Alliedsignal Inc.

Honeywell International Inc.

US Government As Represented by the Secretary of the Army

Rutgers, the State University of New Jersey

Jerry C LaSalle

Ravi Batra

Mohammad Behi

Derek Raybould

Santosh K Das

Sheldon J Cytron

Donald T Rorabaugh

George A Glandz

James F Stevenson

Anthony J Fanelli

David J Skinner

John N Tervo

Joan V Burlew

V R Ramanan

Gary B Marsh

Brian Jeffrey Snow

Richard Bye

Jyh-Woei J Lu

Edward V Limoncelli

Bryan C Sherman

Eoin Joseph Barry

Tools and methods are provided for use in a process for sintering a metal injection molded body where the body comprises a material and having a first end, a second end, and a flowpath extending therebetween, the flowpath having a diameter. The tool assembly comprises an insert and an endcap. The insert is configured to be disposed in the body flowpath and has an inner surface, an outer surface, a first end, a second end, a channel, a slot having a width, an inner diameter and an outer diameter. The endcap is configured to be inserted at least partially into the channel at the insert first end when the slot width is increased, and at least a portion of the endcap has an outer diameter that is substantially equal to or larger than the insert inner diameter.

Advanced sintering process and tools for use in metal injection molding of large parts

A process for adjusting the level of water or water soluble additives in aqueous-based powder injection molding compounds for the purpose of recycling scrap material, controlling shrinkage or rehydrating dry feedstock. Depending on the objective, the process may require material granulation equipment, equipment for the addition or removal of water and mixing equipment. The molding compounds may be comprised of either recycled scrap material before being heat-treated or dry, virgin feedstock material.

Recycle methods for water based powder injection molding compounds

This invention provides a process for forming sintered, molded articles having improved dimensional stability. More particularly, this invention pertains to process for forming heat sinks. This process includes forming a substantially uniform copper composition comprising a polysaccharide binder, water, and copper particles; molding the copper composition under conditions sufficient to form a solid molded intermediate; and sintering the solid molded intermediate at a sufficient temperature and for a sufficient time to form a heat sink.

Aqueous nonferrous feedstock material for injection molding

Molded green parts are fused together to form a bond or joint during the sintering process. The molded green parts are held in intimate contact with each other and sintered at temperatures sufficient to fuse the parts together. The process may entail dry fusing of part-to-part or it may include the use of a flux between the parts being fused together to enhance the bond.

Co-sintering of similar materials

A composition for forming molded metal containing articles having improved stability. More particularly, a corrosion resistant composition for forming injection molded articles having a sodium silicate corrosion inhibiting additive. The corrosion inhibitor prevents metal oxidation when a metal containing powder is mixed with a water based binder, providing stability to the article and preventing generation of hydrogen gas. This significantly enhances the shelf life of the moldable composition prior to molding.

Stable aqueous iron based feedstock formulation for injection molding

A heat exchanger includes one or more parts composed of a braze clad aluminum alloy having a composition defined essentially by the formula: Al 1.1% Mn 1.1% Mg 0.15 Cu and being brazed to other aluminum parts. The heat exchanger exhibits usable strength at operating temperatures ranging up to 232.degree. C. �450.degree. F!, and is especially suited for use in the charge air cooler of a diesel engine.

Heat exchanger having aluminum alloy parts exhibiting high strength at

A calcia mold facecoat is applied to a mold for casting parts composed of reactive metals such as titanium and titanium aluminide. The facecoat is composed of a calcium carbonate based slurry comprising a dense grain calcium carbonate powder and an aqueous based binder. It is applied to a wax or plastic pattern used in the lost wax process for fabricating a casting shell. The mold is built using multiple dipping of alumina-silicate slurries, and then fired at high temperatures in an oxygen rich environment. The metal part is cast before the fired mold can cool below about 800.degree. C. Organometallic based slurry binders are avoided and significant cost savings are realized owing to the benign nature of the aqueous based suspensions with respect to the environment.

Inert calcia facecoats for investment casting of titanium and

A rapidly solidified, low density aluminum base alloy consists essentially of the formula Al.sub.bal Li.sub.a Cu.sub.b Mg.sub.c Zr.sub.d wherein 'a' ranges from about 2.2 to 2.5 wt %, 'b' ranges from about 0.8 to 1.2 wt %, 'c' ranges from about 0.4 to 0.6 wt % and 'd' ranges from about 0.4 to 0.8 wt %, the balance being aluminum plus incidental impurities. The alloy is especially suited to be consolidated to produce a strong, tough, low density aircraft landing wheel.

Rapidly solidified aluminum lithium alloys having zirconium for aircraft

A component composed of a rapidly solidified aluminum-lithium alloy is subjected to thermal treatment at a temperature greater than 500.degree. C. for a time period greater than 5 hours under a protective atmosphere. Thus case toughened, the component exhibits notched impact toughness from 40 to 250% greater than that exhibited prior to the thermal treatment.

Rapidly solidified case toughend aluminum-lithium components

A rapidly solidified zirconium containing aluminum lithium alloy powder consisting essentially of the formula Al.sub.bal Li.sub.a Cu.sub.b Mg.sub.c Zr.sub.d where 'a' ranges from 2.1 to 3.4 wt %, 'b' ranges from about 0.5 to 2.0 wt %, 'c' ranges from 0.2 to 2.0 wt % and 'd' ranges from greater than about 0.6 to 1.8 wt %, the balance being aluminum. The powder is degassed in a vacuum at a temperature of at least about 450.degree. C. Components consolidated from the powder exhibit high tensile strength and elongation together with excellent notched impact toughness.

Toughness enhancement of powder metallurgy zirconium containing

An Al-Li alloy consists essentially of the formula Al.sub.bal Li.sub.a Cu.sub.b Mg.sub.c Zr.sub.d wherein 'a' ranges from about 1.9 to 3.4 wt %, 'b' ranges from about 0.5 to 2.0 wt %, 'c' ranges from 0.2 to 2.0 wt % and 'd' ranges from about 0.3 to 1.2 wt %, the balance being aluminum. The alloy is solidified at a cooling rate of about 10.sup.3 .degree.-10.sup.4 .degree. C./sec by spray forming, and is characterized by a substantial absence of prior particle boundaries.

Toughness enhancement of Al-Li-Cu-Mg-Zr alloys produced using the spray

This invention describes a process for producing copper alloys by rapid sdification in order to improve their strength and thermal stability after being exposed to elevated temperatures. The method used to rapidly solidify the molten alloy is either by use of a high pressure non-oxidizing gas spray to atomize the molten alloy into a powder or to pour the molten alloy onto a rotating wheel to form a ribbon which is then attrited into powder. The powder is canned, compacted to full density and cold worked to the desired shape.

Method of producing copper alloys with manganese and selenium to improve

A method for making uranium-tungsten alloy of high strength comprising raly chilling a molten solution of tungsten in uranium to form a ribbon. Subsequent to pulverizing and consolidation, heating effects a precipitation of tungsten in the uranium to effect significant strengthening. A strengthened uranium with 1/2-5%, by weight of tungsten is particularly useful for KE penetrators.

Precipitation strengthened uranium tungsten alloy

A component consolidated from a rapidly solidified aluminum-lithium alloy containing copper, magnesium and zirconium is subjected to a preliminary aging treatment at a temperature of about 400.degree. C. to 500.degree. C. for a time period of about 0.5 to 10 hours; quenched in a fluid bath; and subjected to a final aging treatment at a temperature of about 100.degree. C. to 250.degree. C. for a time period ranging up to about 40 hours. The component exhibits increased strength and elongation, and is especially suited for use in lightweight structural parts for land vehicles and aerospace applications.

Strength enhancement of rapidly solidified aluminum-lithium through

A rapidly solidified, low density aluminum base alloy consisting essentially of the formula Al.sub.bal Li.sub.a Cu.sub.b Mg.sub.c Zr.sub.d wherein 'a' ranges from about 2.1 to 3.4 wt %, 'b' ranges from about 0.5 to 2.0 wt %, 'c' ranges from about 0.2 to 2.0 wt % and 'd' ranges from about 0.4 to 1.8 wt %, the balance being aluminum is consolidated to produce a strong, tough low density article.

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Montclair, NJ, United States of America

Jerry C LaSalle