Abstract: A bright finish aluminum alloy on high strength aluminum or aluminum alloy lamination is disclosed including a bright finish top sheet, a high strength aluminum or aluminum alloy substrate, and an adhesive bonding the bright finish metal top sheet to the high strength aluminum or aluminum alloy substrate to provide a bright finish aluminum on high strength aluminum or aluminum alloy lamination product having brighter finish than a sheet product of said high strength aluminum or aluminum alloy and higher strength than a sheet product of said bright finish aluminum of the same thickness as said lamination product, wherein said lamination product withstands galvanic corrosion. In one aspect, the bright finish metal top sheet is 5657 aluminum foil. In one aspect, the high strength aluminum alloy is 5182 alloy sheet.

Abstract: A novel electrolytic reduction cell apparatus and method are disclosed for the production of aluminum, including a copper insert inside the cathode collector bar. In one aspect, a melting allowance slot is provided. In one aspect, the copper insert resides in a slot in the collector bar, the slot having a width dimension of 0.001-0.009 inch (0.0025-0.00229 cm) or 0.1%-0.9% more than the dimension of the copper insert. In one aspect, the copper insert resides in a slot in the collector bar, the slot having a length dimension of 0.25-0.97 inch (0.635-2.5 cm) or 0.37-1.44% more than the dimension of the copper insert. In one aspect, the copper insert is located from a point proximate about 2 inches (5 cm) from the cell center to a point proximate about 69.35 inches (176 cm) from the cell center towards the first cell wall. In one aspect, the copper insert cross-section is about 0.042 to about 0.125 times the cross-sectional area of the cathode collector bar.

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 tip 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 method of producing commercial purity aluminum in an electrolytic reduction cell comprising inert anodes is disclosed. The method produces aluminum having acceptable levels of Fe, Cu and Ni impurities. The inert anodes used in the process preferably comprise a cermet material comprising ceramic oxide phase portions and metal phase portions.

Abstract: Alpha alumina particles are made by heating particles of alumina with an aqueous solution containing a dissolved fluorine-containing compound and an acid; separating the particles from the solution and then calcining the particles at a temperature not greater than about 1025° C. The alumina particles preferably have an LOI in the range of about 1-20 wt. %; more preferably about 1-6 wt. %. Alpha alumina particles of the invention are more readily ground into smaller particles than alpha alumina particles made by calcining at higher temperatures. The remaining soda in the alpha alumina is found to be highly soluble in hot water. The process produces low soda content (0.01 wt. % Na2O or less) alpha alumina crystals from alumina feedstocks with 0.5 wt. % or more initial soda levels. The alpha alumina crystals produced are as large as 30-40 microns. Most typically; the size range is between 2 and 8 microns.

Abstract: An electrolytic cell and electrolytic process for producing a metal by reduction of a metal oxide dissolved in a molten salt bath containing at least one chloride and at least one fluoride. A solid conductor of oxide ions is interposed between the anode and the cathode. The solid conductor preferably comprises zirconia, stabilized in cubic form by addition of a divalent or trivalent metal oxide such as yttria.

Abstract: A light weight, structurally stiff instrument panel reinforcement structure for motor vehicle bodies. The reinforcement structure includes driver side and passenger side cross tubes that are preferably aluminum alloy extrusions, and a center stack support that is preferably a magnesium alloy casting connecting the cross tubes. The driver side cross tube supports a steering column assembly. The driver side cross tube has a greater average wall thickness than the passenger side cross tube. The driver side cross tube is hydroformed so that a middle portion has larger bending and torsion resistance than the end portions.

Abstract: An aluminum alloy sheet, plate, casting or extrusion having a surface layer containing magnesium oxide and aluminum oxide is cleaned with an acidic solution. The cleaned component has an aluminum oxide layer that is pretreated with a phosphorus-containing organic acid to form a functionalized layer. A layer of polymeric adhesive is applied to the functionalized layer, and the adhesive layer is joined to a metal support structure to form a vehicle assembly.

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 process and apparatus are disclosed for electrolytically smelting alumina to produce aluminum metal, including providing a combination solid oxide fuel cell and electrolytic smelting cell for the production of aluminum from refined alumina positioned near tile solid oxide fuel cell. In one aspect, an alumina ore refinery for producing the refined alumina is positioned near the solid oxide fuel cell, and refined alumina is passed at a temperature of at least 900.degree. C. directly from the alumina ore refinery to the electrolytic smelting cell. In one aspect, the solid oxide fuel cell incorporates a planar construction having a solid state cathode material of lanthanum strontium manganate, a solid electrolyte of yttria stabilized zirconia, and a nickel/yttria stabilized zirconia cermet anode.

Abstract: A reflective laminated strip includes an aluminum alloy or steel strip having a cleaned and conversion coated outer surface, an adhesive layer adjacent the conversion coated outer surface, and a polymer layer joined to the adhesive layer. An exterior side of the polymer layer is coated with a reflective metal layer that is preferably stainless steel, chromium, nickel or aluminum having a thickness of less than about 5000 .ANG.. In a preferred embodiment, an interior side of the polymer layer is coated with an adhesion-promoting metal layer or metal oxide layer having a thickness of about 50-5000 .ANG..

Abstract: A non-corrosive metal on aluminum or aluminum alloy lamination is disclosed including a non-corrosive metal top sheet, an aluminum or aluminum alloy substrate, and an adhesive bonding the non-corrosive metal top sheet to the aluminum or aluminum alloy substrate to provide a non-corrosive metal on aluminum or aluminum alloy lamination product having lighter weight and less cost than a sheet product of the non-corrosive metal of identical thickness, wherein the lamination product withstands galvanic corrosion between the non-corrosive metal top sheet and the aluminum or aluminum alloy substrate. In one aspect, the non-corrosive metal top sheet is stainless steel. In one aspect, the non-corrosive metal top sheet is nickel or nickel alloy.

Abstract: Aluminum is produced by electrolytic reduction of alumina in a cell having a cathode, an inert anode and a molten salt bath containing metal fluorides and alumina. The inert anode preferably contains copper, silver and oxides of iron and nickel. Reducing the molten salt bath temperature to about 900-950.degree. C. lowers corrosion on the inert anode constituents.

Abstract: Aluminum alloy sheet is provided with a primer layer comprising a reaction product of aluminum oxide or hydroxide and a vinylphosphonic acid-acrylic acid copolymer, coated with a polymer coating composition containing polyvinyl chloride or an epoxy. The polymer coated aluminum alloy sheet is shaped into container bodies for food containers or container end panels for aluminum food and beverage containers.

Abstract: An aluminum alloy substrate is pretreated with an aqueous solution containing an organophosphorus compound, preferably a vinyiphosphonic acid-acrylic acid copolymer, before coating the substrate with a polymer. Passing the substrate through the solution contaminates it with aluminum and other elements. The pretreatment solution is rejuvenated by removing aluminum with a cation exchange resin that preferably contains a styrene-divinyl benzene copolymer functionalized with sulfonate groups. Rinsing the substrate contaminates the rinse water with the copolymer. The rinse water is concentrated by reverse osmosis or membrane ultrafiltration and returned to the pretreatment solution.

Abstract: A process for separating oil from a lubricant composition containing solid particles. The contaminated lubricant composition is mixed with liquid or supercritical CO.sub.2 before the lubricant composition and CO.sub.2 mixture is filtered through a filter medium. The CO.sub.2 is then evaporated, leaving an oil residue. Mixing the lubricant composition with CO.sub.2 before filtration prevents the filter medium from being blinded by solid particles.

Abstract: A sheet material suitable for imaging by laser radiation includes a substrate, an adhesive layer comprising a thermoplastic or elastomeric polymer coated onto the substrate, and a particle layer adhered to the adhesive layer and comprising a plurality of carbon or metal or mineral particles that are subject to laser ablation. The particle layer preferably contains alumina particles. The adhesive layer may be filled with particles and is preferably filled with titanium dioxide particles that are more sensitive to laser radiation than the thermoplastic or elastomeric polymer. Preferably, a silicone or silicate layer that is not subject to laser ablation overlies the particle layer.

Abstract: A process for making an aluminum alloy lighting sheet product having a reflective surface protected by a UV-stable polymer coating. An aluminum alloy sheet is chemically brightened in an aqueous acidic solution, conversion coated, and then coated with a UV-stable polymer. Alternatively, an aluminum alloy sheet is chemically etched in an aqueous alkaline solution, conversion coated, and then coated with a UV-stable polymer. The UV-stable polymer may be clear or it may contain about 0.5-10 wt. % amorphous silica particles and polytetrafluoroethylene particles. In another embodiment, an aluminum alloy sheet surface is cleaned, chemically conversion coated and then coated with a coating composition containing a UV-stable polymer and 0.5-10 wt. % silica particles and polytetrafluoroethylene particles, both having an average size of about 0.5-5 microns.

Abstract: A novel laser-induced precipitation process is disclosed for forming purified alumina hydrate from a sodium aluminate solution by illuminating with light wave energy produced by the near infrared wavelength, linearly polarized output of a laser. In one aspect, supersaturated sodium aluminate solution is treated by illuminating with light wave energy to produce a photo-induced nucleation of purified gibbsite aluminum trihydroxide crystals. Near infrared pulses of light wave energy, spatially and temporally overlapped inside the supersaturated sodium alumina, form a precipitated purified alumina hydrate without the need for external seed to be added.

Abstract: A peelable and heat sealable lidstock material for steel end containers. The container of the invention is suitable for holding various foods, including instant coffee, powdered baby formula and soup mixes. The lidstock material includes a film containing an ethylene-carboxylic acid copolymer, polybutylene and a particulate inorganic filler.