Abstract: An adhesive bonding process for making vehicle structures wherein a surface portion of an aluminum alloy body is anodized in an aqueous solution of hypophosphorous acid (H3PO2) to form an anodic oxide coating. A layer of adhesive is applied onto the surface portion and the adhesive coated anodized surface portion is joined to an adjacent metal structure. The phosphorous acid anodizing is preferably carried out for less than 1 minute at about 5-40 volts and a current density of about 1-50 mA/cm2 in a solution containing about 1-25 wt % hypophosphorous acid. Anodization time is more preferably about 10-30 seconds and is about 20 seconds in a particularly preferred embodiment.

Abstract: A method for aluminum recovery during the carbothermic production of aluminum in a smelting furnace (1,2) is disclosed, where during carbothermic reduction of alumina, aluminum and aluminum suboxide vapors are produced (3, 4), which are reacting with carbon. Reactive carbon is generated in situ by the cracking of hydrocarbon compounds (6) in a separate closed reactor vessel (5) at a temperature greater than about 1955° C. Solid aluminum carbide that formed during the reaction can then be recycled by a conduit (8) to the primary reactor for reduction to aluminum, and reactor gas (10) can be fed to a cooler (9).

Abstract: A printing plate for computer-to plate lithography having a laser-ablatable member supported by a substrate. At least one portion of the laser-ablatable member is formed form an acrylic polymer containing laser-sensitive particles. The laser-sensitive particles absorb imaging radiation and cause the portion of the laser-ablatable member containing the laser sensitive particles and any overlying layers to be ablated.

Abstract: Fluorgyp is converted to calcium sulfate by reacting sulfuric acid in the fluorgyp with calcium carbonate having a small particle size. The resulting product is useful as a set retarding agent for cement.

Abstract: A process for producing aluminum metal by carbothermic reduction of alumina ore. Alumina ore is heated in the presence of carbon at an elevated temperature to produce an aluminum metal body contaminated with about 10-30% by wt. aluminum carbide. Aluminum metal or aluminum alloy scrap then is added to bring the temperature to about 900-1000° C. and precipitate out aluminum carbide. The precipitated aluminum carbide is filtered, decanted, or fluxed with salt to form a molten body having reduced aluminum carbide content.

Abstract: The present invention relates to an improved composite panel that is suitable for architectural and display applications and an advantageous method for making the composite panel. The composite panel comprises a foamed plastic core and two metallic skin layers bonded to the plastic core. The composite panel exhibits an effective bond strength sufficient to prevent peeling of the skin layers under normal use conditions, at least one visually flat surface substantially free of surface defects, and a stiffness to weight ratio of at least about 500 lbf-in/lbm/ft2.

Abstract: A cermet anode of an electrolytic cell is protected from thermal shock during cell start-up by coating an outer surface portion of the anode with a coating composition comprising carbon or aluminum or a mixture thereof. A particularly preferred coating composition includes an aluminum underlayer adjacent the outer surface portion of the anode, and a carbon overlayer overlying the underlayer. A support structure assembly supporting the cermet anode includes a high alumina ceramic material. In a preferred embodiment, the high alumina ceramic material is protected from thermal shock and corrosion by the coating composition of the invention.

Abstract: A process for repairing a hole in the crust of an electrolytic cell. The hole is repaired by covering it with a receptacle containing solid particles. The receptacle comprises a polymeric material. More preferably, the receptacle comprises a cellulosic material, such as paper, polymer-impregnated paper, or cardboard. A closed paper bag having at least two paper layers and weighing about 15-20 lb. (6.8-9.1 kg) is particularly preferred. When the electrolytic cell produces aluminum by electrolysis of alumina, the solid particles comprise an aluminum compound such as alumina, aluminum fluoride, cryolite, or a mixture of such compounds. Two preferred forms of alumina include smelting grade alumina (SGA) and alumina dust collected by an electrostatic precipitator (ESP dust).

Abstract: The present invention relates to a process for carbothermic production of aluminum where molten bath aluminum carbide and aluminum oxide are produced in a low temperature compartment (2), and continuously flow into a high temperature compartment (3) where the aluminum carbide is reacted with alumina to produce a top aluminum layer (31), where the aluminum layer (31) forms a layer on the top of a molten slag layer and is tapped from the high temperature compartment (3) at outlet (5), and where off-gases from the two compartments are treated in reactors fed by one or more columns (9, 19). According to the invention the low temperature compartment (2) and the high temperature compartment (3) are located in a common reaction vessel (1) where the low temperature compartment is separated from the high temperature compartment by an underflow partition wall (4).

Abstract: A cermet inert anode having a reduced level of contaminating surface metal is disclosed. Methods for preparing cermet inert anodes and methods for treating cermet inert anodes are also disclosed. The methods generally use an oxidizing agent to convert metals on the surface of the anode to inert oxides and/or to otherwise remove the metal contaminants. The inert anodes of the present invention may be used in electrolytic reduction cells for the production of commercial purity aluminum, as well as other metals.

Abstract: A process for electrolyzing Al2O3 to produce aluminum in a low temperature bath containing AlCl3 and an alkali metal chloride. The bath is maintained at a temperature of less than about 300 ° C. Solid aluminum is produced at the cathode in a frozen layer of the alkali metal chloride.

Abstract: A molded plastic panel for covering an exterior building wall includes a laterally directed lead fin, a laterally extending groove below the lead fin, and a rearwardly directed middle wall between rows of simulated shingles, all for joining laterally adjacent panels. A side flange extending outwardly of the panel may also be included. The molded plastic panel preferably also includes at least one row of simulated shingles separated by a plurality of gaps each having a randomly varying width in order to camouflage spacings between adjacent panels that change because of thermal contraction and expansion. In a particularly preferred embodiment, the panel body includes a locking tab and a folding flange. The folding flange includes a locking lip for engaging a locking tab on an adjacent panel and a flexible hinge connecting the locking lip to the panel body. The flexible hinge allows the folding flange to be disconnected from the locking tab when replacing a single panel.

Abstract: A sunshade for shading window exteriors includes at least one connecting bracket for attachment to a window mullion, a blade support strut attached to the connecting bracket at a first joint, and a plurality of louvered blades supported by the blade support strut at a second joint. The pivot angle at the first joint may be varied to extend the louvered blades a desired distance from the window mullion. The louvered blades are positioned at a preselected fixed profile angle on the second joint in order to optimize shading at the latitude where the sunshade is installed. In a preferred embodiment, the louvered blades have top walls supporting photovoltaic cells and the sunshade includes electric cables for connecting the photovoltaic cells to an electric circuit.

Abstract: A flashing assembly includes a sill horizontal, a sill flashing for attaching the assembly to a substrate, and at least one sill clip for interconnecting the sill horizontal and the sill flashing. The sill horizontal, sill flashing, and sill clip all preferably include aluminum alloy extrusions. The sill clip connects the sill horizontal to the sill flashing without through fasteners.

Abstract: A process for making lithographic sheet material suitable for imaging by laser radiation. A metal substrate is electrocoated in a bath containing a polymeric resin and laser-sensitive particles, thereby depositing a laser ablatable layer on a principal surface of the metal substrate. In one embodiment, the laser-ablatable layer is treated with a corona discharge for a time sufficient to render the layer non-ink wettable. In other preferred embodiments, the laser-ablatable layer is overcoated with an overlayer such as a non-ink wettable silicone layer or a water-wettable layer comprising an organophosphorus polymer, preferably a copolymer of acrylic acid and vinylphosphonic.

Abstract: An electrolytic cell for aluminum production, including a cell wall, a bus bar, a carbonaceous cathode block, and a collector bar connecting the bus bar with the cathode block. The collector bar comprises a ferrous metal body including a solid spacer and a sheath defining a cavity containing a copper insert. The spacer has an external end portion connected with the bus bar and an internal end portion that is preferably spaced inwardly of the cell wall. The spacer separates the copper insert from the bus bar, thereby reducing heat loss from the cell.

Abstract: A process for making printing plate material suitable for imaging by laser radiation. A metal substrate is electrocoated in a bath containing a polymeric resin and laser-sensitive particles, thereby depositing a laser ablatable layer on a principal surface of the metal substrate. In one embodiment, the laser-ablatable layer is treated with a corona discharge for a time sufficient to render the layer non-ink wettable. In other preferred embodiments, the laser-ablatable layer is overcoated with an overlayer such as a non-ink wettable silicone layer or a water-wettable layer comprising an organophosphorus polymer, preferably a copolymer of acrylic acid and vinylphosphonic acid.

Abstract: A cermet composite material is made by treating at an elevated temperature a mixture comprising a compound of iron and a compound of at least one other metal, together with an alloy or mixture of copper and a noble metal. The alloy or mixture preferably comprises particles having an interior portion containing more copper than noble metal and an exterior portion containing more noble metal than copper. The noble metal is preferably silver. The cermet composite material preferably includes alloy phase portions and a ceramic phase portion. At least part of the ceramic phase portion preferably has a spinel structure.

Abstract: A device for adjusting the distance between the anode and the cathode of an electrolytic cell having a compartment, at least one anode partially disposed in a molten metal producing salt bath and a layer of molten metal above a cathode. The device includes a displacement device partially disposed within the layer of molten metal, and an actuator to move the displacement device generally vertically.

Abstract: A cathode assembly for use in a Hall-Heroult electrolytic cell, the assembly including a cathode block which receives two primary cathode collector bars and one secondary cathode collector bar disposed therebetween. The primary collector bars each have an electrical interface with the cathode block which is sized to be equal to or greater than an electrical interface between the secondary collector bar and the cathode block. The primary collector bars are electrically connected to the cathode block only along an interior portion of the cathode block and the secondary collector bar is fully connected to the cathode block. This arrangement improves current distribution through the cathode assembly by minimizing the amount of current passing through the ends of the cathode block.