EP2343142A2 - Composition métallurgique en poudre et procédé pour la fabrication d'un produit à base de métallurgie de poudre renforcé de nanofibres - Google Patents

Composition métallurgique en poudre et procédé pour la fabrication d'un produit à base de métallurgie de poudre renforcé de nanofibres Download PDF

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Publication number
EP2343142A2
EP2343142A2 EP10175876A EP10175876A EP2343142A2 EP 2343142 A2 EP2343142 A2 EP 2343142A2 EP 10175876 A EP10175876 A EP 10175876A EP 10175876 A EP10175876 A EP 10175876A EP 2343142 A2 EP2343142 A2 EP 2343142A2
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Prior art keywords
melting point
powder
base material
grains
high melting
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EP10175876A
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German (de)
English (en)
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EP2343142A3 (fr
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György Dutkay
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    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C47/00Making alloys containing metallic or non-metallic fibres or filaments
    • C22C47/14Making alloys containing metallic or non-metallic fibres or filaments by powder metallurgy, i.e. by processing mixtures of metal powder and fibres or filaments
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F1/00Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • B22F1/10Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
    • B22F1/105Metallic powder containing lubricating or binding agents; Metallic powder containing organic material containing inorganic lubricating or binding agents, e.g. metal salts
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10Sintering only
    • B22F3/1039Sintering only by reaction
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C1/00Making non-ferrous alloys
    • C22C1/10Alloys containing non-metals
    • C22C1/1084Alloys containing non-metals by mechanical alloying (blending, milling)
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C32/00Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ
    • C22C32/0089Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with other, not previously mentioned inorganic compounds as the main non-metallic constituent, e.g. sulfides, glass
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C33/00Making ferrous alloys
    • C22C33/02Making ferrous alloys by powder metallurgy
    • C22C33/0207Using a mixture of prealloyed powders or a master alloy
    • C22C33/0228Using a mixture of prealloyed powders or a master alloy comprising other non-metallic compounds or more than 5% of graphite

Definitions

  • the present invention relates to a powder composition that can be used in powder metallurgy, a sintering process of such a powder composition and a nanofiber reinforced powder metallurgy product obtained by the sintering process.
  • MIM Metal Injection Moulding
  • the most appropriate binder is, for example, a polyolefin polymer that can be dissolved by halohydrocarbons, as U.S. Pat. No. 6,790,252 teaches, or an alcohol or water soluble polymeric material according to the disclosure of U.S. Pat. No. 6,171,360 .
  • the final product is prepared by a usual heat treatment, performed in a furnace, of the green part consisting of merely the metallic powder.
  • nanofibers have to be produced beforehand that takes place generally via an independent process and far away from the place where said metallurgical powder technologies are actually practiced.
  • the material of the nanofibers utilized varies over a broad scale.
  • the most well-known nanofibrous material is carbon nanotubes (CNT), the greatest amount of which is produced by well-known processes.
  • CNT carbon nanotubes
  • U.S. Pat. No. 7,629,553 discloses a production method of metal oxide nanoparticles through vaporizing metallic salts in plasma arcs and by condensing.
  • the production of metallic nanofibers from metallic salts is disclosed e.g. by U.S. Pat. No. 7,648,554 .
  • U.S. Pat. No. 7,531,155 teaches the production of silicon nanofibers by means of ultrasonic treatment from powdered silicon made porous by etching. When said nanofibers are used in powder metallurgical processes, independently of their way of production, they are simply mixed with metallic powders and the thus obtained composition of nanofibers and metallic powder is processed then by powder metallurgical techniques known per se.
  • powder metallurgical parts also containing nanofibers exhibit obviously improved mechanical properties compared to those of powder metallurgical products prepared traditionally. Their properties concerned, however, fall behind the properties that could be expected in view of the properties of the nanofibers.
  • the major reason for this is that the nanofibers mixed with the metallic powder before processing do not become integrated into the surface structure of the metallic grains, instead they, like ropes, loosely surround and only anchor said individual metal grains to one another.
  • the aim of the present invention is to provide a powder metallurgical powder composition and process, as possible alternatives to the above discussed prior art powder metallurgical powder compositions and methods, that eliminate or at least alleviate disadvantages of the known techniques.
  • an objective of the present invention is to define a powder composition, by means of which final products of much lower porosities, in certain cases with no pores at all, as well as with much greater strengths could be obtained when compared to respective properties of the powder metallurgical products manufactured by former processes.
  • a further objective of the invention is to provide a powder metallurgical process by means of which the advantageous properties of the nanofibers within the powder metallurgical product, e.g. their strength enhancing effect, prevail to an extent which is in harmony with the expectations.
  • a yet further objective of the invention is to enhance dimensional stability/precision of the powder metallurgical product by means of the process.
  • a granulated lubricant of high melting point is mixed with the granulated material forming the base material of the powder metallurgical product; said lubricant gets melted during the sintering process and coats the surfaces of the grains of the granulated material forming the base material of the product and thereby, on the one hand, it joins said grains together via acting as brazing material and, on the other hand, due to the heat treatment applied, it transforms into nanostructures, in particular nanofibers, in situ within the volume of the granulated material forming the base material of the product and by becoming integrated into the surface structure of said grains in this form it improves the joining forces acting amongst the grains. Said joining force improved due to the in situ created nanostructures/nanofibers increases the mechanical strength of the whole powder metallurgical product.
  • the aimed objectives are achieved by a powder metallurgical powder composition according to Claim 1.
  • Preferred embodiments of the powder composition are represented by the compositions according to Claims 2 to 11.
  • said objectives are achieved by providing powder metallurgical processes in accordance with Claims 12 and 13.
  • a preferred further variant of said processes is set forth by Claim 14.
  • the burden of the high melting point lubricant used within the powder mixture provided by the inventive powder composition is that it, on the one hand, acts as lubricant amongst the grains of the base material only at the high temperature of compression (650 to 800 degrees Celsius) and, on the other hand, during the compression and the possible additional heat treatment it does not escape from the part, instead it joins the individual grains via acting as brazing material by getting cooled and covering the surfaces of the grains of the base material in a layer of the order of nanometer in thickness.
  • the melting temperature of the high meting point lubricant utilized is at least 550 degrees Celsius, preferably at least 600 degrees Celsius, and said lubricant reaches an adequate viscosity between about 700 to 800 degrees Celsius.
  • Said high melting point lubricant is a multicomponent eutectic or it exhibits a composition close to that of a multicomponent eutectic. Consequently, its practical melting point, as well as the temperature boundaries mentioned before can be set to the above or any other values as required by the process according to the invention by carefully selecting the relative ratios of the involved components.
  • the melt of the lubricant dissolves at least partially the oxides on the grain surfaces and hence becomes integrated into the surface structure of the grains, thus the sliding/shear forces acting in the step of compression cannot separate said lubricant from the grain surfaces.
  • the molten lubricant flattens into a thin layer between the grains, while said grains pass through a plastic deformation on one another and the accidental void spaces, microcavities between the grains get filled with the molten lubricant. Therefore, after said compression-moulding no elastic reflexion takes place and the porosity of the green blank remains at a low level.
  • the powder metallurgical powder compositions according to the invention can be comprised of various grains as base material.
  • the grains used can equally be metallic grains, to mention only a few examples e.g. iron, copper or nickel grains, various metal oxides of high melting point, to mention only a few examples e.g. alumina (Al 2 O 3 ), zirconia (ZrO 2 ) or titania (TiO 2 ) grains and any other grains similar to these, or various high-strength metal carbide grains, to mention only a few examples e.g. tungsten carbide (WC), titanium carbide (TC) or silicon carbide (SiC) grains and any other grains similar to these.
  • tungsten carbide WC
  • TC titanium carbide
  • SiC silicon carbide
  • a composition or a mixture of the above listed various kinds of grains in any ratios can also be used as base material for the powder metallurgical compositions.
  • the mean grain size of the grains of the base material ranges between 0.01 mm and 5 mm, thus it is much larger than that of the high melting point lubricant.
  • the mean grain size of the grains of the high melting point lubricant utilized in the powder metallurgical powder compositions according to the invention is preferably 10 to 700 nm, more preferably 50 to 500 nm.
  • the high melting point lubricant is admixed to the base material in dry and at least partially crystalline form in an amount of 0.01 to 10%, more preferably 0.05 to 9%, and even most preferably 0.1 to 8%; here the % values are calculated per unit mass of the base material.
  • silica (SiO 2 ) that forms major component of the high melting point lubricant is typically present in an amount of 30-60% by weight (of the total powder composition), preferably 35-55% by weight.
  • Silica content of the high melting point lubricant is typically 30-85% by weight, preferably 35-80% by weight if a metal oxide and/or a metal carbide grain based base material is used.
  • the base material is of composite type, that is, it contains both metallic grains and metal oxide or metal carbide grains
  • silica that forms major component of the high melting point lubricant is typically present in an amount of 30-60% by weight, preferably 35-55% by weight.
  • inorganic alkali metal oxides, inorganic alkali-earth metal oxides and inorganic semimetal oxides differing from silica forming at least one further component of the high melting point lubricant are present in various amounts compared to one another depending on the type of the base material.
  • inorganic alkali metal oxide sodium oxide (Na 2 O) in an amount of at most 15% by weight, preferably at most 10% by weight alone and at least partially in crystalline form, as well as potassium oxide (K 2 O) in an amount of at most 20% by weight, preferably at most 15% by weight alone and also at least partially in crystalline form can be used highly preferably.
  • inorganic alkali-earth metal oxide calcium oxide (CaO) in an amount of at most 30% by weight, preferably at most 25% by weight alone and at least partially in crystalline form, as well as barium oxide (BaO) in an amount of at most 20% by weight, preferably at most 15% by weight alone and also at least partially in crystalline form can be used highly preferably.
  • CaO calcium oxide
  • BaO barium oxide
  • boron oxide (B 2 O 3 ) with glass forming capability in an amount of at most 25% by weight, preferably at most 20% by weight alone and at least partially in crystalline form can be used highly preferably.
  • composition of the high melting point lubricant used in the powder composition highly depends on the chemical nature of the grains selected for the base material of said powder composition. Based on the above teaching and general knowledge, however, a person skilled in the art can easily determine specific compositions for the high melting point lubricant depending on the chemical nature of the grains to be utilized.
  • the compression-moulding or injection moulding takes place at such temperatures of the mixture comprising the grains of the base material and the powder of the high melting point lubricant that are higher than the melting temperature of the lubricant, but lower than the melting temperature of said grains. That is, the powder metallurgical process according to the invention differs from the injection moulding technique of molten metals in that here injection moulding takes place not above the melting temperature of the metal but in a state heated to at least the melting temperature of the high melting point lubricant of the powder mixture and an afterpressure is also applied.
  • a further advantage of the inventive powder metallurgical process is that the technology of processing the powdery mixture into a final product fits excellently into the known and used technologies, and can be performed by exploiting the production devices of those technologies.
  • An intermediate result of the inventive process is a part that has much lower porosity and much higher mechanical strength than a traditional one.
  • the process can be preferably combined with traditional cold pressing.
  • a further low melting point lubricant preferably e.g. zinc stearate
  • the high melting point lubricant unable to exercise its lubricating/sliding effect at temperatures below about 550 degrees Celsius.
  • the melting temperature of said low melting point lubricant is at most 250 degrees Celsius, preferably at most 200 degrees Celsius.
  • the low melting point lubricant in particular zinc stearate acts as lubricating material, the high melting point lubricant remains ineffective.
  • Said high melting point lubricant will exercise its effect at the temperature of sintering. This temperature falls between at least the melting temperature of the high melting point lubricant and at most the melting temperature of the grains in the base material that have the lowest melting temperature.
  • the actual effect of said high melting point lubricant is that, on the one hand, it gets molten over the grain surfaces and thereby fully or partially fills up the intergranular pores and joins the individual grains together by acting as brazing material, and, on the other hand, upon heat treatment it partially transforms into nanofibers, preferably a part of which becomes integrated into the surface structure of the grains.
  • cold pressing is completed and zinc stearate is evaporated from the green part at a first temperature, then sintering is performed at a second temperature (being preferably much) higher than said first temperature, in particular at a temperature close to the melting temperature of a surface oxide layer forming on the surfaces of the grains of the base material when said base material is mixed with the high melting point lubricant, i.e. preferably at about 650 to 840 degrees Celsius and for a period of a few minutes.
  • any traditional lubricant known by the skilled person in the art can be used as the low melting point lubricant.
  • the usage of zinc stearate (the melting temperature of which is 130 degree Celsius) is highly preferred.
  • An iron-based powder metallurgical part is produced using an iron powder with the mean grain size of 80-100 micron as the base material, produced and made available by Hoegenas under the code of NC 24.100.
  • the high melting point lubricant is prepared by admixing preferably 45% by weight SiO 2 , 15% by weight B 2 O 3 , 10% by weight CaO, 5% by weight K 2 O, also 5% by weight Na 2 O and 20% by weight BaO.
  • the thus obtained crystalline oxide mixture is then ground until a mean grain size of at least 0.5 micron is reached.
  • the mill product is added to the iron powder in an amount of 5% calculated per unit mass of the iron powder and the thus obtained mixture is then homogenized through mixing in a ball-grinder.
  • zinc stearate as a low melting point lubricant, is also added to the powder composition in an amount of 0.8% calculated per unit mass of said powder composition.
  • the zinc stearate is dispersed within the powder composition essentially in a homogeneous manner.
  • said powder mixture is filled into a mould and pressed to a desired shape at room temperature and 500 MPa pressure.
  • the green part is removed from the mould and is heated to about 200 degrees Celsius within a controlled-atmosphere furnace and maintaining the green part at this temperature, the zinc stearate is evaporated from it. After this, the furnace and the green part arranged therein are heated to about 960 degrees Celsius and kept at this temperature for 2 hours. The green part undergone the heat treatment is finally cooled or allowed to cool down to room temperature.
  • Transformation of the powder metallurgical powder composition detailed in Example 1 into a powder metallurgical product is accomplished by hot pressing.
  • no low melting point lubricant is added to the powder mixture, instead the mixture of the iron powder and the high melting point lubricant mill product is heated to about 750 degrees Celsius and compression-moulding is performed under 100 MPa pressure. After this, the thus obtained green part is kept under pressure for 2 minutes and then is removed from the mould.
  • the part at issue is basically ready now, however, its mechanical properties can be significantly improved by means of a heat treatment that takes place for further 2 hours at about 960 degrees Celsius.
  • the powder metallurgical process according to the invention exploits a yet further mechanism to improve the strength of the powder metallurgical product.
  • This mechanism is the ⁇ at least partial ⁇ transformation of the oxide mixture used as the high melting point lubricant to nanostructures upon heat treatment. The course of transforming can be seen in the SEM photos (see Figures 1 to 3 ) of the sample fractures of powder metallurgical products containing iron grains as the base material.
  • Figure 1 an iron grain 1 of the initial powder composition is shown before pressing, said grain became coated by the oxide mixture powder during the admixture.
  • Figure 2 illustrates a fracture surface of the iron grain based green part obtained by pressing and heat treatment.
  • nanofibers 4 nearly perpendicular to the fracture surface, as well as nanofibers 5 lying in the plane of the fracture surface.
  • Figure 3 shows a different portion of the fracture surface of the green part, wherein upon melting due to the heat treatment, the oxide mixture forming the tiny gobs 3 of Fig.
  • the high melting point lubricant in excess that has been not transformed into nanostructures covers the surfaces of the grains of the base material in a thin layer and partially also hides the nanofibers.
  • the mass ratio of nanofibers and other nanosized formations, as well as their dimension and composition are of statistical nature; starting from the same powder metallurgical powder composition and performing the same powder metallurgical technique, these characteristic properties will vary from product to product.
  • the nanofibers enhancing the strength of the product are present in each product prepared form the powder metallurgical powder composition according to the invention by the inventive powder metallurgical process.
  • Figures 4 and 5 illustrate the coverage of the grains of the powder composition by the molten high melting point lubricant; said figures are SEM photos taken on the exposed outer surfaces of the base material samples made of granulated powder of electrolytical copper coded CH-L10, as the base material, with a mean grain size of about 10 micron.
  • the samples show the nanostructure formations on copper base material produced upon heat treatment from the high melting point lubricant with a composition discussed in Example 1.
  • the surface of the sample is covered by a melt 13 that spreads mainly in a continuous manner. Uncovered surface portions are provided partially by pores 12 between copper grains and partially by copper grain surfaces 9, 11 projecting out of the surface covered by the melt 13.
  • the major effect of the heat treatment of the base material mixed up with the high melting point lubricant and being compression-moulded is that it brazes the nanofibers created in situ from the lubricant upon heat treatment to the copper grain surfaces covered by the melt 13 layer with a thickness that falls into the range of nanosizes. It should be here noted that a yet further effect of said high melting point lubricant is that it joins the grains of the base material mechanically to one another in an electrically insulated manner.
  • the at least two components forming the high melting point lubricant are at least partially fluidic and due to their different partial vapour pressures, different amounts thereof will escape from the metal body via material transport of the vapour of their own constitutional water.
  • vapour pressures of the released constitutional waters of the component that firstly gets molten and also of the further component(s) force the melt of the component that firstly gets molten into the open pores and thus decrease their penetrability or block them.
  • high vapour/gas pressures build up within the closed microcavities forming in this way from the pores, which is a fundamental requirement for the formation of nanostructures.
  • the partial pressure of silicon dioxide is the lowest among that of the other components within the added oxide mixture, this preserves in the greatest amount compared to the initial equilibrium composition. Therefore, silicon dioxide will give the largest mass portion of the precipitations, that is, the nanostructures/nanofibers formed will be majorly based on silicon.
  • heat treatment interconnects neighbouring grains with a plurality of nm sized fibers by the brazing material provided by the molten high melting point lubricant covering the grain surfaces or by penetrating through the layer of said brazing material and becoming integrated thereinto. Consequently, the mechanical properties of the obtained product will be significantly better than those of the products prepared by traditional powder metallurgical technologies.
  • the powder metallurgical process according to the invention is also suitable for processing mixtures of metallic and non-metallic (such as e.g. oxide or carbide) grains, that is, so-called composite materials, since the high melting point lubricants used in the initial composite powder compositions of such substances get fused over the surfaces of the non-metallic grains and thereby join the grains of the base material together similarly, as if they were metallic grains.
  • metallic and non-metallic such as e.g. oxide or carbide
  • inventive process results in powder metallurgical products with improved dimensional accuracy at significantly lower energy consumption and tooling costs, along with more advantageous physical properties compared to those of similar products manufactured by the known prior art solutions.
  • the technology according to the invention is a waste-free and clean, environment-friendly technology in contrast with the metallurgical, plastic shaping or machining technologies widely used nowadays.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Inorganic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Manufacturing & Machinery (AREA)
  • Powder Metallurgy (AREA)
EP10175876.1A 2009-09-08 2010-09-08 Composition métallurgique en poudre et procédé pour la fabrication d'un produit à base de métallurgie de poudre renforcé de nanofibres Withdrawn EP2343142A3 (fr)

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HU0900560A HU0900560D0 (en) 2009-09-08 2009-09-08 Low porosity powder metallurgical details and method for producing them

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EP2343142A2 true EP2343142A2 (fr) 2011-07-13
EP2343142A3 EP2343142A3 (fr) 2014-05-14

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN112276073A (zh) * 2020-09-23 2021-01-29 山东鲁银新材料科技有限公司 一种包含二氧化硅作为膨松剂和流速增强剂的粉末冶金组合物

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EP0846782A1 (fr) 1992-09-09 1998-06-10 STACKPOLE Limited Procédé de préparation d'un alliage à base de métal pulvérulent
US6171360B1 (en) 1998-04-09 2001-01-09 Yamaha Corporation Binder for injection molding of metal powder or ceramic powder and molding composition and molding method wherein the same is used
US6790252B2 (en) 2001-04-18 2004-09-14 Hard Metals Partnership Tungsten-carbide articles made by metal injection molding and method
US7531155B2 (en) 2003-02-21 2009-05-12 Applied Nanotech Holdings, Inc. Method of producing silicon nanoparticles from stain-etched silicon powder
US7629553B2 (en) 2005-06-08 2009-12-08 Unm.Stc Metal oxide nanoparticles and process for producing the same
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Publication number Priority date Publication date Assignee Title
US2289569A (en) 1941-05-07 1942-07-14 Gen Motors Corp Powder metallurgy
US4452756A (en) 1982-06-21 1984-06-05 Imperial Clevite Inc. Method for producing a machinable, high strength hot formed powdered ferrous base metal alloy
EP0846782A1 (fr) 1992-09-09 1998-06-10 STACKPOLE Limited Procédé de préparation d'un alliage à base de métal pulvérulent
US6171360B1 (en) 1998-04-09 2001-01-09 Yamaha Corporation Binder for injection molding of metal powder or ceramic powder and molding composition and molding method wherein the same is used
US6790252B2 (en) 2001-04-18 2004-09-14 Hard Metals Partnership Tungsten-carbide articles made by metal injection molding and method
US7648554B2 (en) 2002-08-01 2010-01-19 Daiken Chemical Co., Ltd. Metal nanoparticles and method for manufacturing same
US7531155B2 (en) 2003-02-21 2009-05-12 Applied Nanotech Holdings, Inc. Method of producing silicon nanoparticles from stain-etched silicon powder
US7629553B2 (en) 2005-06-08 2009-12-08 Unm.Stc Metal oxide nanoparticles and process for producing the same

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN112276073A (zh) * 2020-09-23 2021-01-29 山东鲁银新材料科技有限公司 一种包含二氧化硅作为膨松剂和流速增强剂的粉末冶金组合物

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EP2343142A3 (fr) 2014-05-14

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