Abstract: A method of casting metal wherein the molten metal is deposited on a moving planar substrate formed from an insulating refractory material. The deposited liquid metal is maintained as a liquid until the turbulence induced by the pouring of the metal onto the substrate is minimized.

Abstract: The apparatus and method for spray casting a spray of molten metal on a moving substrate. The leading edge of the spray pattern is deflected away from or into the spray pattern to eliminate the cooler and less dense particles of the leading edge from contacting the substrate. The deflector preferably has a surface of non-wetting material to prevent the build up of material thereon.

Abstract: A method of casting a copper based composite which includes a second phase ceramic particles. A copper or copper based alloy containing a eutectic reactive element is spray cast with the ceramic particles being injected into the spray cast stream of material prior to its being deposited onto the moving substrate. The eutectic reactive element diffuses into the ceramic particles and provides a good bond between the copper based matrix and the second phase ceramic particles. The ceramic particles may be selected from the group consisting of oxides, borides, nitrides, carbides and mixtures thereof. The eutectic reactive materials may include zirconium, chromium, titanium, aluminum and magnesium.

Abstract: A frangible projectile made from powdered metals comprising a body of either iron and carbon, or of iron and alumina. The powdered metals are compacted, sintered, and cooled.

Abstract: A technique for improving the peel strength of copper and copper based alloy materials, and particularly for copper or copper based alloy materials which may be wrought or electrolytically deposited copper foil having an antitarnish treatment applied thereto, preferably by the use of a chromate-containing solution. The material is subjected to a rinse containing a silane coupling agent, which preferably is an organofunctional silane, and more preferably is an alkoxysilane derivative. Both the original peel strength and the peel strength after storage of the material so treated is enhanced.

Abstract: A process for making ultra-thin foil utilizing a copper or copper alloy foil carrier. The foil carrier is pretreated prior to the deposition of the ultra-thin layer of copper or copper alloy thereon. The pretreatment includes cleaning the carrier by treatment with an aqueous acid solution preferably containing an oxidizer, rinsing the carrier and then treating the carrier with an aqueous solution of chromic acid and phosphoric acid to apply a film to the carrier.

Abstract: A method of imparting tarnish and corrosion resistance to a copper or copper alloy foil in which the foil is first coated with a thin layer of zinc on at least one side. Thereafter, the foil is treated with an aqueous solution of chromic acid and sulfuric acid. The foil may then be rinsed in a dilute basic solution having a pH greater than 8 and then dried.

Abstract: An apparatus to perform the electrostatic transfer of a developed image from a master having a permanent latent image therein to a receiving surface in which the master is moved between a first position remote from said receiving surface to a second position in overlying relation with said receiving surface for image transfer. A wicking station is moveable between a first position and a second position to deposit an insulating solvent on said receiving surface and return to its first position at a slower speed than the speed of the master returning to its first position. Gap spacer strips are provided which are played out over the receiving surface as the wicking station moves to its second position. The gap spacer strips in combination with a drive motor serve to return the wicking station to its first position.

Abstract: A method of producing a grain refined copper base alloy containing iron in the amount of less than 2.3% by weight and which is cast into an ingot by conventional direct chill casting. Calcium is added to the melt before casting, preferably in the form of a copper-clad or iron-clad calcium feedwire.

Abstract: A baseplug for a target-penetrating projectile containing an explosive in which the baseplug is fabricated in two components each preferably fabricated from a powdered pyrophoric material. The powdered pyrophoric material may be zirconium or titanium or alloys thereof which is charged with hydrogen which upon burning of the baseplug is released to increase the fine start capability of the projectile.

Abstract: The present invention relates to copper-iron-nickel alloys having utility in electronic applications because of their low coefficients of expansion and high thermal conductivities. Alloys in accordance with the present invention consist essentially of from 10% to about 80% copper and the balance iron plus nickel with the ratio of iron to nickel being in the range of from about 1.5:1 to about 2.0:1. Preferred alloys have an iron to nickel ratio in the range of from about 1.6:1 to about 1.9:1. The process includes casting the alloy and treating the iron-nickel phase of alloy to minimize its surface volume. The treating step may comprise speroidizing the iron-nickel phase or applying an electromagnetic stirring force to the alloy during the casting step.

Abstract: A metal extrusion process and apparatus in wich a semisolid material is fed into a passageway formed between first and second members, with one of the members being moved toward a die such that the moveable member draws the semisolid material through the passageway and through the die means.

Abstract: A metal extrusion process and apparatus in which a semisolid material is fed into a passageway formed between first and second members, with one of the members being moved toward a die such that the semisolid material is drawn through the passageway and solidifies before passing through the die means.

Abstract: The present invention relates to a technique for forming silicon carbide coated porous filters for use in filtering molten metal, especially copper and copper alloy melts. The technique comprises preparing a silicon carbide containing slurry having a viscosity in the range of about 1 to about 50, preferably from about 5 to about 30, centipoise and impregnating a rigid porous substrate material with the slurry. In a preferred embodiment, the slurry contains mono-aluminum phosphate as a binding agent, ethylene glycol as a wetting agent, powdered silicon carbide having a maximum settling rate of about 0.1 mm./min. and the balance essentially water. After draining of the excess slurry, the coated substrate material is heated to substantially prevent foaming of the coating during firing and fired to bond the silicon carbide coating to the substrate material.

Abstract: A molten metal spray-depositing apparatus employs an ejection nozzle for receiving a molten metal stream and having a configuration for confining and imparting mechanically an angular momentum thereto which produces stream break-up into a metal particle spray when the stream becomes unconfined upon exiting the nozzle. There are stationary and rotating versions of the ejection nozzle. The stationary ejection nozzle has a flow channel with internal angular elements, such as spiral grooves, which engage the moving molten metal stream to impart angular momentum thereto as it passes through the channel. The rotating ejection nozzle may have internal elements within the flow channel, such as notches or serrations, which engage the moving molten stream and cause it to rotate with the nozzle as it passes through the channel. The two nozzles can also be combined to impart the angular momentum and accomplish melt stream break-up.

Abstract: A method and apparatus for casting a grain refined ingot from a metallic melt supplied to a casting mold through a feed tube. The feed tube is provided with at least one cooling passageway through which a cooling fluid cyclically flows to form a zone of fine dendrites on the inner peripheral surface of the mold. An inductor is provided to reheat the zone of fine dendrites to detach dendrite arms into the melt which serve as nuclei for grain refinement as the melt solidifies into a cast ingot in the mold.

Abstract: A process for etching copper or a copper base material with an aqueous solution consisting essentially of peroxydisulfuric acid, up to about 500 ppm of a halide addition and the balance water is described. The process includes off-line generation/regeneration of the etching solution. An electrochemical cell for generating/regenerating the etching solution is also described.

Abstract: A molten metal gas-atomizing spray-depositing apparatus has an atomizer for atomizing a stream of molten metal into metal particles in a divergent spray pattern thereof being of higher temperature at a center region of the pattern than at an outer peripheral region thereof. A substrate is continuously movable along an endless path and has an area thereon disposed below the atomizer for receiving a deposit of the particles in the spray pattern to form a product on the substrate being substantially uniform in thickness. The deposit-receiving substrate area has consecutively arranged upstream, intermediate and downstream portions upon which respective inner, intermediate and outer cross-sectional portions of the metal deposit are layered one upon the next to form the product.

Abstract: A treatment for metal foil, particularly copper or copper alloy foil, to be used in electrical and electronic applications wherein the bond strength of the foil is improved. The treatment includes applying an aqueous solution of chromic acid phosphoric acid to the foil, rinsing the foil in an aqueous solution having a pH of at least 8 and thereafter forming a plurality of copper or copper oxide dendritic structures on at least one side of the foil. The foil may be further treated by applying a coating of zinc or other suitable material over the dentritic structure and an anti-tarnish treatment applied. The anti-tarnish treatment includes applying a thin coating of zinc to the smooth side of the foil followed by treating the foil with a chromic acid sulfuric acid solution to provide a layer of chromate on both surfaces. The foil is then further treated by rinsing with an aqueous solution of a pH of at least 8 and dried.

Abstract: A process and apparatus for producing metal foil comprises supplying an isotopically polished continuous cathode, a high volume turbulent flow of electrolyte and rigorous filtration to exclude chlorides, sulfides, organics and other impurities from the electrolyte. The foil so produced is free from micro-voids and able to withstand substantially higher biaxial stresses than conventional electrodeposited foil. The micro void free structure also decreases the diffusion rate of an underlying substrate.