Abstract: Apparatus for the production of a metal article comprises means for maintaining a reservoir of molten metal with a free surface, means for rotating the free surface of the reservoir about an axis such that the molten metal is atomized and thrown outwardly away from the said surface by centrifugal action, and a substrate in the path of the atomized particles of said molten metal, whereby a solid article may be built up on the substrate by solidifying the atomized particles thereon. The molten metal may be produced by melting an electrode or otherwise.An annular solid metal article is disclosed having excellent mechanical properties. The solid metal article is produced in a single step by a spray deposition process. Molten metal is centrifugally atomized to splat and build up on a cooled mold surface disposed around the centrifuge means. Controlled relative reciprocatory movement in the direction of the rotational axis of the centrifuge is provided.

Abstract: An improved method of forming titanium alloy in sheet form is taught. The sheet is formed by plasma spraying larger particles of greater than 100 .mu.m diameter onto a receiving surface to form a sheet having a rough surface due to the larger particles. An RF powered gun is employed to form the deposit using the larger particles. The formed sheet is separated from the substrate and rolled to reduce the sheet thickness as well as to render the rough surface smoother and more even.

Abstract: A method of casting is provided in which a rheocast deposit is formed by atomizing a stream of molten metal or metal alloy by subjecting the stream of molten metal or metal alloy to relatively cold gas directed at the stream, and directing the resultant spray of metal droplets at a collector. The deposit is provided with a rheocast type structure by extracting heat from the metal droplets such that the material deposited at the collector includes solid phase particles in a liquid phase which, upon solidification, forms a microstructure characterized by a fine network of microsegregate at the grain boundaries or coring across the grains and which, above the solidus region of the said metal or metal alloy, exhibits thixotropic properties. The rheocast deposit may be thixotropically deformed either during or after deposition.

Abstract: A number of individual silicon carbide filaments are assembled to form a tape. The tape is passed across a drum in a low pressure plasma deposition apparatus where the surface of the drum is formed of a polished and cooled refractory metal. The tape is sprayed with a plasma spray of the titanium base alloy metal to form a sheet of such metal on the tape and on the surface of the drum. The deposited sheet including the silicon carbide reinforcement tape is removed from the drum surface by peeling. The peeled product is a composite of titanium base sheet metal which is impregnated with the filaments of silicon carbide, i.e. a metal impregnated tape.

Abstract: A device for gas atomizing a liquid stream, such as a stream of molten metal or metal alloy, has an atomizing device including, for example, an annular opening for receiving the stream. The atomizing device is arranged for applying atomizing gas to the stream so as to form a spray of atomized particles. At least a part of the atomizing gas, and preferably all, is applied by means movable relative to the stream whereby movement is imparted to the spray. This movement leads to improved uniformity or control of deposition.

Abstract: Molten metal is sprayed onto a rotational mandrel which oscillates axially and an axial translatory extraction motion is superimposed for removing the built-up hollow from the mandrel.

Abstract: A mould 13 which may be of graphite, ceramic material, or metal is formed with an internal surface 14 accurately machined to the required shape of the surface of the rotary dresser which is being formed. Diamond particles 15 are then adhered to the surface 14 by any suitable adhesive. A metal surfacing powder is then applied to build up a metal layer 16 by means of an arc plasma spray surfacing gun 20 to melt the powder particles and a high velocity gas flow to propel the particles onto the diamond coated layer. A layer of a low melting point dimensionally stable alloy may be cast on top of metal layer 16 onto the internal bore. The mould 13 is then removed and the external surface accurately ground to final form. A supporting steel core may be added.

Abstract: A metal powder is produced by inert gas atomization processes. The atomizon process is regulated to provide a preselected level of inert gas alloyed in the metal.

Abstract: A process is disclosed for producing discontinuous metal foils. The process involves entraining metal powder particles in a carrier gas and passing the powder particles through a high temperature zone at a temperature above the melting point of the powder particles to melt at least about 50% by weight of the powder particles and thereafter resolidifying the resulting high temperature treated material by impacting the material against a substrate to form the foils.

Abstract: Metal forming process and apparatus are described.The process comprises directing a stream (4) of atomized droplets of molten metal onto a chill surface (5) such that the metal is partially solidified to form a slurry of solidified metal suspended in liquid metal. The slurry is then collected (for example, in a casting mold 7) and then cast or otherwise formed before solidification is complete. It is particularly preferred that the stream of atomized droplets is directed onto a fully solidified layer (6) of the same metal on the chill surface.

Abstract: An apparatus for manufacturing solidified metallic forms from levitated molten metal including a levitation conduit having an interior surface for accommodating the metal to be levitated, and a device for introducing the metal to the levitation conduit. Induction coils induce a moving magnetic field in the levitation conduit to levitate the metal upwardly through the conduit, and to maintain the outer surface of the levitated metal while molten out of pressured contact with the interior surface of the levitation conduit. The molten metal output is provided to a chamber in which a device re-forms the molten metal output and solidifies it.

Abstract: High melting point metallic, e.g., steel mold members are facilely and inexpensively produced by depositing, e.g., flame-spraying, droplets of a melt of a metal having a high melting point onto the front face surface of an elastomeric silicone mold pattern, said elastomeric silicone containing from 20 to 90% by weight of finely divided particulates of at least one refractory filler, and thereafter permitting said melt to solidify.

Abstract: A low pressure plasma or laser spray metal deposition process for the manufacture of a vacuum interrupter contact with a tailored composition gradient through the thickness of the contact.

Abstract: A process for producing a hollow metal cast product having a desired interior contour is provided. The process comprises the steps of preparing a first lost model having an outer contour substantially corresponding to a desired interior contour of the finished product, depositing a metallic or ceramic material or a mixture thereof over the surface of said first lost model by spraying to form a layer defining a hollow core block, placing said hollow core block in a first mold, pouring or injecting a material for forming a second lost mold into said first mold to form a second lost model, coating a refractory material over said second lost model to form a second mold for casting, removing second lost mold to form a cavity, casting a molten metal or alloy into said cavity, and staving said second mold to take out a finished product.

Abstract: In a process and apparatus for forming an ingot having a length at least twice as great as its characteristic sectional dimension, droplets of molten metal are sprayed onto a catching surface of a dummy bar which is rotated about its axis and moved in a removal direction along its axis. Layers of spray built up on the catching surface form an ingot. Boundary surfaces may be provided for shaping one of the surfaces of the formed ingot. In the case of a hollow ingot, the boundary surfaces are in the form of a partially cylindrical mandrel extending axially into a hollow dummy bar.

Abstract: A method and apparatus for casting rapidly solidified metal ingots wherein molten metal is centrifugally formed into molten droplets that are rapidly solidified under controlled conditions into metal particles which are cast against a rotating mold cavity within which the metal particles are consolidated into an ingot to be subsequently worked to a billet.

Abstract: A metal matrix composite (e.g. of SiC in a metal alloy) is made by the steps of atomizing a stream of molten metal to form a spray of hot metal particles by subjecting the stream to relatively cold gas directed at the stream, applying to the stream or spray relatively cold solid particles of a material of different composition from the metal, and depositing the metal having the particles incorporated therein. The deposit is made into a shaped metal matrix composite by reheating it to a controlled temperature substantially above the liquidus of the metal at which it flows under pressure and casting the fluid deposit to give the shaped product.

Abstract: Metal to be cast is melted in melting chamber of casting furnace. Molten metal flows through a nozzle of the melting chamber is atomized by a stream of heated compressed air. Droplets of molten metal are carried by the air stream to a mold onto which the metal is cast to form a thin even molding. The hot air stream prevents the molten metal droplets from solidifying until they reach the mold. The amount of metal cast and the thickness of the molding may be controlled by adjusting the velocity of the air stream and the distance from the nozzle to the mold.

Abstract: A method is disclosed for applying hard tungsten carbide particles to the surface of metal stabilizers used in the drilling of oil, gas, geothermal and water wells. The process consists of applying a soft, elastic metal powder to the surface of the substrate. Large tungsten carbide particles, which have also been coated with the soft powder, are placed on top of the layer of soft powder. The particles are then covered with additional soft powder, which powder is then fused to form a homogeneous, large tungsten carbide particle containing mixture bonded to the substrate. A hard matrix is applied and fused over the large tungsten carbide particle containing mixture. The large tungsten carbide particles, which have a low coefficient of expansion, are thereby contained in a soft elastic metal matrix which acts as an expansion and cushion material, while the hard matrix presents a less resilient, more wear resistant surface.

Abstract: A rotary drum comprises a hollow cylindrical outer member, a coaxial hub, and a plurality of spokes pivotally connected to the outer member and to the hub, all the spokes being aligned at the same oblique angle to the radius at the respective connections to the hub. Thermal expansion of the outer member relative to the spokes is accommodated by rotation of the outer member relative to the hub and a consequent change in the oblique angle, so minimizing thermally induced stresses in the spokes. The drum may be used in the production of a metal by deposition from the vapor phase onto the outer surface of the drum.

Abstract: A process and apparatus for converting a stream of desilized and desulfurized pig iron into steel plates of unlimited length. A spray caster is employed utilizing a substantially cylindrical heat-absorbing target surface and a projector rotatable about a vertical axis substantially co-axial with the axis of the cylindrical target surface. A non-oxidizing atmosphere is maintained about the projector and within the space surrounded by the target surface. A pulverulent oxide, chosen from the class consisting of mill scale, iron oxide, the oxide of an alkaline metal which completely evaporates at the temperature of the molten pig iron, the oxide of a desired alloying metal and combinations thereof, is injected into the molten stream of pig iron. The molten stream of pig iron is caused to flow vertically upon the projector, as the projector is rapidly rotated.

Abstract: A method for forming small-orifices 20 in the face plate 10 of an injector 12, especially a liquid propellant injector for a rocket engine. A stainless steel base plate is given a first layer 28 of electrodeposited Ni and fuel feed passages 24 and 26, respectively, are formed therethrough for fuel and oxidizer transfer. The feed passages 24 and 36 are filled with wax and silver is worked into the surface of the wax to permit electrodeposition of face plate 10. Connecting bores 42 to the perforations are made through the face plate nickel layer 40. Plastic mandrels 44 are fabricated, having legs 46 with support sections 48 and orifice-forming sections 50 and coupling tabs 54 for tying the legs 46 together. The support legs 48 of the mandrels 44 are inserted in the connecting bores for support and another layer 60 of Ni is electrodeposited to enclose the orifice-forming sections 50 of the mandrel legs 46.

Abstract: A substantially radiation absorbing layer of metal having a microstructured surface characterized by a plurality of randomly positioned discrete protuberances of varying heights and shapes, which protuberances have a height of not less than 20 nanometers nor more than 1500 nm, and the bases of which contact the bases of substantially all adjacent protuberances is disclosed. The metal layer, which may be a coating on a variety of substrates, is useful as a radiation absorber (particularly solar). A method is disclosed for producing such layers.

Abstract: In a process for making metal strip 7, a spray 9, 10 of molten metal is directed towards a nip 13 formed by two smooth cooled rolls 6, the rolls being rotated so that the nip hot-compacts the sprayed metal to yield a strip emerging from the exit of the nip. Splats formed by droplets of the molten spray impinging on the rolls 6 before reaching the nip 13 do not stick completely to the roll surfaces but at least partially detach themselves on freezing and form a new surface on which subsequent droplets of the spray land; when the nip is reached, the partially detached frozen droplets and their overlying deposit, on both rolls, are compacted hot.

Abstract: A fluid-cooled article, such as a turbomachinery blading member, is provided with a fluid passage by a method of depositing a first material on a work surface of a mandrel by low pressure plasma deposition. A first member thus generated is separated from the mandrel. In one form, an inner surface of the first member is provided with a surface groove. After depositing a sacrificial material in the groove, a cover material is applied to entrap the sacrificial material. Removal of the sacrificial material provides the fluid passage.

Abstract: Very finely granular metal powders are produced by atomizing a liquid jet of metal by means of a gas jet which, in addition to a continuous band of sound frequencies, contains at least one discrete sound frequency which is at least 5 decibel above the average intensity of this band, and which is generated in a rotationally symmetrical device by means of a nozzle (4) which has the shape of a hollow cone and by means of an annular resonance space (7) with an annular edge (6) and is projected concentrically against the liquid jet of metal at a total opening angle of an average 35.degree. to 55.degree.. The atomization zone of the gas jet should preferably contain at least three discrete sound frequencies which are each at least 10 decibel above the sound intensity of the continuous band.

Abstract: A method of making a dental prosthesis includes providing an upper or a lower impression of the oral cavity of a patient; and filling such impression with a castable mixture comprising (1) a ceramic composition containing a major proportion of magnesia and a significant minor proportion of alumina and (2) an aqueous composition containing silica as the essential ingredient, the ratio of the aqueous silica composition to the ceramic composition being such as to render the latter flowable. The mixture is then permitted to harden in the impression, and the resulting hardened model is removed from the impression. Thereafter, a liquefied metal composition is spray-coated on to a selected portion of the model to form a metallic prosthetic base, which is separated from the selected portion of the model and provided with a porcelain coating on its exterior surface.

Abstract: Hydrophobic cellular material is coated with a thin hydrophilic polymer skin which stretches tightly over the outer surface of the foam but which does not fill the cells of the foam, thus resulting in a polymer-coated foam structure having a smoothness which was not possible in the prior art. In particular, when the hydrophobic cellular material is a specially chosen hydrophobic polymer foam and is formed into arbitrarily chosen shapes prior to the coating with hydrophilic polymer, inertial confinement fusion (ICF) targets of arbitrary shapes can be produced by subsequently coating the shapes with metal or with any other suitable material. New articles of manufacture are produced, including improved ICF targets, improved integrated circuits, and improved solar reflectors and solar collectors.

Abstract: A method of manufacturing durable metal molds whereby metal melt-spraying is utilized. The method comprises the steps of spraying a first model with a low melting point metal, removing the first model, casting a second low melting point metal into the space vacated by removal of the first model to form a second model, removing the second model, spraying the second model with a high melting point metal, melting said second model out of the mold formed by spraying the high melting point metal, reinforcing the space vacated by the melting of the second model with sand, and reinforcing the space to the rear of the mold with metal, cement, or any suitable material. The sand is subsequently removed to form a durable metal mold.

Abstract: A method is provided for producing a composite moulding plunger, the plunger including a flanged base mounting for the plunger, the flange having a reduced coaxially extending annular portion to which is adherently bonded a hollow conical plunger formed of flame sprayed material, the conical plunger extending from the base mounting and terminating into a rounded end or peak, the plunger having a wall thickness ranging from about 0.5 to 10 mm. The hollow plunger is preferably formed of a flame sprayed nickel-base alloy selected from the group consisting of Ni-Si-B, Ni-Cr-Si-B and Ni-Cr and a copper alloy.

Abstract: A device for producing metallic particles utilizing the Coanda Effect to draw one stream of gas toward another stream of gas flowing over a foil. Molten metal is introduced between the two gas streams, and the resulting interaction breaks up the molten metal flow into particles of appropriate size, shape, composition and the like. Various embodiments can be used for the process of producing cast articles, while other versions can be used for the process of coating and deposition of the particles in liquid, solid or partially solidified form onto a substrate.

Abstract: A method for forming small-diameter, angled ducts and manifolds in a face plate for a rocket-engine injector or the like. A surface of a circular base plate 16 is formed with an annular flange 18 thereon having two inwardly sloping sides 11 and 13. Grooves 20, 22 are machined along the intersections of the sides 11 and 13 with the surface of the base plate 16 for propellant-containing manifolds 36 and 38. Grooves 10 are etched in spaced sets of two down the sloping sides of the flange from the flange top 24 to the manifold grooves 20,22. The grooves 10, 20, 22 are filled with wax 23 and a layer 26 of metal is electrodeposited over the grooved surface of the base plate 16 to cover the top 24 of the flange 18, the deposited layer forming orifice ducts and propellant manifolds from the grooves. This layer 26 is machined down to a depth at which the orifice ducts 34 are exposed so that orifices 12 appear at the surface 30 of the machined layer. The wax 23 is now removed by heat or a solvent.

Abstract: A method for making metallic glass powder is disclosed, which involves atomizing a jet of molten glass forming metal alloy by impinging with a moving body to form a stream of discrete molten droplets of the metal alloy, followed by impinging that stream on a travelling chill surface to effect rapid solidification of the molten droplets. The powder can be fabricated into solid articles.

Abstract: A method of manufacturing a bearing block comprises flame spraying a light alloy layer on to the outside of an antifriction alloy bush, to build up the block to required outer dimensions. The outside of the block may be finish machined after the flame sprayed layer has been applied.

Abstract: The present invention is an improvement over, and an adaptation to continuous casting, of known processes in which a molten metal such as steel is atomized under non-oxydizing conditions and projected at high velocity against a suitable target. The distance to the target is such that the atomized particles solidify on their way and hit the target in a solid, yet still plastic, state to be welded onto said target by their kinetic energy. Applicant has found a way to adapt such process to continuous operation, and more particularly, to production of wide slabs of great length and relatively small thickness, say, typical 1.5".times.60" section and achieving that at great speeds of operation, such as 100 to 500 tons per hour which speed makes it possible to place it upstream of a continuous hot strip mill and thus produce, say, 0.060".times.60" strips in one continuous operation, from molten metal. (Such mills cannot maintain their thermal balance if the speed of the workpiece is too slow).

Abstract: The die comprises at least one set of opposed linearly configurated die elements spaced in substantially parallel relationship to define a longitudinally configurated die space therebetween dimensioned to pass therethrough a sheet of the molten material, the die elements defining a nozzle assembly characterized by oppositely disposed orifice-bearing surfaces. Each of the linear die elements has a gas pressure manifold for receiving atomizing gas under superatmospheric pressure, each of the oppositely disposed nozzle-defining surfaces having at least one array of orifices extending therealong and embracing each side of the longitudinally configurated die space defined by the oppositely disposed linear die elements. Conduits are provided for communicating the orifices with the gas manifold, the array of orifices in each of the die elements being convergently directed towards the other through an included angle of, for example, 40.degree.

Abstract: A device for producing metallic particles utilizing the Coanda Effect to draw one stream of gas toward another stream of gas flowing over a foil. Molten metal is introduced between the two gas streams, and the resulting interaction breaks up the molten metal flow into particles of appropriate size, shape, composition and the like. Various embodiments can be used for the process of producing cast articles, while other versions can be used for the process of coating and deposition of the particles in liquid, solid or partially solidified form onto a substrate.

Abstract: In a method of forming a thin (<2 .mu.m) unbacked metal foil having a desired curviplanar shape, a soluble polymeric film, preferably comprising polyvinyl alcohol, is formed on a supporting structure having a shape that defines the desired shape of the foil product. A layer of metal foil is deposited onto one side of the soluble film, preferably by vacuum vapor deposition. The metallized film is then immersed in a suitable solvent to dissolve the film and thereby leave the metal foil as an unbacked metal foil element mounted on the supporting structure. Aluminum foils less than 0.2 .mu.m (2,000 .ANG.) thick and having an areal density of less than 54 .mu.g/cm.sup.2 have been obtained.

Abstract: The present invention relates to method and apparatus for fabricating materials and objects, and processing and refining metals in space by means of available sunlight energy.

Abstract: A method for replicating laser mirror surfaces is described which comprises careful preparation, as, for example, by single point diamond turning, on a master block, of a master surface having the contour corresponding to the desired laser mirror surface, vapor depositing onto the master surface a thin metallic layer, and vapor depositing the laser mirror faceplate material to the desired thickness. The selected master block material has a coefficient of thermal expansion mismatch with that of the deposited faceplate material so that the master block shrinks and separates away from the deposited faceplate upon cooldown from the vapor deposition temperature.

Abstract: A method is disclosed for predetermining the magnitude of the average release peel strength at the interface between a vapor deposited copper film and a flexible aluminum carrier sheet to which the copper has been previously directly applied. The resulting copper-to-aluminum adherence is due to the formation of a preferential diffusion bond.

Abstract: An apparatus is set forth for the continuous production of highly cooled metal splats. Melted metal is poured onto a spinning atomization disc means whereby liquid metal droplets leave the disc means in a horizontal plane. An annular cooling gas jet flowing normal to the particle plane around the disc deflects the heavier liquid droplets to a conical splat plate which is fixed to rotate with said disc, where the droplets splat and cool, and are ejected by centrifugal force. An annular space is located between said conical splat plate and said rotary atomization means for permitting the gas and other solidified particles to pass downwardly to a shield which directs the particles to a collection area.

Abstract: A method for making a cutting tool such as a tap, reamer or the like, in which the entire surface of a soft high speed steel blank is coated with a formation of titanium nitride, heat treated, and then finish ground by conventional means to define the cutting edges.

Abstract: An apparatus is disclosed for manufacturing splat foils by disintegration and rapid solidification of metallic melts. The apparatus has a self-consuming electrode disposed above a rotatable counter electrode. Attached to the counter-electrode is a conical plate which is cooled by a fluid circulating through its interior. The application of electrical energy to the electrodes causes the self-consuming electrode to melt and drop melt droplets onto the rotating counter-electrode. Centrifugal force causes the melt droplets to fly off the counter-electrode and contact the conical plate at which point they are rapidly cooled to form thin foils. A housing surrounds the electrodes and conical plate to collect the cooled foils and to permit the apparatus to operate in an inert atmosphere, if desired.

Abstract: A method of manufacturing a mold adapted to be used for casting bodies of fiber-reinforced composites. A model of the body to be cast is prepared and coated with a one-piece dense shell of refractory metallic oxide deposited by plasma or flame spraying and the model is then separated from the shell by conventional physical or chemical treatment.

Abstract: An exact replica of a tool for deep drawing, moulding, extruding and the like is manufactured by a method according to the present invention by thermally spraying the wearing surface of the tool to be produced onto a negative replica of the tool to be produced, said last replica being constituted of an easily fusible metal with a lower melting point than the plastic material used for backing up (1) the easily fusible negative replica and (2) the thermally sprayed wearing surface of the tool. According to the method of the invention the wearing surface of the tool can be constituted of steel, carbide or oxide.

Abstract: A method of manufacturing a mold adapted to be used for casting bodies of ber-reinforced composites. A model of the body to be cast is prepared and coated with a one piece dense shell of refractory metallic oxide deposited by plasma or flame spraying and the model is then separated from the shell by conventional physical or chemical treatment.

Abstract: A method of fabricating a funnel-shaped miniature electrode with thin walls and very sharp edges for use in a field ionization source for ionizing components of a fluid sample is disclosed, which method includes the use of a female mold, or matrix, formed with a stepped, generally frustoconical-shaped aperture therethrough. The aperture wall includes a plurality of different diameter generally tapered wall sections of decreasing size in going along the aperture axis, with the smallest diameter section at the one end being of short length and small diameter. It is convenient, but not necessary, to coat the aperture wall with a parting layer which aids in the separation of the subsequently-formed miniature funnel-shaped electrode from the female mold and facilitates cleaning of the mold for reuse.

Abstract: This invention relates to the making of negatives intended for the production of bodies which contain cavities of predetermined shapes.The term "negative" signifies a disposable core member, for example as used in some molding techniques such as the lost wax process. The negative at least partly matches the cavities which latter form two independent systems of regularly distributed intersecting channels with the channels in any one same system intercommunicating via ducts which are themselves regularly distributed.

Abstract: A method and apparatus for manufacturing a shaped precision article from molten metal or molten metal alloy wherein a gas atomized stream of molten metal or molten metal alloy is directed at a collecting surface to form a coherent deposit, the stream being cooled in flight by the atomizing gas, which is at ambient, preferably room temperature, sufficient heat being extracted by the relatively cold atomizing gas from the stream of molten metal in flight such that formation of the coherent deposit is independent or substantially independent of the thermal properties and temperature of the collecting surface, provided the temperature of the collecting surface is below the melting point of the metal or metal alloy being sprayed; and the deposit is worked as by a die to form the precision metal or metal alloy article.