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US4154900A
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Composite material of ferrous cladding material and aluminum cast matrix and method for producing the same
Assignee: Taiho Kogyo Co Ltd
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Filing: 1977-05-12
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Granted: 1979-05-15
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Expires: 1997-05-12
Abstract
Abstract A composite material of a ferrous cladding material and an aluminum cast matrix which composite material exhibits excellent performance and a method for producing the same which can be carried out quite easily. The composite material comprises a ferrous cladding material, powder particles bonded to the ferrous cladding material, seizing portions defined by the powder particles, and a cast matrix of aluminum or its alloy held by the seizing portions. The method comprises the steps of spreading powder particles over a ferrous cladding material, bonding the powder particles to the ferrous cladding material by sintering, and casting aluminum or its alloy over the sintered surface. Further, a metallic layer can be formed between the bonded powder particles and the cast aluminum, by plating.
Inventors
- 👤 Yoshihiro Kaku
- 👤 Kiyotaka Hiraoka
- 👤 Mikio Sugiura
- 👤 Yoshio Kato
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-27 04:21
CPC Classifications
B; B22; B22D; B22D19/00; B22D19/08; B22D19/0081; B22F; B22F7/00; B22F7/02; B22F7/04; B22F7/06; B22F7/08; Y; Y10; Y10T; Y10T428/00; Y10T428/12; Y10T428/12014; Y10T428/12028; Y10T428/12063; Y10T428/12069; Y10T428/12104; Y10T428/1216; Y10T428/12444; Y10T428/12451
Claims Analysis
Total Claims: 20
Claim 1
Independent Claim
113 words
A composite article consisting essentially of: a ferrous cladding member; a single layer of a single thickness of spaced-apart generally spherical particles tightly bonded to the surface of said ferrous cladding member by sintering, said particles having a particle size in the range of from 40 to 150 mesh and being made or iron, iron alloy, copper, copper alloy or mixture thereof, said particles being located so as to define undercut cavities therebetween; and a cast matrix of aluminum or aluminum alloy solidified from the molten state while in contact with said particles and said cladding member, said cast matrix filling said undercut cavities and also defining a surface layer covering said particles.
Claim 2
Dependent Claim
113 words
A composite article consisting essentially of: a ferrous cladding member; a single layer of a single thickness of spaced-apart generally spherical particles tightly bonded to the surface of said ferrous cladding member by sintering, said particles having a particle size in the range of from 40 to 150 mesh and being made or iron, iron alloy, copper, copper alloy or mixture thereof, said particles being located so as to define undercut cavities therebetween; and a cast matrix of aluminum or aluminum alloy solidified from the molten state while in contact with said particles and said cladding member, said cast matrix filling said undercut cavities and also defining a surface layer covering said particles.
Claim 3
Dependent Claim
20 words
A composite article as claimed in claim 1 in which said particles are made of iron, bronze or mixture thereof.
Claim 4
Dependent Claim
18 words
A composite article as claimed in claim 1 in which said ferrous cladding member is made of steel.
Claim 5
Dependent Claim
134 words
A composite article consisting essentially of: a ferrous cladding member; a single layer of a single thickness of spaced-apart generally spherical particles tightly bonded to the surface of said ferrous cladding member by sintering, said particles having a particle size in the range of from 40 to 150 mesh and being made of iron, iron alloy, copper, copper alloy or mixture thereof, said particles being located so as to define undercut cavities therebetween; a thin layer of metal plated on said particles and the surface of said ferrous cladding member and diffused therein; and a cast matrix of aluminum or aluminum alloy solidified from the molten state while in contact with said thin layer, said cast matrix filling said undercut cavities and also defining a surface layer covering said particles and said thin layer.
Claim 6
Dependent Claim
134 words
A composite article consisting essentially of: a ferrous cladding member; a single layer of a single thickness of spaced-apart generally spherical particles tightly bonded to the surface of said ferrous cladding member by sintering, said particles having a particle size in the range of from 40 to 150 mesh and being made of iron, iron alloy, copper, copper alloy or mixture thereof, said particles being located so as to define undercut cavities therebetween; a thin layer of metal plated on said particles and the surface of said ferrous cladding member and diffused therein; and a cast matrix of aluminum or aluminum alloy solidified from the molten state while in contact with said thin layer, said cast matrix filling said undercut cavities and also defining a surface layer covering said particles and said thin layer.
Claim 7
Dependent Claim
20 words
A composite article as claimed in claim 4 in which said particles are made or iron, bronze or mixture thereof.
Claim 8
Dependent Claim
18 words
A composite article as claimed in claim 4 in which said ferrous cladding member is made of steel.
Claim 9
Dependent Claim
19 words
A composite article as claimed in claim 4 in which said thin layer is made of copper or zinc.
Claim 10
Independent Claim
152 words
A method for producing a composite article of a ferrous cladding member and a cast aluminum matrix, consisting essentially of the steps of: spreading a single layer of a single thickness of generally spherical particles in spaced-apart relation on the surface of a ferrous cladding member, said particles having a particle size in the range of from 40 to 150 mesh and being made of iron, iron alloy, copper, copper alloy or mixture thereof, said particles being located so as to define undercut cavities therebetween; sintering the assembly of said ferrous cladding member and said particles to tightly bond said particles to the surface of said ferrous cladding member; casting molten aluminum or molten aluminum alloy onto the sintered assembly of said ferrous cladding member and said particles to fill said undercut cavities and to form a surface layer covering said particles and then solidifying said molten aluminum or molten aluminum alloy.
Claim 11
Independent Claim
152 words
A method for producing a composite article of a ferrous cladding member and a cast aluminum matrix, consisting essentially of the steps of: spreading a single layer of a single thickness of generally spherical particles in spaced-apart relation on the surface of a ferrous cladding member, said particles having a particle size in the range of from 40 to 150 mesh and being made of iron, iron alloy, copper, copper alloy or mixture thereof, said particles being located so as to define undercut cavities therebetween; sintering the assembly of said ferrous cladding member and said particles to tightly bond said particles to the surface of said ferrous cladding member; casting molten aluminum or molten aluminum alloy onto the sintered assembly of said ferrous cladding member and said particles to fill said undercut cavities and to form a surface layer covering said particles and then solidifying said molten aluminum or molten aluminum alloy.
Claim 12
Dependent Claim
18 words
A method according to claim 8 in which said particles are made of iron, bronze or mixture thereof.
Claim 13
Dependent Claim
16 words
A method according to claim 8 in which said ferrous cladding member is made of steel.
Claim 14
Dependent Claim
30 words
A method according to claim 8 in which said casting step comprises placing said sintered assembly in a metal mold and die casting said molten aluminum or molten aluminum alloy.
Claim 15
Independent Claim
176 words
A method for producing a composite article of a ferrous cladding member and a cast aluminum matrix, consisting essentially of the steps of: spreading a single layer of a single thickness of generally spherical particles in spaced-apart relation on the surface of a ferrous cladding member, said particles having a particle size in the range of from 40 to 150 mesh and being made of iron, iron alloy, copper, copper alloy or mixture thereof, said particles being located so as to define undercut cavities therebetween; sintering the assembly of said ferrous cladding member and said particles to tightly bond said particles to the surface of said ferrous cladding member; plating a thin layer of diffusible metal on said particles and the surface of said ferrous cladding member; casting molten aluminum or molten aluminum alloy onto the assembly of said ferrous cladding member, said particles and said plated layer to fill said undercut cavities and to form a surface layer covering said particles and said plated layer and then solidifying said molten aluminum or molten aluminum alloy.
Claim 16
Independent Claim
176 words
A method for producing a composite article of a ferrous cladding member and a cast aluminum matrix, consisting essentially of the steps of: spreading a single layer of a single thickness of generally spherical particles in spaced-apart relation on the surface of a ferrous cladding member, said particles having a particle size in the range of from 40 to 150 mesh and being made of iron, iron alloy, copper, copper alloy or mixture thereof, said particles being located so as to define undercut cavities therebetween; sintering the assembly of said ferrous cladding member and said particles to tightly bond said particles to the surface of said ferrous cladding member; plating a thin layer of diffusible metal on said particles and the surface of said ferrous cladding member; casting molten aluminum or molten aluminum alloy onto the assembly of said ferrous cladding member, said particles and said plated layer to fill said undercut cavities and to form a surface layer covering said particles and said plated layer and then solidifying said molten aluminum or molten aluminum alloy.
Claim 17
Dependent Claim
18 words
A method according to claim 12 in which said particles are made of iron, bronze or mixture thereof.
Claim 18
Dependent Claim
16 words
A method according to claim 12 in which said ferrous cladding member is made of steel.
Claim 19
Dependent Claim
30 words
A method according to claim 12 in which said casting step comprises placing said sintered assembly in a metal mold and die casting said molten aluminum or molten aluminum alloy.
Claim 20
Dependent Claim
18 words
A method according to claim 12 in which said thin plated layer is made of zinc or copper.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1982-05-14 | 1982-11-13 | 1983-05-15 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1986-05-14 | 1986-11-13 | 1987-05-15 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1990-05-14 | 1990-11-13 | 1991-05-15 | $7700.00 | Window Closed / Lapsed |