Hoeganaes Corporation

Howard G Rutz

Christopher Oliver

Brooks Quin

Francis G Hanejko

Sidney Luk

Johan Arvidsson

W John Porter, Jr

K S Narasimhan

An iron powder composition comprising an iron powder coated with a substantially uniform coating of a thermoplastic material and admixed with a boron nitride powder and a method of utilizing the mixture to produce a magnetic core component is provided. The iron powder mixture is formulated with up to about 1% by weight of boron nitride which reduces the stripping and sliding die ejection pressures during high temperature molding and also improves the permeability of the magnetic part over an extended frequency range.

Thermoplastic coated magnetic powder compositions and methods of making

Methods of making sintered parts from a metal powder composition that contains an amide lubricant are provided. The composition comprises an iron-based powder and a lubricant that is the reaction product of a monocarboxylic acid, a dicarboxylic acid, and a diamine. The composition is compacted in a die, preferably at an elevated temperature of up to about 370.degree. C., at conventional compaction pressures, and then sintered according to standard powder-metallurgical techniques.

Method of making a sintered metal component and metal powder

A method for heating metal powder, e.g., iron powder, comprises irradiating the powder with microwaves. The powder may be coated with various materials to enhance the heating effects of the microwave. For example, the powder may be coated with a non-emissive material, such as a ceramic material. The powder may also be coated with a dipole material, such as water or plastic, or a dielectric material.

Methods and apparatus for heating metal powders

A method is provided for producing a high strength iron based component by powder metallurgical techniques but without sintering. A powder composition of iron-based particles coated or admixed with a thermoplastic material is compacted under heat and pressure by traditional powder metallurgical techniques. The pressed component is then heat treated at a temperature above the glass transition temperature of the thermoplastic material for a time sufficient to bring the component to the heat treatment process temperature. The resulting component has increased strength and can be used as a structural component or as a magnetic core component.

Thermoplastic coated iron powder components and methods of making same

Method of making a sintered metal component

Methods of doubly coating iron particles. The methods comprise treating the iron particles with phosphoric acid to form a layer of hydrated iron phosphate at the surfaces of the iron particles. The particles are heated in an inert atmosphere at a temperature and for a time sufficient to convert the hydrated layer to an iron phosphate layer. The particles are then coated with a termoplastic material to provide a coating of thermoplastic material substantially uniformly circumferentially surrounding the iron phosphate layer. Doubly-coated iron particles provided in accordance with this invention are generally useful for forming magnetic components and cores for use in high frequency switching applications.

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Newtown, PA, United States of America

Howard G Rutz