Base Metal One Or More Of Beryllium(be), Magnesium(mg), Or Aluminum(al) Patents (Class 75/249)
  • Patent number: 5118368
    Abstract: Disclosed are high strength magnesium-based alloys consisting essentially of a composition represented by the general formula (I) Mg.sub.a M.sub.b X.sub.d, (II) Mg.sub.a Ln.sub.c X.sub.d or (III) Mg.sub.a M.sub.b Ln.sub.c X.sub.d, wherein M is at least one element selected from the group consisting of Ni, Cu, Al, Zn and Ca; Ln is at least one element selected from the group consisting of Y, La, Ce, Sm and Nd or a misch metal (Mm) which is a combination of rare earth elements; X is at least one element selected from the group consisting of Sr, Ba and Ga; and a, b, c and d are, in atomic percent, 55.ltoreq.a.ltoreq.95, 3.ltoreq.b.ltoreq.25, 1.ltoreq.c.ltoreq.15 and 0.5.ltoreq.d.ltoreq.30, the alloy being at least 50 percent by volume composed of an amorphous phase.
    Type: Grant
    Filed: June 7, 1991
    Date of Patent: June 2, 1992
    Assignees: Tsuyoshi Masumoto, Japan Metals & Chemicals Co., Ltd., Yoshida Kogyo K.K.
    Inventors: Tsuyoshi Masumoto, Akihisa Inoue, Takashi Sakuma, Toshisuke Shibata
  • Patent number: 5114505
    Abstract: A composite aluminum-base alloy having a mechanically alloyed matrix alloy. The matrix alloy has about 4-40 percent by volume aluminum-containing intermetallic phase. The aluminum-containing intermetallic phase includes at least one element selected from the group consisting of niobium, titanium and zirconium. The intermetallic phase is essentially insoluble in the matrix alloy below one half of the solidus temperature of the matrix alloy. The balance of the matrix alloy is principally aluminum. A stiffener of 5 to 30 percent by volume of the composite aluminum-base alloy is dispersed within the metal matrix.
    Type: Grant
    Filed: August 30, 1990
    Date of Patent: May 19, 1992
    Assignee: Inco Alloys International, Inc.
    Inventors: Prakash K. Mirchandani, Raymond C. Benn, Walter E. Mattson
  • Patent number: 5104444
    Abstract: An aluminum alloy is prepared from an aluminum alloy powder having a composition of:lubricating componentPb: 3 to 15 Wt %;hardening componentSi: 1 to 12 Wt %;rainforcement componentone or more selected among Cu, Cr, Mg, Mn, NiZn, Fe and: 0.2 to 5.0 Wt %;and remainder of aluminum as principal material or matrix.To the aluminum alloy powder set forth above, powder state Pb in 3 to 12 Wt % is added. With the mixture of the aluminium alloy powder and Pb powder, a billet is formed. For the billet, extrustion process is performed in a extrusion ratio greater than or equal to 40. In the extruded block, Si particle dispersed in the aluminum matrix is in a grain size smaller than or equal to 12 .mu.m. Furthermore, at least of half of added Pb power particle is dispersed to have greater than or equal to 0.74 of circularity coefficient.
    Type: Grant
    Filed: August 7, 1989
    Date of Patent: April 14, 1992
    Assignees: Nissan Motor Company, Limited, NDC Co., Ltd.
    Inventors: Masahiko Shioda, Masashi Arita, Katsuji Tanizaki, Koue Ohdawa, Takeshi Sakai
  • Patent number: 5100736
    Abstract: A polymer-reinforced metal matrix composite is disclosed which is formed by lending metal particles and polymer particles to form a homogeneous powder blend, and consolidating the powder blend to form a unitary mass. The unitary mass is then plastically deformed such as by extrusion in the presence of heat so as to cause an elongation thereof, whereby the metal particles form a matrix and the polymer particles form elongated filaments uniformly dispersed throughout the matrix and aligned in the direction of elongation of the unitary mass. An aluminum matrix reinforced with polyether-etherketone is shown to have enhanced specific strength and modulus over those of the aluminum alone.
    Type: Grant
    Filed: February 19, 1991
    Date of Patent: March 31, 1992
    Assignee: The United States of America as represented by the Secretary of the Navy
    Inventors: Gilbert J. London, William E. Frazier, John G. Williams
  • Patent number: 5098469
    Abstract: A powder metallurgy process for producing near-net shape, near-theoretical density structures of multiphase nickel, aluminum and/or titanium intermetallic alloys is provided by employing pressureless sintering techniques. The process consists of blending a brittle aluminide master alloy powder with ductile nickel powder, so as to achieve the desired composition. Then, after cold compaction of the powdered mixture, the compact is liquid phase sintered. The four step liquid phase sintering process is intended to ensure maximum degassing, eliminate surface nickel oxide, homogenize the alloy, and complete densification of the alloy by liquid phase sintering.
    Type: Grant
    Filed: September 12, 1991
    Date of Patent: March 24, 1992
    Assignee: General Motors Corporation
    Inventor: Vadim Rezhets
  • Patent number: 5087304
    Abstract: Magnesium base metal alloy sheet is produced by rolling the rolling stock extruded or forged from a billet at a temperature ranging from 200.degree. C. to 300.degree. C. The billet is consolidated from rapidly solidified magnesium based alloy powder that consists of the formula Mg.sub.bal Al.sub.a Zn.sub.b X.sub.c, wherein X is at least one element selected from the group consisting of manganese, cerium, neodymium, praseodymium, and yttrium, "a" ranges from about 0 to 15 atom percent, "b" ranges from about 0 to 4 atom percent, "c" ranges from about 0.2 to 3 atom percent, the balance being magnesium and incidental impurities, with the proviso that the sum of aluminum and zinc present ranges from about 2 to 15 atom percent. The alloy has a uniform microstructure comprised of fine grain size ranging from 0.2-1.0 .mu.m together with precipitates of magnesium and aluminum containing intermetallic phases of a size less than 0.1 .mu.m.
    Type: Grant
    Filed: May 6, 1991
    Date of Patent: February 11, 1992
    Assignee: Allied-Signal Inc.
    Inventors: Chin-Fong Chang, Santosh K. Das
  • Patent number: 5071474
    Abstract: A magnesium base metal component is forged from a billet by subjecting the billet to a forging process using multiple steps in a closed-die or an open-die forging and a forging temperature ranging from 200.degree. C. to 300.degree. C. The billet is compacted from a rapidly solidified magnesium based alloy defined by the formula Mg.sub.bal Al.sub.a Zn.sub.b X.sub.c, wherein X is at least one element selected from the group consisting of manganese, cerium, neodymium, praseodymium, and yttrium, "a" ranges from about 0 to 15 atom percent, "b" ranges from about 0 to 4 atom percent, "c" ranges from about 0.2 to 3 atom percent, the balance being magnesium and incidental impurities, with the proviso that the sum of aluminum and zinc present ranges from about 2 to 15 atom percent. The alloy has a uniform microstructure comprised of a fine grain size ranging from 0.2-1.0 .mu.m together with precipitates of magnesium and aluminum containing intermetallic phases of a size less than 0.1 .mu.m.
    Type: Grant
    Filed: June 15, 1990
    Date of Patent: December 10, 1991
    Assignee: Allied-Signal Inc.
    Inventors: Derek Raybould, Chin-Fong Chang, Santosh K. Das
  • Patent number: 5061323
    Abstract: A powder-derived aluminum alloy is provided which contains throughout its se aluminum alloy matrix a fine dispersion of elemental molybdenum particles. The articles formed from the alloy exhibit improved resistance to environmentally-assisted cracking, such as stress corrosion cracking and corrosion fatigue, at room and moderately elevated temperatures. An aluminum alloy powder of a composition usually used to produce high-strength aluminum alloys is blended with molybdenum powder to form a homogeneous powder blend containing up to about 1.0% by weight molybdenum. The powder blend is consolidated, including compacting it and extruding or otherwise hot working it to a total reduction ratio of at least 16 to 1. The hot-worked product is then heat treated in a conventional manner to maximize other desirable properties, such as strength.
    Type: Grant
    Filed: October 15, 1990
    Date of Patent: October 29, 1991
    Assignee: The United States of America as represented by the Secretary of the Navy
    Inventor: John J. DeLuccia
  • Patent number: 5057379
    Abstract: A coating for a heat engine part, particularly a turbo-machine part made of superalloy, comprises an electrophoretically deposited metallic structure of cellular form with uniformly disposed cells of predetermined size, the structure preferably being composed of M, Cr, Al, and Y, where M denotes Ni, Co, Fe and mixtures thereof. The cellular metallic structure is consolidated by a sintering treatment, which may be reactive, or metallization, preferably in the vapor phase, and the coating is completed by a ceramic material applied by plasma spraying.
    Type: Grant
    Filed: May 23, 1988
    Date of Patent: October 15, 1991
    Assignees: Societe Nationale d'Etude et de Construction de Moteurs d'Aviation "S.N.E.C.M.A.", Association pour la Recherche et le Developpement des Methodes et Processus Industriels A.R.M.I.N.E.S.
    Inventors: Dominique M. M. Fayeulle, Jean-Paul Henon, Rene J. Morbioli
  • Patent number: 5045972
    Abstract: A thermally conductive diamond metal composite consisting essentially of 5 to 80 volume percent diamond particles having a particle size ranging from about 1 to 50 .mu.m and a metal matrix comprising a thermally conductive metal. Preferably, a fine metal powder having particle size below 53 microns is utilized as the source for the metal matrix.
    Type: Grant
    Filed: August 27, 1990
    Date of Patent: September 3, 1991
    Assignee: The Standard Oil Company
    Inventors: Edward C. Supan, Joseph F. Dolowy, Jr., Bradley A. Webb
  • Patent number: 5039476
    Abstract: A method for the production of a metallic powder molding material is disclosed which comprises a step of imparting mechanical energy due to at least one of such physical actions as vibration, pulverization, attrition, rolling, shocks, agitation, and mixing a metallic particles in a vessel whose interior is held under vacuumized atmosphere or an atmosphere of inert gas thereby enabling the metallic particles to contact each other and acquire improvement in surface quality and a step of hot molding the metallic particles thereby producing a molding material.
    Type: Grant
    Filed: July 19, 1990
    Date of Patent: August 13, 1991
    Assignee: Ube Industries, Ltd.
    Inventors: Mitsuru Adachi, Akio Okamoto, Hideki Iwai, Yoshiharu Waku
  • Patent number: 5034053
    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.
    Type: Grant
    Filed: November 21, 1990
    Date of Patent: July 23, 1991
    Assignee: Sumitomo Electric Industries, Ltd.
    Inventors: Tetsuo Nakai, Mitsuhiro Goto
  • Patent number: 5024813
    Abstract: A Mg-Ti type alloy comprises 0.04 to 99.96% by weight of Ti and 99.96 to 0.04% by weight of Mg. The Mg-Ti type alloy is produced by compounding and mixing at least one of a powder of Ti and a powder of titanium hybride with a powder of Mg, so that the Ti composition in a sintered product may be in a range of 0.04 to 99.96% by weight; forming the resulting mixture into a predetermined shape, and sintering the formed material at a temperature in a range of from a solid phase point of Mg to a liquid phase point.
    Type: Grant
    Filed: June 19, 1989
    Date of Patent: June 18, 1991
    Inventor: Katsuhiro Nishiyama
  • Patent number: 5022918
    Abstract: A heat-resistant aluminum alloy sinter comprises 5 to 12% by weight of Cr, less than 10% by weight of at least one selected from the group consisting of Co, Ni, Mn, Zr, V, Ce, Fe, Ti, Mo, La, Nb, Y and Hf, and the balance of Al containing unavoidable impurities. A silicon carbide fiber is included for reinforcing the sinter in a fiber volume fraction range of 2 to 30%.
    Type: Grant
    Filed: December 1, 1988
    Date of Patent: June 11, 1991
    Assignee: Honda Giken Kogyo Kabushiki Kaisha
    Inventors: Seiichi Koike, Hiroyuki Horimura, Masao Ichikawa, Noriaki Matsumoto
  • Patent number: 5017334
    Abstract: Self-supporting bodies are produced by reactive infiltration of a parent metal into a boron carbide material which may contain one or both of a boron donor material and a carbon donor material. The reactive infiltration typically results in a composite comprising a boron-containing compound, a carbon-containing compound and residual metal, if desired. The mass to be infiltrated may contain one or more inert fillers admixed with the boron carbide material, boron-containing compound and/or carbon-containing compound. The relative amounts of reactants and process conditions may be altered or controlled to yield a body containing varying volume percents of ceramic, metal, ratios of one ceramic to another and porosity.
    Type: Grant
    Filed: December 5, 1989
    Date of Patent: May 21, 1991
    Assignee: Lanxide Technology Company, LP
    Inventors: Terry D. Claar, Steven M. Mason, Kevin P. Pochopien, Danny R. White, William B. Johnson
  • Patent number: 5006417
    Abstract: A ternary metal matrix composite comprising a metallic binding matrix material and a reinforcement material consisting essentially of an insoluble ceramic and a semi-metal. The ternary metal matrix composite of the invention has a coefficient of thermal expansion which is lower and more consistent than that of known binary composites using similar materials. The coefficient of thermal expansion may be tailored to meet specific application needs. The invention also has a low density, good thermal conductivity, dimensional stability, and formability. In one form of the invention, the insoluble ceramic and semi-metal contain the same element. In a preferred form of the invention, the ternary metal matrix composite comprises an aluminum alloy matrix and a reinforcement material of silicon carbide and silicon.
    Type: Grant
    Filed: June 9, 1988
    Date of Patent: April 9, 1991
    Assignee: Advanced Composite Materials Corporation
    Inventors: Michael B. Jackson, Peter A. Roth
  • Patent number: 5000781
    Abstract: The invention provides an aluminum based alloy consisting essentially of the formula Al.sub.bal Fe.sub.a X.sub.b, wherein X is at least one element selected from the group consisting of Zn, Co, Ni, Cr, Mo, V, Zr, Ti, Y and Ce, "a" ranges from about 7-15 wt %, "b" ranges from about 2-10 wt % and the balance is aluminum. The alloy has a predominately microeutectic microstructure. The invention also provides a method and apparatus for forming rapidly solidifed metal, such as the metal alloys of the invention, within an ambient atmosphere. Generally stated, the apparatus includes a moving casting surface which has a quenching region for solidifying molten metal thereon. A reservoir holds molten metal and has orifice means for depositing a stream of molten metal onto the casting surface quenching region. A heating mechanism heats the molten metal contained within the reservoir, and a gas source provides a non-reactive gas atmosphere at the quenching region to minimize oxidation of the deposited metal.
    Type: Grant
    Filed: November 28, 1988
    Date of Patent: March 19, 1991
    Assignee: Allied-Signal Inc.
    Inventors: David J. Skinner, Paul A. Chipko, Kenji Okazaki
  • Patent number: 4990181
    Abstract: The present invention is directed to porous sintered aluminide structures of aluminum, nickel, titanium, and/or rare earth metal. A process is disclosed for forming and sintering aluminides. Other components are optionally added to the aluminide compositions to vary the physical properties of the resultant structure.
    Type: Grant
    Filed: March 14, 1989
    Date of Patent: February 5, 1991
    Assignee: Corning Incorporated
    Inventors: Kim D. Pierotti, Srinivas H. Swaroop, Raja R. Wusirika
  • Patent number: 4985072
    Abstract: The polycrystalline magnetic substance for magnetic refrigeration in or gas refrigeration accordance with the present invention comprises a plurality of magnetic alloy fine crystalline powders that include at least one kind of rare-earth element selected from the group of Y, La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, and Yb, with the remainder metal consisting substantially of 2 kinds selected from Al, Ni, Co, and Fe, and a metallic binder which forms a compact together with the fine crystalline particles, where the abundance ratio of the metallic binder in the compact is 1 to 80% by volume.
    Type: Grant
    Filed: September 22, 1988
    Date of Patent: January 15, 1991
    Assignee: Kabushiki Kaisha Toshiba
    Inventors: Masashi Sahashi, Hiromi Niu, Koichiro Inomata
  • Patent number: 4963322
    Abstract: The invention relates to a process for the production of aluminum alloy components retaining a good fatigue strength when used hot.This process consists of producing an alloy containing by weight 11 to 26% silicon, 2 to 5% iron, 0.5 to 5% copper, 0.1 to 2% magnesium, 0.1 to 0.4% zirconium and 0.5 to 1.5% manganese, subjecting the alloy in the molten state to a fast solidification means, bringing it into the form of parts or components and optionally subjecting the latter to a heat treatment at between 490.degree. and 520.degree. C., followed by water hardening and annealing at between 170.degree. and 210.degree. C.These components are used more particularly as rods, piston rods and pistons.
    Type: Grant
    Filed: September 20, 1989
    Date of Patent: October 16, 1990
    Assignee: Pechiney Recherche Groupement d'Interet Economique
    Inventor: Jean-Francois Faure
  • Patent number: 4961779
    Abstract: Disclosed are(1) a composite material of aluminum powder containing spherical carbon particles;(2) a composite material of aluminum powder having a good self-lubricity and a high wear resistance and consolidated with a mixture of(i) 100 parts by weight of aluminum particles of about 1 to about 200 .mu.m in mean particle size; and(ii) about 1 and about 100 parts by weight of spherical carbon particles of about 1 to about 50 .mu.m in mean particle size; and(3) a composite material of aluminum powder having a good self-lubricity, a high wear resistance and a high strength and consolidated with a mixture of(i) 100 parts of aluminum alloy particles containing about 0.3 to about 15% by weight of magnesium and having a mean particle size of about 1 to about 200 .mu.m; and(ii) about 1 to about 100 parts by weight of spherical carbon particles having a mean particle size of about 1 to about 50 .mu.m.
    Type: Grant
    Filed: April 10, 1989
    Date of Patent: October 9, 1990
    Assignee: Toyo Aluminium Kabushiki Kaisha
    Inventors: Jun Kusui, Akiei Tanaka, Masahiko Kawai
  • Patent number: 4954170
    Abstract: High density compacts are made by providing a compactable particulate combination of Class 1 metals selected from at least one of Ag, Cu and Al, with material selected from at least one of CdO, SnO, SnO.sub.2, C, Co, Ni, Fe, Cr, Cr.sub.3 C.sub.2, Cr.sub.7 C.sub.3, W, WC, W.sub.2 C, WB, Mo, Mo.sub.2 C, MoB, Mo.sub.2 B, TiC, TiN, TiB.sub.2, Si, SiC, Si.sub.3 N.sub.4, usually by mixing powders of each, step (1); uniaxially pressing the powders to a density of from 60% to 95%, to provide a compact, step (2); hot densifying the compact at a pressure between 352 kg/cm.sup.2 (5,000 psi) and 3,172 kg/cm.sup.2 (45,000 psi) and at a temperature from 50.degree. C. to 100.degree. C. below the melting point or decomposition point of the lower melting component of the compact, to provide densification of the compact to over 97% of theoretical density; step (3); and cooling the compact, step (4).
    Type: Grant
    Filed: June 30, 1989
    Date of Patent: September 4, 1990
    Assignee: Westinghouse Electric Corp.
    Inventors: Maurice G. Fey, Natraj C. Iyer, Alan T. Male, William R. Lovic
  • Patent number: 4950452
    Abstract: The present invention provides high strength, heat resistant aluminum-based alloys having a composition represented by the general formula Al.sub.a M.sub.b Ce.sub.c, wherein M is at least one metal element selected from the group consisting of V, Cr, Mn, Fe, Co, Ni, Cu and Nb; and a, b and c are atomic percentages falling within the following ranges:50.ltoreq.a.ltoreq.93, 0.5.ltoreq.b.ltoreq.35 and 0.5.ltoreq.c.ltoreq.25,the aluminum alloy containing at least 50% by volume of amorphous phase. The aluminum-based alloys are especially useful as high strength, high heat resistant materials in various applications and since they exhibit superplasticity in the vicinity of their crystallization temperature, they can be easily processed into various bulk materials by extrusion, press woring or hot-forging at the temperatures within the range of the crystallization temperature .+-.100.degree. C.
    Type: Grant
    Filed: March 16, 1989
    Date of Patent: August 21, 1990
    Assignees: Yoshida Kogyo K. K., Tsuyoshi Masumoto
    Inventors: Tsuyoshi Masumoto, Akihisa Inoue, Katsumasa Odera
  • Patent number: 4946500
    Abstract: An aluminum based metal matrix composite is produced from a charge containing a rapidly solidified aluminum alloy and particles of a reinforcing material present in an amount ranging from about 0.1 to 50 percent by volume of the charge. The charge is ball milled energetically to enfold metal matrix material around each of the particles while maintaining the charge in a pulverulant state. Upon completion of the ball milling step, the charge is consolidated to provide a powder compact having a formable, substantially void free mass. The compact is especially suited for use in aerospace, automotive, electronic, wear resistance critical components and the like.
    Type: Grant
    Filed: September 12, 1988
    Date of Patent: August 7, 1990
    Assignee: Allied-Signal Inc.
    Inventors: Michael S. Zedalis, Paul S. Gilman
  • Patent number: 4943319
    Abstract: Disclosed is herein a process for producing a molding product of Al or Cu composite material, which comprises admixing a functional material capable of improving the desired property of the composite material by dispersion into a matrix to a powder of metal selected from Al, Cu or alloys thereof constituting the matrix, charging the dust directly into a molding die, applying cold dust core molding under the pressure of greater than 5 t/cm.sup.2 of facial pressure and applying a diffusing treatment at a temperature higher than 300.degree. C.
    Type: Grant
    Filed: December 30, 1988
    Date of Patent: July 24, 1990
    Assignee: Kabushiki Kaisha Kobe Seiko Sho
    Inventors: Masahiro Yanagawa, Mutsumi Abe, Kenichi Aota, Takashi Motoda
  • Patent number: 4938810
    Abstract: The present invention relates to an aluminum alloy powder.Aluminum alloy powder having a high Si content is known but its heat resistance, wear resistance, and strength are poor.The aluminum alloy powder according to the present invention is characterized in that it contains from approximately 10.0% to approximately 30.0% of silicon and at least one element selected from the group consisting of from approximately 5.0% to approximately 15.0% of nickel, from approximately 3.0% to approximately 15.0% of iron, and from approximately 5.0% to approximately 15.0% of manganese, the silicon crystals in the aluminum alloy powder being 15 .mu.m or less in size. Due to the high content of nickel, iron, and manganese, the matrix is hardened and strengthed by the presence of finely dispersed intermetallic compounds and the silicon crystals, and thereby the high-temperature characteristics are improved.The shaped body, e.g.
    Type: Grant
    Filed: October 18, 1988
    Date of Patent: July 3, 1990
    Assignees: Showa Denko Kabushiki Kaisha, Kabushiki Kaisha Riken
    Inventors: Fumio Kiyota, Tatsuo Fujita, Tadao Hirano, Shin'ichi Horie
  • Patent number: 4938809
    Abstract: A complex part composed of rapidly solidified magnesium base metal alloy is produced by superplastic forming at a temperature ranging from 160.degree. C. to 275.degree. C. and at a rate ranging from 0.00021 m/sec. to 0.00001 m/sec., to improve the formability thereof and allow forming to be conducted at lower temperatures. The rapidly solidified magnesium based alloy has a composition consisting essentially of the formula Mg.sub.bal Al.sub.a Zn.sub.b X.sub.c, wherein X is at least one element selected from the group consisting of manganese, cerium, neodymium, praseodymium and yttrium, "a" range from 0 to about 15 atom percent, "b" ranges from 0 to about 4 atom percent and "c" ranges from about 0.2 to 3 atom percent, the balance being magnesium and incidental impurities, with the proviso that the sum of aluminum and zinc present ranges from about 2 to 15 atom percent. Such an alloy contains fine grain size and finely dispersed magnesium-, aluminum- rare earth intermetallic phases.
    Type: Grant
    Filed: May 23, 1988
    Date of Patent: July 3, 1990
    Assignee: Allied-Signal Inc.
    Inventors: Santosh K. Das, Chin-Fong Chang, Derek Raybould
  • Patent number: 4929415
    Abstract: A method for sintering and forming powder is disclosed. In this method a high voltage of 3 KV or more is applied to a mold filled with powder using an electrode which maintains a high current of 50 KA cm.sup.-2 or greater for a period of time from 10 to 500 microseconds. A device for practicing this method is also disclosed.
    Type: Grant
    Filed: March 1, 1988
    Date of Patent: May 29, 1990
    Inventor: Kenji Okazaki
  • Patent number: 4917739
    Abstract: The present invention provides a method for producing an aluminum alloy which includes the step of carbo-thermically reducing an aluminous material to provide an alloy consisting essentially of the formula Al.sub.bal TM.sub.d Si.sub.e, wherein TM is at least one element selected from the group consisting of Fe, Ni, Co, Ti, V, Zr, Cu and Mn, "d" ranges from about 2-20 wt %, "e" ranges from about 2.1-20 wt %, and the balance is aluminum and incidental impurities. The alloy is placed in the molten state and rapidly solidified at a quench rate of at least about 10.sup.6 K/sec to produce a rapidly solidified alloy composed of a predominately microeutectic and/or microcellular structure.
    Type: Grant
    Filed: April 29, 1988
    Date of Patent: April 17, 1990
    Assignee: Allied-Signal Inc.
    Inventors: Colin M. Adam, Kenji Okazaki, David J. Skinner, Robert G. Corey
  • Patent number: 4915605
    Abstract: A method of consolidating metal powders selected from the group consisting essentially of aluminum, aluminum alloys, and aluminum metal matrix composites includes: pressing the powder into a preform, and preheating the preform to elevated temperatures; providing a bed of flowable pressure transmitting particles; positioning the preform in such relation to the bed that the particles encompass the preform; and pressurizing the bed to compress the particles and cause pressure transmission via the particles to the preform, thereby to consolidate the body into desired shape. Typically, the metal powder has surface oxide, and such pressurizing is carried out to break up, partially or fully, the surface oxide.
    Type: Grant
    Filed: May 11, 1989
    Date of Patent: April 10, 1990
    Assignee: Ceracon, Inc.
    Inventors: Hing Chan, Brian L. Oslin, Raymond L. Anderson
  • Patent number: 4909841
    Abstract: A process of hot pressing of materials to form articles or compacts is characterized by the steps: (A) providing a compactable particulate mixture; (B) uniaxially pressing the particles without heating to provide article or compact (22); (C) placing at least one article or compact (22) in an open pan (31) having an insertable frame (32) with edge surfaces (34) that are not significantly pressure deformable, where the inside side surfaces of the frame are parallel to the central axis B--B of the open pan, and where each article or compact is surrounded by fine particles of a separating material; (D) evacuating air from the container and sealing the articles or compacts inside the container by means of top lid (36); (E) hot pressing the compacts at a pressure from 352.5 kg/cm.sup.2 to 3,172 kg/cm.sup.
    Type: Grant
    Filed: June 30, 1989
    Date of Patent: March 20, 1990
    Assignee: Westinghouse Electric Corp.
    Inventors: Natraj C. Iyer, Alan T. Male, William R. Lovic
  • Patent number: 4898612
    Abstract: A friction-actuated extrusion process utilizes a comminuted rapidly solidified aluminum alloy ribbon as the in-feed for a continuous friction-actuated extruder. Gumming and flow problems are eliminated. The resulting product is devoid of surface blistering and has improved ambient and elevated temperature mechanical properties.
    Type: Grant
    Filed: August 31, 1988
    Date of Patent: February 6, 1990
    Assignee: Allied-Signal Inc.
    Inventors: Paul S. Gilman, Michael S. Zedalis
  • Patent number: 4889557
    Abstract: An aluminium alloy made of consolidated rapid-quenched aluminium alloy powder by using an improved metallurgical method basically comprises, by weight percent, less than 30% silicone, less than 8% iron, less than 7% copper and less than 0.2% oxygen, the balance being substantially aluminium. The consolidated rapid-quenched aluminium alloy powder has features that it contains less than 0.2% oxygen, and the material made from the rapid-quenched aluminium alloy powder has a high limit compressibility factor, rate of reduction and tensile strength. Thus the aluminium alloy material obtained is suitable for structural members such as pistons for internal combustion engines.
    Type: Grant
    Filed: March 24, 1988
    Date of Patent: December 26, 1989
    Assignee: Toyota Jidosha Kabushiki Kaisha
    Inventors: Yasuo Iwata, Shigenori Mae, Yoshio Urai, Takayuki Tsunoda
  • Patent number: 4889582
    Abstract: A stable age hardenable aluminum alloy which has useful mechanical properties at temperatures up to at least 900.degree. F. (482.degree. C.). The alloy contains 5-15% iron, 1-5% molybdenum and 0.2-6% vanadium with balance aluminum and is processed by rapid solidification from the melt to form a particulate which is consolidated to form a bulk article.
    Type: Grant
    Filed: October 27, 1986
    Date of Patent: December 26, 1989
    Assignee: United Technologies Corporation
    Inventors: James W. Simon, Jr., Kathleen Gorman
  • Patent number: 4879095
    Abstract: A rapidly solidified aluminum-base alloy consists essentially of the formula Al.sub.bal Fe.sub.a Si.sub.b V.sub.c, wherein "a" ranges from 3.0 to 7.1 atom percent, "b" ranges from 1.0 to 3.0 atom percent, "c" ranges from 0.25 to 1.25 atom percent and the balance is aluminum plus incidental impurities, with the provisos that (i) the ratio (Fe+V): Si ranges from about 2.33:1 to 3:33:1 and (ii) the ratio Fe:V ranges from 11.5:1 to 5:1. The alloy exhibits high strength, ductility and fracture toughness and is especially suited for use in high temperature structural applications such as gas turbine engines, missiles, airframes and landing wheels.
    Type: Grant
    Filed: April 17, 1987
    Date of Patent: November 7, 1989
    Assignee: Allied-Signal Inc.
    Inventors: Colin M. Adam, Richard L. Bye, Santosh K. Das, David J. Skinner
  • Patent number: 4878967
    Abstract: A rapidly solidified aluminum-base alloy consists essentially of the formula Al.sub.bal Fe.sub.a Si.sub.b X.sub.c wherein X is at least one element selected from the group consisting of Mn,V,Cr,Mo,W,Nb,Ta, "a" ranges from 2.0 to 7.5 atom percent, "b" ranges from 0.5 to 3.0 atom percent, "c" ranges from 0.05 to 3.5 atom percent and the balance is aluminum plus incidental impurities, with the proviso that the ratio {Fe+X}:Si ranges from about 2.0:1 to 5.0:1. The alloy exhibits high strength, ductility and fracture toughness and is especially suited for use in high temperature structural applications such as gas turbine engines, missiles, airframes and landing wheels.
    Type: Grant
    Filed: September 8, 1987
    Date of Patent: November 7, 1989
    Assignee: Allied-Signal Inc.
    Inventors: Colin M. Adam, Richard L. Bye, Santosh K. Das, David J. Skinner
  • Patent number: 4869751
    Abstract: A dispersion strengthened, non-heat treatable aluminum base alloy is formed into useful shapes by compacting under vacuum a powder composed of particles produced by rapid solidification of the alloy to obtain a compacted billet; forming said billet into rolling stock at a temperature ranging from incipient forming temperature to about 500.degree. C.; and rolling the stock to reduce the thickness thereof by subjecting the stock to at least one rolling pass, the stock having a percent thickness per pass ranging up to about 25 percent and a stock temperature ranging from about 230.degree. C. to about 500.degree. C.
    Type: Grant
    Filed: April 15, 1988
    Date of Patent: September 26, 1989
    Assignee: Allied-Signal Inc.
    Inventors: Michael S. Zedalis, Paul S. Gilman, Derek Raybould
  • Patent number: 4867806
    Abstract: Al-alloy containing Si, Fe, Cu and Mg and at least one kind of Mn and Co in the basic composition range of 8.0.ltoreq.Si.ltoreq.30.0 wt. %, 2.0.ltoreq.Fe.ltoreq.33.0 wt. %, 0.8.ltoreq.Cu.ltoreq.7.5 wt. %, 0.3.ltoreq.Mg.ltoreq.3.5 wt. %, 0.5.ltoreq.Mn.ltoreq.5.0 wt. % and 0.5.ltoreq.Co.ltoreq.3.0 wt. %, are provided in a powder state. A sindered member formed of these Al-alloys has a high strength and reveals excellent heat-resistivity and stress corrosion cracking resistivity. A structural member made of the sintered all-alloy is manufactured through the steps of subjecting a powder press-shaped body formed at a temperature of 350.degree. C. or lower and at a pressure of 1.5.about.5.0 ton/cm.sup.2 to hot extrusion working at a temperature of 300.degree..about.400.degree. C. to form a raw material for forging, and then forge shaping the raw material at a temperature of 300.degree..about.495.degree. C.
    Type: Grant
    Filed: May 31, 1988
    Date of Patent: September 19, 1989
    Assignee: Honda Giken Kogyo Kabushiki Kaisha
    Inventor: Haruo Shiina
  • Patent number: 4857109
    Abstract: A rapidly solidified magnesium based alloy contains finely dispersed magnesium intermetallic phases. The alloy has the form of a filament or a powder and is especially suited for consolidation into bulk shapes having superior combination of strength, ductility and corrosion resistance.
    Type: Grant
    Filed: May 11, 1987
    Date of Patent: August 15, 1989
    Assignee: Allied-Signal Inc.
    Inventors: Santosh K. Das, Chin-Fong Chang
  • Patent number: 4853035
    Abstract: A metal article is consolidated from a rapidly solidified magnesium based alloy. After consolidation, the alloy has a microstructure containing precipitates of intermetallic phase of average size less than 0.1 .mu.m. The article has a thickness of at least 1 mm measured in the shortest dimension, and exhibits a superior combination of strength, ductility and corrosion resistance.
    Type: Grant
    Filed: April 16, 1987
    Date of Patent: August 1, 1989
    Assignee: Allied-Signal Inc.
    Inventors: Santosh K. Das, Chin-Fong Chang
  • Patent number: 4838936
    Abstract: Spiral parts, such as orbiting and fixed scroll plates having involute wraps, for use in scroll compressors, the parts having low coefficient of thermal expansion and high tensile strength and Young's modulus, are formed by combining a self-lubricating power into aluminum raw material powder prior to compression and forging. As an alternative to and in conjunction with the foregoing, temperatures during preform heating and in the die for forging are controlled to be in respective ranges of 300.degree. to 500.degree. C. and 150.degree. to 500.degree. C. Aluminum alloy fine powder preferably has a particle diameter no larger than 350 .mu.m. The self-lubricating powder preferably forms 1 to 25% of the mix by volume, and contains at least one member selected from the group consisting of graphite, BN, and MoS.sub.2.
    Type: Grant
    Filed: May 23, 1988
    Date of Patent: June 13, 1989
    Assignee: Sumitomo Electric Industries, Ltd.
    Inventor: Kiyoaki Akechi
  • Patent number: 4834941
    Abstract: An Al-alloy containing Si, Fe, Cu and Mg and at least one of Mn and Co in the basic composition range of 8.0.ltoreq.Si.ltoreq.30.0 wt. %, 2.0.ltoreq.Fe.ltoreq.33.0 wt. %, 0.8.ltoreq.Cu.ltoreq.7.5 wt. %, 0.3.ltoreq.Mg.ltoreq.3.5 wt. %, 0.5.ltoreq.Mn.ltoreq.5.0 wt. % and/or 0.5.ltoreq.Co.ltoreq.3.0 wt. %, provided in a powder state. A sindered member formed of these Al-alloys displays high strength, excellent heat-resistivity and stress corrosion cracking resistivity. A structural member made of the sintered Al-alloy is manufactured through the steps of subjecting a powder press-shaped body formed at a temperature of 350.degree. C. or lower and at a pressure of 1,5.about.5.0 ton/cm to hot extrusion working at a temperature of 300.degree..about.400.degree. C. to form a raw material for forging, and then forge shaping the raw material at a temperature of 300.degree..about.495.degree. C.
    Type: Grant
    Filed: February 1, 1988
    Date of Patent: May 30, 1989
    Assignee: Honda Giken Kogyo Kabushiki Kaisha
    Inventor: Haruo Shiina
  • Patent number: 4834942
    Abstract: An aluminum-titanium alloy and a process of making it, the alloy consisting ssentially of aluminum, 4-6 wt. % titanium, 1-2 wt. % carbon, and 0.1-0.2 wt % oxygen. The alloy is an aluminum matrix supersaturated with titanium, and having throughout a fine, homogeneous dispersion of Al.sub.3 Ti particles. It is fine grained and has grain boundary dispersoids of carbides and oxides, predominantly of aluminum. An aluminum-titanium melt is rapidly solidified and then mechanically alloyed in the presence of a carbon-bearing agent. The resulting powder is degassed and hot consolidated to form articles which exhibit high strength, ductility, and creep resistance at temperatures greater than 200.degree. C.
    Type: Grant
    Filed: January 29, 1988
    Date of Patent: May 30, 1989
    Assignee: The United States of America as represented by the Secretary of the Navy
    Inventors: William E. Frazier, Michael J. Koczak
  • Patent number: 4832734
    Abstract: Discloses hot working by rolling or forging of mechanically alloyed aluminum-base alloys containing 5 to 35 volume percent of an aluminum transition metal intermetallic phase, e.g. Al.sub.3 Ti which is insoluble in the solid aluminum matrix. Hot working is carried out at a temperature above about 370.degree. C.
    Type: Grant
    Filed: May 6, 1988
    Date of Patent: May 23, 1989
    Assignee: Inco Alloys International, Inc.
    Inventors: Raymond C. Benn, Prakash K. Mirchandani, Walter E. Mattson
  • Patent number: 4832737
    Abstract: A high temperature-resistant aluminum alloy is disclosed, comprising an aluminum matrix containing a dispersion mixture of reinforcing aluminum-iron particles with 2-16% nickel and/or cobalt, 1-6% copper and 1-3% manganese. The weight ratio of the copper to manganese is between about 2:1 and 1:1, and the intermetallic phases of the type AlCuMn, Al.sub.3 Ni and/or Al.sub.9 Co.sub.2 are present in spherical forms.
    Type: Grant
    Filed: September 18, 1986
    Date of Patent: May 23, 1989
    Assignee: Vereinigte Aluminium-Werke Aktiengesellschaft
    Inventors: Ignaz Mathy, Gunther Scharf
  • Patent number: 4832741
    Abstract: A green pressed article of high strength and of low relative density, formed from a heat-resistant aluminum alloy of the Al/Fe/X or Al/Cr/X type, where X is Ti, Ce, Zr, Hf, V, Nb, Cr, Mo or W, is produced by a powder-metallurgical process, wherein an alloy melt is atomized to form fine particles by means of an inert gas jet, with which 0.5 to 2% by volume of oxygen is admixed, and the powder produced in this manner is compacted. Nitrogen, argon or helium can be employed as inert gas. The green pressed article is preferably formed from a small proportion of coarser, non-spherical particles and a greater proportion of finer, spherical particles.
    Type: Grant
    Filed: May 6, 1988
    Date of Patent: May 23, 1989
    Assignee: BBC Brown Boveri AG
    Inventor: Malcolm J. Couper
  • Patent number: 4828632
    Abstract: A rapidly solidified aluminum-base alloy consists essentially of the formula Al.sub.bal Fe.sub.a Si.sub.b V.sub.c, wherein "a" ranges from 3.0 to 7.1 atom percent, "b" ranges from 1.0 to 3.0 atom percent, "c" ranges from 0.25 to 1.25 atom percent and the balance is aluminum plus incidental impurities, with the provisos that (i) the ratio [Fe+V]:Si ranges from about 2.33:1 to 3:33:1 and (ii) the ratio Fe:V ranges from 11.5:1 to 5:1. The alloy exhibits high strength ductility and fracture toughness and is especially suited for use in high temperature structural applications such as gas turbine engine components, automotive engine components, missiles and airframes.
    Type: Grant
    Filed: June 5, 1987
    Date of Patent: May 9, 1989
    Assignee: Allied-Signal Inc.
    Inventors: Colin M. Adam, Richard L. Bye, Santosh K. Das, David J. Skinner
  • Patent number: 4822414
    Abstract: Al-based alloys comprising predetermined amounts of Cr and Ti with the balance being Al and inevitable impurities. The alloys are made by powder metallurgy by which the additive elements are finely dispersed in an Al matrix. The alloys may further comprise up to 5 wt. %. of Fe.
    Type: Grant
    Filed: May 18, 1987
    Date of Patent: April 18, 1989
    Assignee: Kabushiki Kaisha Kobe Seiko Sho
    Inventors: Katsuyuki Yoshikawa, Hidetoshi Inoue, Tsukasa Shiomi, Shojiro Oie, Mutsumi Abe
  • Patent number: 4818308
    Abstract: Aluminum alloy comprises 10 to 36 wt % of Si, 2 to 10 wt % of at least one metal selected from the group consisting of Fe, Ni, Co, Cr and Mn, and remainder consisting essentially of aluminum. The aluminum alloy further includes 1.0 to 12 wt % of Cu and 0.1 to 3.0 wt % of Mg. In a method for producing the aluminum alloy the steps comprises preparing powder mixtures including Si, at least one of metal selected from the group consisting of Fe, Ni, Co, Cr and Mn, and remainder consisting essentially of Al, producing aluminum alloy powders, compacting the aluminum alloy powders into a shape and hot working the aluminum alloy powder compact.
    Type: Grant
    Filed: December 10, 1986
    Date of Patent: April 4, 1989
    Assignee: Sumitomo Electric Industries, Inc.
    Inventors: Yusuke Odani, Kiyoaki Akechi, Nobuhito Kuroishi
  • Patent number: 4799978
    Abstract: The aluminum alloy comprises by weight 81 to 91.8 percent aluminum, 4 to 8 percent iron, 4 to 8 percent nickel and 0.1 to 3 percent chromium. The preferred nominal composition is 86 percent aluminum, 6 percent iron, 6 percent nickel, and 2 percent chromium.
    Type: Grant
    Filed: October 2, 1987
    Date of Patent: January 24, 1989
    Assignee: Lockheed Corporation
    Inventors: Sharon L. Langenbeck, Gregory J. Hildeman