2721 results about "Iron alloys" patented technology

A method of manufacturing a bit body, other drilling-related component, or other article of manufacture, including fabricating a particulate-based matrix and infiltrating the particulate-based matrix with a binder that includes cobalt or iron. The binder may be a cobalt alloy or an iron alloy. The particulate-based matrix may be disposed within a non-graphite mold. The particulate-based matrix and binder are placed within an induction coil and an alternating current is applied to the induction coil in order to directly heat the binder, permitting the binder to infiltrate or otherwise bind the particles of the matrix together. The molten binder may then be directionally cooled by forming a cooling zone around an end portion of the bit body and increasing the size of the cooling zone relative to the bit body. The invention also includes a bit body, other drilling-related component, or other article of manufacture which includes a particulate-based matrix that is bound together with a binder that includes iron or cobalt.

A method for coating a surface of a component formed from aluminum or an alloy thereof includes the step of cold gas-dynamic spraying a powder material on the component surface to form a coating, the powder material comprising at least one alloy from the group consisting of titanium, a titanium alloy, nickel, a nickel alloy, iron, an iron alloy, aluminum, an aluminum alloy, copper, a copper alloy, cobalt, and a cobalt alloy. In one embodiment, the method further includes the step of heat treating the turbine component after the cold gas-dynamic spraying.

A method of fabricating an acoustic resonator includes forming a ferromagnetic compensator, such as one comprised of a nickel-iron alloy, which at least partially offsets temperature-induced effects introduced by an electrode-piezoelectric stack. The compensator has a positive temperature coefficient of frequency, while the stack has a negative temperature coefficient of frequency. By properly selecting the thickness of the compensator, temperature-induced effects on resonance may be neutralized. Alternatively, the thickness can be selected to provide a target positive or negative composite temperature coefficient of frequency. In order to prevent undue electromagnetic losses in the ferromagnetic compensator, a metallic flashing layer may be added to at least partially enclose the compensator.

Particulate skeletal iron catalyst is provided which contain at least about 50 wt. % iron with the remainder being a minor portion of a suitable non-ferrous metal and having characteristics of 0.062-1.0 mm particle size, 20-100 m2/g surface area, and 10-40 nm average pore diameter. Such skeletal iron catalysts are prepared and utilized for producing synthetic hydrocarbon products from CO and H2 feeds by Fischer-Tropsch synthesis process. Iron powder is mixed with non-ferrous powder selected from aluminum, antimony, silicon, tin or zinc powder to provide 20-80 wt. % iron content and melted together to form an iron alloy, then cooled to room temperature and pulverized to provide 0.1-10 mm iron alloy catalyst precursor particles. The iron alloy pulverized particles are treated with NaOH or KOH caustic solution at 30-95° C. temperature to extract and/or leach out most of the non-ferrous metal portion, and then screened and treated by drying and reducing with hydrogen and to provide the smaller size skeletal iron catalyst material. Such skeletal iron catalyst is utilized with CO+H2 feedstream for Fischer-Tropsch reactions in either a fixed bed or slurry bed type reactor at 180-350° C. temperature, 0.5-3.0 mPa pressure and gas hourly space velocity of 0.5-3.0 L/g Fe/hr to produce desired hydrocarbon products.

The invention discloses an aluminum-based dot matrix material based on 3D printing technology. In the dot matrix material, industrial pure aluminum or any aluminum alloy is employed as a base body. Unit cell configuration and a periodic structure thereof are modeled and designed with CATIA software and the model is produced from high-molecular materials through the 3D printing technology. An investment casting shell mould is prepared from soluble gypsum and the aluminum-based dot matrix material is prepared through an air-pressure seepage process. The aluminum-based dot matrix material can be in a pyramid type, a Kagome type and a grating type in the unit cell configuration. The invention also provides a sandwiched plate composite structure composed of the dot matrix material and a compact surface plate. The diameter of a unit cell bar is 0.5-5.0 mm, the length of the unit cell bar is 0.5-15.0 mm, and an included angle between the unit cell bar and a protective surface is 30-70 degrees. The compact surface plate is made from industrial pure aluminum, aluminum alloy, iron alloy or high-molecular materials. The dot matrix material with the industrial pure aluminum as the base body can reach higher than 5 MPa/g*cm<-3> in specific compressive strength.

An element for an inductive coupler in a downhole component comprises magnetically conductive material, which is disposed in a recess in annular housing. The magnetically conductive material forms a generally circular trough. The circular trough comprises an outer generally U-shaped surface, an inner generally U-shaped surface, and two generally planar surfaces joining the inner and outer surfaces. The element further comprises pressure relief grooves in at least one of the surfaces of the circular trough. The pressure relief grooves may be scored lines. Preferably the pressure relief grooves are parallel to the magnetic field generated by the magnetically conductive material. The magnetically conductive material is selected from the group consisting of soft iron, ferrite, a nickel iron alloy, a silicon iron alloy, a cobalt iron alloy, and a mu-metal. Preferably, the annular housing is a metal ring.

An electrode for an ignition device is made from a Ni-based nickel-chromium-iron alloy which has improved resistance to high temperature oxidation, sulfidation, corrosive wear, deformation and fracture includes, by weight of the alloy: 14.5-25% chromium; 7-22% iron; 0.2-0.5% manganese; 0.2-0.5% silicon; 0.1-2.5% aluminum; 0.05-0.15% titanium; 0.01-0.1% total of calcium and magnesium; 0.005-0.5% zirconium; 0.001-0.01% boron, and the balance substantially Ni. It may also include at least one rare earth element selected from the group consisting of: yttrium, hafnium, lanthanum, cerium and neodymium in amounts ranging from 0.01-0.15% by weight, and incidental impurities, including cobalt, niobium, molybdenum, copper, carbon, lead, phosphorus or sulfur. These total of these impurities will typically be controlled to limits of 0.1% cobalt, 0.05% niobium, 0.05% molybdenum, 0.01% copper, 0.01% carbon, 0.005% lead, 0.005% phosphorus and 0.005% sulfur. The ignition device may be a spark plug which includes a ceramic insulator, a conductive shell, a center electrode disposed in the ceramic insulator having a terminal end and a sparking end with a center electrode sparking surface, and a ground electrode operatively attached to said shell having a ground electrode sparking surface, the center electrode sparking surface and the ground electrode sparking surface defining a spark gap therebetween. At least one of the center electrode or the ground electrode includes the solution-strengthened Ni-based nickel-chromium-iron alloy. The Ni-based nickel-chromium-iron alloy electrodes of the invention may also include a core with thermal conductivity greater than that of the Ni-based nickel-chromium-iron alloy, such as copper or silver or their alloys.

The invention discloses a rare earth aluminum alloy, and a method and a device for preparing the same. The alloy contains at least one rare earth metal of lanthanum, cerium, praseodymium, neodymium, gadolinium, terbium, dysprosium, holmium, erbium, thulium, lutetium, scandium and yttrium, the content of raw earth is 5 to 98 weight percent, and the balance is aluminum and inevitable impurities. The device for preparing the rare earth aluminum alloy is characterized in that: a) graphite serves as an electrolysis bath, a graphite plate is an anode, a tungsten bar is a cathode and a molybdenum crucible serves as a rare earth aluminum alloy receiver; b) the diameter of the tungsten bar is 30 to 55 mm; and c) the anode of the graphite consists of a plurality of graphite plates. The rare earth aluminum alloy, and the method and the device for preparing the same have the advantages that: the alloy has uniform components, little segregation and low impurity content; technology for preparing the rare earth aluminum alloy through fusion electrolysis can maximally replace a process for preparing single medium-heavy metal through metallothermic reduction, greatly reduce energy consumption and the emission of fluorine-containing tail gas and solid waste residue, improve current efficiency and metal yield and reduce the consumption of auxiliary materials and the energy consumption; and the rare earth aluminum alloys with different rare earth contents can be obtained by controlling different electrolytic temperatures and different cathode current densities.

The invention relates the dysprosium-iron alloy technology with fused salt electrolysis process and device, belonging to rare-earth products preparing field. The method comprises the following steps: at high temperature, dysprosium oxide melting at fluoride, dysprosium oxide beginning ionizing; at the condition of 95V/M direct current field, separating out Dy3+ on the surface of iron cathode, deacidizing Dy3+ to Dy, and alloying Dy and Fe to form Dy-Fe. O2- is oxygenated to O2 on the surface of graphite cathode, and it reacts with carbite to form CO2. The melting point of dysprosium-iron (20úÑFe) is 1046Deg.C, and the melting point of Dy is 1407Deg.C, so the electrolyzation is carried out at 1050Deg.C. The invention has the advantages of low investment, low cost, simple technology, continuous production and low impurity content.

A wear resistant, high-impact iron alloy member (20,22) suitable for use in an impact rock crusher and a method of making the same. The invention provides a white iron alloy member (20,22) having at least one wear surface (24) with carbide granules encapsulated in a matrix (28) of white iron and contained in a selected region adjacent the wear surface (24) of the member (20,22). The iron alloy member is made by a method of casting comprising the steps of: placing a molding insert (35,40) in a mold (60) at a selected location adjacent the wear surface (24); positioning a quantity of carbide granules (29), most preferably tungsten carbide granules 29, in the molding insert (35,40) before pouring; and pouring molten white iron alloy into the mold (60) to form the casting. The tungsten carbide granules (29) are substantially contained at a selected location by the molding insert (35,40), and the resulting casting (20,22) can be heat treated and cooled to provide a component for a rock crusher or the like which exhibits improved resistance to wear.

A control system and method of use that enables friction stir welding of metal matrix composites, ferrous alloys, non-ferrous alloys, and superalloys when using a superabrasive tool, wherein the control system and method enables control of various operational aspects of a friction stir welding mill in order to make it possible to perform friction stir welding that is repeatable, reliable, and results in a superior finished workpiece.

The magnetic composite material of the present invention is used as a working substance in the magnetic refrigeration system and comprising at least two phases, including, a first phase composed of an intermetallic compound represented by a general formula: La(Fe(Co, Ni)Si)₁₃, having an NaZn₁₃ type crystal structure, and a second phase is composed of an iron alloy containing Si. The first phase is precipitated in an expansion size of 100 μm or less in average. Preferably, the magnetic composite material contains Fe as a principal component, La in an amount from 4 atomic % to 12 atomic %, Si in an amount from 2 atomic % to 21 atomic %, and Co and Ni in a total amount from 0 atomic % to 11 atomic %, and the total amount of Fe, Co and Ni being from 75 atomic % to 92 atomic %.

A process comprises manufacturing an electromigration-resistant under-bump metallization (UBM) flip chip structure comprising a Cu layer by applying to the Cu layer a metallic reaction barrier layer comprising NiFe. The solder employed in the flip chip structure comprise substantially lead-free tin. A structure comprises a product produced by this process. In another embodiment a process comprises manufacturing an electromigration-resistant UBM Sn-rich Pb-free solder bump flip chip structure wherein the electromigration-resistant UBM structure comprises a four-layer structure, or a three-layer structure, wherein the four layer structure is formed by providing 1) an adhesion layer, 2) a Cu seed layer for plating, 3) a reaction barrier layer, and 4) a wettable layer for joining to the solder, and the three-layer structure is formed by providing 1) an adhesion layer, 2) a reaction barrier layer, and 3) a wettable layer. In a further embodiment, the reaction barrier layer comprises metals selected from Ni, Fe, Pd, Pt, Co, Cu and their alloys, and combinations thereof. A structure comprises a product produced by the immediately foregoing process.

A magnetic core made of a mixed material including powder of an amorphous soft magnetic iron alloy and about 10% by volume or more of nonmagnetic inorganic powder, the amorphous soft magnetic iron alloy being expressed by the following composition:

Fe_{100-a-b-x-y-z-w-t}CO_aNi_bM_xP_yC_zB_wSi_t

wherein M is one or two or more elements selected from among Cr, Mo, W, V, Nb, Ta, Ti, Zr, Hf, Pt, Pd and Au, and a, b, x, y, z, w and t represent composition ratios satisfying 0 atom %≦x≦3 atom %, 2 atom %≦y≦15 atom %, 0 atom %≦z≦8 atom %, 1 atom %≦w≦12 atom %, 0.5 atom %≦t≦8 atom %, 0 atom %≦a≦20 atom %, 0 atom %≦b≦5 atom %, and 70 atom %≦(100-a-b-x-y-z-w-t)≦80 atom %.

The invention relates to a process and a device for smelting chromium irons and chromium-containing molten iron by using chromium ore powder, which belongs to metallurgical industry steel-making raw material. The process comprises the following steps: mixing chromium iron containing raw materials with reducing agent, solvent and catalyst to prepare ultra fine powder, mixing to make pelletizing materials, sending the pelletizing materials into a reducing furnace, obtaining chromium irons pellets after the reduction reaction, and directly adding reduced pellets into a lining electroslag furnace for being smelted into the chromium-iron alloy or the chromium-containing molten iron. The device comprises an internal-external heating vertical reducing furnace, a lining electroslag furnace and a residual heat recovery system. The invention has the advantages that: firstly, the reduction temperature is low, the speed is high, the energy consumption is reduced, the production cost is lowered, the production efficiency is high, and the uniformity of the quality is good; secondly, the degree of mechanization is high, the procedure is simple, the yield is large, the mass production can be performed; thirdly, the waste of raw materials is reduced, the environment pollution is lowered; fourthly, the source of raw materials adopting the chromium ore powder and chromium-containing waste, the cost is low; fifthly, the waste resource can be recycled so as to save the resource consumption; and sixthly, the high-temperature pellets are directly smelted by adopting the lining electroslag furnace, the heat efficiency is high, the energy consumption is low, the material purity is high and the quality is good, and the device is simple with less investment.

Electric motor components, such as a plurality of electromagnetic poles of an annular stator, are formed of soft magnetic composites comprising compacted, electrically isolated iron alloy particles. Embodiments comprise predetermining particular alloy compositions and processing conditions, such as compaction pressures and temperatures, and post compaction heat treating temperatures and atmospheres, for an intended mode of operation, thereby improving manufacturing efficiency and reliability in tailoring soft magnetic composite components for particular design situations.

A method for smelting ferronickel alloy from laterite nickel oxide ore belongs to the ferronickel alloy smelting technical field. A direct reduction technique of carbon-bearing pellets in a rotary hearth furnace is adopted to reduce the nickel oxide in nickel ores to iron and nickel; then iron and nickel are smelted; the solid solutions of nickel and iron are agglomerated, cooled, shattered and subjected to magnetic selection, so that the granular ferronickel alloy with high sulfur content is obtained; and the ferronickel alloy is melted and desulphurized, so that the purified ferronickel alloy is obtained. The invention has the advantages that compared with the traditional process without separation in advance, the follow-up smelting process of the method can save a great amount of energy source for the greatly reduced quantity of slag; and the crude ferronickel obtained through smelting contains relatively low Si content.

A cobalt-iron alloy film having saturation magnetization of at least about 2.30 Telsa. The film alloy includes about 55 wt % to about 75 wt. % iron and the remainder cobalt. The film is made by a process in which the film is electrodeposited from an aqueous medium which includes one or more ferrous salts, one or more cobaltous salts, a buffer having a pKa of about 6 to about 8, at least one carboxylic acid having a pKa of between about 3.5 and about 5.5, an aromatic sulfinic acid or its salt and optionally, a halide salt and/or a surfactant. The alloy film is useful as a write head in magnetic recording.

The invention discloses a method for recycling valuable metals in manganese series waste batteries. In the method, the manganese, iron, zinc and lithium metal resources in a waste zinc-manganese dry battery, a waste alkaline-manganese battery and a waste lithium-manganese primary battery and a waste lithium ion battery taking lithium manganate or lithium manganate derivative as a positive electrode material are comprehensively utilized by pyrometallurgy and made into products such as manganese-iron alloy and zinc oxide, wherein the total mass of manganese and iron in the prepared manganese-iron alloy reaches over 90%, and the manganese-iron alloy can be applied to steel enterprises and stainless steel enterprises; and the total mass of zinc and lithium in zinc oxide reaches over 40%, and zinc oxide can be applied to wet refining of zinc and lithium. The method disclosed by the invention has the characteristics of high resource utilization and recovery rate, simple technology and high recovery value.

A thin-film write head employing pole pieces formed of an electroplated body-centered cubic (BCC) nickel-iron alloy with a saturation flux density (B_S) of 1.9 to 2.3 T (19 to 23 kG) and an acceptable coercivity (H_C) of about 80 to about 160 A/m (1-2 Oe). The iron content of the electroplated nickel-iron alloy is from 64% to 81% by weight. The two-layer pole fabrication process holds magnetic anisotropy and coercivity to useable values while improving saturation flux density and optimizing magnetostriction. This is accomplished by first electroplating a BCC nickel-iron layer onto an underlying seed layer and then annealing the two layers to reduce coercivity to less than about 160 amps/meter and raise magnetization to acceptable levels.

A biphasic nanoporous vitreous carbon material with a cementitious morphology characterized by presence of non-round porosity, having superior hardness and tribological properties, as useful for high wear-force applications. The biphasic nanoporous vitreous carbon material is produced by firing, under inert atmosphere, of particulate vitrified carbon in a composition containing (i) a precursor resin that is curable and pyrolyzable to form vitreous carbon and, optionally, (ii) addition of one or more of the following: solid lubricant, such as graphite, boron nitride, or molybdenum disulfide; a heat-resistant fiber reinforcement, such as copper, bronze, iron alloy, graphite, alumina, silica, or silicon carbide; or one or more substances to improve electrical conductivity, such as dendritic copper powder, copper “felt” or graphite flake, to produce a superior vitreous carbon that is useful alone or as a continuous phase in reinforced composites, in relation to conventional glassy carbon materials.

The ferritic iron alloy is particularly suitable as a material for current collectors used in SOFC solid electrolyte high-temperature fuel cells. The material has a high chromium content upwards of 22% by weight, and a molybdenum content of 1 to 10% by weight. Additionally, there is provided 0.01 to 1.5% by weight of yttrium, rare earth metals, and/or their oxides. The alloy in particular has a high resistance to corrosion under the standard cell atmospheres in the temperature range from 700.degree. to 900.degree. C.