US2008156401A1PendingUtilityA1

Enhancement of Material Properties by Infiltration of Powder Metal Part: Formulation and Method of Application Thereof

43
Individually held — no corporate assignee on recordPriority: Jan 3, 2007Filed: Jan 3, 2008Published: Jul 3, 2008
Est. expiryJan 3, 2027(~0.4 yrs left)· nominal 20-yr term from priority
Inventors:Arun ChattopadhyayJessu Joys
B22F 1/10C23C 10/52C23C 26/02C22C 9/00C23C 10/30B22F 3/26
43
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Claims

Abstract

Infiltration compositions comprising chromium and at least about 80% copper. The infiltration compositions may further comprise iron, zinc, manganese, antimony and/or lubricants. Also, methods for infiltrating powder metal parts comprising contacting a powder metal part with the infiltration composition comprising chromium and at least about 80% copper and heating the powder metal part and infiltration composition to a temperature sufficient to melt the infiltration composition and allow the infiltration composition to infiltrate through pores in the powder metal part.

Claims

exact text as granted — not AI-modified
1 . An infiltration composition comprising at least about 80% copper and chromium. 
     
     
         2 . The infiltration composition of  claim 1  further comprising at least about 0.5% iron or at least about 0.5% manganese. 
     
     
         3 . The infiltration composition of  claim 1  comprising about 0.1% to about 3.5% chromium. 
     
     
         4 . The infiltration composition of  claim 3  comprising about 0.1% to about 3.5% iron, up to about 0.2% zinc, up to about 0.2% manganese and up to about 0.2% lubricants. 
     
     
         5 . The infiltration composition of  claim 4  wherein the lubricant is fatty acid based. 
     
     
         6 . The infiltration composition of  claim 1  comprising at least about 90% by weight copper. 
     
     
         7 . The infiltration composition of  claim 1  further comprising antimony. 
     
     
         8 . The infiltration composition of  claim 7  comprising about 0.01% to about 0.5% antimony. 
     
     
         9 . The infiltration composition of  claim 1  wherein the chromium is part of an alloy with a metal selected from the group consisting of iron, manganese, copper and combinations thereof. 
     
     
         10 . The infiltration composition of  claim 1  wherein chromium powder is bound to the infiltration composition by a binder selected from the group consisting of hydrocarbon binder, acrylic binder, phenolic binder and combinations thereof. 
     
     
         11 . The infiltration composition of  claim 1  in the form of a paste. 
     
     
         12 . The infiltration composition of  claim 11  wherein the copper is in the form of a spherical powder, irregular powder or combinations thereof. 
     
     
         13 . The infiltration composition of  claim 11  wherein the paste comprises pre-alloyed copper powders of Cu—Zn, Cu—Sn, Cu—Cr, Cu—Ni, Cu—Mn, Cu—Sb, Cu—Pb, Cu—Bi, Cu—P, Cu—Al and combinations thereof. 
     
     
         14 . The infiltration composition of  claim 11  wherein the paste further comprises a material selected from the group consisting of gelled petroleum, ethereal poly-alcohols, fatty alcohols, mineral oil and combinations thereof. 
     
     
         15 . A powder metal part comprising the infiltration composition of  claim 1 . 
     
     
         16 . A method for infiltrating a powder metal part with an infiltration composition comprising the steps of providing an infiltration composition comprising at least about 80% copper and chromium, providing the powder metal part, contacting powder metal part with the infiltration composition and heating the powder metal part while the powder metal part is in contact with the infiltration composition to a temperature that allows the infiltration composition to melt and infiltrate through pores in the powder metal part. 
     
     
         17 . The method of  claim 16  wherein the infiltration composition comprises at least about 0.1% by weight chromium. 
     
     
         18 . The method of  claim 17  wherein the infiltration composition comprises about 0.5% to 3.5% by weight chromium, about 0.1% to 3.5% by weight iron, up to about 2.0% by weight of zinc, up to about 2% by weight of manganese and up to about 2% by weight of lubricants. 
     
     
         19 . The method of  claim 18  wherein the lubricant is fatty acid based. 
     
     
         20 . The method of  claim 16  wherein the infiltration composition comprises at least about 90% copper. 
     
     
         21 . The method of  claim 16  wherein the infiltration composition further comprises antimony. 
     
     
         22 . The method of  claim 21  wherein the antimony is used in amounts of about 0.01% to about 0.5%. 
     
     
         23 . The method of  claim 16  wherein the infiltration composition is in a form selected from the group consisting of compressed blocks, extruded bars, extruded cylinders, extruded hollow tubes and solid pastes. 
     
     
         24 . The method of  claim 16  wherein the solid pastes are compounded with a material selected from the group consisting of gelled petroleum, ethereal poly-alcohols, fatty alcohols, mineral oil and combinations thereof. 
     
     
         25 . The method of  claim 16  wherein the temperature is at least about 800° C.

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