Abstract: There is provided a substantially fully dense powdered metal composite comprising a highly conductive metal or metal alloy matrix having dispersed therein discrete microparticles of a refractory metal oxide and discrete macroparticles of an additive metal or metal alloy, such as a nickel/iron alloy. The respective components undergo minimal alloying because sintering is not utilized in forming the composite. These composites are characterized by high thermal or electrical conductivity and a desired property attributable to the composite forming additive metal or metal alloy. The composites are useful in forming lead frames for integrated circuit chips, electric lamp lead wires, and electrical contact members.

Abstract: A process for making a strip or sheet comprising dispersion strengthened metal or dispersion strengthened metal alloy which comprises rolling directly from dispersion strengthened metal powder to a green strip or sheet density of from at least 90% to 95% of theoretical density, sintering the green strip or sheet in an inert atmosphere at a temperature and for a period of time sufficient to form a rigid body; reducing the thickness of the strip or sheet by at least 25% by cold rolling or hot rolling and resintering at sintering temperature of at least about 1800.degree. F. for 40 to 75 or more minutes.

Abstract: An improved resistance welding electrode cap adapted to being internally cooled with a flow of coolant has a main body portion with a nose root at one end and an electrical and coolant connection projecting from the other, the area of the root being substantially smaller than that of the direct projection of the main body portion, a pronounced nose projecting from the root. The whole nose is of dispersion-strengthened copper, as is at least the main body portion. Such cap provides astonishingly improved performance for resistance welding, even of galvanized steel, and particularly of double-sided, galvanized cold-rolled steel sheet.

Abstract: A process and a product produced thereby, for forming rod or bar or tube stock or strip, comprising a sheath and a densified dispersion strengthened metal core. Powdered dispersion strengthened copper is put into a metal can and compressively reduced to size and density. The relationship between the tensile strength of the core when fully densified and the cold worked tensile strength of the can is important to the nature of the product.

Abstract: Substantially completely deoxidized, consolidated dispersion-strengthened copper stock of sizable cross section and particulates capable of being thus consolidated into such stock are shown. The stock exhibits ductility substantially greater than that of otherwise corresponding stock which contains about 100-500 ppm of available oxygen. Also shown is a staged powder deoxidation process using hydrogen or like reducing gas followed by the sequestration of remaining available oxygen with a minute proportion of diffusible, normally solid oxygen getter.

Abstract: A process for making a novel alloy of a dispersion strengthened copper by blending dispersion strengthened copper powder and a powdered modifying metal, heat treating the blend to form the alloy, and the compacting and working the compact to densify it.

Abstract: An improved process for producing electrolytic iron is primarily based on maintaining the electrolytic bath at a low concentration of ferrous sulfate ions in combination with a certain concentration of NH.sub.3 and pH in the electrolytic bath. The electrolytic iron chips produced in accordance with this process are much more friable. A substantial improvement is obtained in an efficient grinding of the chips to -100 mesh (Tyler Screen) and smaller.