Patent ID: 6761852
Filing Date: 2004-07-13
Classification: B22F,C22C

Abstract:
A process to manufacture an aluminum object having a complex shape, comprising:providing a first powder of aluminum particles having a first average size; providing a second powder of additive particles, known to form a eutectic mixture with aluminum oxide, having a second average size; forming a eutectic mixture by mixing said powders together in a relative concentration by weight and then adding a binder material, thereby forming a feedstock; injecting said feedstock into a mold thereby forming a green part; releasing said green part from said mold and removing all of said binder, thereby forming a skeleton; heating said skeleton at a temperature sufficient to melt said eutectic mixture, thereby facilitating sintering of said aluminum particles to form said object to a density that is at least 95% that of bulk; and wherein said relative weight concentration of each powder is in inverse proportion to its average particle size.