Abstract: Cotton-like aggregates (B) including grinding chips from an iron-based metal and a grinding fluid containing oil and water are compression molded for forming a brittle compact (C) having the fibrous grinding chips roughly sheared and excessive water and oil removed therefrom. The brittle compact (C) is crushed for further finely shearing the grinding chips and the resultant grinding chips are mixed with a solidification assistant (D) for producing an iron-based powder material (E) containing the solidification assistant (D).

Abstract: The present invention relates to improved metallurgical powder compositions that incorporate solid lubricants, methods for preparing and using the same, and methods of making compacted parts. The solid lubricants contain functionalized polyalkylene lubricants substituted with functional groups selected from the group consisting of a phosphate group, phosphite group, hypophosphate, hypophosphite, polyphosphate, thiophosphate, dithiophosphate, thiocarbamate, dithiocarbamate, borate, thiosulfate, sulfate group, or sulfonate group.

Abstract: This invention uses nanoparticle mixtures to broaden the range of economic materials, improve performance across this broader range, and thereby lower costs of hydride and other storage systems. Nanoparticles can have dramatically different mechanical, chemical, electrical, thermodynamic, and/or other properties than their parent (precursor) materials. Because of this fundamental characteristic, nanophase materials can greatly improve the range of possibilities of materials selection, performance, cost, and practicality for hydride storage systems, advancing the early commerciality of such systems for hydrogen fuel cells or other applications. Among such hydrogen storage improvements are cheaper and better-performing metals, alloys, and/or compounds; lower weight; and reduced storage volumes.

Abstract: The present invention provides a metal slurry for electrode formation which slurry is high in dispersion property and enables formation of high density electrode films. The metal slurry for electrode formation is composed of a spherical metal powder of 0.1 to 2.0 ?m in mean particle size and a dispersion medium. By making the spherical metal powder have a mean particle size falling within the range from 0.1 to 2.0 ?m, there can be obtained a metal slurry for electrode formation which slurry can be coated through a nozzle and is high in dispersion property, without using expensive nanoparticles. In addition, as the dispersion medium, water or lower molecular weight alcohols can be used. Furthermore, the dispersion property can be improved by further adding a dispersant of 10 wt % or below (exclusive of zero) in relation to the metal powder.

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

Abstract: A combination comprising a bed of a particulate copper-containing catalyst bed, a guard bed in the form of shaped units formed from lead carbonate and/or basic lead carbonate particles having an average (by volume) particle size below 100 ?m.

Abstract: A silver clay that can be obtained by sintering at a low temperature. A silver powder for silver clay is a fine Ag powder having an approximate average particle diameter equal to or less than 2 ?m incorporated at 15 to 50 weight %, with the remainder being an Ag powder having an average particle diameter that exceeds approximately 2 ?m and is equal to or less than approximately 100 ?m. The silver clay includes this silver powder incorporated at approximately 50 to 95 weight %, a binder at approximately 0.0 to 8 weight %, an oil at approximately 0.1 to 3 weight %, and a surface active agent at approximately 0.03 to 3 weight %, with the remainder being water.

Abstract: The present invention relates to a pre-alloyed powder and its use as a bond powder in the manufacture of powder metallurgy parts and of diamond tools in particular. A pre-alloyed powder is disclosed, based on the iron-copper dual phase system, additionally containing Co, Ni, Mo, W, oxides or carbides as reinforcing elements in the iron phase, and Sn in the copper phase.

Abstract: Gold powders and methods for producing gold powders. The powders preferably have a small particle size, narrow size distribution and a spherical morphology. The method includes forming the particles by a spray pyrolysis technique. The invention also includes novel devices and products formed from the gold powders.

Abstract: The invention aims to provide a binder for powder metallurgy, the binder containing an epoxy resin which is liquid at room temperature and a curing agent having at least one functional group selected from the group consisting of amino, mercapto and carboxyl groups. The binder involves few problems in point of workability and safety, suppress the scattering of graphite, and is superior in powder characteristics. The invention also provides a mixed powder for powder metallurgy using the binder and a method for producing the mixed powder.

Abstract: A composite nanoparticle material comprising a plurality of cores and a plurality of shells. At least one of the cores is encapsulated by one of the shells. An oxygen storage material comprising a plurality of oxygen storage catalyst cores. A plurality of oxygen transport shells. At least one of the oxygen storage catalyst cores is encapsulated by one of the oxygen transport shells.

Abstract: A thermal spray composition and method of deposition for abradable seals for use in gas turbine engines, turbochargers and steam turbines. The thermal spray composition comprises a mixture of metal-clad solid lubricant particles and unclad solid lubricants particles for producing an abradable seal used in the compressor section of gas engines, aircraft engines, radial compressors and the like. The metal is selected from alloys of Ni, Co, Cu, Fe and Al, preferably Ni alloys, and the solid lubricant is at least one of hexagonal boron nitride, graphite, calcium fluoride, lithium fluoride and molybdenum disulphide, preferably hexagonal boron nitride or hexagonal boron nitride and graphite.

Abstract: A soft magnetic powder material which includes an iron system powdered particle having an insulating coat with high insulation performance, a polyamide system resin, and a thermoplastic resin having a melting point equal to or higher than 200° C.

Abstract: 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.

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

Abstract: A lead-free solder powder that can include a plurality of lead-free solder particles each having a general spherical shape with a diameter of 20–60 ?m. Each of the lead-free solder particles can contain Sn, Ag and Bi, with respective concentrations set such that the lead-free solder alloy has a melting temperature lower than a predetermined heat-resistant temperature of a work to be soldered.

Abstract: The present invention relates to a thermal spraying powder capable of reliably allowing the achievement of a thermal sprayed coating having superior characteristics. A thermal spraying powder according to a first embodiment of the invention includes a predetermined amount of each of molybdenum, boron, cobalt, and chromium. The total content of molybdenum, boron, cobalt, and chromium in the thermal spraying powder is no less than 95% by weight. The primary crystal phase of the thermal spraying powder is multi-element ceramics containing at least one of cobalt and chromium along with molybdenum and boron. A thermal spraying powder according to a second embodiment of the invention includes a predetermined amount of each of molybdenum, boron, nickel, and chromium. The total content of molybdenum, boron, nickel, and chromium in this thermal spraying powder is no less than 95% by weight.

Abstract: PCD materials of this invention comprise diamond crystals that are bonded together with a catalyst/binder material. The PCD material is prepared by combining diamond grains with a catalyst/binder material either as a premixture or by infiltration during sintering. The PCD material comprises 15 percent by volume or less diamond grains sized 20 micrometers or less. The diamond grains are pressurized under elevated temperature conditions to form the desired PCD material. PCD materials of this invention can constitute the exclusive material phase of a PCD construction, or can form one or more material phase in a multi-phase material microstructure, wherein the multiple material phase can be arranged in an ordered/oriented or random fashion. PCD materials of this invention display improved properties of impact and fatigue resistance, and functional toughness, when used in complex wear environments, when compared to conventional PCs materials comprising intentionally added fine-sized diamond grains.

Abstract: A metal powder is formed by the steps of preparing a reducing agent solution, preparing a mixed metallic salt solution by dissolving a nickel salt and a copper salt in a solvent, and mixing the reducing agent solution and the mixed metallic salt solution so that the copper salt is reduced to precipitate copper particle nuclei and then the nickel salt is reduced to precipitate nickel around the copper particle nuclei. A metal power produced by this production method, a conductive paste containing the metal powder and a monolithic ceramic electronic component in which internal electrodes are formed using the conductive paste are also disclosed.

Abstract: The present invention relates to improved metallurgical powder compositions that incorporate solid lubricants, methods for preparing and using the same, and methods of making compacted parts. Ejection properties, such as stripping pressure and sliding pressure, of compacted parts can be improved by using the solid lubricants. The solid lubricants contain functionalized polyalkylene glycol lubricants that contain a phosphate group, phosphite group, hypophosphate group, hypophosphite group, polyphosphate group, thiophosphate group, dithiophosphate group, thiocarbamate group, dithiocarbamate group, borate group, thiosulfate group, sulfate group, a sulfonate group or combinations thereof.

Abstract: The present invention relates to a powdered niobium for a capacitor, characterized in that the content of each of the elements such as iron, nickel, cobalt, silicon, sodium, potassium and magnesium is about 100 ppm by weight or less or that the total content thereof is about 350 ppm by weight or less is used, a sintered body thereof, a sintered body comprising niobium monoxide crystal and/or diniobium mononitride crystal, a capacitor using the sintered body and the production method of the capacitor. A capacitor using the above described niobium sintered body has a large capacity per the unit weight, a good specific leakage current value and excellent high temperature property.

Abstract: When copper powder manufactured by a wet reduction method is kneaded with resin in a high filling rate, it is difficult to maintain a low viscosity. The invention is to solve the problem of high viscosity without changing the characteristics such as particle size and specific surface area of the copper powder obtained by a wet reduction method. This invention relates to copper powder for an electrically conductive paste wherein copper powder manufactured by a wet reduction method is subjected to a surface-flattening treatment in which the particles are mechanically collided each other.

Abstract: An ultrafine metal powder slurry with high dispersibility includes an organic solvent; a surfactant having a hydrophilic group and a lipophilic group; and an ultrafine metal powder in an amount more than 60% by mass and less than 95% by mass. In the slurry, the hydrophilic group of the surfactant is at least one selected from a sulfonato group, sulfo group, sulfonyldioxy group, polyoxyethylene group with carboxyl group, and polyoxyethylene group with phosphate group, and the lipophilic group is an alkyl containing 12 or more carbon atoms or an alkylphenyl. The ultrafine metal powder slurry includes no aggregated particles, exhibits good dispersibility and is useful as a metal material for conductive pastes. The slurry can save a part of process steps in conventional conductive paste production processes, can shorten a process time and can save in labor.

Abstract: The present invention relates to economic and environment-friendly slurries and their preparation, handling, and spray drying for the production of cemented carbide based hard metals. The slurry is ethanol-water based and contains metallic and metal carbide raw materials as well as polyethylene glycol (PEG) and a very low concentration of polyethylenimine (PEI). The concentration of PEI is 0.01-<0.1% of the raw material weight. As a result, low-viscous slurries are produced which require less use of ethanol, energy, manpower and equipment time in their preparation, handling, and spray drying.

Abstract: A nitrogen containing metal powder wicth a large specific surface area, and containing a suitable quantity of nitrogen dispersed uniformly within the metal is produced with good productivity, and provides a solid electrolytic capacitor with a high capacitance, minimal leakage current, and excellent long term reliability. This nitrogen containing metal powder has a ratio W/S between the nitrogen content W [ppm] of the powder, and the specific surface area S [m2/g], as measured by a BET method, that falls within a range from 500 to 3000. This type of powder can be produced by a process in which a metal salt containing the metal is reacted with a reducing agent and undergoes reduction within a diluent salt, thereby generating the metal, wherein a nitrogen containing gas is introduced into the space contacting the reaction melt comprising the metal salt, the reducing agent and the diluent salt, thereby generating the metal and incorporating the nitrogen within the metal.

Abstract: The invention concerns a method of preparing an iron-based powder comprising the steps of mixing and heating an iron-based powder, at least one oligomer amide type lubricant, at least one fatty acid and optionally one or more additives to a temperature above the melting point of the lubricant and subsequently cooling the obtained mixture. The invention also comprises the mixture of the iron-based powder, the oligomer amide type lubricant and the fatty acid.

Abstract: The surface of the body of powder additive for use in powder metallurgy is coated with an organic binder, thereby obtaining powder additive to cause adhesion of the powder additive to the surface of iron-based powder by the organic binder, thereby providing a powder additive with no segregation of components and excellent flowability and compression, and an iron-based powder mixture manufactured by mixing the powder additive and the iron-based powder.

Abstract: An Nb solid electrolytic capacitor is disclosed which comprises: an anode body made from an Nb-based material, the anode body having a nitrogen content of about 7,500 ppm to about 47,000 ppm; a dielectric layer formed over the surface of the anode body; a solid electrolyte layer formed on the dielectric layer; and a cathode body formed on the surface of the solid electrolyte layer. The Nb solid electrolytic capacitor shows small bias dependence. A method for preparing the same is also disclosed which comprises steps of: forming an anode body from an Nb-based material, the anode body having a nitrogen content of about 7,500 ppm to about 47,000 ppm; forming a dielectric layer over the surface of the anode body; forming a solid electrolyte layer on the dielectric layer; and forming a cathode body on the electrolyte layer.

Abstract: Disclosed is a rapidly expanding metallic mixture treated for oxidation prevention thereof at room temperature, comprising a metal salt and a metal powder, which prevents its spontaneous explosion due to oxidation of the metal powder in the mixture at room temperature during storage, or dysfunction of the mixture upon blasting work because of altered mixing ratios between the metal salt and the metal powder. The rapidly expanding metallic mixture is characterized in that the mixture is added with a water repellent such as oil or an inorganic preservative, or is coated with a resin and formed to the size of 0.1-100 mm3.

Abstract: A clay composition for shaping noble metal is formed of a kneaded mixture of a mixed powder of noble metal having as main components thereof 30 to 70% by weight of a powder having an average particle diameter in the range of 2.2 to 3.0 ?m and 70 to 30% by weight of a powder having an average particle diameter in the range of 5 to 20 ?m with an aqueous solution of an organic binder.

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

Abstract: A magnetite-iron based composite powder includes magnetite with a ratio of X-ray diffraction intensity to that of &agr;-Fe of about 0.001 to about 50 and has an average primary particle size of about 0.1 to about 10 &mgr;m. The composite powder can highly dehalogenate organic halogen compounds and exhibits satisfactory absorption power of high frequency electromagnetic waves after molding. An ultrafine nonferrous inorganic compound powder may adhere to the surface of the composite powder, or at least the composite powder may adhere to the surfaces of small particles of a nonferrous inorganic compound to thereby yield a composite powder composition. The composite powder can be produced by partial reduction of a material powder containing a hematite based powder or by complete reduction and subsequent partial oxidation of the material powder.

Abstract: The present invention concerns a powder metal composition for producing powder metal components comprising a Co-based pre-alloyed powder, with irregularly shaped particles comprising at least 15% by weight Cr and less than 0.3% by weight C, admixed with graphite.

Abstract: A magnetite-iron based composite powder includes magnetite with a ratio of X-ray diffraction intensity to that of &agr;-Fe of about 0.001 to about 50 and has an average primary particle size of about 0.1 to about 10 &mgr;m. The composite powder can highly dehalogenate organic halogen compounds and exhibits satisfactory absorption power of high frequency electromagnetic waves after molding. An ultrafine nonferrous inorganic compound powder may adhere to the surface of the composite powder, or at least the composite powder may adhere to the surfaces of small particles of a nonferrous inorganic compound to thereby yield a composite powder composition. The composite powder can be produced by partial reduction of a material powder containing a hematite based powder or by complete reduction and subsequent partial oxidation of the material powder.

Abstract: A powder blend for use in laser sintering and a method for forming tough, strong, wear-resistant, corrosion-resistant infiltrated metal products are provided. The powder blend comprises a steel alloy, a polymeric binder and a high melting temperature fine particulate which are blended together, then applied layer by layer to a working surface in a laser sintering system, exposed a layer at a time to fuse together the powder until a green part of high strength is formed, and then the green part is infiltrated with a metal infiltrant in a non-reducing gas atmosphere at an effective temperature for an effective period of time. The preferred steel is a mild steel alloy.

Abstract: Magnetic alloy powder for a permanent magnet contains: R of about 20 mass percent to about 40 mass percent (R is Y, or at least one type of rare earth element); T of about 60 mass percent to about 79 mass percent (T is a transition metal including Fe as a primary component); and Q of about 0.5 mass percent to about 2.0 mass percent (Q is an element including B (boron) and C (carbon)). The magnetic alloy powder is formed by an atomize method, and the shape of particles of the powder is substantially spherical. The magnetic alloy powder includes a compound phase having Nd2Fe14B tetragonal structure as a primary composition phase. A ratio of a content of C to a total content of B and C is about 0.05 to about 0.90.

Abstract: A metal powder composed of nickel or an alloy thereof and used for a producing a conductivity-afforded material is provided, in which particles are integrated in particle aggregates having a chain structure. The average diameter of the particle aggregates is in the range of 30 to 200 nm, and the average length thereof is in the range of 0.5 to 50 &mgr;m. The increased conductivity bestowing effect can be obtained by the addition of a small amount of the metal powder.

Abstract: Novel powders or particles are formed by associating them with relatively small proportions of hydrolysable liquid material. The resulting particle/liquid mass is placed in a mold and sintered under conditions of heat and pressure that enables at least some of the hydrolysable liquid to react within the sintered mass. The sintered mass displays a controllable range of properties such as increased density, increased tensile strength, and improved natural polish finish. The hydrolysable liquid may partially hydrolyze and/or react with the powders and particles, but the liquid is not completely (not 100%) reduced to an inorganic oxide prior to introduction to the mold and performance of the sintering process.

Abstract: Provided are a method for preparing metallic nickel powders capable of decreasing the content of an alkaline metal in the metallic nickel powders, metallic nickel powders with the low content of an alkaline metal, a conductive paste including metallic nickel powders with the low content of an alkaline metal, and a multi-layer ceramic capacitor (MLCC) including a nickel inner electrode with the low content of an alkaline metal. The method for preparing the metallic nickel powders includes heating a mixture including an organic base, a nickel precursor compound, and a polyol. Wherein, the nickel precursor compound is converted to the metallic nickel powders through reduction by the organic base and the polyol. In the method, the organic base is used instead of the hydroxide of an alkaline metal such as NaOH and KOH. Therefore, the content of an alkaline metal such as sodium and potassium that can be incorporated as an impurity into the metallic nickel powders can be significantly reduced.

Abstract: The present invention provides a conductor composition that is prepared in the form of an ink or a paste and is for forming conductor films having excellent heat resistance on a piezoelectric ceramic material. This composition comprises a platinum powder that is a principal conductor-forming component, and a rare earth oxide powder having a mean particle size in a range of approximately 10 to approximately 100 nm.

Abstract: A three-dimensional object of a desired shape is made by irradiating an optical beam on a metal powder layer to form a sintered layer and by laminating such sintered layer one above another. A metal powder composition for use in making such a three-dimensional object includes an iron-based powder material, a nickel and/or nickel alloy powder material, a copper and/or copper alloy powder material, and a graphite powder material. The graphite powder material acts to enhance the wettability during melting and to reduce microcracks during solidification.

Abstract: A powder blend for use in laser sintering and a method for forming tough, strong, wear-resistant, corrosion-resistant infiltrated metal products are provided. The powder blend comprises a steel alloy, a polymeric binder and a high melting temperature fine particulate which are blended together, then applied layer by layer to a working surface in a laser sintering system, exposed a layer at a time to fuse together the powder until a green part of high strength is formed, and then the green part is infiltrated with a metal infiltrant in a non-reducing gas atmosphere at an effective temperature for an effective period of time. The preferred steel is a mild steel alloy.

Abstract: A method of forming a powder metal material or article includes the steps of molding a compact from a metallurgical powder, and then sintering the compact. The metallurgical powder may include at least one of a stainless steel powder and a low-chromium steel-base powder, and about 0.5 to about 15 weight percent of glass powder. Alternatively, the metallurgical powder may include at least one of a stainless steel powder and a low-chromium steel-base powder, about 3 to about 15 weight percent molybdenum, and about 1 to about 15 weight percent of nickel-base alloy powder. The present invention also is directed to metallurgical powders useful in and materials and articles made by the methods of the present invention. Such articles include, but are not limited to, valve guides for internal combustion engine EGR systems, valve seats, exhaust system components, combustion chambers, other combustion engine parts subjected to high temperature, and chemical industry valve and corrosion parts.

Abstract: The present invention provides a lubricant system in the pressing of powders to form a part. The lubricant system is a solid at ambient conditions. However, upon application of pressure during the pressing of the metal parts, the lubricant system forms a liquid phase along the walls of cavity in which the powder is being pressed. The lubricant system may also be used in connection with a polar powder thereby providing certain beneficial results.

Abstract: The invention aims to provide a binder for powder metallurgy, the binder containing an epoxy resin which is liquid at room temperature and a curing agent having at least one functional group selected from the group consisting of amino, mercapto and carboxyl groups. The binder involves few problems in point of workability and safety, suppress the scattering of graphite, and is superior in powder characteristics. The invention also provides a mixed powder for powder metallurgy using the binder and a method for producing the mixed powder.

Abstract: The present invention relates to terminal electrode compositions for multilayer ceramic capacitors. More specifically, it relates to terminal electrode compositions for multilayer ceramic capacitors which have a metal oxide component selected from SnO2, V2O5 and MoO3. The compositions can be fired at a low temperature in a nitrogen atmosphere.

Abstract: A powder metal mixture comprises a lubricant powder conventionally used to produce powder metal parts in combination with micronized cellulose fibers in an amount less than 2% by weight of the mixture. The addition of fibers with the lubricant increases green strength of a part made by compacting the mixture and improves dimensional conformance.

Abstract: A powder metal mixture comprises a lubricant powder conventionally used to produce powder metal parts in combination with a modified lubricant. A lubricant conventionally used to compact and sinter a chosen powder metal mixture is modified by adding to it starch particles smaller than the average metal particle, and optionally, micronized cellulose fibers in so small an amount that the modified lubricant is present in an amount less than 2% by weight of the mixture. The Hall apparent density and the Hall flow rate of a powder metal mixture made with the modified lubricant of starch or (starch+fibers) remains within the ranges deemed desirable for production of compacted powder metal parts. Using the modified lubricant in lieu of the conventional lubricant increases green strength of a part made by compacting the mixture and improves dimensional conformance.

Abstract: Copper metal powders, methods for producing copper metal powders and products incorporating the powders. The copper metal powders have a small particle size, narrow size distribution and a spherical morphology. The method includes forming the metal particles in a continuous manner.

Abstract: A niobium powder is provided for producing a niobium capacitor enhanced in the thermal stability of oxide films on niobium, with less leak current and less deterioration of leak current after application of thermal loads. The niobium powder contains form 0.005 to 0.10 mass % of hydrogen and from 0.002 to 5 mass % of sulfur and, further preferably, one or both of magnesium and aluminum in an amount from 0.002 to 1 mass % in total. The specific surface area of the powder is 1 to 10 m2/g and the average particle diameter of the secondary particles is 10 to 200 &mgr;m.