Abstract: An electronic apparatus such as a portable computer comprises an electronic apparatus frame and a raised portion provided on that region of the electronic apparatus frame which engages an ejector pin projecting from inside a mold device and formed thicker than the other part of the electronic apparatus frame.

Abstract: Improved targets for use in DC_magnetron sputtering of aluminum or like metals are disclosed for forming metallization films having low defect densities. Methods for manufacturing and using such targets are also disclosed. Conductivity anomalies such as those composed of metal oxide inclusions can induce arcing between the target surface and the plasma. The arcing can lead to production of excessive deposition material in the form of splats or blobs. Reducing the content of conductivity anomalies and strengthening the to-be-deposited material is seen to reduce production of such splats or blobs. Other splat limiting steps include smooth finishing of the target surface and low-stress ramp up of the plasma.

Abstract: Improved assembly and methods for manufacturing a three-dimensional object are described. The assembly includes a crucible for holding molten metal, an orifice disposed in the bottom of the crucible through which a jet of molten metal can flow towards a movable substrate, and a mechanically oscillating member immersed in the molten metal for controlling the flow of molten metal through the orifice and for breaking the flow of molten metal into the sequence of molten metal drops. As the drops land on the movable substrate, a three-dimensional object is built up. Continuously variable diameter or controllable planar jets may be used as the orifices. In forming drops from the output of a planar jet, the jet is first broken up by the oscillating member into horizontal cylindrical ligaments and the ligaments are then broken up into drops by acoustic energy applied by audio loudspeakers adjacent the falling ligaments. The assembly and methods are useful in the fields of rapid prototyping and materials processing.

Abstract: The apparatus comprises a device for supplying molten metal, a device for heating molten metal such that it remains fluid while within the apparatus, a device for applying a magnetic field in a direction perpendicular to the device for supplying molten metal, a device for transmitting electric current directly through molten metal to exert a force in a first direction on molten metal, where the device for transmitting can reverse the direction of the current to a second direction, opposite of the first direction, to form a droplet of molten metal, and a receiver for the droplet where the accumulation of a multitude of droplets upon the receiver results in the formation of the desired metal part. The mixing chamber can include a rotary electrode arrangement which mixes the molten metal by movement.

Abstract: An apparatus for the accurate formation of a three-dimensional article comprises providing a first quantity and a second quantity of substantially uniform size droplets of a desired material wherein each droplet has a positive or negative charge. Each quantity of droplets is focused or aligned into a narrow stream by passing the droplets through or adjacent an alignment means which repels each droplet toward an axis extending through the alignment means. The droplets are deposited in a predetermined pattern at a predetermined rate onto a target to form the three-dimensional article without a mold of the shape of the three-dimensional article. The droplets of the first quantity and the second quantity are supplied at different distances, whereby the droplets of the first quantity bond to each other and the droplets of the second quantity do not bond to each other or to the first quantity of droplets.

Abstract: A process for manufacturing large diameter, spray formed billets, rings, or tubular forms by spraying atomized molten metal onto a rotating surface. The rotating surface has a collector surface that is maintained at a predetermined temperature or reheated to the predetermined temperature by an external heat source. The external heat source impinges upon the collector surface to form a reheated or preheated zone. The external heat may be provided by a laser, high temperature flame, plasma arc, electric induction or radiation source. The molten metal is sprayed onto the collector surface in the reheated or preheated zone. Apparatus for carrying out the process is also disclosed.

Abstract: A mold for casting aluminum or aluminum alloy made of a copper alloy having a thermal conductivity of not less than 0.20 cal/s.cndot.cm.degree.C. The mold cavity surface is locally or entirely formed with a coated layer. The coated layer may be either (i) a cermet layer including of at least one element selected from the group consisting of Co, Cu, Cr and Ni, or (ii) a Co--, Ni--, Cr --or Mo-based hard alloy layer. The copper alloy mold exhibits distinguished thermal conductivity and resistance to melt damages.

Abstract: An apparatus for manufacturing a solid spherical body of solder having high sphericity and high dimensional accuracy comprising a flat plate having a plurality of holes which penetrate the flat plate opening at its upper and lower surfaces, said upper surface being made of material which is not easily wetted by moltens or semi-molten substances, a space to be filled with said molten or semi-molten substance, a cylinder connected with said space, a piston which can elevate within said cylinder pressing said substance in said space upwards and ejecting it at said upper surface of said flat plate through the plurality of holes and a driving device which can move said piston up and down and the spherical bodies are formed by the action of the surface tension of the substance ejected.

Abstract: A method and apparatus for the production of a deposit such as a bar (1) is provided. The deposit has a longitudinal outer surface (2) and a front face deposition surface (3). The spray deposition comprises atomized droplets produced by outer and inner sprays (4 and 5). The outer and inner sprays (4 and 5) are both directed such that, during deposition, a substantial proportion of droplets from both sprays are deposited on the front face (3) of the forming deposit. The inner spray (5) has a higher gas to metal ratio than the outer spray allowing an increase of both deposition and final product yield.

Abstract: Metal is spray cast onto a moving substrate using at least two sprays, the first of which has a solid fraction greater than 20% at the time the spray contacts the substrate, but less than the solid fraction of the second spray.

Abstract: Lower structure of a mould for the pressure casting of flat products such as slabs and method for mount and removing the lower spacer of this mould is provided. The lower structure of the mould includes an intermediate beam (26) resting freely on a frame (3) whose upper surface opposite to its surface bearing on the frame (3) carries a lower spacer (4) which is fixed by clips (37) on the beam (26). At least one positioning pin (54) is engaged in a housing (55) at the front part of the frame (3). A plurality of members (47) for holding the intermediate beam (26) on the frame are distributed according to the length of the beam (26). These members each comprise a part (46) which can be engaged longitudinally in a coupling device (45) attached to the beam (26) and which can be actuated in order to hold the beam (26) on the frame (3) or, on the other hand, in order to release it.

Abstract: A mold for lead casting comprising a porous metal material which does not form an alloy with molten lead and which has a thermal conductivity of from 3-15 kcal/(m.multidot.hr.multidot..degree.C.) and having a percentage of pores having a radius larger than or equal to 40 microns being 7% or less of the total pore volume. The porous metal material has a permeability of at least 0.2 ml/sec.multidot.cm.sup.2 at a material thickness of 10 mm and ambient pressure of 0.02 kg/cm.sup.2. A casting mold enabling casting of a lead grid without using a lubricant due to the lubricity of the mold material itself is realized.

Abstract: A method for producing nodular or compacted graphite iron castings in a mould having a sprue, an ingate and a mould cavity, having a first part below and a second part above the level of the ingate, comprises delivering particulate magnesium-containing and silicon-containing treatment agent from a dispenser into a stream of molten metal entering the sprue such that the treatment agent is added at a constant rate of addition while the first part of the mould cavity is filled with iron, and at a decreasing rate while the second part is filled. The addition of the treatment agent is controlled by means of apparatus comprising a container, a measuring and data capture device connected via signal transforming means to a control means, conveyor means located below the container and connected to the signal transforming means, and means for injecting the particulate treatment agent into the metal stream.

Abstract: A molten metal gas-atomizing spray-depositing apparatus has an atomizer which employs a pressurized gas flow for atomizing a stream of molten metal into a spray pattern of semi-solid metal particles and producing a flow of the particles along with the gas flow in a generally downward direction. The apparatus also has a substrate disposed below the atomizer for impingement on the substrate of the gas flow at a steady state temperature resulting from heat transfer by the metal particles to the gas flow and for receiving a deposit of the particles in the spray pattern to form a product thereon.

Abstract: A stream of molten metal is atomized to form a spray and additional cooling is achieved by applying to the stream or spray relatively cold solid particles. The solid particles are preferably injected into the spray and may be formed from overspray particles recycled from the deposition process.

Abstract: The handle is made by casting in a two part mold. The lower mold part includes a vertical split post having two vertical spaced posts with their upper ends in the form of lateral tabs. The upper mold part has a flat wall member cooperating with the lateral tabs.

Abstract: Metal castings are prepared using rigid closed molds by submerging the mold in a bath of lower temperature molten metal, with removal of the mold from the bath being handled to hold the metal inside the mold, but to allow the excess metal to run off the exterior of the mold without metal freezing thereto which could cause damage or locking-in of the mold.

Abstract: Metal castings are prepared using thin rigid closed molds by submerging the mold in a bath of high temperature molten metal, with removal of the mold from the bath being handled to hold the metal inside the mold, but to allow the excess metal to run off the exterior of the mold without metal freezing there which could cause damage or locking-in of the mold.

Abstract: The present invention concerns a process and an apparatus for moulding ingots of ferro-alloys by chill casting in a cooled copper mould.The apparatus comprises:an ingot mould (1) of copper, which is formed from two mould halves (2), at least one of which comprises a plurality of impressions (10) of the ingots to be moulded, communicating with each other by way of ducts (11, 12) and opening in the upper part by way of an ingate (18),means (5) for cooling each mould half (2) by a heat exchange fluid,means (9) for bringing the two mould halves into contact and into sealing relationship,means for moving the two mould halves away from each other, andmeans (7, 8) for guiding the mould halves in their movement away from each other and in their movement of coming into sealing relationship.

Abstract: Metal founding in a glass-ceramic mold which is reusable.

Abstract: A machine for manufacturing high strength flexure hinges having use in accelerometers. A source of metal material is splat-cooled after it has been heated to a molten state. An induction heater heats the metal material to the molten state and the molten metal is rapidly cooled while being pressed between two water cooled wheels. The wheels are provided with indentations and protuberances on their surfaces to produce flexure hinges and strengthening beams. A chute is provided to catch the flexures as they leave the wheels preventing damage to them.

Abstract: A casting support for use in automatic cast trim machines having improved casting retention characteristics and being suitable for use in machines having a simple rail for the return of spiders to the melting pot. This support is characterized by a projection supporting an enlarged end about which the casting is formed, with suitable regions adjacent the projection to provide positive locking of the extensions of the casting around the projection to prevent separation of the casting in that area and the resulting loosening thereof upon the rotation of the index mechanism in the cast trim machine. Shrinking of the casting during cooling in combination with the locking of the casting provides positive orientation of the casting on the support, yet ready removal thereof by a simple punch.

Abstract: An automated apparatus for sequentially forming integrally fused battery terminals on a plurality of storage batteries is described wherein a head means having a mold means adjustably mounted thereon is automatically movable with respect to a vertical axis, and has slidably mounted thereon a burning means for automatically producing a variable-intensity flame for melting said battery elements to form said integrally fused battery terminal during a vertical stroke thereof. An automated post burn station is further described having a conveyor means for advancing batteries sequentially to said burning station and for aligning said batteries with respect to said station for the above described fusing process. A plurality of novel sensors incorporated into the automated post burn station facilitates the rapid, automatic processing of batteries, while providing a high degree of safety and reliability.