Loose Particulate Mixture (i.e., Composition) Containing Metal Particles Patents (Class 75/255)
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Patent number: 5876481Abstract: A steel powder consisting of a combination of purified steel and prealloyed manganese, chromium, molybdenum and nickel. The steel powder is used in the production of metal parts using powder metallurgy. The addition of the prealloyed elements results in a metal part having greater strength and hardness with a low oxygen content and good compressibility.Type: GrantFiled: June 14, 1996Date of Patent: March 2, 1999Assignee: Quebec Metal Powders LimitedInventors: Fran.cedilla.ois Chagnon, Yves Trudel
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Patent number: 5876634Abstract: Tin oxide doped with an electrochromically effective amount of a metal, e.g. antimony or niobium, which provides a color change when the doped tin oxide is exposed to an electrochemical potential in the presence of mobile ions. Particles of electrochromic doped tin oxide, e.g. coated on a white or pastel pigment substrate, have a contrast ratio greater than 1.2, where contrast ratio is a measure of electrochromic functionality of a material and is the ratio of reflectance of the material in an oxidized state to the color of the material in a reduced state and where color is a photodiode measurement of the value of light reflected off the oxidized or reduced material from a constant source of light shining on the material. Such doped tin oxide-containing particles are useful as electrochromic material in display devices.Type: GrantFiled: December 23, 1996Date of Patent: March 2, 1999Assignee: Monsanto CompanyInventor: James P. Coleman
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Patent number: 5863618Abstract: A method for producing an atomized powder of chromium carbide particles dispersed in a nickel chromium matrix in which chromium in the powder is from 55 to 92 weight percent of the powder.Type: GrantFiled: October 3, 1996Date of Patent: January 26, 1999Assignee: Praxair St Technology, Inc.Inventors: William John Crim Jarosinski, Lewis Benton Temples, Calvin Henry Londry
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Patent number: 5863870Abstract: An iron or copper based metal powder useful for plasma deposition of a coating that has a dry coefficient of friction 0.75 or less and readily conducts heat through the coating. The powder comprises (a) H.sub.2 O atomized and annealed particles consisting essentially of (by weight) carbon 0.15-0.85%, oxygen 0.1-0.45%, an air hardening agent selected from manganese and nickel of 0.1-06.5%, and the remainder iron or copper, with at least 90% of the particles having oxygen and iron or copper combined in the lowest atomic oxygen form for an oxide of such metal.A method of making anti-friction iron powder that is economical, selectively produces FeO and promotes fine flowable particles. The method comprises (a) steam atomization of a molten steel that excludes other oxygen, the steel containing carbon up to 0.4% by weight to produce a collection of comminuted particles, and (b) annealing the particles in an air atmosphere for a period of time of 0.25-2.0 hours in a temperature range of 800.degree.-1400.degree. F.Type: GrantFiled: August 18, 1997Date of Patent: January 26, 1999Assignee: Ford Global Technologies, Inc.Inventors: V. Durga Nageswar Rao, Robert Alan Rose, David Alan Yeager, Carlo Alberto Fucinari
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Patent number: 5864071Abstract: Powdered ferrous metal compositions are disclosed which provide for increased corrosion resistance through the admixing of powder aluminum containing compositions with standard ferrous metal compositions prior to forming the powder metal parts. In a preferred embodiment, the aluminum ranges is admixed as an FeAl alloy powder with the standard ferrous metal composition. The present invention further includes a powder metal ferrous part formed from the composition produced by a method including the steps of (i) providing a ferrous powder metal composition, (ii) admixing a powder aluminum containing composition with the ferrous composition to form a blended mixture, and (iii) forming a powder metal part from at least a portion of the blended mixture.Type: GrantFiled: April 24, 1997Date of Patent: January 26, 1999Assignee: Keystone Powdered Metal CompanyInventor: John C. Kosco
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Patent number: 5850047Abstract: A method of producing copper powder having little variation in its particle size and an excellent monodispersion properties. A copper complex ion solution is prepared from a copper-containing solution and a complexing agent, then a reducing agent is added to the copper complex ion solution to precipitate metallic copper. The copper-containing solution herein contains copper sulfate, copper formate, copper pyrophosphate, copper chloride or copper carbonate and the complexing agent is at least one carboxylate or phosphate.Type: GrantFiled: March 11, 1997Date of Patent: December 15, 1998Assignee: Murata Manufacturing Co., Ltd.Inventors: Hiroji Tani, Naoaki Ogata
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Patent number: 5846270Abstract: A magnetic-abrasive powder includes a magnetic component of a powder of a magnetic material, an abrasive component of a powder of an abrasive material, and an adhesive which adhesively connects particles of the magnetic material with particles of the abrasive material.Type: GrantFiled: April 6, 1998Date of Patent: December 8, 1998Inventors: Savva Feygin, Gennady Kremen, Leonid Igelstyn
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Patent number: 5844153Abstract: A mixed metal powder for hard metal alloys comprising cobalt, 1 to 10 parts per weight tungsten and 1 to 10 parts by weight of aluminum and a hard metal alloy containing the mixed metal powder binder in an amount of from 2 to 12 parts by weight per about 100 parts by weight of a metal carbide for corrosion resistant hard metal tools.Type: GrantFiled: July 12, 1996Date of Patent: December 1, 1998Assignee: EMTEC Magnetics GmbHInventors: Manfred Schlatter, Jurgen Koppe, Volker Eichhorst
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Patent number: 5840166Abstract: A rare earth metal-nickel hydrogen storage alloy having a composition represented by the formula (1) (R.sub.1-x L.sub.x) (Ni.sub.1-y M.sub.y).sub.z . . . (1) (R: La, Ce, Pr, Nd; L: Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, Y, Sc, Mg, Ca; M: Co, Al, Mn, Fe, Cu, Zr, Ti, Mo, Si, V, Cr, Nb, Hf, Ta, W, B, C; 0.05.ltoreq.x.ltoreq.0.4, 0.ltoreq.y.ltoreq.0.5, 3.0.ltoreq.z<4.5), the alloy including in an amount of not less than 30 volume % and less than 95 volume % thereof crystals each containing not less than 5 and less than 25 antiphase boundaries extending perpendicular to C-axis of a crystal grain of the alloy per 20 nm along the C-axis, not less than 60% and less than 95% of added amount of the element represented by L in the formula (1) being arranged in antiphase areas, and a method for producing the same.Type: GrantFiled: March 7, 1997Date of Patent: November 24, 1998Assignee: Santoku Metal Industry Co. Ltd.Inventor: Akihito Kaneko
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Patent number: 5830257Abstract: A manufacturing method for an alumina-dispersed reinforced copper alloy according to the invention is an improved method which is capable of manufacturing efficiently alumina-dispersed reinforced copper having both good electro-conductivity used for wire-manufacturing-material and good mechanical property, the manufacturing method comprises the steps of obtaining powders constituted by particles having aluminum-contained copper alloy-oxide, allowing to mill aluminum-contained copper alloy powder within the air atmosphere by milling device with mechanical-alloying-operation due to shock compression, converting aluminum into aluminum-oxide by heat-treatment of the powders within inert atmosphere, implementing reduction-treatment of the converted member within the reducing atmosphere, and executing hot extrusion the reduction-treated-material.Type: GrantFiled: August 22, 1996Date of Patent: November 3, 1998Assignee: Yazaki CorporationInventors: Hirohiko Fujimaki, Manabu Kiuchi, Tetsuya Takaai, deceased
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Patent number: 5832360Abstract: A bond for a single layer metal bond abrasive tool can be easily chemically and electrochemically stripped from the metal core of a recovered used tool to facilitate reuse of the core. Relative to conventionally bonded tools, the speed of stripping the novel bond is quick, and the stripped core has a smooth, clean surface which needs only minimal mechanical repair prior to reuse. In one aspect, the novel bond consists essentially of a ternary bond composition of copper, tin and titanium, in which the copper and tin are pre-alloyed and the pre-alloy and titanium component are incorporated in the bond composition as fine particle size powders. In another aspect, the bond is a quaternary bond composition consisting essentially of copper, tin, titanium and silver. The powder components can be used dry or mixed with a fugitive liquid binder as a paste. The novel bond can be brazed at lower temperature than copper/tin/titanium bonds prepared otherwise.Type: GrantFiled: August 28, 1997Date of Patent: November 3, 1998Assignee: Norton CompanyInventors: Richard M. Andrews, Bradley J. Miller, Marcus R. Skeem, Ren-Kae Shiue
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Patent number: 5796018Abstract: Ferrous powder particles are coated with vaporized phosphorus in a fluid-bed reactor to obtain homogeneous coatings of phosphorus. The coated powders are useful feed for pressed structural parts, exhibiting improved green density, compressibility and sintered density thus improving magnetic and tensile properties.Type: GrantFiled: January 29, 1997Date of Patent: August 18, 1998Assignees: Procedyne Corp., Magna-Tech P/M Labs.Inventors: Kenneth H. Moyer, David J. Geveke, Thomas R. Parr, Robert B. Roaper
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Patent number: 5785897Abstract: A coating solution for forming a transparent and electrically conductive film contains fine conductive metal or alloy particles dispersed in a polar solvent and having a diameter not exceeding 50 nm. The metal particles are of silver and at least one of palladium, copper and gold. The alloy particles are of an alloy of silver with at least one of palladium, copper and gold. The solution permits the use of a baking temperature which is as low as 150.degree.-450.degree. C.Type: GrantFiled: February 19, 1997Date of Patent: July 28, 1998Assignee: Sumitomo Metal Mining Co., Ltd.Inventors: Atsushi Toufuku, Kenji Adachi
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Patent number: 5782955Abstract: A metallurgical silicon or ferrosilicon in the form of granulates having an average size of less than 10 mm and in which the total oxygen concentration is less than 0.05% by weight, and a process for manufacture of this silicon or ferrosilicon consisting of a carbothermal reduction of silica in an electric oven, chlorine-based refining of the liquid metal, and granulation of the refined liquid metal in water under an inert atmosphere. The silicon may be used for silicone manufacture or as a constituent of an aluminum alloy, and the ferrosilicon, as a steel additive used to obtain magnetic sheet metals for electrical construction.Type: GrantFiled: January 11, 1996Date of Patent: July 21, 1998Assignee: Pechiney ElectrometallurgieInventors: Maurice Sales, Thomas Margaria
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Patent number: 5776225Abstract: A clean refractory metal sponge fines product is made from refractory metal sponge fines free of refractory metal oxides, carbides, nitrides and binary iron alloys; silicon carbide, oils, greases and organic compounds; salt; dust; dirt; pieces of iron, iron alloy and tungsten carbide; and light contaminants. The sponge fines are vigorously washed and rinsed with a displacement wash to remove the bulk of the wash fluid and subject to a counter-current wash to yield clean refractory metal sponge fines. The clean sponge fines can be pressed into briquettes and sintered at elevated pressures, or mixed with an alkali metal refractory metal halide slat, pressed at elevated pressures into sponge fines/salt briquettes and dried or pressed into briquettes, dried and packaged, or pressed into briquettes and stored wet. The briquettes are non-pyrophoric.Type: GrantFiled: November 21, 1996Date of Patent: July 7, 1998Inventor: Joseph A. Megy
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Patent number: 5766305Abstract: A metal powder composition for metallization is for use in forming a metallized film from a paste comprising Cu and Ti powder and consists essentially of about 95 to 99.5% Cu and 0.5 to less than 5% Ti by weight. The above-mentioned paste is then applied onto a substrate and then fired to provide a metallized substrate.Type: GrantFiled: September 12, 1996Date of Patent: June 16, 1998Assignee: Tokin CorporationInventors: Youhei Watabe, Shinichi Iwata, Tomeji Ohno
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Patent number: 5766304Abstract: An iron-base mixture and method for powder metallurgy containing iron-base powder, an alloy powder including at least copper, copper oxide or both, and an organic substance for bonding the alloy powder to the iron-base powder, wherein said copper powder or copper oxide powder has a particle size of agglomeration, when evaluated by the micro-track method, of about 5 .mu.m to 28 .mu.m, and wherein the particles of copper or copper oxide have a primary particle size which, when evaluated by the BET method, is about 0.2 .mu.m to 1.5 .mu.m.Type: GrantFiled: April 24, 1996Date of Patent: June 16, 1998Assignee: Kawasaki Steel CorporationInventors: Satoshi Uenosono, Kuniaki Ogura
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Patent number: 5759228Abstract: A nozzle for an electric dispersion reactor includes two coaxial cylindrical bodies, the inner one of the two delivering disperse phase fluid into a continuous phase fluid. A potential difference generated by a voltage source creates a dispersing electric field at the end of the inner electrode.Type: GrantFiled: January 16, 1996Date of Patent: June 2, 1998Assignee: Martin Marietta Energy Systems, Inc.Inventors: Warren G. Sisson, Michael T. Harris, Timothy C. Scott, Osman A. Basaran
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Patent number: 5753005Abstract: A source powder for a wear-resistant sintered material, consisting essentially of, in weight percentages, Cr: 3.0 to 6.0%, 2 Mo+W: 10.0 to 20.0%, V: 1.0 to 8.0%, Co: 10.0% or below, C: 0.20% to {0.01(2 Mo+W)+0.24 V}%, Si: 0.1 to 1.0%, Mn: 0.1 to 1.0% and the balance being Fe and unavoidable impurities, or one prepared by adding 0.10 to 0.8% of S to the above composition. This powder can be compacted into a green compact having a high green density, which can further give a wear-resistant sintered material having a high sintered density, hardness and strength.Type: GrantFiled: January 10, 1997Date of Patent: May 19, 1998Assignees: Hitachi Powdered Metals Co., Ltd., Mitsubishi Steel Mfg. Co., Ltd.Inventors: Yoshimasa Aoki, Kei Ishii, Yukio Tokuyama, Yuji Soda
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Patent number: 5736261Abstract: A conductive paste in which cracks do not occur even at boundaries between areas of different film thicknesses comprises spherical and flake-form silver powders, a low softening point glass frit, organic rhodium material and an organic vehicle; the proportion of the flake-form silver powder with respect to the total amount of silver powder is in the range 15 to 80 wt % and the proportion of the rhodium contained in the organic rhodium material with respect to the total amount of silver powder is 0.0001 wt % or less.Type: GrantFiled: November 22, 1995Date of Patent: April 7, 1998Assignee: Murata Manufacturing Co., Ltd.Inventor: Haruhiko Kano
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Patent number: 5733649Abstract: A matrix powder for formation along with an infiltrant into a matrix for use as a wear element or for use in retaining at least one discrete hard element. The matrix powder including macrocrystalline tungsten carbide particles, crushed sintered cemented macrocrystalline tungsten carbide particles, tungsten carbide, and an iron-based component.Type: GrantFiled: September 23, 1996Date of Patent: March 31, 1998Assignee: Kennametal Inc.Inventors: Harold E. Kelley, William E. Silvis, Charles J. Terry
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Patent number: 5733664Abstract: A matrix powder for formation along with an infiltrant into a matrix for use as a wear element or for use in retaining at least one discrete hard element. The matrix powder includes crushed sintered cemented tungsten carbide particles. The composition of the crushed sintered cemented tungsten carbide comprises between about 6 weight percent and about 13 weight percent binder metal and between about 87 weight percent and about 94 weight percent tungsten carbide.Type: GrantFiled: December 18, 1995Date of Patent: March 31, 1998Assignee: Kennametal Inc.Inventors: Harold E. Kelley, William E. Silvis, Charles J. Terry, Gary R. Peterson
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Patent number: 5702501Abstract: A clayish composition for producing a molded article of noble metal consists essentially of a noble metal powder, starch and a water-soluble cellulose resin as organic binder and water. The contents of the starch and the water-soluble cellulose resin each fall in the range of 0.02-3.0% by weight, based on the total amount of the organic binder and the noble metal powder. A method for producing the sintered article of noble metal consists essentially of a step for producing the clayish composition mentioned above, a step of molding the clayish composition in a desired shape, a step of drying the molded article and a step of sintering the dried molded article.Type: GrantFiled: September 10, 1996Date of Patent: December 30, 1997Assignee: Aida Chemical Industries Co., Ltd.Inventors: Yukio Osawa, Katsuhiko Shimamoto, Shinichi Ishigaki, Hitoshi Araki, Yukio Nakata, Atsushi Fujimaru
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Patent number: 5698800Abstract: The present invention provides a mixed raw material which is capable of producing a porous metal sintered product having high porosity and fine and uniform pores. The mixed raw material for producing a porous metal sintered product is a composition including 0.05 to 10% of water-insoluble hydrocarbon organic solvent having 5 to 8 carbon atoms, 0.05 to 5% of surfactant, 0.5 to 20% of water-soluble resin binder, 5 to 80% of metallic powder having an average particle size of 0.5 to 500 .mu.m, optionally 0.1 to 40% of combustible agent for accelerating pore formation, and optionally, 0.1 to 15% of plasticizer consisting of at least one of polyhydric alcohols, oils and fats, ethers and esters, with a balance of water.Type: GrantFiled: August 2, 1996Date of Patent: December 16, 1997Assignee: Mitsubishi Materials CorporationInventors: Koji Hoshino, Toru Kohno
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Patent number: 5695861Abstract: Solder active braze compositions are disclosed which enable the formation of circuit traces having improved leach resistance during soldering operations so that it is not necessary to apply protective coatings onto the circuit traces. Additionally, the solder active braze compositions disclosed herein can be readily soldered to so that it is not necessary to separately apply a coating onto the circuit trace so that electrical connections can be made to the traces by soldering. Also disclosed are electronic assemblies comprising circuit traces formed from the particular solder active braze compositions, and methods of forming such electronic assemblies.Type: GrantFiled: October 18, 1995Date of Patent: December 9, 1997Assignee: CTS CorporationInventor: Terry R. Bloom
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Patent number: 5690716Abstract: A thermal spray powder for producing high hardness, low friction, wear resistant coatings on friction surfaces, comprising a blend of an agglomerated molybdenum/dimolybdenum carbide powder and a self-fluxing NiCrFeBSi alloy powder.Type: GrantFiled: February 17, 1995Date of Patent: November 25, 1997Assignee: Osram Sylvania Inc.Inventor: Sanjay Sampath
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Patent number: 5678165Abstract: A plastically deformable aqueous mixture capable of being shaped into a body, the mixture being composed of any one or combination of ceramic, glass-ceramic, glass, molecular sieve, carbon, or metal powders, cellulose ether organic binder, water insoluble hydrophobic polymer co-binder having an average molecular weight of at least about 8,000, plasticizer, and water. A method of making a body which involves mixing the above components in a high shear mixer at a temperature of about 30.degree. C. to 70.degree. C. to form a homogeneous mixture, extruding the mixture at a temperature of about 30.degree. C. to 70.degree. C. into a green body, followed by drying and firing to produce the product body.Type: GrantFiled: December 6, 1995Date of Patent: October 14, 1997Assignee: Corning IncorporatedInventor: Shy-Hsien Wu
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Patent number: 5667554Abstract: Base metal resistors based on a new approach to alloy formation of nickel and chromium metals are presented that are rugged and offer excellent stability. Fine particle size nickel and chromium powders together with fluxing agents are blended together in a preselected ratio with a glass fret and screening agent. The composition is subsequently printed and fired in a nitrogen furnace at approximately 900.degree. C. to 930.degree. C. These resistors are compatible with other prior art base metal conductors, resistors and dielectrics.Type: GrantFiled: April 19, 1996Date of Patent: September 16, 1997Assignee: CTS CorporationInventor: Charles C. Y. Kuo
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Patent number: 5666634Abstract: The invention has for its object the provision alloy steel powders for Cr-based high strength sintered bodies having high tensile strength, fatigue strength and toughness which are adapted for use in parts for motor vehicles and parts for OA apparatus.The composition of the alloy steel powder comprises, by wt %, not larger than 0.1% of C, not larger than 0.08% of Mn, 0.5-3% of Cr, 0.1-2% of Mo, not larger than 0.01% of S, not larger than 0.01% of P, not larger than 0.2% of O, optionally one or more of 0.2.about.2.5% Ni, 0.5.about.2.5% Cu and the balance being inevitable impurities and Fe. The sintered body has substantially the same composition provided that the content of C alone is limited to 0.2-1.2%.The manufacturing method comprises molding the above alloy steel powder, sintering the resulting green compact at a temperature of 1100.degree.-1300.degree. C. and immediately cooling at a cooling rate of 10.degree.-200.degree. C./minute.Type: GrantFiled: December 23, 1994Date of Patent: September 9, 1997Assignee: Kawasaki Steel CorporationInventors: Shigeru Unami, Osamu Furukimi
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Patent number: 5663124Abstract: An iron or copper based metal powder useful for plasma deposition of a coating that has a dry coefficient of friction 0.75 or less and readily conducts heat through the coating. The powder comprises (a) H.sub.2 O atomized and annealed particles consisting essentially of (by weight) carbon 0.15-85%, oxygen 0.1-0.45%, an air hardening agent selected from manganese and nickel of 0.1-6.5%, and the remainder iron or copper, with at least 90% of the particles having oxygen and iron or copper combined in the lowest atomic oxygen form for an oxide of such metal.A method of making anti-friction iron powder that is economical, selectively produces FeO and promotes fine flowable particles. The method comprises (a) steam atomization of a molten steel that excludes other oxygen, the steel containing carbon up to 0.4% by weight to produce a collection of comminuted particles, and (b) annealing the particles in an air atmosphere for a period of time of 0.25-2.0 hours in a temperature range of 800.degree.-1400.degree. F.Type: GrantFiled: December 9, 1994Date of Patent: September 2, 1997Assignee: Ford Global Technologies, Inc.Inventors: V. Durga Nageswar Rao, Robert Alan Rose, David Alan Yeager, Carlo Alberto Fucinari
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Patent number: 5656787Abstract: A process of forming a sintered article for powder metal comprising blending carbon and ferro alloys and lubricant with compressible elemental iron powder, pressing said blended mixture to form sintering said article, and then high temperature sintering said article in a reducing atmosphere to produce a sintered article having a high density from a single compression.Type: GrantFiled: November 21, 1995Date of Patent: August 12, 1997Assignee: Stackpole LimitedInventors: Rohith Shivanath, Peter Jones, Danny Thien Duc Thieu
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Patent number: 5649994Abstract: A wear resistant coating includes a mixture or compound of Cobalt and Phosphorous either alone or mixed with one or more alloys to provide a coating for metallic surfaces rendering the metallic surfaces more resistant to wear. A preferred combination of Cobalt and Phosphorous utilized in the present invention consists of 89%, by weight, Cobalt and 11%, by weight, Phosphorous, which combination is at approximately the "eutectic" ratio, that is, that combination of Cobalt and Phosphorous exhibiting the lowest melting point. The 89Co-11P alloy is mixed with a second alloy including, by weight, about 61.1%Co, 8%Cr, 2.5%Si, 0.04%C, and 28%Mo. Preferred environments of application of the inventive coating include surgical blades, files and burrs, guide slots, drills and drill guides, surgical instruments and medical prostheses and for abrasive particles. The subject coatings have achieved a micro-hardness of 1500 DPH (Diamond Pyramid Hardness), approximately equal to the Rockwell C75 hardness.Type: GrantFiled: October 24, 1994Date of Patent: July 22, 1997Inventor: Kenneth Henry Holko
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Patent number: 5649277Abstract: An apparatus and process for the free-forming manufacture of three-dimensal components. A powder-binder mixture, or a material with a high melting point, is plasticized or made molten, by raising the temperature inside a process chamber. The resulting molten material is discharged under pressure through a nozzle which is arranged at the end of the process chamber. The material inside the process chamber is deposited in layers. The processing direction and processing speed of the nozzle are programmed. An embodiment of the invention is disclosed in which a non-molten powder is deposited and supported by the deposition of a second powder alongside the non-molten powder.Type: GrantFiled: June 13, 1994Date of Patent: July 15, 1997Assignee: Fraunhofer-Gesellschaft Zur Foerderung Der Angewandten Forschung E.V.Inventors: Mathias Greul, Ewald Staskewitsch, Wilhelm Steger, Theo Pintat, Martin Geiger, Klaus Melchior
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Patent number: 5643352Abstract: The present invention features a new iron material for use in situ with a hydrogen-air fuel cell, to generate the hydrogen to fuel the fuel cell. The iron material is made up of freshly-ground particles of iron, ranging in diameter size from approximately 25 to 1,200 .mu.m, with an average-sized distribution having at least twenty per cent (20%) of the particles less than about 300 .mu.m in diameter, and having an average particle density approximately ranging from about 1 to 7.8 g/cc, and a surface area greater than approximately 0.001 meters.sup.2 /g. The particles are in a freshly ground state, in situ, for enhancing their reactivity in producing hydrogen for the fuel cell.Type: GrantFiled: June 7, 1995Date of Patent: July 1, 1997Assignee: H Power CorporationInventor: John Werth
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Patent number: 5641580Abstract: A molybdenum-based composite powder for thermal spray applications. The composite powder includes a molybdenum-chromium, molybdenum-tungsten, or molybdenum-tungsten-chromium alloy dispersion strengthened with molybdenum carbide (Mo.sub.2 C). The molybdenum-based composite powder may be combined with a nickel-based or cobalt-based alloy to form a two-phase powder blend. The coatings from such powders are made up of molybdenum-based alloy lamellae and, in the two-phase embodiments, nickel-based or cobalt-based alloy lamellae. The coatings exhibit improved corrosion resistance and strength while retaining good sprayability.Type: GrantFiled: October 3, 1995Date of Patent: June 24, 1997Assignee: Osram Sylvania Inc.Inventors: Sanjay Sampath, Jack E. Vanderpool
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Patent number: 5641920Abstract: Provided is a powder and binder system for manufacturing sintered parts from particulate material, and a method of injection molding parts for sintering. The particulate material includes ceramic, metallic and intermetallic powders. Preferably, selected powder particles are coated with one or more additives depending on their shape and surface chemistry to create a powder system. The additives may include antioxidants, coupling agents, surfactants, elasticizing agents, dispersants, plasticizer/compatibilizers and lubricants. The surface active additives are designed to improve the interface between the powder and the binder. The powder system may be mixed or compounded with a binder system in an inert atmosphere to form a powder and binder system, or feedstock, for powder molding. The binder system, may contain one or more components which are removed prior to the sintering the powder. The powder and binder system may also be molded about an expendable core which is extracted prior to sintering.Type: GrantFiled: September 7, 1995Date of Patent: June 24, 1997Assignee: Thermat Precision Technology, Inc.Inventors: Karl Frank Hens, Joseph A. Grohowski, Jr.
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Patent number: 5640666Abstract: A method of producing a composite powder by providing particles of (I) tungsten, niobium, zirconium, titanium or mixtures thereof, (II) silicon and (III) carbon in a proportion relative to each other so as to possess an overall chemical composition in that segment of the ternary diagram of FIGS. 2(a), 2(b), 2(c) and 2(d) designated A, and subjecting the particles to a mechanical alloying process under conditions and for a time sufficient to produce the composite powder. Also disclosed is a method of forming a substantially oxygen-free composition of matter comprising a matrix substance of WSi.sub.2, NbSi.sub.2, ZrSi.sub.2, TiSi.sub.2 or alloys thereof having SiC dispersed therein, the method comprising consolidating the above-described composite powder. Also disclosed is a method of forming oxidation- and wear-resistant coatings by subjecting the composite powder whose composition lies in segment A to a metallurgical process such as plasma spraying.Type: GrantFiled: October 2, 1995Date of Patent: June 17, 1997Assignee: University of FloridaInventors: S. Jayashankar, Michael J. Kaufman
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Patent number: 5637132Abstract: Lead-free metallurgy powder for use in manufacturing a shaped bronze part by powder metallurgy techniques which consists essentially of a substantially homogeneous blend of metal powders having about 90 parts copper, about 10 parts tin and an amount of bismuth in the range from an amount effective to improve the machinability of the shaped bronze part up to about 5% weight are disclosed. Lead-free metallurgy powder for use in manufacturing a shaped brass part by powder metallurgy techniques which consists essentially of a substantially homogeneous blend of metal powders about 70-90 parts copper, about 10-30 parts zinc and an amount of bismuth in the range from an amount effective to improve the machinability of the shaped brass part up to about 5% weight are also disclosed.Type: GrantFiled: May 15, 1995Date of Patent: June 10, 1997Assignee: United States Bronze Powders, Inc.Inventors: Paul Matthews, Thomas Pelletier, II
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Patent number: 5635255Abstract: Erosion and wear resistant iron alloy, comprising: Cr 20.0-36.0% by weight, B 2.5-5.0% by weight, Mn 0.5-3.2% by weight, Si 0.05-0.6 by weight, Mo 0.3-2.5% by weight, V 0.05-0.3% by weight, Nb 0.03-0.3% by weight, P 0.5% by weight or less, C 0.05-0.3% by weight, and a trace of unavoidable impurities, which confers superior corrosion and wear resistance upon abraded or corroded portions by coating or molding.Type: GrantFiled: November 28, 1995Date of Patent: June 3, 1997Assignee: Samsung Heavy Industries Co., Ltd.Inventors: Kwang W. Kwon, Kang H. Kim
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Patent number: 5628814Abstract: A nickel-base superalloy article has a coating having a composition, in weight percent, of from about 10 to about 20 percent cobalt, from about 14 to about 25 percent chromium, from about 2 to about 12 percent aluminum, from 0 to about 0.2 percent yttrium, from about 0.001 to about 3 percent boron, from about 1 to about 10 percent silicon, balance nickel and incidental impurities. The coating is preferably applied by mixing together two powders, one with a higher solidus temperature and one with a lower solidus temperature, whose net composition is that of the coating. The powder mixture is compacted with a binder, applied to a surface of the article, and heated to a temperature above the lower solidus temperature.Type: GrantFiled: November 22, 1995Date of Patent: May 13, 1997Assignee: General Electric CompanyInventors: Jim D. Reeves, David E. Budinger, Robert A. Anderson
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Patent number: 5607780Abstract: Disclosed are a target material for magneto-optical recording medium having a structure formed by sintering of an RE-TM phase (A) having a composition with an RE content higher than that of the composition of an intermetallic compound represented by the chemical formula TM.sub.2 RE, and a TM-RE phase (B) having a composition with an RE content equal to or lower than that of the composition of an intermetallic compound represented by the chemical formula TM.sub.2 E, wherein RE denotes at least one rare earth element selected from the group of elements consisting of Nd, Gd, Tb, Dy, Ho and Er, and TM denotes at least one element selected from the group of metals of the iron group which consists of Fe, Co and Ni; and a process for producing the same.Type: GrantFiled: May 20, 1994Date of Patent: March 4, 1997Assignee: Hitachi Metals, Ltd.Inventors: Kaoru Masuda, Takashi Meguro
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Patent number: 5605561Abstract: Tantalum powder obtained by adding magnesium powder to tantalum powder which is prepared by reducing potassium tantalum fluoride with sodium metal, without conventional heat-treatment for agglomeration, to remove oxygen present in the tantalum powder, then washing with an acid and drying; an anode body for electrolytic capacitors produced by sintering the tantalum powder; and, an electrolytic capacitor which comprises the anode body incorporated therein. The tantalum powder has a large specific surface area and accordingly, the electrolytic capacitor in which the anode body produced from the tantalum powder is incorporated has an extra high capacity, i.e., a CV ranging from 70000 to 80000. The probability of causing ignition during the production process is substantially reduced and thus the tantalum powder can be handled with safety.Type: GrantFiled: September 6, 1995Date of Patent: February 25, 1997Assignee: Starck Vtech Ltd.Inventors: Katsuo Iwabuchi, Tadashi Komeya, Hiroshi Oki, Dieter Behrens
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Patent number: 5605559Abstract: Alloy steel powders capable of obtaining high strength in a sintered state and having excellent compacting compressibility and methods of manufacturing a sintered body. The alloy steel powder comprises, by wt %, about 0.5-2% of Cr, not greater than about 0.08% of Mn, about 0.1-0.6% of Mo, about 0.05-0.5% of V, not greater than about 0.015 of S, not greater than about 0.2% of O, and the balance being Fe and incidental impurities. The alloy steel powder is compacted and sintered at a temperature of about 1100.degree.-1300.degree. C. and then cooled at a cooling rate no higher than about 1.degree. C./s in a temperature range of from about 800.degree. C. to 400.degree. C. The alloy steel powder can contain Nb and/or Ti and one or more of Co, W and B. Additionally, Ni powder and/or Cu powder may be adhered and dispersed onto the surface of the alloy steel powder.Type: GrantFiled: February 22, 1995Date of Patent: February 25, 1997Assignee: Kawasaki Steel CorporationInventors: Shigeru Unami, Satoshi Uenosono
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Patent number: 5597401Abstract: A clean refractory metal SWARF particle product is made from refractory metal SWARF. The SWARF particles are produced with coolant at a temperature less than 650.degree. C. to prevent formation of refractory metal oxides and nitrides. The SWARF particles are comminuted to reduce the particle size of the SWARF slivers and to liberate residual coolant The comminuted SWARF slivers are washed with a displacement wash to remove the bulk of the coolant and subject to a counter current wash to remove substantially all of the coolant components to produce to clean SWARF particles. The clean SWARF particles can be pressed into briquettes and sintered at elevated pressures or mixed with an alkali metal refractory metal halide salt, pressed at elevated pressures into SWARF/soft briquettes and dried. The briquettes are non-pyrophoric.Type: GrantFiled: November 15, 1994Date of Patent: January 28, 1997Inventor: Joseph A. Megy
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Patent number: 5595608Abstract: A permanent magnet which contains R, T and B as main ingredients wherein R is Y or a rare earth element and T is Fe or Fe and Co and has a primary phase of R.sub.2 T.sub.14 B is produced by compacting a mixture of 60 to 95 wt % of a primary phase-forming master alloy and a grain boundary phase-forming master alloy both in powder form and sintering the compact. The primary phase-forming master alloy has columnar crystal grains of R.sub.2 T.sub.14 B with a mean grain size of 3-50 .mu.m and grain boundaries of an R rich phase and contains 26-32 wt % of R. The grain boundary phase-forming master alloy is a crystalline alloy consisting essentially of 32-60 wt % of R and the balance of Co or Co and Fe. In anther form, a permanent magnet which contains R, T and B as main ingredients wherein R is yttrium or a rare earth element, T is Fe or Fe+Co/Ni and has a primary phase of R.sub.2 T.sub.Type: GrantFiled: November 2, 1994Date of Patent: January 21, 1997Assignee: TDK CorporationInventors: Katashi Takebuchi, Shinya Fujito, Shinya Hashimoto, Koichi Yajima
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Patent number: 5580367Abstract: An improved flaked tantalum powder and process for making the flaked powder are disclosed. The powder is characterized by having a Scott density greater than about 13 g/in.sup.3 and preferably at least about 90% of the flake particles having no dimension greater than about 55 micrometers. Agglomerates of the flaked tantalum powder, provide improved flowability, green strength and pressing characteristics compared to conventional flaked tantalum powders. The improved flaked tantalum powder can be made by preparing a flaked tantalum and then reducing the flake size until a Scott density greater than about 18 g/in.sup.3 is achieved. The invention also provides pellets and capacitors prepared from the above-described flaked tantalum powder.Type: GrantFiled: April 17, 1995Date of Patent: December 3, 1996Assignee: Cabot CorporationInventor: James A. Fife
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Patent number: 5577546Abstract: Particles of metal alloys and composites have been developed that are particularly suitable for use in producing thixotropic alloys and in the injection molding of such alloys. The particulate material comprises particles of metal alloy or composite, wherein a substantial proportion of the particles is shaped such that the ratio of the length of the largest dimension of a particle to the effective diameter of the particle is in the range of 1.0 to 4.0 and the substantial proportion of particles has a particle size wherein the largest dimension of the particles lies within the range of 0.5 to 5.0 mm. This allows convenient handling of the particles whilst also avoiding binding or clogging of the screw, in the case where a screw extruder is used.Type: GrantFiled: April 24, 1995Date of Patent: November 26, 1996Assignee: Comalco Aluminium LimitedInventors: Anthony R. Kjar, Ronald G. Iacocca, Randall M. German, John L. Mihelich
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Patent number: 5571305Abstract: Atomized steel powder having excellent machinability, containing about S 0.005 wt % to 0.3 wt %, Cr 0.03 wt % to 0.3 wt %, Mn 0.03 wt % to 0.5 wt %, O 0.30 wt % or less, and the balance Fe and incidental impurities, and sintered steel that can be manufactured therefrom. In particular, each of specific components is limited to a preferred range so that atomized steel powder exhibiting excellent machinability, dimensional accuracy and wear resistance and sintered steel that can be manufactured therefrom are provided.Type: GrantFiled: August 31, 1994Date of Patent: November 5, 1996Assignee: Kawasaki Steel CorporationInventors: Satoshi Uenosono, Hiroyuki Ishikawa, Kuniaki Ogura
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Patent number: 5560761Abstract: Tantalum powder used as an anode material for an electrolytic capacitor comprising usual tantalum powder (having an average particle size ranging from 1.0 to 5.0 .mu.m) mixed with tantalum powder having an average particle size on the order of nanometers (ranging from 10 to 500 nm) in an amount ranging from 1 to 25 parts by weight per 100 parts by weight of the former; an anode body for use in an electrolytic capacitor which is produced by sintering the tantalum powder; an electrolytic capacitor in which the anode body is incorporated.Type: GrantFiled: September 6, 1995Date of Patent: October 1, 1996Assignee: Starck Vtech Ltd.Inventor: Hiroo Naito
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Patent number: 5556446Abstract: Brass powder metallurgy compositions for use in manufacturing a brass part by powder metallurgy techniques. The compositions comprise from about 70-90% wt. copper, 10-30% wt. zinc, and from about 0.1-1.5% wt. graphite as an addition to improve the machinability of the resultant compacted brass part. The compositions preferably contain less than 2% wt. lead.Type: GrantFiled: May 19, 1995Date of Patent: September 17, 1996Assignee: United States Bronze PowdersInventors: Paul E. Matthews, Thomas W. Pelletiers, II