US4594219A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Powder metal consolidation of multiple preforms
Assignee: POWMET FORGINGS LLC
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Filing: 1985-08-02
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Granted: 1986-06-10
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Expires: 2005-08-02
Abstract
Abstract The method of producing a metallic, ceramic, or metal ceramic, part, employing powdered material, that includes: (a) forming two or more oversize powder material preforms respectively corresponding to two or more sections of the ultimate part to be produced, (b) placing said preforms in side-by-side relation, and (c) consolidating said preforms at elevated temperature and pressure to weld said sections together and to reduce the sections to ultimate part size.
Inventors
- 👤 Alfred F. Hostatter
- 👤 Wayne P. Lichti
- 👤 John G. Papp
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-05 10:57
CPC Classifications
B; B22; B22F; B22F7/00; B22F7/06; B22F7/062; Y; Y10; Y10S; Y10S228/00; Y10S228/903; Y10S29/00; Y10S29/048
Claims Analysis
Total Claims: 31
Claim 1
Independent Claim
100 words
The method of producing a metallic, ceramic, or metal ceramic, part, employing powdered material, that includes: (a) forming two or more oversize powder material preforms respectively corresponding to two or more sections of the ultimate part to be produced, (b) placing said preforms in adjacent relation, and (c) consolidating said preforms at elevated temperature and pressure to weld said sections together and to reduce the sections to ultimate part size, (d) said consolidation step carried out by embedding said preforms in a grain bed, heated to about 2000° F., and pressurizing the grain to transmit consolidating force to the preforms.
Claim 2
Independent Claim
100 words
The method of producing a metallic, ceramic, or metal ceramic, part, employing powdered material, that includes: (a) forming two or more oversize powder material preforms respectively corresponding to two or more sections of the ultimate part to be produced, (b) placing said preforms in adjacent relation, and (c) consolidating said preforms at elevated temperature and pressure to weld said sections together and to reduce the sections to ultimate part size, (d) said consolidation step carried out by embedding said preforms in a grain bed, heated to about 2000° F., and pressurizing the grain to transmit consolidating force to the preforms.
Claim 3
Dependent Claim
18 words
The method of claim 1 including joining said preforms in said adjacent relation prior to said (c) step.
Claim 4
Dependent Claim
13 words
The method of claim 2 wherein said joining includes adhesively bonding said preforms.
Claim 5
Dependent Claim
13 words
The method of claim 2 wherein said joining includes mechanically interconnecting said preforms.
Claim 6
Dependent Claim
18 words
The method of claim 4 wherein said mechanical interconnecting includes providing tongue and groove interfitting of the preforms.
Claim 7
Dependent Claim
15 words
The method of claim 2 wherein said mechanical interconnecting includes tack welding of the preforms.
Claim 8
Dependent Claim
29 words
The method of claim 1 including placing dry metal or ceramic powder between sides of said preforms which are then placed together as per step (b) of claim 1.
Claim 9
Dependent Claim
20 words
The method of claim 7 wherein the powder is placed in a layer having thickness between 0.0001 and 0.005 inches.
Claim 10
Dependent Claim
45 words
The method of claim 1 wherein said (a) step includes forming a recess at the interface in at least one of the preforms and locating an insert in said recess, the insert maintained in said recess during said (c) step, and then removing the insert.
Claim 11
Dependent Claim
27 words
The method of claim 9 wherein the insert has a composition selected from the group that includes: ceramic graphite refractory alloy or metal alloy quartz cemented carbide
Claim 12
Dependent Claim
20 words
The method of claim 10 wherein said ceramic is selected from the group that includes silica zirconia alumina carbide nitride
Claim 13
Dependent Claim
38 words
The method of claim 9 wherein said preforms are formed to be elongated and to have elongated sides, the recess having sections formed in both of said preforms, said (b) step carried out to register said recess sections.
Claim 14
Dependent Claim
35 words
The method of claim 12 wherein said recess extends through the two preforms placed together as per step (b) of claim 1, and including locating an insert in said recess prior to said step (c).
Claim 15
Dependent Claim
12 words
The method of claim 13 wherein said part comprise an elongated tool.
Claim 16
Dependent Claim
36 words
The method of claim 9 wherein said insert is smaller than said recess, and including placing powder metal or ceramic in the recess and about the insert to clad the recess walls during said (c) step.
Claim 17
Independent Claim
32 words
The method of one of claims 9 and 15 including temporarily joining said insert to at least one of the preforms and in position in the recess, prior to said (c) step.
Claim 18
Dependent Claim
15 words
The method of claim 1 wherein said preforms respectively have different metallic or chemical compositions.
Claim 19
Dependent Claim
25 words
The method of claim 1 wherein said (b) step is preceeded by sintering or pre-consolidating said preforms at elevated temperature to partially reduce their sizes.
Claim 20
Dependent Claim
32 words
The method of claim 18 wherein said sintering or pre-consolidation step is carried out to densify the preforms to between 75% and 85% of their ultimate densities achieved by said (c) step.
Claim 21
Dependent Claim
19 words
The method of claim 18 wherein said (c) step is carried out at preform temperature of about 2000° F.
Claim 22
Dependent Claim
33 words
The method of claim 1 wherein the grain consists of material selected from the group consisting essentially of spherical, carbonaceous or ceramic particles, and is at about 2000° F. during said (c) step.
Claim 23
Dependent Claim
19 words
The method of claim 18 wherein said preforms have composition consisting of iron alloyed with nickle, carbon and molybdenum.
Claim 24
Dependent Claim
13 words
The method of claim 18 wherein said ultimate part has H-shaped cross section.
Claim 25
Dependent Claim
12 words
The method of claim 23 wherein said part comprises a connecting rod.
Claim 26
Dependent Claim
27 words
The method of claim 18 including placing dry metal powder between sides of said preforms which are then placed together as per step (b) of claim 1.
Claim 27
Dependent Claim
42 words
The method of claim 18 wherein said (a) step includes forming a recess in at least one of the preforms and locating an insert in said recess, the insert maintained in said recess during said (c) step, and then removing the insert.
Claim 28
Dependent Claim
38 words
The method of claim 26 wherein said preforms are formed to be elongated and to have elongated sides, the recess having sections formed in both of said preforms, said (b) step carried out to register said recess sections.
Claim 29
Independent Claim
36 words
The method of one of claims 1-15, 17-20 and 21 wherein one or more of the sections of the final part is or are formed to consist of a fully dense metal, metal-ceramic, or ceramic composition.
Claim 30
Independent Claim
115 words
The method of producing a metallic, ceramic, or metal ceramic, part, employing powdered material, that includes: (a) forming two or more oversize powder material preforms respectively corresponding to two or more sections of the ultimate part to be produced, (b) placing said preforms in adjacent relation, and (c) consolidating said preforms at elevated temperature and pressure to weld said sections together and to reduce the sections to ultimate part size, (d) said consolidation step carried out by embedding said preforms in a grain bed, and pressurizing the grain to transmit consolidating force to the preforms, the temperatures of the grain bed and of the preforms prior to consolidation being between 900° F. and 4000° F.
Claim 31
Independent Claim
115 words
The method of producing a metallic, ceramic, or metal ceramic, part, employing powdered material, that includes: (a) forming two or more oversize powder material preforms respectively corresponding to two or more sections of the ultimate part to be produced, (b) placing said preforms in adjacent relation, and (c) consolidating said preforms at elevated temperature and pressure to weld said sections together and to reduce the sections to ultimate part size, (d) said consolidation step carried out by embedding said preforms in a grain bed, and pressurizing the grain to transmit consolidating force to the preforms, the temperatures of the grain bed and of the preforms prior to consolidation being between 900° F. and 4000° F.
References Cited (Backward Citations)
US4141482A
Cited
US4485961A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1989-06-09 | 1989-12-09 | 1990-06-10 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1993-06-09 | 1993-12-09 | 1994-06-10 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1997-06-09 | 1997-12-09 | 1998-06-10 | $7700.00 | Window Closed / Lapsed |