Abstract:
Gas permeable molds and mold segments having open porosity (60) are disclosed. Blind vents (56) in the mold wall's (54) outside surface (52) allow for an uninterrupted molding surface (62) while enhancing the gas permeability provided by the open porosity (60). Methods of making such gas permeable molds include forming them from sintered material. Methods also include the use of solid free-form fabrication followed by sintering. Also disclosed are unitary structures (150), for use in EPS bead molding, having a steam chest portion (152) with gas impermeable walls (156) and a mold section (154) having a gas permeable mold wall (172) having open porosity (176), and, optionally, open and/or blind vents (180, 178). Methods for making such unitary structures (150) include the use of solid free-form fabrication.
Abstract:
Methods for sintering aluminum powder comprise providing aluminum powder and heating the aluminum powder in a nitrogen atmosphere containing a partial pressure of water vapor in the range of about 0.001 kPa to about 0.020 kPa to sinter the aluminum powder to a transverse rupture strength of at least about 13.8 MPa. The aluminum powder is not pressed together by a mechanical force that substantially deforms particles of said aluminum powder either prior to or during the step of heating. Articles comprising sintered aluminum powder. The sintered aluminum powder has a transverse rupture strength of at least about 13.8 MPa. The microstructure of the sintered aluminum powder contains no compositional concentration gradients indicative of the use of a sintering aid and no evidence of particle deformation having occurred by an application of a mechanical force prior to or during the sintering of the aluminum powder.
Abstract:
The structural integrity of a metal powder body during heat treatment is enhanced by the in situ formation of metal nanoparticles. The nanoparticles bond to one another and to the metal powder particles of the powder body during heat treatment to provide strength to the powder body prior to the operation of the physical phenomena which transform the powder body into a coherent article. The precursor or precursors from which the nanoparticles are derived are preferably metal salts which are added to the powder or powder body in the form of a solution. The use of conventional binders is optional.
Abstract:
A method for producing a cast article comprises using a porous powder article as a sacrificial pattern. The porous powder article is preferably made using a rapid prototyping process. The porous powder article is used as a sacrificial pattern for a mold into which a molten metal is cast. Some embodiments include a step of proving the porous powder article with a ceramic coating. Methods of making molds and patterns using a porous powder article are also disclosed. The powder comprising the porous powder article may be a metal, ceramic or cermet. In some embodiments, the powder alloys with the molten casting metal. In some other embodiments, the powder and the casting metal form a composite. Sacrificial casting mold patterns comprising porous powder articles and casting molds comprising such sacrificial patterns are also disclosed.
Abstract:
A green article comprising an A-B powder mixture and methods of manufacturing such green articles and corresponding sintered articles are disclosed. The A-B powder mixture consists of a minor volume fraction of a relatively fine powder A and a complementary major volume fraction of a relatively coarse prealloyed powder B wherein the A-B powder mean particle size ratio is at least about 1:5. Metal powder A consists of one or more elemental metals or alloys which has a melting or solidus temperature above the highest sintering temperature at which the A-B powder mixture may be sintered without slumping. Prealloyed metal powder B consists of one or more alloys which are amenable to supersolidus liquid phase sintering. Green articles made from the A-B powder have a wider sintering temperature window than do articles made from prealloyed metal powder B alone.
Abstract:
A computer readable memory to direct a computer to improve the perceived audio quality of a speaker included in that computer. The computer readable memory stores a first, second and third set of instructions. The first set of instructions causes the computer to determine the speaker type. The second set of instructions causes the computer to select a set of default filter coefficients for a digital filter based upon the speaker type. Finally, the third set of instructions causes the computer to realize a digital parametric equalizer using a digital filter and the set of default filter coefficients. Thus, the digital filter alters the audio signal that is input to the speaker, thereby improving the perceived quality of the speaker.
Abstract:
A green article comprising an A-B powder mixture and methods of manufacturing such green articles and corresponding sintered articles are disclosed. The A-B powder mixture consists of a minor volume fraction of a relatively fine powder A and a complementary major volume fraction of a relatively coarse prealloyed powder B wherein the A-B powder mean particle size ratio is at least about 1:5. Metal powder A consists of one or more elemental metals or alloys which has a melting or solidus temperature above the highest sintering temperature at which the A-B powder mixture may be sintered without slumping. Prealloyed metal powder B consists of one or more alloys which are amenable to supersolidus liquid phase sintering. Green articles made from the A-B powder have a wider sintering temperature window than do articles made from prealloyed metal powder B alone.
Abstract:
Methods for sintering aluminum powder comprise providing aluminum powder and heating the aluminum powder in a nitrogen atmosphere containing a partial pressure of water vapor in the range of about 0.001 kPa to about 0.020 kPa to sinter the aluminum powder to a transverse rupture strength of at least about 13.8 MPa. The aluminum powder is not pressed together by a mechanical force that substantially deforms particles of said aluminum powder either prior to or during the step of heating. Articles comprising sintered aluminum powder. The sintered aluminum powder has a transverse rupture strength of at least about 13.8 MPa. The microstructure of the sintered aluminum powder contains no compositional concentration gradients indicative of the use of a sintering aid and no evidence of particle deformation having occurred by an application of a mechanical force prior to or during the sintering of the aluminum powder.
Abstract:
A binder, and a method of using it in conventional powder metallurgy processes and solid free form fabrication including metal powder, or combinations of metals and ceramics, in which the binder contains at least one carbohydrate as the active binding compound. The carbohydrate generally contains between 6 and about 900 carbon atoms and may be selected from various categories including but not limited to: 1) monosaccharides; 2) disaccharides; 3) trisaccharides; and 4) polysaccharides containing the base sugars identified in 1)-3) above; and 5) hydrolyzed starches in which the hydrolysate contains between about 6-900 carbon atoms, including dextrins such as limit dextrin, hydrolyzed amylose, and hydrolyzed amylopectin. The amount of carbohydrate in the binder solution is generally on the order of about 5-50 grams carbohydrate per 100 ml of carrier solution, more preferably 5-30 g/ml, and most preferably 15 g/ml (or comparable amounts on a dry basis).
Abstract:
A green article comprising an A-B powder mixture and methods of manufacturing such green articles and corresponding sintered articles are disclosed. The A-B powder mixture consists of a minor volume fraction of a relatively fine powder A and a complementary major volume fraction of a relatively coarse prealloyed powder B wherein the A-B powder mean particle size ratio is at least about 1:5. Metal powder A consists of one or more elemental metals or alloys which has a melting or solidus temperature above the highest sintering temperature at which the A-B powder mixture may be sintered without slumping. Prealloyed metal powder B consists of one or more alloys which are amenable to supersolidus liquid phase sintering. Green articles made from the A-B powder have a wider sintering temperature window than do articles made from prealloyed metal powder B alone.