VB2, TiVSi2, TiVB4, Ti2AlC, AlCr2C, TiAlV2, V2C, VSi2, Ta3B4, NbTiB4, Al3U2C3 dispersed in matrix. Method for manufacturing these TMMC materials is disclosed. Sintered TMMC density exceeds 98% and closed discontinuous porosity allows performing hot deformation in air without encapsulating.Type: ApplicationFiled: August 7, 2007Publication date: February 12, 2009Inventors: Volodymyr A. Duz, Vladimir S. Moxson, Alexander E. Shapiro
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Patent number: 7488395Abstract: A functionally graded rare earth permanent magnet having a reduced eddy current loss in the form of a sintered magnet body having a composition RaEbTcAdFeOfMg is obtained by causing E and fluorine atoms to be absorbed in a R—Fe—B sintered magnet body from its surface. F is distributed such that its concentration increases on the average from the center toward the surface of the magnet body, the concentration of E/(R+E) contained in grain boundaries surrounding primary phase grains of (R,E)2T14A tetragonal system is on the average higher than the concentration of E/(R+E) contained in the primary phase grains, the oxyfluoride of (R,E) is present at grain boundaries in a grain boundary region that extends from the magnet body surface to a depth of at least 20 ?m, particles of the oxyfluoride having an equivalent circle diameter of at least 1 ?m are distributed in the grain boundary region at a population of at least 2,000 particles/mm2, the oxyfluoride is present in an area fraction of at least 1%.Type: GrantFiled: January 27, 2006Date of Patent: February 10, 2009Assignee: Shin-Etsu Chemical Co., Ltd.Inventors: Hajime Nakamura, Koichi Hirota, Masanobu Shimao, Takehisa Minowa
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Patent number: 7488393Abstract: A rare earth permanent magnet is in the form of a sintered magnet body having a composition R1aR2bTcAdFeOfMg wherein F and R2 are distributed such that their concentration increases on the average from the center toward the surface of the magnet body, the concentration of R2/(R1+R2) contained in grain boundaries surrounding primary phase grains of (R1,R2)2T14A tetragonal system within the sintered magnet body is on the average higher than the concentration of R2/(R1+R2) contained in the primary phase grains, and the oxyfluoride of (R1,R2) is present at grain boundaries in a grain boundary region that extends from the magnet body surface to a depth of at least 20 ?m. The invention provides R—Fe—B sintered magnets which exhibit high magnet performance despite minimal amounts of Tb and Dy used.Type: GrantFiled: January 27, 2006Date of Patent: February 10, 2009Assignee: Shin-Etsu Chemical Co., Ltd.Inventors: Hajime Nakamura, Koichi Hirota, Masanobu Shimao, Takehisa Minowa
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Patent number: 7488394Abstract: A rare earth permanent magnet is in the form of a sintered magnet body having a composition R1aR2bTcAdFeOfMg wherein F and R2 are distributed such that their concentration increases on the average from the center toward the surface of the magnet body, and grain boundaries having a concentration of R2/(R1+R2) which is on the average higher than the concentration of R2/(R1+R2) contained in primary phase grains of (R1,R2)2T14A tetragonal system form a three-dimensional network structure which is continuous from the magnet body surface to a depth of at least 10 ?m. The invention provides R—Fe—B sintered magnets which exhibit a high coercive force.Type: GrantFiled: January 27, 2006Date of Patent: February 10, 2009Assignee: Shin-Etsu Chemical Co., Ltd.Inventors: Hajime Nakamura, Koichi Hirota, Masanobu Shimao, Takehisa Minowa
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Patent number: 7473294Abstract: An object of the present invention is to provide nitrogen-containing metallic powder at high productivity, which powder contains a metal such as niobium or tantalum containing nitrogen uniformly, and enables production of an anode electrode that has high specific capacitance and low leakage current and that exhibits excellent reliability for a prolonged period of time. There is provided nitrogen-containing metallic powder which is a solid solution containing 50-20,000 ppm nitrogen, in which the metal that constitutes the metallic powder is niobium or tantalum. The nitrogen-containing metallic powder is produced through the process in which while a metallic compound is reduced with a reducing agent, a nitrogen-containing gas is introduced into a reaction system to thereby form metal, and nitrogen is simultaneously incorporated into metal.Type: GrantFiled: June 5, 2006Date of Patent: January 6, 2009Assignee: Cabot Supermetals K.K.Inventors: Yukio Oda, Tomoo Izumi, Yoshikazu Noguchi
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Publication number: 20080317620Abstract: A rare earth element magnet comprising molded magnetic powder containing at least one rare earth element, wherein a Fe rich phase covering a part or entire of the surface of particles of the magnetic powder and having a Fe atomic percentage larger than that of the magnetic powder, and an inorganic binder bonding the particles covered with the Fe rich phase.Type: ApplicationFiled: May 6, 2008Publication date: December 25, 2008Inventors: Hiroyuki Suzuki, Takao Imagawa, Yuichi Satsu, Matahiro Komuro, Takashi Yasuhara, Yutaka Matsunobu
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Patent number: 7459105Abstract: A nanostructured monolithic titanium boride (TiB) material and methods of forming such a material are disclosed and described. This material has a room-temperature four-point flexural strength about three times that of commercially available titanium diboride (TiB2). The achievement of nanostructured internal microstructural arrangement having a network of interconnected titanium monoboride whiskers affords a very high strength to this material above some of the best ceramic materials available in the market. The material contains a small amount of titanium, but it is largely made of TiB phase with substantially no TiB2. The nanostructured monolithic titanium boride material can be formed by high temperature processing of a powder precursor having carefully selected weight and size distributions of titanium and titanium diboride powders. Potential applications of this material can include wear resistant components such as die inserts for extrusion dies, nozzles, armor, electrodes for metal refining etc.Type: GrantFiled: July 7, 2005Date of Patent: December 2, 2008Assignee: University of Utah Research FoundationInventor: K. S. Ravi Chandran
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Patent number: 7442225Abstract: The present invention provides a worked molybdenum-alloy material that can be used at higher temperatures than at least temperatures at which known TZM alloys are used. A worked molybdenum-alloy material having high strength and high toughness includes at least one of carbide particles, oxide particles, and boride particles and fine nitride particles dispersed by internal nitriding of an untreated worked molybdenum-alloy material in which a nitride-forming-metal element is dissolved to form a solid solution in a molybdenum matrix and at least one of carbide particles, oxide particles, and boride particles is precipitated and dispersed.Type: GrantFiled: March 27, 2003Date of Patent: October 28, 2008Assignees: Japan Science and Technology Agency, National University Corporation Okayama University, A.L.M.T. Corp.Inventors: Jun Takada, Masahiro Nagae, Makoto Nakanishi, Tomohiro Takida, Tetsushi Hoshika
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Publication number: 20080202820Abstract: The present invention includes consolidated hard materials, methods for producing them, and industrial drilling and cutting applications for them. A consolidated hard material may be produced using hard particles such as B4C or carbides or borides of W, Ti, Mo, Nb, V, Hf, Ta, Zr, and Cr in combination with an iron-based, nickel-based, nickel and iron-based, iron and cobalt-based, aluminum-based, copper-based, magnesium-based, or titanium-based alloy for the binder material. Commercially pure elements such as aluminum, copper, magnesium, titanium, iron, or nickel may also be used for the binder material. The mixture of the hard particles and the binder material may be consolidated at a temperature below the liquidus temperature of the binder material using a technique such as rapid omnidirectional compaction (ROC), the Ceracon™ process, or hot isostatic pressing (HIP). After sintering, the consolidated hard material may be treated to alter its material properties.Type: ApplicationFiled: September 18, 2007Publication date: August 28, 2008Applicant: BAKER HUGHES INCORPORATEDInventors: Jimmy W. Eason, James C. Westhoff, Roy Carl Lueth
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Patent number: 7413591Abstract: The throw-away tip has a shape of substantially flat plate, comprising from 1 to 30% by weight of binder phase comprising at least one kind of Co and Ni, and 70 to 99% by weight of carbonitride phase comprising composite metal carbonitride of Ti and one or more kind other than Ti among metals of groups 4a, 5a and 6a of the Periodic Table, wherein the mean grain size of the carbonitride phase is 1.5 ?m or less, while flexural strength test pieces which are cut out of ten throw-away tips including the side face thereof show flexural strength with a Weibull coefficient of 5 or higher. Throw-away tips having fine carbonitride phase structure and high cutting performance can be made with less variance among individual throw-away tips.Type: GrantFiled: December 23, 2003Date of Patent: August 19, 2008Assignee: Kyocera CorporationInventor: Takashi Tokunaga
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Patent number: 7384444Abstract: A cermet composition represented by the formula (PQ)(RS) comprising: a ceramic phase (PQ) and binder phase (RS) wherein, P is at least one metal selected from the group consisting of Group IV, Group V, Group VI elements, Q is boride, R is selected from the group consisting of Fe, Ni, Co, Mn and mixtures thereof, S comprises at least one element selected from Cr, Al, Si and Y.Type: GrantFiled: August 4, 2006Date of Patent: June 10, 2008Assignee: ExxonMobil Research and Engineering CompanyInventors: Narasimha-Rao Venkata Bangaru, ChangMin Chun, Neeraj Srinivas Thirumalai, Hyun-Woo Jin, Jayoung Koo, John Roger Peterson, Robert Lee Antram, Christopher John Fowler
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Publication number: 20080022806Abstract: A diamond sintered body conventionally used in a cutting tool or the like includes an iron group metal element as a sintering aid, and therefore has a problem in heat resistance. A diamond sintered body not including the iron group metal, on the other hand, does not have sufficient mechanical strength to be used as a tool material, and also does not have conductivity, which makes electrical discharge machining impossible, and thus processing thereof is difficult. A diamond polycrystalline body having high heat resistance and mechanical strength and having conductivity enabling electrical discharge machining is obtained by using only an amorphous or fine graphite-type carbon material as a starting material, adding boron thereto and concurrently performing conversion into diamond and sintering in an ultra-high pressure and temperature condition.Type: ApplicationFiled: December 3, 2004Publication date: January 31, 2008Inventor: Hitoshi Sumiya
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Patent number: 7314531Abstract: A sintered body comprising a main phase consisting of an R2T14B phase (wherein R represents one or more rare earth elements (providing that the rare earth elements include Y), and T represents one or more transition metal elements essentially containing Fe, or Fe and Co), and a grain boundary phase containing a higher amount of R than the main phase, wherein a platy or acicular product exists. This sintered body enables to inhibit the grain growth, while keeping a decrease in magnetic properties to a minimum, and to improve a suitable sintering temperature range.Type: GrantFiled: March 11, 2004Date of Patent: January 1, 2008Assignee: TDK CorporationInventors: Chikara Ishizaka, Gouichi Nishizawa, Tetsuya Hidaka, Akira Fukuno, Yoshinori Fujikawa
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Patent number: 7311788Abstract: A sintered body with a composition consisting of 25% to 35% by weight of R (wherein R represents one or more rare earth elements, provided that the rare earth elements include Y), 0.5% to 4.5% by weight of B, 0.02% to 0.6% by weight of Al and/or Cu, 0.03% to 0.25% by weight of Zr, 4% or less by weight (excluding 0) of Co, and the balance substantially being Fe. This sintered body has a coefficient of variation (CV value) showing the dispersion degree of Zr of 130 or less. In addition, this sintered body has a grain boundary phase comprising a region that is rich both in at least one element selected from a group consisting of Cu, Co and R, and in Zr. This sintered body enables to inhibit the grain growth, while keeping the decrease of magnetic properties to a minimum, and to improve the suitable sintering temperature range.Type: GrantFiled: September 29, 2003Date of Patent: December 25, 2007Assignee: TDK CorporationInventors: Gouichi Nishizawa, Chikara Ishizaka, Tetsuya Hidaka, Akira Fukuno, Yoshinori Fujikawa
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Patent number: 7264683Abstract: The present invention relates to a casting method which employs rapid solidification of metal, rare-earth metal or the like, as well as to a casting apparatus and a cast alloy. A centrifugal casting method includes the steps of pouring a molten material onto a rotary body; sprinkling the molten material by the effect of rotation of the rotary body; and causing the sprinkled molten material to be deposited and to solidify on the inner surface of a rotating cylindrical mold. The axis of rotation of the rotary body and the axis of rotation of the cylindrical mold are caused not to run parallel to each other. The centrifugal casting method can attain a decrease in average deposition rate. As a result, generation of the dendritic ?Fe phase or generation of a segregation phase of Mn or the like is suppressed, thereby realizing a high-performance R-T-B-type rare-earth magnet alloy.Type: GrantFiled: August 17, 2004Date of Patent: September 4, 2007Assignee: Showa Denko k.k.Inventors: Hiroshi Hasegawa, Masahide Utsunomiya, Uremu Hosono, Yoichi Hirose
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Patent number: 7220480Abstract: A cemented carbide including WC, a binder phase based on Co, Ni or Fe, and gamma phase, in which said gamma phase has an average grain size <1 ?m. A method of making the cemented carbide is provided in which the powders forming gamma phase are added as mixed cubic carbides of one or more of Ti, Ta, Nb, Zr, Hf and V, and a ratio, fWC, between an amount of WC (in mol fraction of WC) and an equilibrium gamma phase WC content at a sintering temperature (in mol fraction WC) is given by fWC=xWC/xeWC, wherein fWC is 0.6 to 1.0.Type: GrantFiled: October 12, 2004Date of Patent: May 22, 2007Assignee: Sandvik Intellectual Property ABInventors: Bo Jansson, Susanne Norgren
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Patent number: 7211323Abstract: An improved coating material possessing super-hard and low friction properties and a method for forming the same. The improved coating material includes the use of a noble metal or soft metal homogeneously distributed within a hard nitride material. The addition of small amounts of such metals into nitrides such as molybdenum nitride, titanium nitride, and chromium nitride results in as much as increasing of the hardness of the material as well as decreasing the friction coefficient and increasing the oxidation resistance.Type: GrantFiled: January 6, 2003Date of Patent: May 1, 2007Assignee: U Chicago Argonne LLCInventors: Ali Erdemir, Mustafa Ürgen, Ali Fuat Cakir, Osman Levent Eryilmaz, Kursat Kazmanli, Ozgul Keles
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Patent number: 7208056Abstract: An R-T-B system rare earth sintered magnet having a high mechanical strength and excellent corrosion resistance is provided. The R-T-B system rare earth sintered magnet of the present invention comprises a sintered body comprising a main phase consisting of an R2T14B phase where R represents one or more rare earth elements and T represents one or more transition metal elements essentially containing Fe, or Fe and Co, and a grain boundary phase containing a higher amount of R than the above described main phase, wherein the surface of the above described sintered body is partially covered with a carbon compound layer. In the R-T-B system rare earth sintered magnet of the present invention, the area ratio of the partial surface of the above described sintered body covered with the above described carbon compound layer to the entire surface thereof is preferably between 10% and 90%.Type: GrantFiled: January 31, 2005Date of Patent: April 24, 2007Assignee: TDK CorporationInventors: Makoto Iwasaki, Chikara Ishizaka, Taku Takeishi
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Patent number: 7201810Abstract: A rare earth alloy sintered compact includes a main phase represented by (LR1-xHRx)2T14A, where T is Fe with or without non-Fe transition metal element(s); A is boron with or without carbon; LR is a light rare earth element; HR is a heavy rare earth element; and 0<x<1. The sintered compact is produced by preparing multiple types of rare earth alloy materials including respective main phases having different HR mole fractions, mixing the alloy materials so that the sintered compact will include sintering a main phase having an average composition represented by (LR1-xHRx)2T14A, thereby obtaining a mixed powder, and the mixed powder. The alloy materials include first and second rare earth alloy materials represented by (LR1-uHRu)2T14A (where 0??&<x) and (LR1-vHRV)2T14A (where x<v?1) and including a rare earth element R(=LR+HR) at R1 and R2 (at%), respectively. ?=|R1?R2| is about 20% or less of (R1+R2)/2.Type: GrantFiled: March 29, 2002Date of Patent: April 10, 2007Assignee: Neomax Co., Ltd.Inventors: Hitoshi Morimoto, Yuji Kaneko
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Patent number: 7199690Abstract: An R-T-B system rare earth permanent is provided, which comprises a sintered body comprising: an R2T14B phase (wherein R represents one or more rare earth elements (providing that the rare earth elements include Y) and T represents one or more transition metal elements essentially containing Fe, or Fe and Co) as a main phase; and a grain boundary phase containing a higher amount of R than the above main phase, wherein, when Pc (permeance coefficient) is 2, if a total flux is defined as f1 under the application of an effective magnetic field of 240 kA/m (providing that an effective magnetic field=an applied magnetic field?a demagnetizing field, and each value of them is absolute value), if a total flux is defined as f2 under the application of an effective magnetic field of 800 kA/m, and if a total flux is defined as f3 under the application of an effective magnetic field of 2,000 kA/m, a magnetization rate a (=f1/f3×100) is 40% or more, and a magnetization rate b (=f2/f3×100) is 90% or more.Type: GrantFiled: March 24, 2004Date of Patent: April 3, 2007Assignee: TDK CorporationInventors: Tetsuya Hidaka, Kazuya Sakamoto, Kazuo Sato, Hironari Okada
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Patent number: 7175687Abstract: A cermet composition represented by the formula (PQ)(RS) comprising: a ceramic phase (PQ) and binder phase (RS) wherein, P is at least one metal selected from the group consisting of Group IV, Group V, Group VI elements, Q is boride, R is selected from the group consisting of Fe, Ni, Co, Mn and mixtures thereof, S comprises at least one element selected from Cr, Al, Si and Y.Type: GrantFiled: April 22, 2004Date of Patent: February 13, 2007Assignee: ExxonMobil Research and Engineering CompanyInventors: Narasimha-Rao Venkata Bangaru, ChangMin Chun, Neeraj Srinivas Thirumalai, Hyun-Woo Jin, Jayoung Koo, John Roger Peterson, Robert Lee Antram, Christopher John Fowler
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Patent number: 7175718Abstract: A material for a rare earth permanent magnet having a high magnetic coercive force and a high residual magnetic flux density. 28 to 35% by weight of at least one rare earth element selected from the group consisting of neodymium, praseodymium, dysprosium, terbium, and holmium, 0.9 to 1.3% by weight of boron, 0.25 to 3% by weight of phosphorus, iron, and inevitable impurities. It can further comprise 0.1 to 3.6% by weight of cobalt and 0.02 to 0.25% by weight of copper.Type: GrantFiled: June 19, 2001Date of Patent: February 13, 2007Assignee: Mitsubishi Denki Kabushiki KaishaInventors: Hideharu Nobutoki, Suguru Nagae, Satoru Hayasi
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Patent number: 7172641Abstract: A composite of M/AlMgB14 or M alloy/AlMgB14 is synthesized, where M=Al, Ti, W, or Cu. Small particles and/or fibers of AlMgB14 are distributed throughout a metal matrix to strengthen the resulting composite.Type: GrantFiled: June 18, 2004Date of Patent: February 6, 2007Assignee: Iowa State University Research Foundation, Inc.Inventors: Bruce Allan Cook, Alan Mark Russell, Joel Lee Harringa, S. Bulent Biner, Iver Anderson
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Patent number: 7147686Abstract: A rare earth magnet comprises rare earth magnet particles and a rare earth oxide being present between the rare earth magnet particles. The rare earth oxide is represented by a following general formula (I): R2O3??(I) where R is any one of terbium, dysprosium, holmium, erbium, thulium, ytterbium, and lutetium.Type: GrantFiled: June 23, 2003Date of Patent: December 12, 2006Assignee: Nissan Motor Co., Ltd.Inventors: Tetsurou Tayu, Hideaki Ono, Munekatsu Shimada, Makoto Kano
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Patent number: 7128774Abstract: The present invention relates to a cutting tool insert for metal machining comprising tungsten carbide in a binder phase of tungsten or a tungsten alloy. The insert contains, in addition, W2C in an amount such that in the x-ray diffraction pattern the peak ratio W2C(101)/W(110) is <0.3. This particular microstructure is obtained by an additional heat treatment at about 1200° C. after the sintering.Type: GrantFiled: August 26, 2004Date of Patent: October 31, 2006Assignee: Sandvik Intellectual Property ABInventors: Susanne Norgren, Bo Jansson, Peter Littecke
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Patent number: 7090730Abstract: 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: GrantFiled: November 13, 2003Date of Patent: August 15, 2006Assignee: Shin-Etsu Chemical Co., Ltd.Inventors: Tadao Nomura, Takehisa Minowa
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Patent number: 7066975Abstract: An object of the present invention is to provide nitrogen-containing metallic powder at high productivity, which powder contains a metal such as niobium or tantalum containing nitrogen uniformly, and enables production of an anode electrode that has high specific capacitance and low leakage current and that exhibits excellent reliability for a prolonged period of time. There is provided nitrogen-containing metallic powder which is a solid solution containing 50–20,000 ppm nitrogen, in which the metal that constitutes the metallic powder is niobium or tantalum. The nitrogen-containing metallic powder is produced through the process in which while a metallic compound is reduced with a reducing agent, a nitrogen-containing gas is introduced into a reaction system to thereby form metal, and nitrogen is simultaneously incorporated into metal.Type: GrantFiled: June 20, 2002Date of Patent: June 27, 2006Assignee: Cabot Supermetals, K.K.Inventors: Yukio Oda, Tomoo Izumi, Yoshikazu Noguchi
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Patent number: 7067197Abstract: A method of forming a sputtering target and other metal articles having controlled oxygen and nitrogen content levels and the articles so formed are described. The method includes surface-nitriding a deoxidized metal powder and further includes consolidating the powder by a powder metallurgy technique. Preferred metal powders include, but are not limited to, valve metals, including tantalum, niobium, and alloys thereof.Type: GrantFiled: January 6, 2004Date of Patent: June 27, 2006Assignee: Cabot CorporationInventors: Christopher A. Michaluk, Shi Yuan, James Maguire
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Patent number: 7048808Abstract: The present invention provides a rare-earth sintered magnet exhibiting desirable magnetic properties in which the amount of Nd and/or Pr forming a non-magnetic phase in a grain boundary phase is reduced. Specifically, the present invention provides a rare-earth sintered magnet having a composition of (R1x+R2y)T100-x-y-zQz where R1 is at least one element selected from the group consisting of all rare-earth elements excluding La (lanthanum), Y (yttrium) and Sc (scandium); R2 is at least one element selected from the group consisting of La, Y and Sc; T is at least one element selected from the group consisting of all transition elements; Q is at least one element selected from the group consisting of B and C, and including, as a main phase, a crystal grain of an Nd2Fe14B crystalline structure, wherein: molar fractions x, y and z satisfy 8?x?18 at %, 0.1?y?3.Type: GrantFiled: October 1, 2001Date of Patent: May 23, 2006Assignee: Neomax Co., Ltd.Inventors: Yuji Kaneko, Katsuya Taniguchi, Takao Sekino
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Patent number: 7041148Abstract: High-permeability, low-core-loss soft magnetic composite materials, compositions containing the same, and methods for making the same are described. These magnetic materials are made by forming fiber or flake shaped particles from a ferromagnetic material, annealing the particles, and then coating an insulating material on the particles. These particles can then be compacted to form an article that has high permeability, high saturation, low core loss, and is a suitable replacement for laminations in various applications, such as motors.Type: GrantFiled: March 3, 2003Date of Patent: May 9, 2006Assignee: General Electric CompanyInventors: Luana Emiliana Iorio, Paul Alfred Siemers, Gerald Burt Kliman, Krishnamurthy Anand, Amitabh Verma
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Patent number: 7014811Abstract: A method for producing rare earth sintered magnets includes the steps of pressing and compacting an alloy powder for the rare earth sintered magnets, thereby preparing a plurality of green compacts, arranging the green compacts on a receiving plane in a direction in which a projection area of each of the green compacts onto the receiving plane is not maximized, and heating the green compacts, thereby sintering the green compacts and obtaining a plurality of sintered bodies.Type: GrantFiled: June 25, 2002Date of Patent: March 21, 2006Assignee: Neomax Co., Ltd.Inventors: Daisuke Harimoto, Yuji Kaneko, Akira Nakamura
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Patent number: 7011692Abstract: A powder composition for a capacitor comprising a tantalum or niobium and a compound having a silicon-oxygen bond, at least a part of which may be nitrided and which has an average particle size of from 0.1 to 5 ?m; a sintered body using the composition; and a capacitor constituted by the sintered body as one part electrode, and another part electrode. A capacitor favored with high reliability, lower dissipation level of power and smaller deterioration of capacitance than conventional tantalum capacitors using tantalum can be produced by using a sintered body of the powder composition for a capacitor.Type: GrantFiled: October 14, 2003Date of Patent: March 14, 2006Assignee: Showa Denko K.K.Inventors: Kazumi Naito, Kazuhiro Omori, Nobuyuki Nagato
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Patent number: 6994755Abstract: Disclosed are methods for producing compositionally modified sintered RE—Fe—B-based rare earth permanent magnets, by the addition of small amounts of Nd, Cu, Ti, Nb, or other transition metals, and mixtures thereof, to maximize fracture toughness with corresponding improved machinability, while maintaining maximum energy product, said method comprising the steps of: (a) prepare a magnetic composition; (b) melt the composition and form powders with an average particle size smaller than 5 microns from the same; (c) press the powder under a magnetic field to obtain green compacts, which are then sintered at from about 1030° C. to 1130° C., and heat treating the sintered material at from about 570° C. to 900° C.Type: GrantFiled: November 13, 2002Date of Patent: February 7, 2006Assignees: University of Dayton, Electron Energy CorporationInventors: Shiqiang Liu, Jinfang Liu
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Patent number: 6995119Abstract: Superconducting phases comprising magnesium diboride related composites and methods of preparation.Type: GrantFiled: October 7, 2003Date of Patent: February 7, 2006Assignee: Northwestern UniversityInventor: David C. Dunand
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Patent number: 6984271Abstract: A rare earth magnet to be used in a motor. The rare earth magnet comprises rare earth magnet particles. Additionally, a rare earth oxide is present among the rare earth magnet particles, the rare earth oxide being represented by the following general formula (I): R2xR?2(1?x)O3??(I) where each of R and R? is one element selected from the group consisting of yttrium (Y), lanthanum (La), cerium (Ce), praseodymium (Pr), neodymium (Nd), samarium (Sm), europium (Eu), gadolinium (Gd), terbium (Tb), dysprosium (Dy), holmium (Ho), erbium (Er), thulium (Tm), ytterbium (Yb) and lutetium (Lu), and 0<x<1.Type: GrantFiled: March 26, 2004Date of Patent: January 10, 2006Assignee: Nissan Motor Co., Ltd.Inventors: Tetsurou Tayu, Takae Ono, legal representative, Makoto Kano, Munekatsu Shimada, Yoshio Kawashita, Takeshi Yamauchi, Hideaki Ono, deceased
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Patent number: 6966953Abstract: Compositionally modified, sintered RE-Fe—B-based rare earth permanent magnets demonstrate the optimum combination of mechanical and magnetic properties, thereby maximizing fracture toughness with corresponding improved machinability, while maintaining the maximum energy product (BH)max.Type: GrantFiled: November 13, 2002Date of Patent: November 22, 2005Assignees: University of Dayton, Electron Energy CorporationInventors: Shiqiang Liu, Jinfang Liu
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Patent number: 6964693Abstract: A method for forming dendritic metal powders, comprising the steps of: (1) heating a powder comprising non-dendritic particles, under conditions suitable for initial stage sintering, to form a lightly sintered material; and (2) breaking the lightly sintered material to form a powder comprising dendritic particles. In one embodiment, the lightly sintered material is broken by brushing the material through a screen. Another aspect of the present invention comprises the dendritic particles that are produced by the method described above. These particles can comprise any suitable metal, such as transition metals, rare earth metals, main group metals or metalloids or an alloy of two or more such metals. The particles can also comprise a ceramic material, such as a metal oxide. These particles are characterized by a dendritic, highly anisotropic, morphology arising from the fusion of substantially non-dendritic particles, and by a low apparent density relative to the substantially non-dendritic starting material.Type: GrantFiled: March 31, 2003Date of Patent: November 15, 2005Assignee: Mykrolis CorporationInventors: Robert S. Zeller, Christopher J. Vroman
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Patent number: 6960319Abstract: 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: GrantFiled: October 27, 1995Date of Patent: November 1, 2005Assignee: The United States of America as represented by the Secretary of the ArmyInventor: Deepak Kapoor
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Patent number: 6890368Abstract: The present invention provides: a material, which is dense, with a density of ?90%, bulk dry self-lubricating, with a coefficient of friction of <0.3, constituted by a matrix that endows it with suitable strength, with a Rm of ?400 MPa in a medium to high temperature range of 300° C.???600° C.; said matrix including particles of solid lubricant in its volume; mechanical parts formed from said material; a method of manufacturing said material.Type: GrantFiled: May 20, 2003Date of Patent: May 10, 2005Assignees: SNECMA Moteurs, SNECMA ServicesInventors: Frédéric Braillard, Claude Mons, Philippe Perruchaut, Didier Ribot, Joël Vigneau
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Patent number: 6840978Abstract: A porous metal body having a foam structure of 500 ?m or less in average pore diameter, wherein the skeleton is composed of an alloy primarily including Fe and Cr, and Cr carbide or FeCr carbide is uniformly dispersed in the texture. The metal porous body is produced by preparing a slurry primarily containing an Fe oxide powder having an average particle diameter of 5 ?m or less, at least one powder selected from metallic Cr, Cr alloys, and Cr oxides, a thermosetting resin, and a diluent, applying a coating of this slurry to a resin core body having a foam structure, performing drying, and thereafter, performing firing in a non-oxidizing atmosphere so as to produce a metal porous body having the aforementioned skeleton structure.Type: GrantFiled: April 25, 2002Date of Patent: January 11, 2005Assignee: Sumitomo Electric Industries, Ltd.Inventors: Takahiro Matsuura, Keizo Harada
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Patent number: 6835225Abstract: A niobium sintered body which is prepared in such a manner that a niobium powder is sintered at a temperature of 500° C. to 2000° C. and allowed to stand at a maximum sintering temperature for 60 minutes to 150 minutes in the course of sintering. The niobium sintered body of the present invention is characterized in that a product (CV) of a capacitance (C) per unit mass and a forming voltage (V) is 90,000 &mgr;F·V/g or more, and a value obtained by dividing a product of a mean particle diameter (D50) of a primary particle of said niobium powder and a leakage current (LC) by said CV is 5×10−4 &mgr;m·&mgr;A (&mgr;F·V) or less. And there can be provided a well-balanced capacitor with respect to a preferably low leakage current value regardless of the large capacitance, that is, a highly reliable capacitance.Type: GrantFiled: February 7, 2003Date of Patent: December 28, 2004Assignee: Showa Denko K.K.Inventors: Kazumi Naito, Isao Kabe
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Publication number: 20040231460Abstract: The invention includes a cermet composition represented by the formula (PQ)(RS) comprising: a ceramic phase (PQ) and a binder phase (RS) wherein,Type: ApplicationFiled: April 22, 2004Publication date: November 25, 2004Inventors: ChangMin Chun, Narasimha-Rao Venkata Bangaru, Hyun-Woo Jin, Jayoung Koo, John Roger Peterson, Robert Lee Antram, Christopher John Fowler
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Patent number: 6814776Abstract: An iron-based rare-earth alloy powder includes: a first iron-based rare-earth alloy powder, which has a mean particle size of 10 &mgr;m to 70 &mgr;m and of which the powder particles have aspect ratios of 0.4 to 1.0; and a second iron-based rare-earth alloy powder, which has a mean particle size of 70 &mgr;m to 300 &mgr;m and of which the powder particles have aspect ratios of less than 0.3. The first and second iron-based rare-earth alloy powders are mixed at a volume ratio of 1:49 to 4:1. In this manner, an iron-based rare-earth alloy powder with increased flowability and a compound to make a magnet are provided.Type: GrantFiled: July 30, 2003Date of Patent: November 9, 2004Assignee: Neomax Co., Ltd.Inventors: Hirokazu Kanekiyo, Hirokazu Kitayama, Satoshi Hirosawa, Toshio Miyoshi
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Patent number: 6814775Abstract: A sintered cubic boron nitride (cBN) compact for use in a tool is composed of between about 60 and 80 vol-% cBN having a volumetric mean particle size of between about 3 to 6 &mgr;m and between about 40 and 20 vol-% of a ceramic binder phase. The ceramic binder is composed of between about 20 and 60 vol-% of one or more of a carbide, nitride, or boride of a Group IVB or VIB metal, and between about 40 and 80 vol-% of one or more of carbides, nitrides, borides, or oxides of aluminum. The cBN compact additionally contains between about 3 and 15 wt-% tungsten. The cBN compacts are especially useful in machining iron and like chemically reactive parts, especially where such parts are powder metal parts.Type: GrantFiled: May 14, 2003Date of Patent: November 9, 2004Assignee: Diamond Innovations, Inc.Inventors: Robert Dean Scurlock, Stephen Lee Dole
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Patent number: 6811620Abstract: An R—T—B system rare earth permanent magnet, which is a sintered body comprising: a main phase consisting of an R2T14B phase (wherein R represents one or more rare earth elements (providing that the rare earth elements include Y), and T represents one or more transition metal elements essentially containing Fe, or Fe and Co); and a grain boundary phase containing a higher amount of R than the above main phase, wherein a product that is rich in Zr exists in the above R2T14B phase. The product that is rich in Zr has a platy or acicular form. The R—T—B system rare earth permanent magnet containing the product enables to inhibit the grain growth, while keeping a decrease in magnetic properties to a minimum, and to obtain a wide suitable sintering temperature range.Type: GrantFiled: March 11, 2004Date of Patent: November 2, 2004Assignee: TDK CorporationInventors: Chikara Ishizaka, Gouichi Nishizawa, Tetsuya Hidaka, Akira Fukuno, Nobuya Uchida
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Publication number: 20040200317Abstract: A powder composition for a capacitor comprising a tantalum or niobium and a compound having a silicon-oxygen bond, at least a part of which may be nitrided and which has an average particle size of from 0.1 to 5 &mgr;m; a sintered body using the composition; and a capacitor constituted by the sintered body as one part electrode, and another part electrode. A capacitor favored with high reliability, lower dissipation level of power and smaller deterioration of capacitance than conventional tantalum capacitors using tantalum can be produced by using a sintered body of the powder composition for a capacitor.Type: ApplicationFiled: October 14, 2003Publication date: October 14, 2004Applicant: SHOWA DENKO K.K.Inventors: Kazumi Naito, Kazuhiro Omori, Nobuyuki Nagato
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Patent number: 6802883Abstract: An iron-based sintered alloy, which consists of from 0.5 to 5% of Ni, from 0.5 to 4% of Cr, from 0.5 to 2% of C, the balance being Fe and unavoidable impurities, and which has a micro-structure comprising an iron-based matrix containing Ni and a part of Cr as solutes and carbides containing the other part of Cr and dispersed in the matrix. The iron-based sintered alloy is appropriate for use as a valve seat of an internal combustion engine. Wear resistance is maintained at a moderate level while the additive amount of alloying elements is decreased to attain low cost.Type: GrantFiled: March 10, 2003Date of Patent: October 12, 2004Assignee: Kabushiki Kaisha RikenInventors: Hiroji Henmi, Akiyoshi Ishibashi