Ford Motor Company Limited

John Richard Baer

John A Mangels

Richard L Allor

Samuel S Shinozaki

Thomas J Whalen

Kevin Patrick Regan

Walter Trela

Method and apparatus incorporating an infrared sensor, in the form of a two-wavelength imaging pyrometer into a metallic spray form process for providing real-time measurement of the surface temperature distribution of a steel billet thereby formed. The steel billets may be advantageously used as tools in metal forming processes, injection molding, die casting tooling and other processes that require hard tooling, such as in the automotive industry. The steel billet is formed based on a goal of uniform surface temperature distribution thereby minimizing thermal stresses induced within the steel article thereby produced.

Method and apparatus for controlling a spray form process based on sensed surface temperatures

The present invention discloses a composition for a valve of an advanced heat engine. The valve comprises grains of aluminum-doped silicon carbide. The grains are of two main types: (1) a matrix of equi-axed grains of alpha and beta SiC for optimum distribution of mechanical properties; and (2) elongated grains of alpha SiC which are distributed within the matrix for reinforcement. The invention also comprises a process for making such valves. The process begins with a powder of aluminum-doped beta-silicon carbide. A binder and a solvent are then added to the powder, and the mixture is agitated while being heated. The mixture is then transferred to an injection mold which is used to form a molded component. The molded component is then sintered and machined into desired dimensions. An annealing step is then performed so that the component exhibits the characteristics of improved strength and toughness.

Composition and process for making an engine valve

A thermally stable, oxidation resistant ceramic Si.sub.3 N.sub.4 material is disclosed. The material has a substantially pure primary phase formed of substantially pure silicon nitride. A substantially pure secondary phase of the material is formed of a material selected from the group consisting essentially of Si.sub.3 N.sub.4 /SiO.sub.2 /4Y.sub.2 O.sub.3, Si.sub.3 N.sub.4 /SiO.sub.2 /2Y.sub.2 O.sub.3 and Si.sub.3 N.sub.4 /4SiO.sub.2 /5Y.sub.2 O.sub.3. The primary phase may be in the form of individual grains and the secondary phase may be in the form of grain boundaries between the individual grains.

Thermally stable silicon nitride material

A method is disclosed in this specification for forming a densified silicon nitride article. The method is initiated by forming a reaction bonded article of moderate density. This moderate density reaction bonded article has a primary phase of substantially pure grains of silicon nitride surrounded by a secondary grain boundary phase. The secondary grain boundary phase contains silicon nitride, silicon dioxide and a densification aid incorporated in the reaction bonded article of moderate density. The compounds forming the secondary grain boundary phase are present either in their pure forms or interacted with one another. The reaction bonded article is packed in a packing powder which contains portions of the pure compounds found in or interacted with one another to define the secondary grain boundary phase. The reaction bonded article of moderate density is heated in the packing powder to a temperature and for a time whereby interaction of the secondary grain boundary phase and the packing powder may take place. The interaction takes place so that a new grain boundary phase can be developed about the substantially pure grains of silicon nitride. The new grain boundary phase developed is a unitary phase of a selected composition.

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Carleton, MI, United States of America

John Richard Baer