The Penn State Research Foundation

Chrysalis Technologies Incorporated

Other

Philip Morris Inc.

L'air Liquide, Societe Anonyme Pour L'etude Et L'exploitation Des

L'air Liquide

Comalco Aluminium Limited

Upchurch Scientific, Inc.

Advanced Materials Technologies Pte, Ltd.

Societe Anonyme Pour L'etude Et L'exploitation Des Procedes Georges

Klinair Environmental Technologies (ireland) Limited

Xform, Inc.

Randall M German

Mohammad R Hajaligol

Seetharama C Deevi

Vinod Kumar Sikka

A Clifton Lilly, Jr

Grier S Fleischhauer

Clive Scorey

Ronald G Iacocca

Anthony Griffo

Eric Streicher

Rene M Cooper

David E Alman

Karl G Shaw

Kazuo P McCoy

Lye-King Tan

Michael L Bailey

Anthony Rudland Kjar

Timothy J Weaver

Julian A Thomas

Sundar V Atre

Grier Fleishhauer

Roger Duffield

Teh Fu Yen

John L Mihelich

John Johnson

Rajkumar Raman

Karthik Sivaraman

Tracy Potter

Anand Lal

Heat dissipation during the operation of integrated circuit chips is an old problem that continues to get worse. The present invention significantly ameliorates this by placing an embedded heat pipe directly beneath the chip. Using powder injection molding, the lower portion of the package is formed first as an initial green part which includes one or more cavities. The latter are then lined with a feedstock that is designed to produce a porous material after sintering, at which time a working fluid is introduced into the porous cavities and sealed, thereby forming one or more heat pipes located directly below the chip. The latter is then sealed inside an enclosure. During operation, heat generated by the chip is efficiently transferred to points outside the enclosure. A process for manufacturing the structure is also described.

Advanced microelectronic heat dissipation package and method for its manufacture

A powder metallurgical process of preparing a sheet from a powder having an intermetallic alloy composition such as an iron, nickel or titanium aluminide. The sheet can be manufactured into electrical resistance heating elements having improved room temperature ductility, electrical resistivity, cyclic fatigue resistance, high temperature oxidation resistance, low and high temperature strength, and/or resistance to high temperature sagging. The iron aluminide has an entirely ferritic microstructure which is free of austenite and can include, in weight %, 4 to 32% Al, and optional additions such as &lE;1% Cr, &gE;0.05% Zr &lE;2% Ti, &lE;2% Mo, &lE;1% Ni, &lE;0.75% C, &lE;0.1% B, &lE;1% submicron oxide particles and/or electrically insulating or electrically conductive covalent ceramic particles, &lE;1% rare earth metal, and/or &lE;3% Cu. The process includes forming a non-densified metal sheet by consolidating a powder having an intermetallic alloy composition such as by roll compaction, tape casting or plasma spraying, forming a cold rolled sheet by cold rolling the non-densified metal sheet so as to increase the density and reduce the thickness thereof and annealing the cold rolled sheet. The powder can be a water, polymer or gas atomized powder which is subjecting to sieving and/or blending with a binder prior to the consolidation step. After the consolidation step, the sheet can be partially sintered. The cold rolling and/or annealing steps can be repeated to achieve the desired sheet thickness and properties. The annealing can be carried out in a vacuum furnace with a vacuum or inert atmosphere. During final annealing, the cold rolled sheet recrystallizes to an average grain size of about 10 to 30 &mgr;m. Final stress relief annealing can be carried out in the B2 phase temperature range.

Method of manufacturing aluminide sheet by thermomechanical processing of aluminide powders

A fuel filter having a formulation of a stable intermetallic compound of materials such as tin and antimony. The filter may have an integral porous structure or may be in the form of particles. It removes trace metal ions such as Ca and Na ions.

Fuel filter and production process

An improved method of applying a particulate material to a substrate, includes the steps of: removing impurities from a surface of the substrate; forming a coating composition having a bonding material and at least one particulate material; applying the coating composition to the substrate surface; and creating a diffusion bond between the substrate, bonding material and particulate material for generating a continuous interface between the substrate surface and particulate material such that the change in mechanical properties between the substrate and particulate material occurs in a direction normal to the plane of the substrate surface, thereby minimizing residual strain and coefficient of thermal expansion mismatch between the substrate and particulate material, the surfaces of individual particles of said particulate material being chemically wetted by the bonding material. The particulate material and the bonding material comprise a layer on the substrate surface.

Method of applying a hard-facing material to a substrate

Solid objects are made by means of a novel multi-step forming, debinding, sintering and infiltrating process, using a metal-ceramic composition. In this process, the mixture is held for a period of time to degas and settle the powdered material from a liquid binder. The packed geometry is then heated to above the melting temperature of the binder to remove the binder portion of the solid geometry. Upon removal of the binder the binder-free solid geometry is raised to a temperature where the metal pre-sinters together into a three-dimensional rigid matrix with interconnected porosity to form a solid precursor. The porous matrix includes the particulate ceramic material and a first metal, which are at least partially sintered. A molten second metal is then introduced to the fill the porous matrix and form an infiltrated matrix. In addition to speed of production, improvements associated with this method include a solid object having improved thermal conductivity, hardness, wear resistance and reduced shrinkage as compared with the rapid tooling techniques taught in the prior art.

Powdered material rapid production tooling method and objects produced therefrom

Thermomechanical processing of plasma sprayed intermetallic sheets

A powder metallurgical process of preparing a sheet from a powder having an intermetallic alloy composition such as an iron, nickel or titanium aluminide. The sheet can be manufactured into electrical resistance heating elements having improved room temperature ductility, electrical resistivity, cyclic fatigue resistance, high temperature oxidation resistance, low and high temperature strength, and/or resistance to high temperature sagging. The iron aluminide has an entirely ferritic microstructure which is free of austenite and can include, in weight %, 4 to 32% Al, and optional additions such as &lE;1% Cr, &gE;0.05% Zr &lE;2% Ti, &lE;2% Mo, &lE;1% Ni, &lE;0.75% C, &lE;0.1% B, &lE;1% submicron oxide particles and/or electrically insulating or electrically conductive covalent ceramic particles, &lE;1% rare earth metal, and/or &lE;3 % Cu. The process includes forming a non-densified metal sheet by consolidating a powder having an intermetallic alloy composition such as by roll compaction, tape casting or plasma spraying, forming a cold rolled sheet by cold rolling the non-densified metal sheet so as to increase the density and reduce the thickness thereof and annealing the cold rolled sheet. The powder can be a water, polymer or gas atomized powder which is subjecting to sieving and/or blending with a binder prior to the consolidation step. After the consolidation step, the sheet can be partially sintered. The cold rolling and/or annealing steps can be repeated to achieve the desired sheet thickness and properties. The annealing can be carried out in a vacuum furnace with a vacuum or inert atmosphere. During final annealing, the cold rolled sheet recrystallizes to an average grain size of about 10 to 30 &mgr;m. Final stress relief annealing can be carried out in the B2 phase temperature range.

Polymer quenched prealloyed metal powder

A powder metallurgical process of preparing a sheet from a powder having an intermetallic alloy composition such as an iron, nickel or titanium aluminide. The sheet can be manufactured into electrical resistance heating elements having improved room temperature ductility, electrical resistivity, cyclic fatigue resistance, high temperature oxidation resistance, low and high temperature strength, and/or resistance to high temperature sagging. The iron aluminide has an entirely ferritic microstructure which is free of austenite and can include, in weight %, 4 to 32% Al, and optional additions such as .ltoreq.1% Cr, .gtoreq.0.05% Zr.ltoreq.2% Ti, .ltoreq.2% Mo, .ltoreq.1% Ni, .ltoreq.0.75% C, .ltoreq.0.1% B, .ltoreq.1% submicron oxide particles and/or electrically insulating or electrically conductive covalent ceramic particles, .ltoreq.1% rare earth metal, and/or .ltoreq.3% Cu. The process includes forming a non-densified metal sheet by consolidating a powder having an intermetallic alloy composition such as by roll compaction, tape casting or plasma spraying, forming a cold rolled sheet by cold rolling the non-densified metal sheet so as to increase the density and reduce the thickness thereof and annealing the cold rolled sheet. The powder can be a water, polymer or gas atomized powder which is subjecting to sieving and/or blending with a binder prior to the consolidation step. After the consolidation step, the sheet can be partially sintered. The cold rolling and/or annealing steps can be repeated to achieve the desired sheet thickness and properties. The annealing can be carried out in a vacuum furnace with a vacuum or inert atmosphere. During final annealing, the cold rolled sheet recrystallizes to an average grain size of about 10 to 30 .mu.m. Final stress relief annealing can be carried out in the B2 phase temperature range.

Method of manufacturing aluminide sheet by thermomechanical processing

A method for making a biocompatible filter whereby a biocompatible powder is sintered to form a disk-shaped filter. The biocompatible powder is first sized to obtain a preselected average particle size. Next, the powder is introduced to a die in which the powder is pressed to a predetermined force to form 'cakes.' The pressed powder 'cakes' are then placed into an oven or furnace, which is heated to a preselected temperature. The powder cakes are held at the elevated temperature to sinter the particles in the powder together. After a preselected amount of time, the now-sintered powder cakes are removed and allowed to cool. This method produces biocompatible filters useful in liquid chromatography and other applications.

Method of making a biocompatible filter

A method is disclosed for controlling a self-propagating reaction in a particulate medium. The method comprises controlling the boundary heat flux of the reaction to produce reaction waves which travel through the particulate medium undergoing a self-propagating reaction. The method provides a product having a unitary, solid structure with layers of alternating density. Preferably the reaction is a reaction between two metals to produce an intermetallic compound or between a metal and a nonmetal to produce a ceramic compound. Nickel aluminide is a preferred intermetallic compound. Also disclosed is a controlled reactive sintering process for producing a finely divided intermetallic compound comprising comminuting the layered body of intermetallic compound. Also disclosed are a process for preparing an abrasive surface composed of a nickel aluminide binder and an abrasive material, an injection molding composition for preparing shaped articles of nickel aluminide, and a process for injection molding shaped nickel aluminide articles of greater than 98% theoretical density.

Process for producing finely divided intermetallic and ceramic powders

The present invention discloses an improved method for compacting powdered materials, including ferrous alloys, non-ferrous metals or non-metal powders, wherein the improved method includes the use of an improved lubricant during the compaction process. The improved lubricant includes vinyl halides, generally, and polytetrafluroethylene, specifically. In a preferred embodiment of the present invention, 0.2 to 0.6 wt. % of the vinyl halide is added to the powdered form of the compactable material before the compaction and sintering of the compactable material.

Method for compacting compactable materials and improved lubricant for

Particulate feedstock for metal injection molding

A process for controlling the carbon content in a metallic piece molded by injection or other process comprising,

Process for controlling carbon content of injection molding steels

A method is disclosed for controlling a self-propagating reaction in a particulate medium. The method comprises controlling the boundary heat flux of the reaction to produce reaction waves which travel through the particulate medium undergoing a self-propagating reaction. The method provides a product having a unitary, solid structure with layers of alternating density. Preferably the reaction is a reaction between two metals to produce an intermetallic compound or between a metal and a non-metal to produce a ceramic compound. Nickel aluminide is a preferred intermetallic compound. Also disclosed is a controlled reactive sintering process for producing a finely divided intermetallic compound comprising comminuting the layered body of intermetallic compound. Also disclosed are a process for preparing an abrasive surface composed of a nickel aluminide binder and an abrasive material, an injection molding composition for preparing shaped articles of nickel aluminide, and a process for injection molding shaped nickel aluminide articles of greater than 98% theoretical density.

Process for making finely divided intermetallic

A process is provided for preparing carbon-containing substantially oxide-free iron powders or iron-based powders or both wherein oxygen impurities from an iron powder are removed without substantial decarburization, by heating the iron powder or iron-based powders or both under a substantially pure hydrogen atmosphere from ambient temperatures to a first intermediate temperature in an enclosure, then replacing the substantially pure hydrogen atmosphere by a substantially pure nitrogen atmosphere in the enclosure and then heating the powder to a second temperature which is higher that the first intermediate temperature, then cooling down the powder under an inert atmosphere to at least a temperature where substantially no more oxidation of the powder occurs, then removing the powder from the enclosure, the first and second temperatures being sufficient to reduce substantially all oxide impurities in the powder without substantial decarburization.

Process for reducing oxides contained in iron powder without substantial

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State College, PA, United States of America

Randall M German