Abstract: A stud welding gun has a forepart which includes the delivery end of an automatic stud-feeder and is secured to the housing by a quick releasable joint so as to be readily replaceable by another forepart supplying a stud of different size. The gun includes a pneumatic piston and piston rod which serves to push a stud into the collet after delivery to the gun. The piston rod is detachable from the piston and means is provided for locking it in the forepart so that it is replaced into the forepart for studs of different size.

Abstract: The quality of welds produced during a percussion welding process are determined in real time by sensing the vibrational impulse signals produced during the percussion welding process, filtering the impulse signal to select a frequency band containing frequency components associated with the vibrations imparted to the forge rod of the welding machine, measuring the mechanical damping characteristics of the selected spectral portion of the signal by determining the log-decrement of the envelope of the signal, and comparing the measured log-decrement value obtained with a preselected threshold value.

Abstract: The present invention discloses a method for welding the front fork of a bicycle which makes each junctures among the joint, the handlebar, and the fork blades simultaneously reach the melting temperature of a weld metal, so that the weld metal located in the joint evenly distributes over each juncture. The present invention also discloses an apparatus for welding the front fork of a bicycle which utilizes two high-frequency induction coils to heat the front fork respectively from the outer surface and the inner surface of the front fork, and controls the voltage applied to the high-frequency induction coils and the time span of the heating throughout all of the heating and welding procedures.

Abstract: Apparatus and method for induction heating "over-the-partition" intercell connections in a lead/acid storage battery by melting both lead risers so as to form a connection over the top of the insulating partition. A mold is suspended on top of the partition and an induction coil is supported on the mold so as to surround the top portion of the intercell lead risers. High frequency alternating electrical current is applied to the coil so as to melt the top portion of the lead risers so that upon fusion thereof in the mold and cooling, the tops of the risers are interconnected. The interconnection bridges the top of the risers and rests on top of the partition. The invention lends itself to mass production in a very short time as compared to present methods. Excellent fusion quality is reliably obtained as compared to present methods.

Abstract: A device for induction welding is provided according to the teachings of the present invention. The device comprises an electrically conducting arrangement for creating a magnetic field. A layer comprising essentially non-magnetic, electrically conducting particles in a support matrix of an electrically non-conducting material is also provided and arranged for modifying the magnetic field such that the available energy may be collected in the welding area (areas).

Abstract: A welder for automated closure of fuel pins by a pulsed magnetic process in which the open end of a length of cladding is positioned within a complementary tube surrounded by a pulsed magnetic welder. Seals are provided at each end of the tube, which can be evacuated or can receive tag gas for direct introduction to the cladding interior. Loading of magnetic rings and end caps is accomplished automatically in conjunction with the welding steps carried out within the tube.

Abstract: A method of manufacturing bimetallic tubes is disclosed. In this method, after an inner tube is inserted into an outer tube, the resulting tube assembly is heated, while pressurizing the inside of the inner tube with a gas, in the presence or absence of a solder material. When using no solder material, the materials of the inner and outer tubes are so selected that a thermal expansion coefficient of the inner tube is smaller than that of the outer tube.

Abstract: A system for impact welding using an electrical coil producing a magnetic field of sufficiently high-intensity to impel a ballistic workpiece into a separate stationary workpiece for producing a weld therein. The pressure on the ballistic workpiece resulting from the magnetic repulsion between the ballistic workpiece and the coil results in the ballistic workpiece being propelled towards the stationary workpiece at sufficient velocity to form a weld. Parameters are provided for varying the voltage and inductance of the capacitor bank for particular driving coil and ballistic workpiece dimensions to obtain matching of the impedances of the capacitor and coil arrangement to the particular ballistic workpiece. The impedance matching maximizes the conversion of electrical energy in the bank to kinetic energy of the workpiece.

Abstract: A system and method using magnetic pressure to propel a ballistic workpiece onto a stationary workpiece at sufficient velocity to produce a weld. Electrical power capacitors are connected to an electromagnetic coil which is positioned adjacent a ballistic workpiece which is propelled by pressures of magnetic force between the ballistic workpiece and the coil onto the adjacent stationary workpiece at sufficient velocity to form a weld.

Abstract: Heat exchanger cores comprising an assembly of elongated vertical and horizontal parts are brazed by induction heating in a vacuum chamber where the magnetic heating field is disposed at an angle to the vertical and horizontal planes for uniform heating. Steel supports for strength and durability are used to hold the cores in the vacuum chamber. A pair of elongated steel fixtures engage opposite sides of each heater core, the fixtures having recesses at their outboard surfaces. A rectangular frame having a pair of support rods is held by brackets within the chamber to orient the plane of the frame parallel to the magnetic field to minimize electrical heating of the frame. The recesses in the fixtures engage the support rods of the frame in a manner to hold the vertical parts in a vertical plane and to prevent rotation of the core by action of the magnetic field on the core.

Abstract: A new inductor, coating, and method adapted to improve the directional control of magnetic flux of an inductor. The method may include using a fluidized bed or other like methods to coat an appropriately masked inductor with a coating composition comprised of a low reluctance material and a binder. The low reluctance material in the coating composition may include such materials as carbonyl iron powder or the like, whereas the binder may comprise a polymeric resin or the like. The present coating composition increases the directional control of magnetic flux, and efficiency of the inductor by selectively distorting the magnetic field and thereby increasing and intensifying the flux density on a subject workpiece being induction heated. The invention is also believed to be usable in improving directional control of magnetic flux in other electrical conductors.

Abstract: The h.f.-heated edges of a split tube are prepared prior to heating by means of contour-rolling the edges in order to obtain a convex contour in which the temperature is isothermically distributed, parallel to the convex edges.

Abstract: A stud welder is provided with a pair of magnetic coils and a compression spring. One of the coils provides the lift to separate electrode held parts and start an arc therebetween. The other coil and the compression spring provide fast follow-up force driving the parts into reengagement to quench the arc and weld the parts together. The combined acceleration of the spring and the booster coil enables the welding of certain materials such as brass which were previously not weldable with stud welders.

Abstract: A heat exchanger assembly is formed of spaced parallel headers connected by an array of spaced flat tubes each in a plane perpendicular to the headers. The header and tube material is clad with a brazing alloy which melts at a temperature slightly below the melting point of the base material. Sinuous metallic ribbons fill the spaces between the flat tubes. The assembly is induction heated by a low frequency alternating magnetic field having its flux lines extending transversely of the tubes and headers and at oblique angles thereto, the angles being selected to cause equal heating thereof for obtaining a uniform temperature throughout the assembly to effect the melting of the alloy and the brazing of the joints. Heat panels heated by the magnetic field to a temperature near that of the assembly are placed opposite outer surfaces of the assembly as required to avoid a radiation loss which would cause a significant temperature differential.

Abstract: A return-flow type impeder assembly useful in induction welding of small tubing wherein the impeder is movably disposed within an enclosure member so that the force of liquid coolant flowing through the assembly between the impeder and enclosure maintain same in substantially coaxial relationship without the use of mechanical spacers or the like.

Abstract: A heat exchanger assembly is formed of spaced parallel headers connected by an array of spaced flat tubes each in a plane perpendicular to the headers. The header and tube material is clad with a brazing alloy which melts at a temperature slightly below the melting point of the base material. Sinuous metallic ribbons fill the spaces between the flat tubes. The assembly is induction heated by a low frequency alternating magnetic field having its flux lines extending transversely of the tubes and headers and at oblique angles thereto, the angles being selected to cause equal heating thereof for obtaining a uniform temperature throughout the assembly to effect the melting of the alloy and the brazing of the joints. Heat panels heated by the magnetic field to a temperature near that of the assembly are placed opposite outer surfaces of the assembly as required to avoid a radiation loss which would cause a significant temperature differential.

Abstract: The arrangement comprises a support at which there is mounted an induction loop through which flows a high-frequency alternating current. By displacing the support or the circuit board possessing the contact pins which are to be soldered, a multiplicity of contact pins at which contact is to be made are simultaneously brought together with the solder material and the solder eyelets of the contact locations into the range of influence of the magnetic alternating field. By appropriately constructing the induction loop there is obtained a simultaneous uniform heating of the contact pins and the contact locations. The arrangement thus renders possible a simultaneous faultless soldering of the contact pins of one or a number of pin rows of multipoint connectors mounted at the circuit boards.

Abstract: A method and apparatus for improved percussive arc welding is disclosed. In this technique a test arc of a voltage no greater than the initiating voltage of the percussive arc welding is first applied across the pieces to be welded. The welding cycle is then performed if, and only if, an arc is detected responsive to the impressing of the test voltage.

Abstract: A method and apparatus for manufacturing metal profile members, hollow bodies and the like wherein a plurality of continuous band-like metal strips of constant wall thickness as viewed in cross-section are continuously fed along separate paths which converge. The band-like metal strips are heated at predetermined selected areas to a welding temperature and then continuously press-welded together to form the profile members. One or more of the band-like metal strips may be deformed by cold-shaping prior to the press-welding operation. Hot-shaping may occur simultaneously with or immediately after the press-welding operation. Also, cold-shaping of the welded material may take place following the press-welding and hot-shaping steps to form a metal profile member of predetermined configuration.

Abstract: Metallic anode holders are suspended by a conveyor, and moved in succession above a table supporting induction-heating coils. The coils can be raised to surround lower depending parts of the holders which may be optionally previously coated with a separating agent to prevent direct contact with the grouting subsequently applied. The associated anode carbon blocks with recesses are conveyed successively beneath a beam supporting induction-heating coils which can be lowered into the recesses which subsequently receive the parts of the holders for grouting therein. It is possible to heat the recesses and the parts of the holders in situ and simultaneously, in which case the grouting operation can be performed without letting the components cool down. Metallic cathode busbars previously installed in a recess of a carbon block are likewise conveyed beneath a beam supporting an induction-heating coil, which serves to heat the busbars and the recess prior to grouting the busbars in the recess.

Abstract: This percussion welding power supply supplies welding energy through an arc between two work pieces that are forced together during or immediately following arcing. The power supply comprises a welding transformer having a primary winding and a secondary winding. Across the secondary winding, welding electrodes are connected for supplying welding current between the secondary winding and the pair of work pieces to be welded together. The power supply further comprises a capacitor bank having a pair of output terminals and means comprising electronic switching means in series with the primary winding and the output terminals for selectively connecting the output terminals across the primary winding. Control means is provided for rendering the switching means conductive, thereby causing the capacitor bank to discharge through the switching means and the primary winding to effect a welding operation.

Abstract: An induction heating process for hardening a metal insert retained in a recess formed in a second component comprises the steps of fitting the insert in place within the recess by an interference fit, machining the interior surface of the insert, locating an induction heater adjacent the surface of the insert to be hardened, the heating element being spaced from the metal surface a predetermined distance, and energizing the heating element from the high frequency electrical power source for an extremely brief period.

Abstract: An apparatus for delivering valves and melting rings for internal combustion engines to an inductor heater for hard facing comprises a tubular body which is adjoined by gravity feed trays, for feeding the work valves and rings to be melted respectively. A rotatable pocket is mounted between the tubular body and the tray for feeding the rings. The work valve and the ring to be melted are fed to the tubular body by gravity. Interaction with a stop mounted on the tubular body causes the valve to fall inside the tubular body with its stem being upwardly directed. After rotating, the pocket puts the ring to be melted onto the valve stem. The valve with the ring put thereupon is placed into the inductor for melting.

Abstract: A method is disclosed for producing one or more contact connections at solder locations between a lacquer-insulated wire and corresponding contact member of an electrical component by use of soft solder. The solder location is heated to a temperature sufficient to melt the lacquer insulation of the wire off and also to insure a secure electrical connection. Both temperature and electrical contact between the wire and contact member are sensed so as to switch off the heat source at the conclusion of soldering.

Abstract: A component comprised of a composite compact, preferably diamond, and a substrate bonded to the compact. A preferred embodiment of the component is a cutter for a drill bit. The compact is comprised of a layer of bonded diamond or boron nitride particles and a base layer of cemented carbide bonded, preferably under high temperatures and pressures, to the particulate layer. The particulate layer is degradable by expvsure to temperatures above a predetermined temperature. The substrate is bonded to the base layer of the compact with a filler metal which, to form a bond, requires the exposure of the surface to be bonded to a temperature substantially greater than the degradation temperature of the particulate layer. The component is fabricated by heating the base layer, filler metal and substrate to a temperature in excess of the degradation temperature while maintaining the temperature of the particulate layer below the degradation temperature via a heat sink.

Abstract: This invention relates to the means of continuously seam-welding the areas to be joined together of steel strips formed like tubes in the production of hot-dip metal-coated steel tubes from steel strips in a continuous supply. This seam welding device is capable of manufacturing electric seam-welded tubes with high efficiency and operational safety.

Abstract: Method of butt-welding metal parts by induction, in particular parts of irregular cross-section such as rails, consisting in pressing the parts against one another with an initial pressure for the entire period of heating, in heating them by induction by means of an inductor which encloses the parts parallel to their contours about the plane of their interface, firstly for a first period at a lower frequency and then, for a second period following the first, at a frequency two to four times higher than the first frequency, and, at the end of the second period, in applying the parts against one another at a forging pressure which is from two to more than six times higher than the initial pressure. The quality of the welded joint is greatly improved and the dimensions of the bulge or upset are limited by restricting the depth of the penetration of the induced current to both sides of the interface by means of two short-circuited turns disposed symmetrically relatively to the inductor to either side thereof.

Abstract: A panel assembling method is disclosed which comprises the steps of coating a thermosetting adhesive on the connection area of a first panel to be fixed to the connection area of a second panel, mating the connection areas of the first and second panels, heating a portion of the connection area of the first or second panel to set the adhesive on the portion, by passing a current, possibly a high-frequency current, through the portion between electrodes which are contacted to it, thereby temporarily assembling the first and second panels, and subsequently heating all of the connection area of the first or second panel to set the adhesive entirely on the connection area. An apparatus for partially setting the thermosetting adhesive is also disclosed.

Abstract: An apparatus for delivery of melting rings and valves to an inductor heater, for hard facing of valves for internal combustion engines by melting rings of heat-resistant alloy upon the working surfaces of valves, comprises gravity feed trays, one for feeding the work valves in a vertical position and the other for feeding work rings laid on their side to a tubular body. Between the exit of the tray for feeding the rings and the tubular body there is installed a horizontal tray which is located under the gravity feed tray for feeding the valves and in the same vertical plane with said tray. The distance between the sliding surfaces of the tray along which the valve head moves and the sliding surfaces of the horizontal tray along which the ring lying on its side moves is less than the length of the valve stem, so that the valve stem enters the hole of the ring and delivers it to the tubular body.

Abstract: What is proposed is a method of assembling nonmagnetic current-conducting components into units along an axis of assembly. The assembly is arranged under the effect of electrodynamic forces formed by the interaction of a primary alternating magnetic field directed along the axis of assembly and a secondary magnetic field. The components to be assembled are placed in the primary magnetic field so that the areas covered by the contours of the currents induced in these components by the magnetic field are located in planes approximately perpendicular to the axis of assembly; and in each adjacent pair of components to be assembled the regions covered by the contours of the induced currents at least partially overlap each other.

Abstract: A method and apparatus for modifying the surface properties of a metal part in which electric current having a frequency of at least 3000 Hz is supplied to a narrow area on the part by means of contacts, one at each end of the area, and a proximity conductor or is induced therein by an induction coil until the metal in the area reaches a temperature at least equal to its melting temperature. A material which will alloy with the metal of the part is added to the molten metal so that when the molten metal is cooled an area of an alloy of the metal and the added material is produced. The added material may be in the form of a gas, powder, salt, wire, rod, bar, foil, etc. and may be applied to the area before, during, or after the melting of the metal of the area. The spacing between the proximity conductor or the induction coil and the work is no greater than three times the width of the proximity conductor or the coil conductor.

Abstract: Method and apparatus for welding a metal part, e.g. a tube or strip, to a thin, flexible metal strip using high frequency electric currents in which the part and strip are continuously advanced to a weld point where they are pressed together. In advance of the weld point, high frequency current is supplied to the part and the strip through contacts engaging them so that portions thereof are heated to welding temperature by the time they reach the weld point. From the point of engagement of the contact with the strip or strips to the weld point the strip material is maintained in a fixed path by a rigid member against which the strip is pressed by tensioning the strip with a pad frictionally engaging the strip. If desired, the current may be fed to the contact engaging the part through a proximity conductor to increase the heating of the part relative to the strip.

Abstract: A metal rod is supplied to a pair of bonding rolls provided with peripheral grooves forming a substantially circular roll pass that also receives at opposite sides of the rod a pair of metal strips of a different metal than that of the rod. The rolls press the strips against the rod and pull all three together through the roll pass, with the strips bent around the rod to enclose it. Before the strips reach the pass, an electric current passes through a length of each one to heat it to a solid-phase bonding temperature and to burn off contaminants. Also, before the rod reaches the rolls, it is heated to a solid-phase bonding temperature by means of an electric induction coil encircling it while it is passing through an enclosure maintained full of a gas providing a controlled atmosphere around the heated portion of the rod. The diameter of the roll pass is small enough to reduce the diameter of the product therein and simultaneously cause solid-phase bonding together of the heated strips and heated rod.

Abstract: A brazing press for securing exterior claddings to bottoms of metallic receptacles, which includes a support structure and a reciprocable mandrel for exerting pressure against the former. The support structure holds a massive inductor block having a flat bottom and containing an inductor coil for respectively pressing and heating the flat portions of the workpieces, and an encompassing sleeve which is associated with an auxiliary inductor and exerts pressure on the peripheral curved portions of the cladding. Either the sleeve with its auxuliary inductor of the inductor block can be supported by said structure through resilient means which are calibrated, whereby auxiliary pressure is exerted on the peripheral curved portions independently from the one exerted on the flat central portion, when said mandrel is pushed against the inductor block.

Abstract: A percussion welder includes a single acting main cylinder having a ram extending through both ends of the cylinder mounting a spring loaded chuck on one end of the ram and an adjustable return spring on its other end.An automated version includes a hollow ram for the main cylinder through which a stud to be welded is blown from an escapement in a vibratory feeder bowl. The escapement has two spaced guide rails which receive the studs in a single column and a block which slides transversely across the end of the rails to pick off a single stud and move it into alignment with a gush of air which blows the stud head first through a tube to the hollow ram. A chuck having a stationary and a movable clamp is mounted on the opposite end of the ram. An actuator is disposed adjacent the chuck and opens the chuck to permit the stud to pass therethrough and at the same time places a platform beneath the chuck to prevent the stud from exiting the chuck more than a selected distance.

Abstract: An apparatus for surfacing valves by fusing in a high-frequency current field refractory alloy rings applied to the seating surfaces of the valves. The apparatus comprises a tubular body provided with chutes adjoining thereto. The chutes are adapted respectively to feed valves and rings to be fused. After a valve and a ring is assembled under the action of gravity inside the tubular body, the valve with the ring to be fused is delivered by a pusher to a mechanism fixing the valve in a heater. The pusher is mounted for reversible movement in the hozizontal plane.

Abstract: Can bodies having welded longitudinal seams with a heat curable coating thereon are carried longitudinally past an induction heater for curing the coating. The induction heater includes first and second stages for respectively rapidly heating the seams to coating curing temperature and then holding the seams at such temperature for a curing period.

Abstract: Methods of heating and welding together portions of a metal part or parts in which the portions are positioned in facing, generally parallel and spaced apart relation and an induction coil overlies the part or parts and is positioned so as to induce oppositely flowing currents in the part or parts which flow in two closed paths, one each side of the portions to be heated. The portions may be stationary or be advanced during heating, and after the portions reach welding temperature, they are pressed together to form a weld therebetween.

Abstract: A method and apparatus for embedding in a surface area of a metal part a plurality of particles of a material having a melting point higher than, and mechanical properties different from, the metal of the part. The metal part is contacted with a pair of contacts, one at each end of the area, and electric current having a frequency of at least 3000 Hz is supplied to the contacts through a proximity conductor or conductors which overlies or overlie the area and which are spaced from the area by not more than five times the conductor width. The current is maintained until the metal of the area reaches a temperature at least equal to the melting temperature thereof and the particles are inserted into the molten metal which is then cooled. If the temperature of the molten metal exceeds the melting temperature of the particles, the molten metal is cooled before the particles completely melt.

Abstract: Submerged percussion welding is disclosed wherein the parts to be welded are in intimate contact with a liquid, such as water, during explosion and vaporization of the arc starter therebetween. In preferred form, one part is mounted to a stationary bottom electrode around which a movable water tank is raised to immerse the part. The other part, mounted to a movable top electrode, is brought into contact with the first part and the weld is completed under water.

Abstract: Surfacing is realized by fusing refractory alloy rings on the effective areas of valves. The apparatus comprises: a heater, a valve clamping device and a manipulator adapted to receive and to convey a valve with a ring on the stem thereof to the heater zone simultaneously positioning said valve head downwards. The manipulator is operatively connected to a platform on which a feed mechanism adapted to feed the valve to the heater and to the valve clamping device, a sprayer and an unloading chute are mounted. According to the motion of the manipulator the platform alternately positions under the heater the operating mechanisms mounted thereon.

Abstract: Metal components having an irregular cross-sectional configuration or made of different metals or alloys are bonded together through a forged joint resulting from application of localized high frequency induction heating combined with high energy rate impacting by preshaping interface portions to be joined as a function of the cross-sectional shapes of the components.

Abstract: The composite roller of the invention comprises a ring of near-resistant material encircling a holding member which latter has an inner portion and two radial flanges between which said ring is axially fixed. Said flanges have grooves at those portions which abut lateral surfaces of said ring. A continuously U-shaped intermediate space is provided axially and radially between ring and holding member.

Abstract: Improved methods of soldering metallic parts having a portion of their surface forming non-planar surfaces, comprising arranging coaxially therewith a metallic means having favorable electromagnetic properties and a different coefficient of expansion from that of the metallic parts so that soldering is effected by the combined action of the heat effect supplied by electromagnetic induction and by radial pressure exerted by said metallic means.

Abstract: Wheel rim blank manufacturing apparatus comprises an elongated mandrel passing through Coiling, Welding and Machining Stations. Flat stock is fed transversely for coiling to cylindrical rim blanks about the mandrel. A transfer slide advances and maintains orientation of coiled rim blanks from the Coiling Station to the Welding Station. At the Welding Station clamps secure the blanks for resistance or high frequency current penetration welding. Internal clamps at the Welding Station have small shoulders for transferring the blanks past a Machining Station where a scarfing tool engages their welded areas. The method includes feeding stock transversely, coiling about a mandrel, advancing blanks along the mandrel, welding, again advancing the blanks, and machining weld areas.

Abstract: An induction heating coil and core structure which provides two distinct magnetic circuits, with the materials to be heated also forming a part of the circuits so that juxtaposed workpieces can be joined together with a layer of heat activatable adhesive by a unitary core structure. A pair of nested U-shaped cores have a differing number of exciter coil turns with at least one common turn wrapped about each of the members to produce a greater amount of flux density in one core than the other to effect a different heat rate between the workpieces which complete each magnetic circuit.

Abstract: An individual metallic, electrical conductor is terminated by heating one end thereof to form an enlarged molten mass, followed by cooling and subsequent shaping of the mass to form a terminal. Multiple conductors are spliced by heating adjacent ends thereof to form an enlarged, common molten mass at the end of each conductor. Alternatively, adjacent ends of multiple metallic conductors may be spliced by heating the ends thereof to form a molten mass at the end of each conductor followed by plunging the molten masses into one another.

Abstract: Simple or complex cross-sectional configuration metal components of an article are bonded together through a forged joint with application of localized high frequency induction heating combined with high energy rate impacting of the metal components together. An improved induction heating and impacting apparatus is provided, including an induction heating element the shape of which varies with substantial variations in the cross-sectional area of each component to provide substantially uniform heating.

Abstract: A method and apparatus for joining zirconium alloy appendages, such as spacers, to zirconium alloy members, such as sheaths for nuclear fuel elements. The appendage, coated with a material that will form a eutectic with a zirconium alloy, is heated to a temperature sufficient to form a eutectic with the coating material. The appendage is heated in proximity with the member such that the member is also heated but to a temperature that is below the alpha to beta transformation temperature. The heated appendage and member are brought together and heating is continued to complete the joining process, again with the temperature of the member remaining below the transformation temperature. The invention provides that there is substantially no alpha to beta transformation of the member or other adverse thermal effects such as residual stresses, geometrical distortions, compositional changes in fuel materials, etc.

Abstract: A forming method in which members are forced together at an interface by causing parallel currents to flow in adjacent conductors, thereby forcing the conductors toward each other in a direction generally normal to the interface.