Inco Limited

James A Bell

Carlos M Diaz

Thomas Francis Stephenson

Thijs Eerkes

Anthony Edward Warner

Kirt Kenneth Cushnie

Bruce R Conard

Victor A Ettel

George Clayton Hansen

Malcolm C Bell

John J deBarbadillo, Ii

Scott Thomas Campbell

Raymond Augustus Bradford

Douglas A Hope

John Francis Brennan

Gaylord Darrell Smith

Juraj Babjak

Pradeep K Rohatgi

William L Mankins

Eberhard Krause

Charles E O'Neill

Samuel W Marcuson

John Ambrose

Grigori S Victorovich

Lloyd Matt Timberg

Stephen Joseph Baksa

Vladimir Paserin

Haydn Davies

Peter Joseph Kalal

Richard Stratton-Crawley

The method provides a process for fabricating metal matrix composites. First the process coats the fibers with nickel by electrodeposition or gaseous deposition to form nickel-coated fibers. Over-plating the nickel-coated fibers with aluminum by either electrodeposition in a non-aqueous electrolyte or gaseous deposition forms aluminum-coated-nickel-coated fibers. Sintering this product under compression, perpendicular to the fiber's central axis, forms the final metal matrix composite. The metal matrix composite has a nickel-aluminum matrix, very few voids and extended unbroken lengths of fibers within the nickel-aluminum matrix.

Method of forming metal matrix fiber composites

This process provides a method of fabricating porous aluminide articles. First the process consists of plating a preform with nickel and aluminum to create a metal-plated structure. The plating of nickel consists of electrodeposition or gaseous plating. The plating of aluminum consists of gaseous deposition of an organometallic-aluminum compound. The preform has either an open felt, woven fabric or a reticulated foam shape. Reactive sintering the metal-plated structure leaves an open nickel-aluminum structure having porosity and excellent strength and oxidation properties above 400.degree. C.

Method of preparing porous nickel-aluminum structures

The invention provides a new method for casting alloys containing a finely divided phase. A bath of the molten metal having a melting point is provided. A finely divided solid metal having a melting point greater than the melting point of molten metal is introduced into the molten metal. The finely divided metal is reacted with the molten metal to form a solid phase within the molten metal. The molten bath is then mixed to distribute the solid phase within the molten metal. The molten alloy is then cast into a solid object containing the solid phase. The solid phase is insoluble in the matrix and has a size related to the initial size of the finely divided solid. The alloy of the invention advantageously consists essentially of, by weight percent, about 3 to 40 aluminum, about 0.8 to 25 nickel, about 0 to 12 copper and balance zinc and incidental impurities. The alloy has a zinc-containing matrix with nickel-containing aluminides distributed throughout the matrix.

Alloys containing insoluble phases and method of manufacturing thereof

Alloys containing insoluble phases and method of manufacture thereof

A porous nickel electrode substrate having a central high conductivity core sandwiched between two layers of porous conductive material such as nickel foam or nickel felt. The porous conductive material is plated with nickel and then sintered. By selectively controlling the plating of nickel on the porous material, variable conductivities may be designed into the substrate.

Porous nickel electrode substrate

The invention provides an aluminum-base composite material. The aluminum-base material contains a uniform distribution of carbide particles and lubricating phase particles such as carbon or graphite. The carbide particles increase hardness for improved wear resistance. The lubricating phase particles provide improved wear resistance and especially improve unlubricated wear resistance under increased loads. Finally, a dispersoid of nickel aluminide intermetallic phase may also be used to provide additional hardness and wear resistance. The composite is formed by introducing carbide particles and lubricating phase such as graphite into a molten aluminum alloy to neutraliize buoyancy and to form an aluminum-base mixture. Mixing the aluminum-base mixture to uniformly distribute carbide and carbon particles throughout the molten aluminum. Carbide and carbon particles counteract each other to remain uniformly distributed throughout the aluminum-base alloy despite prolonged holding or cooling times.

Method of making an aluminum-base metal matrix composite

The invention produces a light metal alloy composite having a nickel coated graphite or carbon with a nickel-containing intermetallic phase within a portion of a casting. A mold is provided to cast a light metal into a predetermined shape. A nickel coated carbon phase structure is placed into a portion of the mold. The light metal is cast into the mold around the carbon structure to wet an interface between the light metal and the nickel coated carbon structure. A nickel-containing intermetallic phase is formed in the light metal proximate the nickel coated carbon to provide increased wear resistance. The light metal is then solidified to form the metal matrix composite.

Nickel coated carbon preforms

A technique for substantially reducing nitrogen oxide (NO.sub.x) emissions in internal combustion engine exhaust gases. The NO.sub.x laden stream is contacted with a As catalytic material supported on a metal plated Ni foam substrate in the presence of a reducing agent. The NO.sub.x is reduced to nitrogen, water and/or carbon, and carbon dioxide.

Catalytic conversion of internal combustion engine exhaust gases

A novel process for the production of nickel hydroxide wherein particulate nickel is reacted with oxygen in the presence of liquid water at a temperature of at least 180.degree. C. The invention also includes the nickel hydroxide product so produced.

Nickel hydroxide

A gas turbine having internally cooled thermal barrier coated turbine blades is disclosed. The turbine blades are made from an alloy substrate exhibiting a low coefficient of thermal expansion, an intermediate bond coating and an exterior ceramic coating. Cooling fluid is supplied from the shaft of the compressor where it flows into and out of the turbine blade. Thermal barrier coated turbine blades result in more efficient gas turbine designs.

Gas turbine cooling

A normally aspirated compounded, overcharged (supercharged) four stroke internal combustion engine, preferably diesel, which is particularly useful in adiabatic (low heat rejection) versions. An auxiliary expansion piston and compression piston reciprocate at least twice as fast as the combustion pistons to increase the volumetric efficiency of the engine as well as to overcharge the air charge within the combustion cylinders. Increased efficiency and simplified construction result.

Compound four stroke internal combustion engine with crossover

The invention provides a method for removing the oxide surface from water atomized metal powders containing an oxidizer capable of oxidizing chromium from a trivalent to a soluble hexavalent state, whereby chromium oxides are removed from the metal powder surface. The powder is then treated with a dilute acid solution essentially devoid of hydrofluoric acid to remove other hydrated oxides from the metal powder surface. The powder is then water washed and dried.

Deoxidation treatment for consolidated atomized metal powder

A composite structure and a method of producing said composite structure from a combination of copper and a low coefficient of thermal expansion nickel-iron alloy is disclosed wherein the copper clads the nickel-iron sheet and is interposed through the central nickel-iron sheet in such a fashion as to provide a substantially isotropic heat transfer path.

Composite structure

A piston-cylinder combination for internal combustion engines made from a varying bonded combination of two or more alloys having dissimilar coefficients of thermal expansion. By regulating the volumetric percentages of the alloys vis-a-vis their location within the piston and cylinder wall, the degree of thermal expansion experienced during operation may be controlled. The concept is especially useful for low heat rejection engines.

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Oakville, Canada

James A Bell