Abstract: The machine is provided with a set of two pairs of die halves 60, 62 (FIG. 7) mounted in a framework on hydraulically actuated piston and cylinder assemblies. The die halves 60 and 62 of each pair are relatively radially reciprocable to grip or release a workpiece 102, 104 and the two pairs of die halves are relatively axially reciprocable to effect cold pressure welding together of end portions of the workpieces 102, 104. Adjoining end faces of the die halves are formed with nose portions 100 having inner anvil edges for effecting welding flash removal from the workpieces.

Abstract: A compressor rotor structure for a gas turbine engine is made by linear friction bonding stub rooted blades and separate platform pieces, to lands between slots in a compressor disc periphery. These results an integral structure in which the periphery of the disc has had metal removed so as to form the slots and the disc is thus lightened, and the stub roots and platform pieces cooperate to form the airflow inner annulus wall.

Abstract: A method is provided for repairing by solid state diffusion a damaged portion of an inner surface of a hole of a metal part. The method comprises machining the hole to a cylindrical diameter sufficient to remove the damaged portion therefrom and provide a new hole with a smooth finish into which a metal bushing is inserted, the outer diameter being of size and finish relative to the machined diameter of the hole to provide a close fit therewith, the composition of the metal bushing being compatible with that of the metal part. A cylindrical metal mandrel of diameter corresponding to the inner diameter of the bushing is inserted into the bushing to provide an assembly thereof with the metal part, the metal mandrel having a mean coefficient of thermal expansion greater than that of the metal bushing for a selected solid state diffusion temperature sufficient to provide pressure against the bushing.

Abstract: A method of providing a joint between articles of materials of different coefficients of thermal expansion comprises providing a preform of Indium between the articles, and, at ambient temperature, applying pressure to the articles to compress the Indium therebetween, the pressure being applied in a cyclical manner. A satisfactory joint is provided without employing complex cleaning of the co-operating surfaces of the constituent parts of the joint.

Abstract: Refractory metals or ceramics are diffusion bonded or densified by assembling the workpieces to be bonded, wrapping the assembly with carbon yarn, heating the wrapped assembly, cooling the assembly and unwrapping. The expansion of the workpieces together with the shrinking of the carbon yarn produces tremendous pressures which cause bonding and densifying of the workpiece.

Abstract: Diffusion bonding of aluminum alloy objects of different sizes and shapes are greatly improved when the surface of the object is exposed to a high energy source which causes a heat treatment or melting and rapid quenching or solidification at the surface. Such treatment results in the formation of finer grains at the surface which enhances the strength of a diffusion bond.

Abstract: A hand-held welding device utilizes a multiple upset cold pressure welding technique to join abutting end surfaces of a pair of wire members. The welding device includes a pair of spaced-apart, parallel tie rods for supporting a stationary V-block in spaced apart relationship with a moveable V-block. A welding die assembly is positioned between and is actuated by the two V-blocks. An end plate is secured to one end of the tie rods adjacent the stationary V-block, while a fixed handle is adjustably secured to the opposite end. A moveable handle is pivotally mounted relative to the fixed handle and includes a working roller which engages the moveable V-block to force the V-blocks against the die assembly. As the V-blocks are forced against the die assembly, the die assembly is operated to force the ends of the wire members against one another to form a cold pressure weld.

Abstract: The present invention is a method for bonding two surfaces without applying heat. The surfaces are prepared so that they both have an outermost layer of aluminum. One of the surfaces has metallized particles that protrude at the desired bonding points. When the two surfaces are brought into contact, the particles pierce the aluminum surface, displacing any aluminum oxide that may be present. This provides two virgin aluminum surfaces on contact with each other, which allows the formation of a metal matrix, thus bonding the two surfaces. The strength of the bond can be controlled by varying the piercing depth and size of the particles. The material for the particles may be chosen so that the bond is both electrically and thermally conductive, either electrically or thermally conductive, or both electrically and thermally insulative.

Abstract: A novel method and apparatus for forming an aluminum container with an exposed metallic insert in the closed end thereof with the aluminum and the secondary metal being coextruded during forming of the container. A particularly synergetic combination is achieved by selecting a spherical insert member and providing concave or depressed region in the bottom of the extrusion die mold to partially receive the spherical element. The aluminum flows around the major diameter of the spherical insert during coextrusion but leaves a bottom portion of the insert exposed for external welding to another component.

Abstract: A method of cold welding of workpieces formed as axially symmetric bodies of rotation, wherein the workpieces are pressed into each other by applying an axial stress to at least one of the workpieces, and the workpieces are imparted a relative turn in a plane perpendicular to the direction of the axial stress.

Abstract: A gun barrel cleaner comprises an elongated flexible shaft having a universal coupling secured to each opposite end and several different cleaning tips selectively threadably and detachably engageable with either universal coupling. One cleaning tip, a gun barrel bore obstruction remover, comprises a cylindrical body portion having a concave face at one end and securing means at the other end for attaching the tip to the shaft. A compact cylindrical container for storing and conveniently transporting the gun barrel cleaner is provided. In addition, an improved method of attaching a cleaning patch to a gun barrel cleaning tip having a patch receiving slot is provided.

Abstract: A coated substrate manufactured by applying a layer of a material to the substrate and generating thermal and pressure waves in the layer by exposing the layer to high intensity, short duration laser radiation, and the process of manufacturing such a coated substrate. The laser radiation is applied in an intensity range that creates an instantaneous surface vaporization of the layer material that in turn drives a pressure wave into the layer. The pressure wave interacts with the layer-substrate interface to create bonding between them of varying strengths and qualities depending on the intensity and duration of the initial laser pulse. A thermal wave is created in some regimes of operation, or results from compressional heating of the layer by the pressure wave, and is of sufficient energy to contribute to the bonding at the interface.

Abstract: For fastening a cover part at a frame part in which both parts have at least a metallic frame structure, spherical segments formed out of the frame part with fasteners in the form of balls are provided while the counter fasteners are constructed as collars which are components of the cover part and extend angularly bent in the direction of the frame part. After inverting the collars over the balls, each collar is pressed flat by a predetermined amount under straightening during a pressing operation in which the frame part serves as supporting surface so that at the end of the deformation operation, the collar is supported at the ball.

Abstract: A cold pressure-welding apparatus has a pressure-welding load detector and a displacement detector for detecting the displacement of pressure-welding parts which are mounted on a cold pressure-welding apparatus main body; and an arithmetic operation control circuit which receives output signals from the detectors to detect yield points on a load-displacement curve, calculates an optimum load for optimally performing cold pressure-welding on the basis of a yield load at a second yield point, and outputs to the cold pressure-welding apparatus main body a signal for stopping cold pressure-welding when an actual pressure-welding load reaches the optimum load.

Abstract: A resistance thermometer having a resistance temperature detector (RTD) element fixedly supported within a tubular metallic sheath by a compacted insulating material is manufactured by integrally connecting in series two tubular metallic sheaths by pressure welding. The first sheath has a smaller diameter portion which can be inserted into and received by the second sheath. The manufacture method includes the steps of: supporting electrical conductors in the first sheath using the insulating material, electrically joining the RTD element to the conductors supported in the first sheath, putting a metallic ring on the smaller diameter portion of the first sheath, inserting the smaller diameter portion of the first sheath into the second sheath with the RTD element being accommodated within the second sheath, and ramming the metallic ring radially inwardly so that the first and second sheaths are integrally bonded by pressure welding.

Abstract: A die (40) for extrusion of optical grade fibers has its hard insert (42) placed under compression within a sleeve (44). Sleeve (44) is provided with a tapered interior surface (50) which matches the tapered exterior surface (48) of the insert (42). A metal lubricating layer (60) is provided between the tapered surfaces. The insert is pressed in to obtain compressive prestressing thereof, and the lubricating metal diffuses at the tapered surfaces to lock the insert in the sleeve.

Abstract: All the layers of the anode foil of an electrolytic capacitor roll (5) are cold welded to a piece of tabbing (8) using radiussed weld tooling (10, 12, 13) which bends the foil layers in the course of the welding operation so as to enable a good weld to be effected. The cathode foil layers are welded to their piece of tabbing in the same way. Optionally the roll may be partially flattened at the time the welds are made.

Abstract: A method of making electrical connections between metal foils laminated to opposing surfaces of a flexible insulating layer, such as may be configured with spiral patterns in the respective metal foils to form inductive-capacitive circuits useful as detectable markers in RF antipilferage systems, and wherein an electrical connection is provided between the opposing foils by first extruding the laminate to shear the insulating layer and to contact the opposing metal foils in the vicinity of the sheared insulator layer and by subsequently forcing the extrusion back into a substantially planar relationship relative to the remainder of the laminate.

Abstract: An improved method and apparatus for the production of multi-gauge strip is disclosed wherein the multi-gauge strip comprises a first strip of metal having a first thickness and extending longitudinally for a given length. A second strip of metal has a second thickness, is narrower in width than the first strip, and coextends longitudinally with the first strip of metal. The first and second strips of metal are intimately bonded in direct metal-to-metal contact without the use of a welding or brazing material. The multi-gauge strip has a first portion extending the given length with a third thickness substantially equal to the sum of the first and second thicknesses and a second portion of substantially constant width extending the given length having a fourth thickness substantially equal to the first thickness.

Abstract: A process for the production of bi-metallic contact rivets with especially thin precious metal layers.

Abstract: A method of making an orificed discharge wall for supplying a plurality of streams of molten inorganic material to be attenuated into filaments comprising inserting elements in apertures in a member; sealing said elements and member within a coating adapted to isostatically transmit pressure to said assembly; applying isostatic pressure to the hermetically sealed elements and member to mechanically seal the elements to the member; and heating the mechanically sealed elements and member to fuse the elements to the member to prevent the unwanted passage of molten glass between said elements and said member, said elements having an orifice to permit the passage of molten glass therethrough to establish said streams.

Abstract: Process for locating solder on a precalculated position on an electrical terminal. Metal strip stock coated with a thin layer of solder is fed through a strip guide for precisely positioning the metal strip stock between a pair of rollers. A solder wire is cold bonded to the metal strip stock and the strip stock is subsequently stamped into a terminal.

Abstract: Two or more pieces of wire of precious and non-precious metals are cold welded at their free ends, for producing a composite electrical contact or contact material, contact surface of which is made of said precious metal or alloys thereof. One of, a plurality of, or all of said free ends are provided with one or more projections of a diameter less than that of the wires which are expanded and flow under welding pressure over the abutting surfaces of the free ends to form bonded surfaces of wires without undesired or unexpected expansion of the wire pieces in their diameters.

Abstract: A tri-metallic electrical contact consisting of a head wire piece and a base wire piece which abut to an intermediate piece at its opposite ends, is produced by cold press operations performed by first and second die and punch sets. The first die and punch set causes plastic deformation of approximately only a half part of the aligned wire pieces, while keeping another half part of these pieces not deformed. The second die and punch set imparts, subsequent to, and independently from, the cold press operation performed by the first die and punch set, plastic deformation to the other half part of the pieces, whereby the abutting surfaces of the three wires are prevented from sliding movements laterally relative to each other during the cold press operations, and whereby irregular or insufficient deformation of the wires due to the differences of yield points of the wires is prevented.

Abstract: An aluminum electrical conductor is electrically joined to a copper electrical conductor by a cold weld lap joint which is substantially free of copper-aluminum intermetallic compounds. The overlapped portions of the conductors are deformed at least 74% and no greater than 82% to achieve a weld joint which has both excellent physical properties and excellent electrical properties. The cold weld lap joint is a reliable electrical connection for electrical circuits experiencing current densities of more than 1000 amperes per square inch and a sustained high temperature of 125.degree. C. and above.

Abstract: A composite metal sintered article combining a metal shell which has been electroformed and/or electroless plated and/or vapor deposited, positioned inside or outside of a metal sintered compact. A method of making the composite metal sintered article using both a powder metallurgy process and a surface treating process. This composite metal sintered article has excellent surface properties and high dimensional accuracy and is favorably used for many kinds of forming molds, dies and structural members, especially for press molds in making glassware.

Abstract: The present invention provides a certain improvement in the method for connecting a pipe to a plate by high pressure welding. This basic method is one in which the pipe is inserted a certain distance into a bore provided in the plate and subsequently the material of the pipe is spread out over the wall surface defining the bore of the plate, under the influence of high pressure and with the aid of a mandrel disposed in the pipe.The improvement provided by the invention basically comprises the steps of positioning within a cooperating punch and die set, the plate with an end section of the pipe inserted into the bore of the plate. The punch and die set have opposed aligned bores accommodating the extension therethrough of the pipe and a mandrel respectively. In addition the punch and die set generally confine the plate at the peripheral edge and opposite sides thereof, and are operable to apply compressive forces to the opposite sides of the plate.

Abstract: A novel anode structure for electron discharge devices, for example, a crossed field oscillator of the magnetron type is fabricated by uniting nonthermally substantially similar cylindrical members each having a boundary wall member and plurality of vane members. The vane member edges are provided with alternate clearance or contacting mating notches to position an annular strap or straps in the complete anode assembly. Less expensive metal castings, such as aluminum, and other suitable vacuum materials, and such techniques as pressure welding and interference fits may be employed without expensive brazing procedures to result in a simplified less expensive anode structure. Different anode vane configurations are simply implemented, such as V-shapes, utilizing castings or similar structures which when joined together form the composite anode assembly.

Abstract: A method of making a self aligning spherical bearing from three parts, a spherical inner race and two outer race components, the method comprising holding one outer race component, positioning and holding the spherical inner race therein, positioning the other outer race component in alignment therewith and friction welding the two outer race components together until the meeting faces of the two outer race components are in contact to provide a controlled clearance between the inner and outer races.

Abstract: Copper-clad steel wire is produced by forming a copper tube around the wire, and drawing down the copper tube and wire to reduce the cross-section of the wire by at least 30%. The wire is annealed, slowly cooled and the cross-section further reduced by at least 10%.

Abstract: A method for bonding a copper terminal member to an aluminum electrical conductor wire. The copper member, having a point at one end, is driven with its pointed end into the terminal end of the aluminum wire, so that a cold weld is produced between the aluminum and copper which forms a good electrical connection.

Abstract: A method of joining metal elements such as heating tubes, pipes, rods, metal cords, or other lengthy elements having similar profiles, with a plate or other flat, molded, metal surface by use of a wire structure which is affixed to at least one of the metal elements at a great number of places.

Abstract: A novel anode structure for electron discharge devices, for example, a crossed field oscillator of the magnetron type is fabricated by uniting nonthermally substantially similar cylindrical members each having a boundary wall member and plurality of vane members. The vane member edges are provided with alternate clearance or contacting mating notches to position an annular strap or straps in the complete anode assembly. Less expensive metal castings, such as aluminum, and other suitable vacuum materials, and such techniques as pressure welding and interference fits may be employed without expensive brazing procedures to result in a simplified less expensive anode structure. Different anode vane configurations are simply implemented, such as V-shapes, utilizing castings or similar structures which when joined together form the composite anode assembly.

Abstract: The method of forming a product, such as an electrical connector, of two different metals wherein a recess is provided in one end of a first metal member for receiving one end of a second metal member of a smaller size. The assembled metal members are placed in a closed die and high pressure is applied to the outermost end of at least one of the metal members to impart relative movement of the metal members toward each other and cause flow of the metal together at the point of juncture with displacement of one metal in the other.

Abstract: A cold welded connection of a first member with a second member, according to which a ribbed portion associated with the first member and having ribs of at least nearly triangular cross section is pressed into a receiving depression which is slightly undersized relative to the ribbed portion thereby cold welding the first and second members together the ribs of the ribbed portion including ribs extending in the direction in which the ribbed portion is being pressed into the receiving depression.

Abstract: A pyroelectric target for a vidicon is effectively sealed in a vacuum-tight envelope by resiliently mounting in a retainer ring bonded by indium to a window transparent to visible and infra-red radiation. The window is then sealed in one end of an envelope which is evacuated.

Abstract: A hermetically sealed electrical component. A conductor passes through a metal body member in which it is sealed by a glass-to-metal seal, extending to the electrical component. The metal body member is soldered or brazed to a support plate. A cap enclosing the component is cold pressure welded to the support plate.

Abstract: Method for forming or deforming a metal workpiece by passing a stress wave through the metal workpiece sufficient to render it momentarily plastic. The apparatus is basically comprised of a stress wave focusing device or amplifier. In operation, a workpiece is placed in a die or shaping means. The stress wave amplifier is then arranged to direct or focus the stress wave to the metal workpiece. Next, a stress wave is generated and passed through the stress wave focusing device, imparting a momentary state of plasticity to the metal workpiece.

Abstract: A method and apparatus for closing and bonding initially open clam-shell housings about articles such as electrical terminals or the like. The housings are initially in strip form, a plurality of the initially open clam-shell housings being interconnected to each other by hinge members which extend outwardly from either the ends or the sides of opposed housing parts. A leading housing of the strip is initially disposed at an assembly station and an article is conveyed laterally into the housing. Subsequently the housing is partially closed by engaging one of the housing parts of a clam-shell housing adjacent the leading housing and moving it towards its opposed housing part to cause corresponding movement of the housing parts of the leading clam-shell housing.

Abstract: A process for bonding a copper or nickel end junction piece to an aluminum electrical conductor wire. The copper or nickel end junction piece is used to make the electrical connection with terminals in meters, fuse boxes, switches and the like, thus eliminating such junctions with the aluminum wire and hence eliminating the possibility of the formation an aluminum oxide connection which may give rise to overheating and subsequent fire. The end junction pieces may be applied on-site after the aluminum wire is cut to the desired length. No special pretreatment of the aluminum wire end is necessary prior to the addition on the end junction piece.

Abstract: An improved pressure welding technique permits high speed room temperature seam bonding of metal sheets. A metal interlay is placed between the faying surfaces to be bonded and the assembly is compressed until the interlay is properly spread over the faying surfaces. The interlay has a cross-section designed to produce a highly differential flow when subjected to external compressive loads. This differential flow causes shear movement between the interlay and the faying surfaces which effects the weld. Joining speeds in excess of 10 feet per second are possible, with a reduction in sheet thickness of about 5 percent.

Abstract: A solid state bonding process of malleable metals employing the isothermal solidification of a liquid interface to overcome bonding problems inherent in certain material combinations especially when subjected to high annealing temperatures. The technique employs the use of a solid metal interliner clad between the two components to be bonded which has a lower melting point than the adjacent components, is diffusible into either one or both of the adjacent components and maintains ductility after alloying with the adjacent components. The composite material is then heat treated above the melting point of the interliner causing momentary liquifying of the interliner, diffusing the liquid metal into either one or both of the adjacent components thereby forming a progressively higher melting point alloy and subsequent isothermal solidification of the high melting alloy to securely bond the two components together.

Abstract: A tool for cold pressure welding workpieces such as coaxial cables together. The tool has a compact arrangement so that it may be hand held and operated. A hydraulic pump and motor are incorporated for providing a force amplification which lends to the compactness and light weight of the assembly. The hydraulic motor operates pairs of dies which dies first grip the ends of the workpieces to be welded and then force these ends into engagement to achieve a cold pressure weld. A pressure relief valve is interposed in the hydraulic circuit for limiting the force applied to the dies. The dies are held in pivotally supported parts of the tool so that the tool may be conveniently opened for inspection, replacement or cleaning of the dies.