Abstract: A method of making a metal slab with a non-uniform cross-sectional shape including providing a spray casting apparatus including a substrate and a plurality of spaced atomization nozzles, the nozzles having a discharge opening and introducing molten metal into the nozzles. The method then includes atomizing the molten metal as it is discharged from the nozzles through the discharge openings by subjecting the discharged molten metal to jets of an atomizing gas in order to form metal droplets for deposition onto the substrate. The deposition of the metal droplets onto the substrate is controlled in order to form the metal slab having a non-uniform cross-sectional shape. A method of making an integrally stiffened metal structure as well as metal and aluminum products made by the above methods are also provided.

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 novel method for producing a ceramic phase particle dispersoid in metal and a novel product composed thereof. The method includes (a) providing a molten composition consisting essentially of molten aluminum alloy containing molten metal selected from the group consisting of Zr, V and combinations thereof, (b) providing a chloride salt containing fine carbon particles; and (c) reacting the chloride salt containing fine carbon particles in the molten aluminum metal with the molten metal to form a uniform distribution of finely sized carbide particles formed and dispersed in-situ in an aluminum alloy matrix.

Abstract: A method of controlling bulk absorption of atomic hydrogen and facilitating degassing of hydrogen from a metal or metal alloy workpiece during heat treatments in furnaces with ambient and/or moisture-laden atmospheres, the method includes exposing the surface of the workpiece to an acidified inorganic salt solution or dispersion, with the inorganic salt of the solution containing a transition metal cation and a sulfate, phosphate or nitrate anion, before being subjected to said heat-treatment, said transition metal cation having an equal or positive standard reduction half-reaction potential relative to metal or metal alloy workpiece, the workpiece exposed to the acidified transition metal sulfate, phosphate or nitrate salt is subjected to a heat treatment.

Abstract: A container closure includes a shell attachable to a container around a container opening thereof. The shell has a shell opening in fluid communication with the container opening when the shell is attached to the container. A tip is received on the shell movable between a closed position sealing the shell opening and an open position. A cover is releasably attached to the shell in a manner indicative of the tip being positioned in the closed position when the cover is attached to the shell. Both the shell and the cover may be provided with tamper-evident bands. The present invention is particularly well adapted to be formed as a push-pull container closure for sports bottles and the like.

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 method of fabricating a plurality of multilayer structures which includes at least one recess defined by a nonplanar surface. The method including the steps of: (a) providing a resilient, compliant material on over one or more stacks of layers including the area over the recess; (b) applying sufficient pressure to the stacks to cause the resilient, compliant material to fill the recess and laminate said stacks; (c) lifting the resilient, compliant material off the stack subsequent to the application of pressure; (d) providing one or more stacks of layers that have not been subjected to step (b); and (e) repeating steps (a)-(d). In a preferred embodiment of the invention steps (a)-(d) are repeated at least ten times without the need to change the resilient compliant material. In a most preferred embodiment of the invention steps (a)-(d) are repeated at least one hundred times.

Abstract: There is claimed a method for depositing fluid material from a linear nozzle in a substantially uniform manner across and along a surface. The method includes directing gaseous medium through said nozzle to provide a gaseous stream at the nozzle exit that entrains fluid material supplied to the nozzle, said gaseous stream being provided with a velocity profile across the nozzle width that compensates for the gaseous medium's tendency to assume an axisymmetric configuration after leaving the nozzle and before reaching the surface. There is also claimed a nozzle divided into respective side-by-side zones, or preferably chambers, through which a gaseous stream can be delivered in various velocity profiles across the width of said nozzle to compensate for the tendency of this gaseous medium to assume an axisymmetric configuration.

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.

Abstract: There is provided a flash activated hydrotalcite which, when extruded to sizes of about 1/16 inch or more, has a crush load strength of at least about 7 pounds. The process for making this extrudate includes: (a) providing a hydrotalcite compound; (b) heating said compound for less than two seconds to one or more temperatures above about 482.degree. C. (900.degree. F.); (c) cooling said heated compound; (d) collecting said cooled compound; (e) forming said compound into an extrudate; and (f) reactivating said extrudate by heating to one or more temperatures above about 400.degree. C. (752.degree. F.) for about 20 minutes or more. Further strength improvements are achieved by exposing these extrudates to steam for at least about 8 hours prior to step (f).

Abstract: Reflective aluminum trim for use in automobiles, trucks, boats and a variety of household and industrial appliances is produced by forming aluminum strip into a desired shape, followed by selective application of a fluoropolymer protective coating to only a partial portion of the show surface of the shaped strip and the application of a thermoplastic to the portions of the show surface not covered by the protective coating. The resulting trim piece has a highly reflective aluminum show surface which has a high distinctness of reflected image. The thermoplastic is preferably co-extruded onto the shaped aluminum strip using an adhesive to bond the thermoplastic directly to an un-coated portion of the aluminum surface. Prior to application of the thermoplastic, a single heating step may be used to cure both the protective coating and the adhesive.

Abstract: Methods for making an aluminum drive shaft for automobiles or trucks or other drive shaft applications from aluminum alloy tube and methods for making drive shafts. The method includes providing an aluminum tube member is joined to drive shaft end members. The method includes the steps of (a) providing a 6000 series type alloy; (b) extruding the alloy within about 500.degree. to 800.degree. F. into a hollow elongate tube; (c) drawing the tube to a reduction of at least 15% in metal cross-sectional area; (d) solution heat treating the alloy at a temperature of at least about 990.degree. F. and then quenching; and (e) reducing the diameter of the tube and increasing the tube wall thickness to provide a relatively short tube length of reduced diameter, a transition section and thicker wall thickness at one or both ends of a drive shaft suitable length of said tube. The transition section has a non-linear wall. In a preferred embodiment, the transition section has central circumferential stiffener section.

Abstract: An aluminum extruded node for interconnecting a longitudinal frame rail and a lateral frame member of a vehicle frame. The extruded node having a pair of longitudinal side walls received within an interior volume defined by the longitudinal frame rail and a pair of transverse side walls received within an interior volume defined by the lateral frame member. Interior wall portions extend between each of the pairs of longitudinal and transverse side walls to define closed cells for increasing the stiffness and structural integrity of the node. The longitudinal frame rail is peripherally welded around an end thereof to the node. The lateral frame member is peripherally welded around an end thereof to the node.

Abstract: A lightweight tailgate assembly for pickup trucks includes several metal panels that are preferably made from a single metal sheet, a plastic reinforcing module between inner and outer metal panels, and fastener means joining the reinforcing module to the inner panel. A preferred assembly also includes hinge means for connection with truck body, and latch means for locking the assembly between opposed rear corner posts in a truck body. A particularly preferred tailgate assembly made with AA 6022 aluminum alloy sheet and a reinforcing module containing nylon and glass fibers weighs about half as much as a conventional steel struck tailgate.

Abstract: A can body embossing apparatus has a first mandrel with a first tooling member adapted to receive thereon a can body and a second mandrel with a second tooling member reciprocally movable from a first position distal the first tooling member to a second position proximate the first tooling member. In the second position, the can body side wall is engaged between the first tooling member and the second tooling member. The first tooling member defines one or more recessed portions therein and the second tooling member defines one or more protuberances extending therefrom and adapted to correspond with the recessed portions. The first mandrel and second mandrel are in mechanical communication throughout the reciprocal movement of the second mandrel such that the first and second tooling members rotate continuously with respect to each other and maintain a substantially constant relative position with respect to each other.

Abstract: A die tool monitor and analysis system identifies tooling changes and maintains tooling in an optimal position, thus maintaining the quality of the manufactured product within a desired tolerance band. A die tool force monitor and analysis system identifies changes in the operational conditions within a press. These identified changes are indicative of tooling changes and in conjunction with a thermal control system, facilitate the thermally induced expansion and contraction of a tooling support structure. The expansion and contraction of the supporting structure displaces the tooling member relative to its counterpart tooling member.

Abstract: An electrolytic cell for reduction of a metal oxide to a metal and oxygen has an inert anode and an upwardly angled roof covering the inert mode. The angled roof diverts oxygen bubbles into an upcomer channel, thereby agitating a molten salt bath in the upcomer channel and improving dissolution of a metal oxide in the molten salt bath. The molten salt bath has a lower velocity adjacent the inert anode in order to minimize corrosion by substances in the bath. A particularly preferred cell produces aluminum by electrolysis of alumina in a molten salt bath containing aluminum fluoride and sodium fluoride.

Abstract: An improved method and apparatus for scoring a metallic container wall, which facilitates scoring thin gauge, hard temper metal such as coated or uncoated aluminum to reduced score residuals wherein the scoring tool has a secondary antifracture score indenter on one or both sides of a primary indenter and in which the outboard secondary indenter has an outboard face angled about 30 to 40 degrees to vertical.

Abstract: Oil and oil additives separated from a contaminated solid particulate filter medium, preferably diatomaceous earth particles. Portions of a mixture of oil, oil additives and the filter medium are compressed into pellets that are extracted with liquid or supercritical CO.sub.2 to form a liquid solution. The solution is separated from the pellets and then heated to 20.degree.-60.degree. C. at a superatmospheric pressure to drive off CO.sub.2 gas, which is preferably recycled by compression into liquid or supercritical CO.sub.2.

Abstract: A convenience easy opening end having a removable panel portion which includes a narrow U-shaped stem portion extending from a larger rounded bulbous portion and with a pull tab attached to the stem portion.