Daniel S Hall

US Patent:

40690440, Jan 17, 1978

Filed:

Feb 3, 1977

Appl. No.:

5/765334

Inventors:

Stanislaw Mocarski - Windsor, Ontario N9E 2B1, CA
Daniel W. Hall - Dearborn Heights MI

International Classification:

B22D 2308
B22F 100

US Classification:

75243

Abstract:

A method of making powder metal compacts having a low but optimized alloy content, the compacts being characterized by improved response to heat treatment (hardenability) and improved physical characteristics. A ferrous based powder is prepared having a predetermined particle size (about -80 mesh), a low O. sub. 2 content (less than. 25%), a predetermined particle shape, less than. 04% carbon and balanced pre-alloyed ingredients (. 2-1. 0% nickel,. 2-. 8% Mo, and. 25-. 6% Mn). A nonferrous based powder having at least a high content of copper (-320 mesh if pure copper or about -200 mesh if alloyed copper) is admixed with the prealloyed ferrous based powder to achieve a Cu content of. 2-2. 1% in the resulting sintered material. Graphite powder is also admixed (. 1-1.

US Patent:

42709512, Jun 2, 1981

Filed:

Dec 8, 1978

Appl. No.:

5/967926

Inventors:

Sang K. Suh - Livonia MI
Daniel W. Hall - Dearborn Heights MI

Assignee:

Ford Motor Company - Dearborn MI

International Classification:

B22F 300

US Classification:

75200

Abstract:

A method of making sintered powder metal parts which particularly includes a hot forging step, is disclosed. Selected powders of a predetermined particle size distribution, are blended and agglomerated by cold compaction into a preform. The preform or briquette is then coated with a thin shell of a chemically inactive radiation absorbing material, preferably graphite, under ambient conditions. The coated briquette is then sintered in a continuous through-put furnace with the temperature maintained at a level of at least 2000. degree. F. and the part being subjected to the furnace heating for a period of 5-30 minutes. The sintered part may then be subjected to direct hot forging with the retained temperature of sintering utilizing the graphite coating as a die lubricant, or the sintered part may be cooled and then subsequently reheated for hot forging, again utilizing the retained graphite coating as a die lubricant. If hot forging is not to be employed, the graphite particles are removed such as by brushing so that sizing, machining or grinding may be carried out without the presence of the graphite coating.

US Patent:

46228420, Nov 18, 1986

Filed:

Dec 13, 1984

Appl. No.:

6/681345

Inventors:

Benjamin I. Bachrach - Dearborn MI
William J. Fuhrman - Bloomfield Hills MI
Daniel W. Hall - Plymouth MI
Gotz S. Hauser - Southfield MI

Assignee:

Ford Motor Company - Dearborn MI

International Classification:

B21C 2502

US Classification:

72467

Abstract:

A die for use in extruding helical gears includes a die orifice at the upper end of the die teeth where the extrusion blank first enters the die. Each tooth is formed with a land directed parallel to the helix on the drive and trail side of the tooth and an end face perpendicular to the helix that intersects either a transition surface, directed perpendicular to the die axis, or a land. Alternatively, the end face can extend entirely across the tooth width from one land to the other without the use of the transition surface. Relief surfaces slope inwardly from the land and provide spaces within which the extrusion blank may expand without undue frictional contact with the die.