Process for producing a compressed metalic powder

Abstract

A powder compact process for producing a compressed powder comprising obtaining a powder-containing sealed mould by filling a mould with a pulverized powder and sealing the powder filled mould, placing the powder-containing sealed mould in an undeformable vessel containing a pre-determined volume of a water with a temperature of 4 °C, preparing a degassing water by sealing the undeformable vessel and evacuating air from the pre-determined volume of the pure water within the sealed vessel, and producing the compressed powder by generating a pressure more than 5000 bar via obtaining an equilibrium mixture of water and ice in a sealed undeformable vessel by placing the undeformable vessel containing the degassed water and the powder-containing sealed mould to a cold environment with a temperature in a range of 0 °C to - 50 °C.

Description

Ref-1403-02-3011PROCESS FOR PRODUCING A COMPRESSED METALIC POWDERTECHNICAL FIELD

[0001] The present disclosure is generally related to an exemplary powder compaction process for producing an exemplary compressed powder as well as an exemplary powder metallurgy method for fabrication an exemplary article using an exemplary produced compressed powder by disclosed powder compaction process.BACKGROUND

[0002] Powder metallurgy method is a process of molding metal parts from a plurality of metal powders by applying a high pressure to make a shape precise. In this method, at first step, a compressed metal powder must be provided and then a sintering process is done at a high temperature in a furnace with a controlled atmosphere, in which the compressed metal powder is welded in a cold state as a solid homogeneous structure. The sintering process is usually carried out at about 80% of a melting point of the compressed metal powder to allow a plurality of particles stick together along an interface of the compressed metal powder particles.

[0003] Various processes are used to produce compressed metal powder. One of these process is cold isostatic press that compress a pulverized metallic powder under a high pressure in a sealed vessel while the powders are poured in a flexible mould. The cold isostatic press has many advantages such as: producing a piece with a more uniform density, producing a part with indented comer and cut in a lower surface of the part, fabricating a plurality of pieces / parts with thinner walls, machining ability of produced parts before sintering, etc. Although, producing a compressed powder via using this process is costly due to requiring expensive equipment for providing a high pressure as well as their maintenance. Also, provided highRef-1403-02-3011 pressure in cold isostatic press is less than 100-200 bar and the powder may compressed for a short time that can affect the fusing of powder particles as well as a quality of final compressed powder and product.

[0004] Therefore, these is a need to develop a cost-effective and easy-to use process that can provide a required pressure for a needed time to fully compress a metallic / ceramic powder.

[0005] Herein, a cost-effective and easy-to use powder compaction process has been developed that can produce a compressed powder using generating a high pressure via obtaining an equilibrium mixture of water and ice in a sealed container with a constant volume for a desired time.SUMMARY

[0006] This summary is intended to provide an overview of the subject matter of the present disclosure, and is not intended to identify essential elements or key elements of the subject matter, nor is it intended to be used to determine the scope of the claimed implementations. Its sole purpose is to present some concepts of one or more exemplary aspects in a simplified form as a prelude to the more detailed description that is presented later. The proper scope of the present disclosure may be ascertained from the claims set forth below in view of the detailed description below and the drawings.

[0007] One or more exemplary embodiments describe an exemplary powder compaction process for producing an exemplary compressed powder. Exemplary powder compaction process may comprise obtaining an exemplary powder-containing sealed mould by filling an exemplary mould with an exemplary powder and sealing the exemplary powder filled-mould and producing exemplary compressed powder by exposing exemplary powder-containing sealed mould to an exemplary generated pressure of an exemplary equilibrium mixture of water and ice.Ref-1403-02-3011

[0008] In an exemplary embodiment, exposing exemplary powder-containing sealed mould to an exemplary generated pressure of an exemplary equilibrium mixture of water and ice may comprise placing the exemplary powder-containing sealed mould in an exemplary undeformable vessel with an exemplary first pre-determined temperature, pouring the exemplary undeformable vessel with an exemplary pre-determined volume of an exemplary water comprising an exemplary second pre-determined temperature, obtaining an exemplary sealed undeformable vessel by sealing the exemplary vessel containing the exemplary predetermined volume of the exemplary water and the exemplary powder-containing sealed mould, preparing an exemplary degassed water by evacuating air from an exemplary inner volume of the exemplary sealed undeformable vessel containing the exemplary pre-determined volume of the exemplary water and the exemplary powder-containing sealed mould, and generating the exemplary equilibrium mixture of water and ice with an exemplary predetermined pressure by subjecting the exemplary sealed undeformable vessel containing the exemplary degassed water to an exemplary cold environment with an exemplary third predetermined temperature. In an exemplary embodiment, the exemplary first pre-determined temperature and the exemplary second pre-determined temperature may be higher than the exemplary third pre-determined temperature.

[0009] In an exemplary embodiment, exemplary first pre-determined temperature and exemplary second pre-determined temperature may be adjusted in 4 °C. In an exemplary embodiment, exemplary first pre-determined temperature and second pre-determined temperature may be equal. In an exemplary embodiment, an exemplary third pre-determined temperature may be in an exemplary range of 0 °C to -50 °C

[0010] In an exemplary embodiment, exemplary pre-determined pressure may be in an exemplary range of 5000 bar to 8000 bar.Ref-1403-02-3011

[0011] In an exemplary embodiment, exemplary mold maybe made of an exemplary flexible material. In one or more exemplary embodiments, exemplary flexible material may be selected from a group of an exemplary silicon, an exemplary elastomer, an exemplary polyurethane, an exemplary poly (urethane urea), an exemplary fiber reinforced polymer composite, or an exemplary combination thereof.

[0012] Furthermore, one or more exemplary embodiments describe an exemplary powder metallurgy method for creating an exemplary article. Exemplary powder metallurgy method may comprise obtaining an exemplary compressed powder from the pulverized powder using an exemplary powder compaction process disclosed in one or more exemplary embodiments of the present disclosure, and producing exemplary article by sintering exemplary compressed powder in an exemplary sintering condition.

[0013] This Summary may introduce a number of concepts in a simplified format; the concepts are further disclosed within the “Detailed Description” section. This Summary is not intended to configure essential / key features of the claimed subject matter, nor is intended to limit the scope of the claimed subject matter.BRIEF DESCRIPTION OF THE DRAWINGS

[0014] The novel features which are believed to be characteristic of the present disclosure, as to its structure, organization, use and method of operation, together with further objectives and advantages thereof, will be better understood from the following drawings in which an exemplary embodiment will now be illustrated by way of example. It is expressly understood, however, that the drawings are for the purpose of illustration and description only and are not intended as a definition of the limits of the present disclosure. Exemplary embodiments will now be described by way of example in association with the accompanying drawings in which:Ref-1403-02-3011

[0015] FIG. 1 illustrates a flowchart of an exemplary compaction process for producing an exemplary compressed powder, consistent with one or more exemplary embodiments of the present disclosure;

[0016] FIG. 2 illustrates an exemplary flowchart of exposing an exemplary powdercontaining sealed mould to an exemplary generated pressure of an exemplary equilibrium mixture of water and ice to produce an exemplary compressed powder, consistent with one or more exemplary embodiments of the present disclosure;

[0017] FIG. 3 an exemplary flowchart of an exemplary powder metallurgy method for producing an exemplary article using an exemplary compressed powder, consistent with one or more exemplary embodiments of the present disclosure;

[0018] FIG. 4 illustrates optical microscopy images of (a) an exemplary produced article from an exemplary bronze compressed powder and (b) an exemplary produced article from an exemplary bronze compressed powder by an exemplary hydraulic press, consistent with one or more exemplary embodiments of the present disclosure;

[0019] FIG. 5 illustrates a scanning electron microscopy (SEM) image of an exemplary produced article from an exemplary bronze compressed powder, consistent with one or more exemplary embodiments of the present disclosure;

[0020] FIG. 6 illustrates a compression stress-strain curve of an exemplary produced article from an exemplary bronze compressed powder, consistent with one or more exemplary embodiments of the present disclosure; and

[0021] FIG. 7 illustrates a picture of an exemplary produced article from an exemplary bronze compressed powder after compression test, consistent with one or more exemplary embodiments of the present disclosure.DETAILED DESCRIPTIONRef-1403-02-3011

[0022] In the following detailed description, numerous specific details are set forth by way of examples to provide a thorough understanding of the relevant teachings related to the exemplary embodiments. However, it should be apparent that the present teachings may be practiced without such details. In other instances, well known methods, procedures, components, and / or circuitry have been described at a relatively high-level, without detail, in order to avoid unnecessarily obscuring aspects of the present teachings.

[0023] The following detailed description is presented to enable a person skilled in the art to make and use the methods and devices disclosed in one or more exemplary embodiments of the present disclosure. For purposes of explanation, specific nomenclature is set forth to provide a thorough understanding of the present disclosure. However, it will be apparent to one skilled in the art that these specific details are not required to practice the disclosed exemplary embodiments. Descriptions of specific exemplary embodiments are provided only as representative examples. Various modifications to the exemplary implementations will be plain to one skilled in the art, and the general principles defined herein may be applied to other implementations and applications without departing from the scope of the present disclosure. The present disclosure is not intended to be limited to the implementations shown, but is to be accorded the widest possible scope consistent with the principles and features disclosed herein.

[0024] Disclosed herein is an exemplary cost-effective and easy-to-use powder compaction process for producing an exemplary compressed powder. In an exemplary embodiment, “powder compaction process” may refer to a process that consolidate an exemplary metal powder and / or an exemplary ceramic powder to an exemplary desired shape under an exemplary determined pressure. In an exemplary embodiment, an exemplary generated pressure from an exemplary equilibrium mixture of water and ice in an exemplary sealed undeformable vessel may be used to consolidate exemplary metal powder and / orRef-1403-02-3011 ceramic powder. In an exemplary embodiment, “sealed undeformable vessel” may refer to a container made of a rigid material with a constant volume that is fully enclosed. Utilizing an exemplary generated pressure from an exemplary equilibrium mixture of water and ice in n an exemplary powder compaction process may be advantageous due to its ability to provide an exemplary pre-determined pressure of at least 5000 bar for an exemplary longer period of time compared to conventional apparatuses that are used for generating an exemplary required pressure in an exemplary powder compaction process. Additionally, the exemplary predetermined pressure can be increased by decreasing the temperature of an exemplary cold environment that is used to creating the exemplary equilibrium mixture of water and ice within the exemplary sealed undeformable vessel.

[0025] FIG. 1 illustrates flowchart of exemplary powder compaction process 100 for producing an exemplary compressed powder, consistent with one or more exemplary embodiments of the present disclosure. In an exemplary embodiment, powder compaction process 100 may comprise: obtaining an exemplary powder-containing sealed mould by filling an exemplary mould with an exemplary powder and sealing the exemplary powder filled- mould (102) and producing an exemplary compressed powder by exposing the exemplary powder-containing sealed mould to an exemplary generated pressure of an exemplary equilibrium mixture of water and ice (104).

[0026] In further detail with respect to step 102, step 102 may comprise obtaining an exemplary powder-containing sealed mould by filling an exemplary mould with an exemplary powder and sealing the exemplary powder filled-mould. In an exemplary embodiment, exemplary powder may be a metal powder, a ceramic powder, a combination thereof, or any types of powder that are well-known for those skilled in the art. In an exemplary embodiment, the exemplary powder may be pulverized utilizing a grinding apparatus until a particle size ofRef-1403-02-3011 the exemplary produced powder is adjusted in a range of 0.10 pm to 100 mp. In an exemplary embodiment, an exemplary grinding apparatus may comprise, for example, but is not limited to, an exemplary mill, an exemplary ball mill, jet mill, roller mill, crystallizer mill, centrifugal mill, and / or other types of grinding apparatus that are well-known for those skilled in the art. In an exemplary embodiment, if a combination of an exemplary plurality of powders are used, an exemplary mixing apparatus may be used to mix the exemplary plurality of powders results in obtaining an exemplary uniform mixture of exemplary plurality of powders. In an exemplary embodiment, the exemplary mixing apparatuses may comprise, for example, but is not limited to, an exemplary V-blender, an exemplary ribbon blender, an exemplary cone blender, an exemplary paddle blender, an exemplary fluid bed blender, an exemplary blunger, and / or other types of mixing apparatuses that are well-known for those skilled in the art. In one or more exemplary embodiment, the exemplary mould may be made of an exemplary flexible material. In an exemplary embodiment, “flexible material” may refer to a type of material that can deform and / or bend out under an applied stress and can be return to its original shape after removing the applied stress. In one or more exemplary embodiment, the exemplary flexible material may be selected from a group of an exemplary silicon, an exemplary elastomer, an exemplary polyurethane, an exemplary poly (urethane urea), an exemplary fiber reinforced polymer composite, an exemplary combination thereof, and / or other type of flexible materials that are well-known for those skilled in the art. In an exemplary embodiment, an exemplary inner surface of the exemplary mould may be made of an exemplary anti-corrosion coating and / or an exemplary anti-corrosion material that can protect the mould from corrosion under an exemplary high pressure. In one or more exemplary embodiments, the exemplary anticorrosion coating may comprise, for example, but is not limited to, an exemplary metallic coating, an exemplary galvanized coating, an exemplary polymeric coating, an exemplary paintRef-1403-02-3011 coating, an exemplary ceramic coating, and / or other types of anti-corrosion coating that are well-known for those skilled in the art. In one or more exemplary embodiments, the exemplary anti-corrosion material may comprise, for example, but is not limited to, stainless steel, an exemplary galvanized material, a combination thereof, and / or other types of anti-corrosion material that are well-known for those skilled in the art.

[0027] In further detail with respect to step 104, step 104 may comprise producing an exemplary compressed powder by exposing the exemplary powder-containing sealed mould to an exemplary generated pressure of an exemplary equilibrium mixture of water and ice. FIG.2 illustrates an exemplary flowchart of exposing an exemplary powder-containing sealed mould to an exemplary generated pressure of an exemplary equilibrium mixture of water and ice to produce an exemplary compressed powder, consistent with one or more exemplary embodiments of the present disclosure. As illustrated in FIG.2, exposing the exemplary powder-containing sealed mould to an exemplary generated pressure of an exemplary equilibrium mixture of water and ice may comprise placing the powder-containing sealed mould in an exemplary undeformable vessel with an exemplary first pre-determined temperature (202), pouring an exemplary undeformable vessel with an exemplary predetermined volume of an exemplary water comprising an exemplary second pre-determined temperature (204), obtaining an exemplary sealed undeformable vessel by sealing the exemplary vessel containing the exemplary pre-determined volume of the exemplary water and the exemplary powder-containing sealed mould (206), preparing an exemplary degassed water by evacuating air from an exemplary inner volume of the exemplary sealed undeformable vessel containing the exemplary pre-determined volume of the exemplary water and powdercontaining sealed mould (208), and generating the exemplary equilibrium mixture of water and ice with an exemplary pre-determined pressure by subjecting the exemplary sealedRef-1403-02-3011 undeformable vessel containing the exemplary degassed water and powder-containing sealed mould to an exemplary cold environment with an exemplary third pre-determined temperature (210). In one or more exemplary embodiment, the exemplary first and second pre-determined temperatures may be higher than the exemplary temperature in the range of 0 °C to -50 °C.

[0028] In further detail with respect to step 202, step 202 may comprise placing the powder-containing sealed mould in an exemplary undeformable vessel with an exemplary first pre-determined temperature. In an exemplary embodiment, the exemplary first pre-determined temperature may be 4 °C. In one or more exemplary embodiments, the first pre-determined temperature of the exemplary undeformable vessel may be in a range of 3 °C to 20 °C. In an exemplary embodiment, the exemplary undeformable vessel may be an exemplary doublewalled compartment that an exemplary ratio of an exemplary inner diameter to an exemplary outer diameter of the exemplary double-walled compartment should be such that the exemplary double-walled compartment can withstand an exemplary generated pressure by the exemplary equilibrium mixture of water and ice. In one or more exemplary embodiment, the exemplary undeformable vessel can have a shape, for exemplar, but is not limited to, cylindrical, spherical, and / or a combination thereof. In one or more exemplary embodiments, the exemplary undeformable vessel may be made of, for example, but is not limited to, an exemplary stainless steel, an exemplary carbon steel, an exemplary nickel / chromium alloy, titanium, and / or a combination thereof In an exemplary embodiment, the exemplary undeformable vessel may comprise at least two parts comprising an exemplary movable part and an exemplary fixed part that the exemplary movable part can be mounted on an exemplary top surface of the exemplary fixed part.

[0029] In further detail with respect to step 204, step 204 may comprise pouring the exemplary undeformable vessel with an exemplary pre-determined volume of an exemplaryRef-1403-02-3011 water comprising an exemplary second pre-determined temperature. In one or more exemplary embodiments, the first pre-determined temperature of the exemplary water may be in a range of 3 °C to 20 °. In one or more exemplary embodiment, the exemplary second pre-determined temperature may be 4 °C. In one or more exemplary embodiments, the exemplary first predetermined temperature of the exemplary undeformable vessel may be as same as the exemplary second temperature of the exemplary water and adjusted less than 4°C. In an exemplary embodiment, an exemplary water used for pouring the exemplary undeformable vessel may comprise purified water, distilled water, double-distilled water, or ultrapure water. “Ultrapure water” may refer to a water that has been purified using a combination of ultrafiltration technologies and ultraviolet photo-oxidation system. In an exemplary embodiment, the exemplary pre-determined volume of water, that may be varied based on an exemplary volume of undeformable vessel, was poured into the exemplary undeformable vessel.

[0030] In further detail with respect to step 206, step 206 may comprise obtaining an exemplary sealed undeformable vessel by sealing the exemplary undeformable vessel containing the exemplary pre-determined volume of the exemplary water and the exemplary powder-containing sealed mould. In an exemplary embodiment, sealing the exemplary sealed undeformable vessel may be done utilizing closing and fixing the exemplary movable part of the exemplary undeformable vessel on the exemplary top surface of the exemplary fixed part of the exemplary undeformable vessel.

[0031] In further detail with respect to step 208, step 208 may comprise preparing an exemplary degassed water by evacuating air from an exemplary inner volume of the exemplary sealed undeformable vessel containing the exemplary pre-determined volume of the exemplary water and powder-containing sealed mould. In an exemplary embodiment, evacuating air fromRef-1403-02-3011 the exemplary inner volume of the exemplary sealed undeformable vessel may comprise connecting an exemplary vacuum evacuation apparatus to the exemplary fixable and / or movable parts of the exemplary undeformable vessel and applying an exemplary low pressure atmosphere to the exemplary inner volume of the exemplary undeformable vessel or embedding at least one hole on the exemplary fixable and / or movable parts of the exemplary undeformable vessel. In an exemplary embodiment, the exemplary vacuum apparatus may comprise, for example, but is not limited to, a vacuum pump and / or other types of vacuum apparatus that are well-known for those skilled in the art.

[0032] In further detail with respect to step 210, step 210 may comprise generating an exemplary equilibrium mixture of water and ice with an exemplary pre-determined pressure by subjecting the exemplary sealed undeformable vessel containing the exemplary degassed water and powder-containing sealed mould to an exemplary cold environment with an exemplary third pre-determined temperature. In an exemplary embodiment, subjecting the exemplary sealed undeformable vessel to the exemplary cold environment may comprise placing the exemplary sealed undeformable vessel to an exemplary refrigeration system for providing an exemplary cold environment with the exemplary third pre-determined temperature for an exemplary pre-determined time. In one or more exemplary embodiments, an exemplary temperature level of an exemplary inner space of the exemplary refrigeration system may be as same as the exemplary third pre-determined temperature. In an exemplary embodiment, the exemplary pre-determined pressure may be created due to generation of the exemplary equilibrium mixture of water and ice because of inability to provide an exemplary required volume for expanding the exemplary degassed water upon freezing to ice within an exemplary constant volume of the exemplary undeformable vessel. In one or more exemplary embodiments, the generated pressure due to production of the exemplary equilibrium mixtureRef-1403-02-3011 of water and ice may compress the exemplary powder within the exemplary mould and the exemplary compressed powder may be produced. In an exemplary embodiment, the exemplary generated pre-determined pressure due to creation of the exemplary equilibrium mixture of water and ice may be more than 8000 bar, more particularly more than 5000 bar. In one or more exemplary particular embodiments, the exemplary pre-determined pressure may be in an exemplary range of 5000 bar to 8000 bar.

[0033] In an exemplary embodiment, the exemplary third pre-determined temperature may be in an exemplary range of 0 °C to -50 °C. In an exemplary embodiment, the exemplary undeformable vessel containing the exemplary degassed water and powder-containing sealed mould may be placed within the exemplary refrigeration system for the exemplary predetermined time of 5 minutes to 60 minutes.

[0034] In one or more exemplary embodiments, the exemplary powder compaction process 100 may further comprise separating the exemplary produced compressed powder from the exemplary mould by heating the exemplary mould to an exemplary fourth temperature. In one or more exemplary embodiments, the exemplary fourth temperature may be an exemplary room temperature. In one or more exemplary embodiments, the exemplary fourth temperature in an exemplary range of 20°C to 100 °C may be applied to the exemplary mould containing the exemplary produced compressed powder to separate the exemplary produced compressed powder.

[0035] Disclosed herein is further an exemplary cost-effective powder metallurgy method for preparing an exemplary article. In an exemplary embodiment, “powder metallurgy method” may refer to a process that produce an exemplary article from an exemplary mixture of metallic and / or ceramic material through compacting the exemplary mixture of metallic and / or ceramic material and sintering an exemplary compressed powder in an exemplaryRef-1403-02-3011 sintering condition in an exemplary temperature below an exemplary melting temperature of the exemplary mixture of metallic and / or ceramic material. In an exemplary embodiment, “article” may refer to a shaped metallic / ceramic material that a plurality of metallic / ceramic particles are physically bonding together.

[0036] FIG.3 illustrates a flowchart of an exemplary powder metallurgy method 300 for producing an exemplary article, consistent with one or more exemplary embodiments of the present disclosure. In an exemplary embodiment, metallurgy method 300 may comprise obtaining an exemplary compressed powder from the exemplary pulverized powder by an exemplary powder compaction process according to one or more exemplary embodiments of the present disclosure (302), and producing the exemplary article by sintering the exemplary compressed powder in an exemplary sintering condition (304).

[0037] In further detail with respect to step 306, step 306 may comprise producing the exemplary article by sintering the exemplary compressed powder in an exemplary sintering condition. In an exemplary embodiment, sintering the exemplary compressed powder produced from an the exemplary powder compaction process 100 consistent with one or more exemplary embodiment of the present disclosure may comprise heating the exemplary compressed powder in an exemplary heating apparatus under an exemplary sintering temperature, an exemplary sintering heating rate, an exemplary sintering gas with an exemplary pre-determined gas flow rate. In an exemplary embodiment, the exemplary sintering temperature may be adjusted in a temperature below an exemplary melting point of the exemplary pulverized powder. In one or more exemplary embodiments, the exemplary sintering temperature may be adjusted in an exemplary temperature in accordance with 70 % to 80 % of melting point of the pulverized powder. The exemplary sintering gas may be chosen based on an exemplary type of the exemplary pulverized power, the exemplary sintering powder, and an exemplary desiredRef-1403-02-3011 physical-mechanical properties of the exemplary produced article. In one or more exemplary embodiments, the exemplary sintering gas may be selected from an exemplary neutral gas, an exemplary reducing gas or an exemplary combination thereof. In an exemplary embodiment, sintering gas may be selected from a group of argon, nitrogen, carbon dioxide, helium, hydrogen, or ammonia, or a combination thereof. In one or more exemplary embodiment, the sintering gas may have an exemplary flow rate in an exemplary range of 0.1000 Lmin1to 100000 Lmin1EXAMPLES

[0038] Hereinafter, one or more exemplary embodiments will be described in further detail with reference to examples. It will be obvious to a person having ordinary skill in the art that these examples may be for illustrative purposes only and are not to be interpreted to limit the scope of the present disclosure.Example 1: Producing of A Bronze Compressed Powder

[0039] In this example, exemplary compressed powder from bronze pulverized powder was produced based on an exemplary method similar process 100. To produce exemplary compressed powder of bronze metal, first an exemplary bronze pulverized powder was poured into an exemplary flexible mould and then exemplary flexible mould contain exemplary pulverized powder was sealed. Afterward, exemplary sealed pulverized powder-containing mould was put within an exemplary undeformable vessel. Following that, an exemplary volume of pure water in a range of 1000 ml to 10000 ml was poured into exemplary undeformable vessel such that exemplary volume of pure water encompassed exemplary sealed pulverized powder-containing mould. In next step, the exemplary undeformable vessel was sealed and an exemplary inner volume of exemplary undeformable vessel was degassed byRef-1403-02-3011 evacuating air and any other existence gases from the inner volume utilizing an exemplary vacuum pump. Following that, exemplary sealed undeformable vessel containing exemplary degassed pure water as well as exemplary sealed pulverized powder-containing mould was placed within a refrigerator to provide an exemplary cold environment with an exemplary temperature of 0 to -50 °C while an exemplary temperature of exemplary sealed undeformable temperature exemplary degassed pure water as well as exemplary sealed pulverized powdercontaining mould was 4 °C. After an exemplary pre-determined time of ...h to... h, the exemplary pulverized powder within the exemplary mould was compressed due to generating an exemplary pressure in a range of 5000 bar to 8000 bar by an exemplary produced equilibrium mixture of water and ice in a constant inner volume of the exemplary sealed undeformable vessel. Afterward, the exemplary sealed undeformable vessel containing exemplary equilibrium mixture of water and ice as well as compressed powder-containing mould was subjected to a room temperature to reduce and / or eliminate the exemplary generated pressure. Following that, the exemplary sealed undeformable vessel was opened and the exemplary produced bronze compressed powder was taken out of the exemplary mould.

[0040] Example 2: Producing of An Article Utilizing A Bronze Compressed Powder

[0041] In this example, exemplary an exemplary article from the exemplary produced bronze compressed powder of “Example 1” was produced based on an exemplary process similar method 300. To produce exemplary article of bronze metal, the exemplary produced compressed powder of “Example 1” was sintering in an exemplary sintering condition comprising an exemplary sintering temperature of 700 °C to °900 C with a heating rate of 5 °C / min for 4 hours under hydrogen gas with a gas flow rate of 600 ml / min.Example 3: Characterization of Article Produced from Bronze Compressed PowderRef-1403-02-3011

[0042] In this example, exemplary produced article from exemplary bronze compressed powder in “Example 2” were characterized by physical and mechanical tests. The morphology and particle size were examined using scanning electron microscopy (SEM) and optical microscopy, respectively. The exemplary results were compared to an exemplary produced article from an exemplary bronze compressed powder using an exemplary hydraulic press.

[0043] The exemplary produced article from exemplary bronze compressed powder (Ai) indicates an exemplary particle size of 115 pm while exemplary produced article from an exemplary bronze compressed powder using an exemplary hydraulic press (A2) a particle size of 84 pm. Also, as illustrated in FIG. 4 a-b, exemplary Ai have a negligible holes between powder particles although the exemplar A2 indicates more holes and particle size has become smaller that confirms the particles are fusing together very well in exemplary Ai.

[0044] Furthermore, SEM image (FIG.5) illustrates that exemplary produced article has an exemplary uniform condensation and very high density. Furthermore, a plurality of air holes on an exemplary surface of exemplary produced article are very small.

[0045] The exemplary results of specific density as well as hardness of exemplary produced article from exemplary bronze compressed powder (Ai) and produced article from an exemplary bronze compressed powder using an exemplary hydraulic press (A2) were listed in Table.l.Table.l: Physical and Mechanical Properties of Samples

[0046] These exemplary results set forth in Table. 1 may indicate that exemplary article produced from exemplary bronze compressed powder by the disclosed process 100 may showRef-1403-02-3011 a higher specific density and hardness compared to exemplary article produced from exemplary bronze compressed powder by common process.

[0047] Furthermore, compression mechanical properties of exemplary produced article from exemplary produced compressed powder (Ai) were examined by compression test. FIG.6 illustrates compression stress-strain curve of Ai, consistent with one or more exemplary embodiments of the present disclosure. The results of compression mechanical properties of the sample Ai was listed in Table.2.Table.2: Compression Mechanical Properties of Exemplary Produced Article from Exemplary Bronze Compressed Powder

[0048] As illustrated in FIG.6 as well as Table.2, exemplary Ai was exhibited an exemplary compressive stress of 612 MPa, an exemplary yield stress of about 187 MPa, and an exemplary strain of -76.52%, an exemplary Young modulus of 3.73 GPa, and an exemplary toughness of 308.44. Additionally, FIG.7 indicates that the exemplary Ai has kept its shape under pressure.

[0049] These results confirmed that the produced article from compressed powder using the exemplary process 100 disclosed in one or more exemplary of the present disclosure have a good physical and mechanical properties to produce different parts in many industries.

[0050] While the foregoing has described what are considered to be the best mode and / or other examples, it is understood that various modifications may be made therein and that the subject matter disclosed herein may be implemented in various forms and examples, and that the teachings may be applied in numerous applications, only some of which have beenRef-1403-02-3011 described herein. It is intended by the following claims to claim any and all applications, modifications and variations that fall within the true scope of the present teachings.

[0051] Unless otherwise stated, all measurements, values, ratings, positions, magnitudes, sizes, and other specifications that are set forth in this specification, including in the claims that follow, are approximate, not exact. They are intended to have a reasonable range that is consistent with the functions to which they relate and with what is customary in the art to which they pertain.

[0052] The scope of protection is limited solely by the claims that now follow. That scope is intended and should be interpreted to be as broad as is consistent with the ordinary meaning of the language that is used in the claims when interpreted in light of this specification and the prosecution history that follows and to encompass all structural and functional equivalents. Notwithstanding, none of the claims are intended to embrace subject matter that fails to satisfy the requirement of Sections 101, 102, or 103 of the Patent Act, nor should they be interpreted in such a way. Any unintended embracement of such subject matter is hereby disclaimed.

[0053] Except as stated immediately above, nothing that has been stated or illustrated is intended or should be interpreted to cause a dedication of any component, step, feature, object, benefit, advantage, or equivalent to the public, regardless of whether it is or is not recited in the claims.

[0054] It will be understood that the terms and expressions used herein have the ordinary meaning as is accorded to such terms and expressions with respect to their corresponding respective areas of inquiry and study except where specific meanings have otherwise been set forth herein. Relational terms such as first and second and the like may be used solely to distinguish one entity or action from another without necessarily requiring or implying any actual such relationship or order between such entities or actions. An element proceeded byRef-1403-02-3011“a” or “an” does not, without further constraints, preclude the existence of additional identical elements in the process, method, article, or apparatus that comprises the element.

[0055] Unless otherwise stated, all measurements, values, ratings, positions, magnitudes, sizes, and other specifications that are set forth in this specification, are approximate, not exact. They are intended to have a reasonable range that is consistent with the functions to which they relate and with what is customary in the art to which they pertain.

[0056] It will be understood that the terms and expressions used herein have the ordinary meaning as is accorded to such terms and expressions with respect to their corresponding respective areas of inquiry and study, except where specific meanings have otherwise been set forth herein. Relational terms such as “first” and “second” and the like may be used solely to distinguish one entity or action from another without necessarily requiring or implying any actual such relationship or order between such entities or actions.

[0057] The Abstract of the Disclosure is provided to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. In addition, in the foregoing Detailed Description, it may be seen that various features are grouped together in various implementations. This is for purposes of streamlining the disclosure, and is not to be interpreted as reflecting an intention that the claimed implementations require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter lies in less than all features of a single disclosed implementation. Thus, the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separately claimed subject matter.While various implementations have been described, the description is intended to be exemplary, rather than limiting and it will be apparent to those of ordinary skill in the art thatRef-1403-02-3011 many more implementations and implementations are possible that are within the scope of the implementations. Although many possible combinations of features are shown in the accompanying figures and discussed in this detailed description, many other combinations of the disclosed features are possible. Any feature of any implementation may be used in combination with or substituted for any other feature or element in any other implementation unless specifically restricted. Therefore, it will be understood that any of the features shown and / or discussed in the present disclosure may be implemented together in any suitable combination. Accordingly, the implementations are not to be restricted except in light of the attached claims and their equivalents. Also, various modifications and changes may be made within the scope of the attached claims.

Claims

Ref-1403-02-3011What is claimed is:

1. A powder compaction process for producing a compressed powder comprising: obtaining a powder-containing sealed mould by filling a mould with a pulverized powder and sealing the powder filled mould; placing the powder-containing sealed mould in an undeformable vessel containing a pre-determined volume of a water with a temperature of 4 °C; preparing a degassing water by sealing the undeformable vessel and evacuating air from the pre-determined volume of the pure water within the sealed vessel; producing the compressed powder by placing the undeformable vessel containing the degassed water and the powder-containing sealed mould to a cold environment with a temperature in a range of 0 °C to -50 °C.

2. A powder compaction process for producing a compressed powder comprising: obtaining a powder-containing sealed mould by filling a mould with a powder and sealing the powder filled-mould; and producing the compressed powder by exposing the powder-containing sealed mould to a generated pressure of an equilibrium mixture of water and ice.

3. The powder compaction process of claim 2, wherein exposing the powder-containing sealed mould to the generated pressure of the equilibrium mixture of water and ice comprises following steps: placing the powder-containing sealed mould in an undeformable vessel with a first pre-determined temperature;Ref-1403-02-3011 pouring the undeformable vessel with a pre-determined volume of a water comprising a second pre-determined temperature; obtaining a sealed undeformable vessel by sealing the vessel containing the predetermined volume of the water and the powder-containing sealed mould; preparing a degassed water by evacuating air from an inner volume of the sealed undeformable vessel containing the pre-determined volume of the water and the powdercontaining sealed mould; and generating the equilibrium mixture of water and ice with a pre-determined pressure by subjecting the sealed undeformable vessel containing the degassed water to a cold environment with a third pre-determined temperature wherein the first pre-determined temperature and the second pre-determined temperature are higher than the third pre-determined.

4. The powder compaction process of claim 3, wherein the first pre-determined temperature and the second pre-determined temperature are adjusted in 4 °C.

5. The powder compaction process of claim 3, wherein the first pre-determined temperature and the second pre-determined temperature are equal.

6. The powder compaction of claim 3, wherein the third temperature is in a range of 0 °C to -50 °C7. The powder compaction process of claim 3, wherein the pre-determined pressure is in a range of 5000 bar to 8000 bar.

8. The powder compaction process of claim 3, wherein the mold is made of a flexible material.

9. The powder compaction process of claim 8, wherein the flexible material is selected from a group of a silicon, an elastomer, a polyurethane, a poly (urethane urea), a fiber reinforced polymer composite, or a combination thereof.Ref-1403-02-301110. A powder metallurgy method for creating an article comprising: obtaining a compressed powder from the pulverized powder by a powder compaction process of any one of claims 1 to 9; and producing the article by sintering the compressed powder in a sintering condition.

11. The powder metallurgy method of claim 10, wherein the sintering condition comprise a sintering temperature, a sintering heating rate under a sintering gas with a pre-determined gas flow rate.

12. The powder metallurgy method of claim 10, wherein the sintering temperature is adjusted in a temperature in accordance with 70-80% of melting point of the pulverized powder.

13. The powder metallurgy method of claim 11, wherein the sintering gas is selected from a group of argon, nitrogen, carbon dioxide, helium, hydrogen, or ammonia.

14. The powder metallurgy method of claim 11, wherein the gas flow rate is adjusted in a range of 0.1000 Lmin1to 100000 Lmin1.

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