Abstract: The present invention provides improved heated manifolds, heaters and nozzles for injection molding, having a high strength metal skeleton infiltrated with a second phase metal having higher thermal conductivity. Also disclosed is method of forming a manifold, heater or nozzle preform and infiltrating the preform with a highly thermally conductive material. The invention also provides a method of simultaneously infiltrating and brazing injection molding components of similar or dissimilar materials together.

Abstract: A method of making an article, such as an electrical connector includes an injection-molded plastic substrate and a pattern of injection-molded metal conductors supported on and mechanically interlocked with the substrate, wherein one of the substrate and the conductors is over-molded onto the other of the substrate and the conductors.

Abstract: The invention relates to a method for producing a composite structure in which a foamed metal core (1) is surrounded with a metal body (3). Said method comprises the following steps: a) producing a foamed metal core (1) with an essentially closed surface; b) introducing the foamed metal core (1) into a pressure diecasting mould; c) filling said pressure diecasting mould at a first casting pressure (p1); d) reducing said first casting pressure (p1) before the pressure diecasting mould has been filled; e) filling the pressure diecasting mould entirely, the first casting pressure (p1) being reduced to zero or almost zero; and f) applying a second casting pressure (p2) and maintaining this for a predetermined holding period.

Abstract: This invention relates to methods and apparatus useful in the ceramics industry. More specifically, this invention relates to the fabrication of high melting, wear-resistant ceramics and ceramic composites at low temperatures. The method involves reacting (1) a fluid formed from melting a metal alloy, comprising at least one reactive metal and at least one non-reactive metal, and having a melting temperature substantially below the product material melting point, typically below about 1500 C., with (2) a rigid, porous material. The reaction should occur for a sufficient time to allow the liquid to infiltrate the porous material and allow the active metal(s) to react with the porous material so as to form a ceramic or ceramic composite having a melting temperature substantially higher than 1500 C.

Abstract: A method of manufacturing a tube-plate structure of metal-matrix composite material in which a single mold is used having a first fiber preform of shape comparable to that of the tube, a second fiber preform of shape comparable to that of the plate, and a third fiber preform surrounding the first fiber preform where it is adjacent to the second fiber preform all placed therein. Thereafter, a metal or a metal alloy is injected into the mold along the axis of the tube via the face of the second preform that is remote from the first preform. This provides a monolithic structure that presents a high degree of thermo-mechanical stability.

Abstract: A method of casting a siliconized silicon carbide part. The method includes providing a pre-casting mix comprised of a silicon carbide powder having a maximum particle size within a range of about 1000 to 2000 microns, and water having a percentage by weight of no more than about 9.5% of the mix. A slurry is formed from the mix and poured into a mold. The water is then removed from the mold within a predetermined period of time to form a solid porous green part. The green part is surrounded with silicon metal, and heated to a predetermined temperature above the melting point of the silicon metal. The silicon metal then siliconizes the green part to form a siliconized silicon carbide part.

Abstract: Throw shoe with one or more pockets, which is intended for centrifugal-type crushers with a vertical shaft provided on its working face of a composite reinforcing structure (6) made of wear-resistant ceramic which has been infiltrated by an iron-based alloy and which is created in situ when the throw shoe is being cast.

Abstract: A method of manufacturing a preform for compounding use which, is to be impregnated with a molten metal to be compounded with a matrix material, is provided. The method includes the step of mixing short fibers, ceramic particles and a binder material together to make a mixture. The average of lengths of the short fibers is 100 to 200 &mgr;m while the volumetric percentage of the short fibers is 1 to 7%. The content of the binder material in the mixture is 0.3 to 5.0 mass %. The method includes also the steps of forming the mixture so as to have a predetermined shape, and sintering the mixture at a temperature of 1000 to 1150° C. to form the preform. Thus, it is restrained that the preform is deformed or an un-reinforced region is formed in the compounded portion.

Abstract: A method is provided for producing a clad metal product having a core and a shell of different materials and suitable for use in forming processes. The method comprises the steps of providing a solid hollow shell member comprising a first metal, the shell open at one end and having an inner surface defining a cavity. A molten second metal from a source of molten metal is introduced into the cavity in sufficient quantity to substantially fill the cavity. The molten second metal is permitted to solidify thereby forming a workpiece having a core and a cladding shell of different metals which are sufficiently metallurgically bonded to one another at their interface. The final work product may be heated to rolling temperature and rolled to form a clad article of predetermined configuration.

Abstract: A process for connecting at least two components, particularly body components of motor vehicles, wherein the first component has an undercut on a side facing the second component. In the area of the undercut, a connection piece is cast to the first component. The connection piece is designed such that, during its solidification, the connection piece is firmly connected with the first component by the contraction of a last-solidifying core area of the connection piece. Then the second component is mounted on the connection piece.

Abstract: System, apparatus, and method for making composite articles. Jewelry items such as finger rings, bracelets, earrings, body jewelry, and the like, are examples of such articles. Medical, dental, and industrial devices or components are other examples. Method of manufacturing an article including a substrate comprising a first material and an inlay comprising a second material includes the steps of preheating the substrate; contacting a depression in a surface of the substrate with the second material; heating the second material at a point contact with the substrate causing it to liquify and flow into the depression; and moving the point of contact along the along the depression in the surface of the substrate while continuously feeding the second material and heating the second material at the point contact with the substrate to cause it to substantially fill the depression.

Abstract: An apparatus for casting molten metal onto a moving strip of material includes a stationary die having upstream and downstream portions with a casting portion, past which the strip of material is capable of being moved. The casting portion has a casting channel extending from the upstream portion through the downstream portion for facing the moving strip to contain and shape the molten metal into a profile against the moving strip. A heating arrangement heats the upstream portion of the stationary die to prevent the molten metal from solidifying within the casting channel at the upstream portion, thereby allowing the molten metal to fill the casting channel. The casting channel at the downstream portion allows the molten metal to cool while passing therethrough to solidify sufficiently to retain the shape of the casting channel when exiting the stationary die.

Abstract: Composite wear component produced by casting and consisting of a metal matrix whose working face or faces include inserts which have a very high wear resistance, characterized in that the inserts consist of a ceramic pad, this ceramic pad consisting of a homogeneous solid solution of 20 to 80% of Al2O3 and 80 to 20% of ZrO2, the percentages being expressed by weights of the constituents, and the pad then being impregnated with a liquid metal during the casting.

Abstract: A method for producing metal/ceramic composite materials includes an injection plunger; a casting chamber having an opening through which casting metal is poured in and a ceramic precursor product is shot in; and a die having a runner and a die cavity. A shot head is used to shoot ceramic powder into a die, so that the powder is compacted to form a porous preform. The preform is infiltrated with liquid metal under pressure in the die.

Abstract: A bar code identification stencil for uniquely identifying a plurality of articles. The stencil includes a carrier strip, which carries an identification code or symbology. The identification code or symbology is formed of a plurality of spaced apart data cells, or data cells, which are used to form a machine readable bar code. The stencil will be made of materials compatible to the manufacturing processes, which make the articles to be marked, and compatible to the materials out of which the articles to be marked are made. The stencil is scalable in size and shape, as are the data cells, or data cells, scalable in size and shape—all as required by the specifications of the data symbology to be directly marked on the part, or article. The bar code is unique for each of the plurality of articles to be identified.

Abstract: A metal casting fabrication method is provided. In accordance with the method, first a metal plate is disposed in the cavity of molding dies. This metal plate includes a first surface formed with a heat insulating layer, and a second surface opposite to the first surface. With the metal plate placed in the cavity, the heat insulating layer is held in contact with the dies, while the opposite or second surface is partially exposed to the cavity. The injected molten metal properly fills the cavity from end to end since its heat is not conducted unduly to the dies via the metal plate.

Abstract: A method of making a bicycle crank arm bar by casting, forging, rolling, heat molding, and cold forging. The bicycle crank arm has an elongated cavity, an axle end, and a pedal end.

Abstract: A metal casting molded body comprising at least one effective surface for machining or processing a material and formed from a compound material, wherein said compound material comprises at least one porous hard material body in a casting matrix made of a metallic casting material, said casting material being seeped into said hard material body.

Abstract: An apparatus for cooling at least one fluid includes separable cold plate and dispenser units. The cold plate unit includes a coolant system, a fluid system and a metallic unit. The coolant system defines a cold plate portion and a tower portion. The cold plate portion of the coolant system has a primary inlet manifold and a primary outlet manifold, and the tower portion has a secondary inlet manifold and a secondary outlet manifold. The coolant system further includes a first plurality of coolant line segments connecting the primary and secondary inlet manifolds and a second plurality of coolant line segments connecting the secondary and primary outlet manifolds. The fluid system also defines a cold plate portion and a tower portion, the portions being in heat exchange relationship with the coolant system. The metallic unit includes unitary cold plate and tower portion which respectively incorporate the cold plate and tower portions of the coolant system and fluid system.

Abstract: A method of manufacturing a tube-plate structure of metal-matrix composite material in which a single mold is used having a first fiber preform of shape comparable to that of the tube, a second fiber preform of shape comparable to that of the plate, and a third fiber preform surrounding the first fiber preform where it is adjacent to the second fiber preform all placed therein. Thereafter, a metal or a metal alloy is injected into the mold along the axis of the tube via the face of the second preform that is remote from the first preform. This provides a monolithic structure that presents a high degree of thermo-mechanical stability.

Abstract: An impermeable ceramic mold is disposed within a steel die and used in a process for pressure casting of elevated melting temperature alloys and pressure infiltration casting of elevated melting temperature alloys having wear resistant particles, included therewith. The ceramic mold provides an insulation layer between the molten metal and the steel die, and prevents welding between the molten metal and the die. The alloy steel die encloses the ceramic mold and provides the strength needed to resist the pressures generated during pressure infiltration casting.

Abstract: A method of joining an aluminum cast member to an aluminum component. The method includes the steps of coating a surface of an aluminum component with flux comprising cesium fluoride, placing the flux coated component in a mold, filling the mold with molten aluminum alloy, and allowing the molten aluminum alloy to solidify thereby joining a cast member to the aluminum component. The flux preferably includes aluminum fluoride and alumina. A particularly preferred flux includes about 60 wt. % CsF, about 30 wt. % AlF3, and about 10 wt. % Al2O3.

Abstract: A fiber reinforced porous preform is positioned within a die cavity defined by upper and lower die members, and the lower die member defines a gate opening in the center portion of a water cooled shot sleeve which receives a vertically moveable shot piston. The area of the gate opening is small relative to the area of the shot sleeve, and the lower die member defines an annular recess above the inner surface of the shot sleeve for entrapping a shell of pre-solidified metal. Air vent slots extend outwardly between the shot sleeve and lower die member and are closed by the shell of pre-solidified metal. The structure prevents pre-solidified metal and air from entering the die cavity.

Abstract: The present invention provides a cast iron component for enveloped casting which is characterized by that the cast iron component has a surface to which enveloped casting is applied and which has a surface roughness such that a maximum height Ry is from 65 to 260 &mgr;m and a mean spacing of profile irregularities Sm is from 0.6 to 1.5 mm; an enveloped casting product using it; and a method for its production.

Abstract: A process for casting or forging a wheel disc upon the end of a metal hoop. The metal hoop is then formed into a wheel rim. The rim and disc are machined to assure concentric tire bead seats.

Abstract: The specification and drawings describe and show an embodiment of and method of forming a liquid flow through heat exchanger structure cast in a metal matrix composite. The composite comprises a preform reinforcement material infiltrated with molten metal. The composite reinforcement material is injection molded around the heat exchanger structure allowing for intimate contact between the composite and structure. The composite formed has a specific coefficient of thermal expansion to match active heat-generating device(s) mounted thereon. The present invention allows for enhanced thermal and mechanical properties by eliminating voids or gaps at the composite to heat exchanger structure interface, these voids or gaps being present in prior art fabrication methods or induced by usage due to thermal cycling of prior art composites.

Abstract: A metallic shell used, for example as a mold, is formed by spray deposition connected to a base by rods or other supports connected to mounting elements which are incorporated in the shell during the deposition process. The shell can incorporate different metals to provide different thermal conductivity in various regions.

Abstract: A method of manufacturing a preform for compounding use which, is to be impregnated with a molten metal to be compounded with a matrix material, is provided. The method includes the step of mixing short fibers, ceramic particles and a binder material together to make a mixture. The average of lengths of the short fibers is 100 to 200 &mgr;m while the volumetric percentage of the short fibers is 1 to 7 %. The content of the binder material in the mixture is 0.3 to 5.0 mass %. The method includes also the steps of forming the mixture so as to have a predetermined shape, and sintering the mixture at a temperature of 1000 to 1150° C. to form the preform. Thus, it is restrained that the preform is deformed or an un-reinforced region is formed in the compounded portion.

Abstract: A superabrasive containing layered composite is provided which comprises a substrate block consisting of either ceramic material and metallic or several metallic materials, and a superabrasive containing body adjacent said substrate block. The superabrasive contains superabrasive particles, and a metallic ingredient which is distributed in the superabrasive containing layer, including a working surface. The superabrasive material may be formed using a compression cell wherein the compression cell comprises a die defined by a vertical wall and a flat closed bottom. Placed in the die, in order from bottom upward, comprises a formed pallet of single body or layers of mixed powder forming a refractory compound, a material mass of a working layer containing diamond particles, a mass of ignition material comprising an SHS composition, and an electrical heating element.

Abstract: Positioning arms for positioning and assembling systems are subjected to high accelerations and must therefore be made lightweight but nevertheless resistant to bending and twisting. The use of composite materials based on metal or ceramic foams and non-expanded materials for positioning arms in positioning and assembling systems allows these positioning arms to be lightweight and nevertheless to have high rigidity. Semifinished products are arranged in the non-expanded material, since a better connection between the semifinished product and material is ensured there than in the metal or ceramic foam.

Abstract: Ceramic oxide pre-forms comprising substantially continuous, ceramic oxide fibers, and methods for making the same. The ceramic oxide pre-forms are useful, for example, as in making metal matrix composites reinforced with substantially continuous, ceramic oxide fibers.

Abstract: The invention provides a substrate processing apparatus using a composite material which permits avoidance of occurrence of damages caused by the difference in thermal expansion between different materials and can be with stand the use at high temperatures. The substrate processing apparatus for processing a substrate is partially (for example, a substrate mounting stage) composed of a composite material 11 consisting of a matrix 12 comprising a ceramics member made of, for example, cordierite ceramics, aluminum nitride and/or a texture filled with an aluminum-based material (for example, aluminum or aluminum and silicon), and a ceramics layer (comprising, for example, Al2O3 and/or AlN) provided on the surface of the matrix 12.

Abstract: An impeller shoe (70) comprising an elongated body (72) of abrasion-resistant material extending longitudinally from an inner end (74) to an outer end (76) and having a pocket (84, 86) defined in the elongated body (72). The pocket (84, 86) has an open end at the front (80) of the elongated body (72) and two opposing sides (88, 90 and 92, 94) extending transversely through the elongated body (72) toward the back (78) of the body. The two sides (88, 90 and 92, 94) of the pocket (84, 86) are oriented substantially parallel to each other and set at an angle with respect to the plane (108) of the back of the body in a direction toward the inner end (74). The pockets (84, 86) also have a substantially even width measured between the two sides (88, 90 and 92, 94) through the length of the pockets. To further extend the wear life of an impeller shoe (104), one or more rods (106) made of higher abrasion-resistant material may be embedded within the impeller shoe (104).

Abstract: The present invention provides improved heated manifolds, heaters and nozzles for injection molding, having a high strength metal skeleton infiltrated with a second phase metal having higher thermal conductivity. Also disclosed is method of forming a manifold, heater or nozzle preform and infiltrating the preform with a highly thermally conductive material. The invention also provides a method of simultaneously infiltrating and brazing injection molding components of similar or dissimilar materials together.

Abstract: A method of forming an aluminum alloy scroll machine component having improved lubricity.

Abstract: A multi-piece crankshaft having a main shaft with two ends adapted to rotate about its axis. A crankpin also has two ends and an axis parallel to but radially spaced from the axis of the main shaft. At least one counterweight extends between one end of the shaft and one end of the crankpin and this counterweight is formed by casting a liquid metal around the ends of the main shaft and crankpin in a molding chamber. In a modification of the crankshaft, a hollow crankpin is disposed within the mold such that each end of the crankpin is positioned within a mold cavity corresponding to a counterweight. Upon casting the liquid metal in the mold cavities forming the counterweights, the molten metal flows inwardly from both ends of the crankpin and joins together to form a continuous metal connection between the counterweights.

Abstract: A bar code identification stencil for uniquely identifying a plurality of articles. The stencil includes a carrier strip, which carries an identification code or symbology. The identification code or symbology is formed of a plurality of spaced apart data cells, or data cells, which are used to form a machine readable bar code. The stencil will be made of materials compatible to the manufacturing processes, which make the articles to be marked, and compatible to the materials out of which the articles to be marked are made. The stencil is scalable in size and shape, as are the data cells, or data cells, scalable in size and shape—all as required by the specifications of the data symbology to be directly marked on the part, or article. The bar code is unique for each of the plurality of articles to be identified.

Abstract: Disclosed are economical methods and apparatus for high throughput pressure infiltration casting. Methods of the invention use a mold vessel as an evacuation chamber along with an evacuation cap to produce superior quality near-net shape finished cast parts with low porosity. Other methods of the invention use an improved heat transfer technique for directionally solidifying molten infiltrant at an increased rate to increase further the throughput of the pressure infiltration casting cycle. The invention also provides apparatus for practicing methods for high throughput pressure infiltration casting. One embodiment of an apparatus of the invention is a removable evacuation cap, often used in conjunction with a fill tube. Another apparatus embodiment is an evacuation cap coupled to a mold vessel which is used as an evacuation chamber.

Abstract: A crank arm for a bicycle includes a crank arm body formed of a first material and a core formed of a second material disposed in the crank arm body. The second material has a specific gravity less than a specific gravity of the first material. The second material may be a porous material such as volcanic glass or some other lightweight material. In the method used to form the crank arm body, a core having a specific gravity lower than a specific gravity of the metal forming the outer portions of the crank arm is positioned in a casting mold so that a melt space is formed around the core. Molten metal is poured into the casting mold, and the molten metal is solidified to form a crank billet such that the core is integrally formed with the metal.

Abstract: A method for injection molding a metallic material is disclosed in which an injecting material comprised of a half-solidified metallic material and a molten metallic material is injected into a cavity of a die from an injection cylinder through a gate thereof. A non-product portion remaining at the gate of the die is separated from a product portion while it is still hot. The separated high-temperature non-product portion is press-formed into a billet in the injection cylinder. Utilization of heat from the injecting material in melting the high-temperature billet enables reuse of the non-product portion remained at the gate and reduction of heat energy required in melting the billet.

Abstract: A method of manufacturing a cylinder for an internal combustion engine, which is manufactured by a process wherein a raw cylinder body having an insert core left remained therein is obtained using an insert core comprising a cylindrical body having almost the same outer diameter as the diameter of bore of the cylinder, and a scavenging port-forming portion projecting radially outward from the cylindrical body and having almost the same cross-sectional configuration as that of the scavenging port, the cylinder bore of the raw cylinder body thus obtained is then subjected to a boring to remove the cylindrical portion of the insert core, and the scavenging port-forming portion of the insert core which is left remained in the raw cylinder body is removed by making use of a press.

Abstract: A mold for producing a silicon ingot having a layered structure comprising an inner silica layer containing at least one layer in which a fused silica powder with a particle size of 100 &mgr;m or less and a fine fused silica sand with a particle size of 100-300 &mgr;m is bonded with a silica binder, and an outer silica layer containing at least one layer in which a fused silica powder with a particle size of 100 &mgr;m or less and a coarse fused silica sand with a particle size of 500-1500 &mgr;m is bonded with a silica binder.

Abstract: A spinning reel face gear is manufactured by a method of molding tooth-ring bearing, obverse-facing gear teeth onto a separately formed gear disk after the gear disk is made. The gear disk is specially configured with circumferentially spaced peripheral indentations to retain the tooth ring strongly against torque when the face gear meshes with a pinion gear in operation in a spinning reel. Manufacturing the face gear in two separate stages adds a degree of freedom in material selection, allowing a lightweight material to be employed for the gear disk, and a high-strength material for forming precision gear teeth to be employed for the tooth ring. The two-stage manufacturing method also enables the tooth ring to be formed onto the gear disk in a mold that does not leave a parting line on the obverse, teeth-bearing face of the tooth-ring when the mold plates are parted.

Abstract: A process for connecting at least two components, particularly body components of motor vehicles, wherein the first component has an undercut on a side facing the second component. In the area of the undercut, a connection piece is cast to the first component. The connection piece is designed such that, during its solidification, the connection piece is firmly connected with the first component by the contraction of a last-solidifying core area of the connection piece. Then the second component is mounted on the connection piece.

Abstract: A tube for a cracker unit in which ethylene is produced withstands, without oxidizing or losing its strength, the elevated temperatures required to effect cracking, yet retards coking. The tube has a shell formed from stainless steel or high nickel alloy and a liner formed from an iron-aluminum alloy. The liner retards the deposit of carbon and its build up known as coking. To form the tube, a high alloy ingot is bored to provide a bore that extends through its center. Then a weld overlay is applied to surface of the bore, with the overlay being derived from a weld metal containing at least 16% aluminum and the balance essentially iron. Thereafter, the ingot is heated to its hot working temperature and extruded through sets of opposed rollers, with the direction of advance being in the direction of the bore. The extruding transforms the ingot into a lined tube.

Abstract: A process for connecting at least two components, particularly body components of motor vehicles, wherein the first component has an undercut on a side facing the second component. In the area of the undercut, a connection piece is cast to the first component. The connection piece is designed such that, during its solidification, the connection piece is firmly connected with the first component by the contraction of a last-solidifying core area of the connection piece. Then the second component is mounted on the connection piece.

Abstract: A multi-piece crankshaft has a main shaft with two ends adapted to rotate about its axis. A crankpin also has two ends and an axis parallel to but radially spaced from the axis of the main shaft. At least one counterweight extends between one end of the shaft and one end of the crankpin and this counterweight is formed by casting a liquid metal around the ends of the main shaft and crankpin in a molding chamber.

Abstract: Molten metal (6) in a furnace (5) and containing particles of solid material (not shown) in suspension is cast in moulds (1) conveyed continuously past the mould-filling station shown by a conveyor (4). To maintain the particles in suspension and keep the metal (6) homogeneous throughout the furnace (5), a paddle-wheel rotor (10) driven by a motor (13) keeps the molten metal in constant movement. A curved guide vane (14) is shaped, placed and oriented so as to divert some of the centrifugal flow from the rotor (10) towards the delivery tube (8) for the moulds (1), thus ensuring that the tube (8) is supplied with freshly-agitated metal.

Abstract: A method of integrating wear plates into a spray formed rapid tool includes the steps of making a model of a desired tool and constructing a ceramic pattern as the inverse of the model. The method also includes the steps of locating at least one wear plate on the ceramic pattern and thermally spraying a metal material against the wear plate and ceramic pattern to form the desired tool and embedding the wear plate into the desired tool.

Abstract: A rigid bar (or segment) on which stones will be at least partially supported is positioned in a rubber mold for creating a wax pattern of the jewelry, injecting wax to form a wax model of the jewelry including the metal bar to fit into an incision in the stones. The model with the metal bar forms the invisible pre-set stone mount. Stones are then placed into set position in the wax pattern on opposite sides of the metal bar. Once the setting is complete, the jewelry is created using known “lost-wax” method of manufacturing jewelry.