Abstract: A piston includes an insert, such as a piston ring insert or crown insert. In order to prevent the insert springing off the piston body in an axial direction, the insert is so formed with a recess or recesses which interlock with projections on the piston body so that the mechanical interlock between them holds the insert securely on the piston body. Further interlocking recesses and projections may be provided which are arranged to prevent relative rotation between the insert and the piston body.

Abstract: An improved method of manufacturing a swash plate assembly for use in a compressor, fluid motor or similar device in which a plurality of pistons are connected, by means of connecting rods, to a swash plate which drives (or is driven by) the pistons. A plurality of piston assemblies are made by casting the piston around one end of a connecting rod section which is formed with a ball thus providing a ball-socket connection therebetween. Mating spherical ends with through-bores to receive the piston connecting rod section are cast-in-place and captured in sockets within the swash plate. The connecting rod section of the pistons is mated to the through-bores of the mating spherical ends and are positioned in an appropriate fixture to a fixed final relationship. The connecting rod sections are secured to the sidewall of each through-bore by a means such as electron-beam welding to secure the overall length of the final assembly.

Abstract: A method for making a drill bit and product resulting therefrom in which carbide elements are coated with carbide and nitride materials such as those of titanium as by chemical vapor deposition after which the elements are cast in molten steel.

Abstract: A metal-capped electrical insulator and method of making same by forming a metal cap on an insulator dielectric by directly casting molten metal round a portion of the dielectric to embed it therein. Before casting the metal (16 or 17), a metal washer (1 ) is placed in contact with the boundary on the insulator at the edge of the portion to be embedded. The washer has a circular groove (2) open on the side through which the molten metal is poured. Before casting, said washer is deformed, by pressing it hard in a metal-casting mould (30) to the dielectric and deflecting the walls (3, 4) of the groove (2) to create an undercut in the metal washer.

Abstract: A method of casting a hollow bodied plate type recuperative heat exchange envelope. The heat exchange envelope comprises first and second envelope halves cast independently, then bonded together by fusion of molten metal of the second envelope half with solidified metal of the first envelope half. The first envelope half includes a lateral flange on opposite sides thereof that is confronted by the molten metal of the second envelope half to form a flange that connects envelope halves providing an increased area of contact therebetween. The flange of the second envelope half includes multiple surface areas that become fused to opposite sides of the first envelope half to form a strong connection impervious to fluid leakage.

Abstract: Method for injecting molten lead from a reservoir into a die mold cavity formed about an aperture in the wall of a plastic battery for casting lead-alloy battery terminal connectors. Batteries are positioned adjacent the molten lead reservoir of the apparatus and mold portions move together to hold the battery containers in a clamp-like action. Molten lead is die cast under pressure into the mold cavity in which a stainless steel threaded nut is positioned. The lead is forced through a heated chamber into a portion of the mold which may be water cooled. The mold is designed to allow venting of gases, thereby eliminating porosity; and the apparatus is designed to provide casting which is free of jagged projections in the sprue hole. The aperture in the battery wall is surrounded by a series of plastic annular rings extending outward from the battery wall but being a part thereof. The molten lead surrounds the annular rings and fills the spaces therebetween when it is injected into the cavity.

Abstract: A method of producing a piston cylinder assembly for use in a windmill in which a compression ring is formed by casting molten metal around a piston head having a number of drilled holes on its side surface while the piston head is positioned within the cylinder. The compression ring formed is attached to the piston head by solidified metal within the drilled holes.

Abstract: A master cylinder body including a cylindrical-shaped inner section of uniform wall thickness formed as by die-casting and an outer section cast on the inner section around the periphery thereof. The extreme simplicity in configuration of the inner section enables it to be formed with no casting defects such as shrinkage cavities which may result in oil leakage therethrough. The inner section and the outer one cast thereon become solidly fused together at the cylindrical interface therebetween as long as the materials used are of the same metallurgical type. Formation of a multitude of annular or helical ridges on the outer periphery of the inner body section further ensures the solid interconnection between the two body sections.

Abstract: A method of fabricating a lighter composite master brake cylinder is disclosed along with the resulting product. A seamless steel tube of critical thickness, closed at one end, and treated by acid etching on its exterior, is oriented vertically within a mold cavity. The tube is pretreated to contain critically dimensioned punched and coined openings for brake fluid filling and fluid delivery. Openings in the cast body are defined by pin cores aligned with the tube openings and are dimensioned to separate the edge of the tube openings from the cast opening. The tube is supported by a plug extending snuggly into the interior of said tube, said plug being joined at one end to the die walls; the cores are also supported by suitable attachment to the die walls.

Abstract: For inclusion as spacer between first and second axially spaced apart members mounted for limited angulation about a common axis, the first member having a seal recess formed in one face, the second member having an end face opposite the seal recess, the improvement of: a laminated torsielastic bushing arranged in one piece, and in the recess.

Abstract: A method and apparatus for producing a conduit intended for communication with a plurality of working-medium sources, which conduit includes at least two connecting elements spaced apart along the length of the conduit and secured thereto. Each connecting element has a through passage communicating with the passage of the conduit and intended for connection with a source of a working-medium. The axis of the through passage is perpendicular to a plane passing through the conduit axis. To make such a conduit, a continuous-surface conduit is fed under pressure to a die-casting machine and is placed in its casting die.

Abstract: A method for producing large castings formed of non-machinable metals provides for inserting machinable plug members in the mold prior to casting, then pouring molten hard metal to fill the mold and surround the inserts. Removing the mold exposes the casting and portions of the inserts which may then be machined. After machining, the inserts are flame-hardened commensurate with the hardness of the casting.

Abstract: A cast iron ingot mold base member containing an integral refractory insert which has been formed into the base member during its casting.

Abstract: A method of connecting a pipe to a pressure conveying element, especially a pipe plate, a pressure container, and a collector, according to which the pressure conveying element is within the region of its intended connection with the pipe provided with lips. After the pipe provided on its inside and outside with a lip has been introduced into the pressure conveying element, the pipe is at its outer lip connected to the lip of the element by a complete through weld. Subsequently a centering bushing is introduced into the pipe and is clamped therein so that the outer surface of the centering bushing together with the inner surface of a bore in the conveying element--which bore is substantially coaxially arranged with regard to the pipe--forms a flat annular trough, whereupon the space between the outside surface of the centering bushing and the inner surface of the trough is filled with welding material.

Abstract: A method of making a metal casting composed of a steel plate and aluminum material interlocked with the steel plate. A plurality of teeth are formed on at least one of the opposed surfaces of the steel plate by raising up a skin of the plate from the same, the teeth providing primary interstices, each of which extends from the steel plate and has at least one face with a number of flaws formed during the formation of the teeth and providing substantially irregular interstices. The casting is then formed by pouring aluminum material in the molten state onto the steel plate surface so that the molten aluminum material penetrates into the primary and irregular interstices, thereby to provide a firm interlocking between the steel plate and the aluminum material upon solidification thereof.

Abstract: A method for repairing eroded bottoms of ingot molds by forming a casting space in the bottom of the mold at the point of erosion, the casting space having an hour-glass type shape, placing the ingot mold on a molding platform so as to close off the bottom of the casting space with a refractory material, placing a protective layer of a compactable refractory material about the interior of the mold and introducing to the casting space an alumino-thermic material and then igniting said alumino-thermic material such that the weld metal from the reaction thereof completely fills the casting space. Methods for repairing the bottoms of closed bottom as well as plug bottom molds are disclosed.

Abstract: A reinforced ferrous metal casting and a method of making a reinforced ferrous metal casting wherein the reinforcing rods are located within tubular metal sheaths such that the metal sheaths become fused and bonded to the casting while the reinforcing rods located within the metal sheaths are not fused with respect to the sheaths and are, therefore, slidable within the casting. The reinforcing rods are preferably spaced from the sheath by a refractory coating.

Abstract: A method of assembling a dynamoelectric machine having a stationary member, a rotatable member, and a pair of means for rotatably supporting the rotatable member within the stationary member. In this method, beams are attached to the stationary member, and opposite end portions of the beams extend from the stationary member. The rotatable means is then mounted with the stationary member and the supporting means with one of the opposite end portions of the beams within means in one of the supporting means for receiving them. The receiving means is at least partially filled with molten metal which solidifies for interconnecting the one opposite end portion of the beams with the one supporting means, and the other of the supporting means is then secured to the other of the opposite end portions of the beams.

Abstract: A method is disclosed for fabricating a rotor housing for a rotary internal combustion engine. A conductive mandrel is prepared having an outer surface complimentary to the resultant rotor housing inner wall, the mandrel is provided with an exterior surface smoothness in the range of 4-12 r.m.s. A functional coating of a composite particle wear-resistant material is electrolytically deposited onto the mandrel (acting as a cathode) to form an assembly, the exposed surface of the assembly is controlled to have a roughness characterized by projections no less than 0.030 inches and concentrated in a number no less than 5/cm.sup.2. The assembly is placed in a die-casting machine where a molten metallic medium is cast thereabout forming a casting which is substantially mechanically locked to the assembly. The mandrel is then stripped from the coating to leave the resultant rotor housing.

Abstract: A threaded opening is formed in a plastic or metallic body formed by molding or casting by providing a wire in a helical configuration supported on a core member and then molding or casting the material about the helical configuration. This helical configuration or insert is initially provided with a thread pitch greater than that desired for the final threaded opening so that shrinkage of the material as it hardens adjusts the greater thread pitch of the helical insert to the desired final value.

Abstract: A composite casting is produced by electrodepositing a wear resistance material onto a core, immersing the core in an aluminium melt and then casting an aluminium alloy around the core, before detaching the latter. The wear resistant layer may be given a roughened surface before immersing in the aluminium melt, by increasing the current density in the later stages of the depositing. The method may be used for casting light metal cylinders for internal combustion engines.