Abstract: A process for sealing a ceramic filter by infiltrating a metal into an end of the filter. The process includes the steps of contacting the end of a porous ceramic filter with a molten metal, whereby the metal enters into the ceramic matrix to substantially fill the void space. The ceramic filter is cooled to form a filter having a ceramic-metal composite portion. The present invention also provides a filter having an infiltrated metal seal. Methods for joining infiltrated ends are also provided.

Abstract: A method for bonding a gyroscope component to a gyroscope body using the solid liquid Inter Diffusion (SLID) process. The resulting bond structure has a larger operating range than the bonding-materials used to create to bond. Mating material layers may be added to the bond to improve bonding between the bonding materials and the component and between the bonding materials and the gyroscope body.

Abstract: A process for joining two or more overlapping metal workpieces includes providing a fastener which is made of metal having a melting point temperature at least as great as that of the workpieces. The fastener is rotated about its central axis and is axially advanced at a predetermined advance rate into engagement with the workpieces so as to cause plasticization of the workpieces at the interface with the fastener, and to cause the fastener to axially penetrate through substantially the entire thickness of the workpieces. The rotation of the fastener is then stopped, and the plastic zone which surrounds the fastener cools to form a metallurgical bond with the fastener. The resulting fastened joint is mechanically superior to conventional mechanically fastened joints made by rivets and the like.

Abstract: This invention relates to a method of joining silicon nitride having on its surface a thin layer of active silicon metal to carbon steel, wherein the active silicon layer is formed through the thermal dissociation of silicon nitride(Si3N4) into silicon(Si) and nitrogen gas(N2). The active silicon layer is directly joined to carbon steel via an induced eutectic melting reaction between the silicon (Si) an iron (Fe) of carbon steel, or via brazing of two materials Ag—Cu alloys. This joining process does not require the use of expensive Ag—Cu—Ti active brazing alloys containing an active metal (Ti) or a sputtering method designed to coat the active metals on surface of silicon nitride.

Abstract: Break-away tethers to secure electronic, mechanical, optical, or other microstructures, during release from one substrate and transfer to another. Microstructures are fabricated with integrated tethers attaching them to a first substrate. The structures are undercut by etching and contacted and bonded to a second substrate. First and second substrates are separated, breaking the tethers.

Abstract: Solderable structures, and related methods for making them, can provide thermal conductivity and/or electrical isolation for electronic devices soldered to the structures. Each of the structures includes a solderable material bonded to a heat sink by a thermally-activated bonding material which provides thermal conductivity between the solderable material and the heat sink and which can be configured as a three-layer bonding film to also provide electrical isolation. The structures can be produced in a highly-automated, rapid way without the need for standard mounting hardware and mechanical preparation of the heat sinks.

Abstract: A process for fixing a graphite-rich material onto a metallic body by mixing graphite powder with a plastic material to obtain a graphite-rich material, pressing the graphite-rich material onto a layer of a metal-rich material, in a single step, forming thereby a green pressing formed of a graphite-rich component and a metal-rich layer, aligning the green pressing with the metallic body to which it is to be fixed, and subjecting the aligned metallic body and green pressing to a heat treatment to bond the metal-rich layer to the metallic body.

Abstract: A wear surface for helicopter shoes is constructed by forming a railed enclosure on a curved base plate, placing a mosaic of smooth-surfaced tungsten carbide blocks on the base plate within the enclosure, brazing the blocks to the plate and rails, and grinding the rails to form a smooth, edgeless transition between the wear surface and the plate surface.

Abstract: A composite structure includes a first nonmetallic component and a second mponent of metal or nonmetal, with the first and second components being joined together by a bonding material which is so introduced by way of a casting process as to permeate to an area between the first and second components.

Abstract: A method and apparatus is disclosed for ultrasonically welding at their edges a strip of their copper foil to a second strip of supporting metal, preferably aluminum or stainless steel having a thickness greater than the copper foil. The welded strips are subsequently sheared into panels for use in making printed circuit boards.

Abstract: A plurality of closed structural metal cells are joined into an aggregate arrangement to form a composite material. Each cell encapsulates a fluid or fluid-like filler therein to provide controllable strength and shock-absorbing characteristics to the material. The resulting closed cell metal composite finds many advantageous uses including use as a prosthetic device, a casting, or an automotive component. The component material is elastically compliant or stiff, depending on the design, as well as lightweight and crush resistant. The material provides desirable physical properties such as thermal and electrical conductivity and shock-absorbing characteristics.

Abstract: A double shear lap joint is formed between metal and composite structure by welding Z-pins in the composite in the joint area to the metal tangs on the metal structure. The joint has modest strength but is less susceptible to shock damage than an adhesive bond or to notch effect crack propagation damage associated with fastened metal/composite joints.

Abstract: A refractory composite structure is formed which comprises a ductile refractory metallic layer with a roughened surface which is tightly bonded to a refractory composite structural shell. The roughened surface is preferably dendritic in form and produced by chemical vapor deposition techniques. The refractory composite structural shell is preferably a carbon-carbon composite formed by applying a carbon filament preform to the roughened surface, infiltrating the preform with a carbon matrix precursor, and carbonizing the precursor.

Abstract: An improved method for fabricating a filter for use in automotive air bag inflators which comprises forming a hollow cylindrical inner core or combustion screen of filter material and outer filter layers wound outward from the surface of the core so as to be maintained in cylindrical relation thereabout. This invention is specifically directed to an improved filter which does not include a perforated support tube and relies on only the interior combustion screen for support in the final wrapping of the remaining filter structure.

Abstract: A modular panel formed by solidifying a composite mixture of material within a frame. The panel is suited for use as a structural component and multiple panels are joined together to form structural components such as foundations, floors, walls and roofs. The panels are fixedly joined as by welding the frames of adjacent panels together. The structural components are similarly joined together as by welding to form a building. The material is primarily wood products and has cement, starch and other materials as a binding agent. The material provides a surface that is suited for conventional finishing material. In addition to providing structural integrity, the panels are relatively light in weight, are not subject to deterioration and provide insulating quality.

Abstract: An aluminum sheet for use in spot welding has an anodic oxide film with a thickness of 50 .mu.m or less on at least one surface thereof. The anodic oxide film is preferably overlaid with a plating layer predominantly comprising at least one metal selected from the group consisting of Zn, Cr, Co, Ni, Fe, and Mn. The aluminum sheet can be produced by subjecting an aluminum or aluminum alloy sheet to anodic oxidation in an acidic solution having a pH of 4 or less conditions of from 2 to 200 V in voltage and from 0.2 to 200 seconds in duration, optionally followed by electroplating in an acidic plating bath.

Abstract: A method of joining two sections of metallic pipe (1), each of which has a thermoplastic polymer lining (3), to form corrosion resistant joints is disclosed. The method comprises inserting a sleeve (10) into each section of two pipes (1) that are to be joined so as to form a fluid tight seal between the liner (3) and the sleeve (10). The end of each section of pipe is then bevelled, and the two sections are welded together so as to form a corrosion resistant weld between each section of pipe and each sleeve and between each of the sleeves. The method is particularly useful in the lining of metallic pipe in the field e.g. in pipelines, without having to form flange joints.

Abstract: This invention relates to butt joining methods. Such methods of this type, generally, allow fiber reinforced metal matrix composite components having a metal matrix and a fiber reinforcement to be butt joined in order to form a large integral structure.

Abstract: The present invention relates to a novel process for forming macrocomposite bodies and the novel bodies formed thereby. Particularly, a suitable matrix metal, typically in a molten state, is in contact with a suitable mass of filler material or preform located adjacent to, or in contact with, at least one second material in the presence of a suitable reactive atmosphere in an impermeable container, at least at some point during the process, which permits a reaction to occur between the reactive atmosphere and the molten matrix metal and/or mass of filler material or preform and/or impermeable container, thereby causing molten matrix metal to infiltrate the mass of filler material or preform due to, at least in part, the creation of a self-generated vacuum. Such self-generated vacuum infiltration occurs without the application of any external pressure or vacuum.

Abstract: The present invention relates to the formation of a macrocomposite body by spontaneously infiltrating a permeable mass of filler material or a preform with molten matrix metal and bonding the spontaneously infiltrated material to at least one second material such as a ceramic or ceramic containing body and/or a metal or metal containing body. Particularly, an infiltration enhancer and/or infiltration enhancer precursor and/or infiltrating atmosphere are in communication with a filler material or a preform, at least at some point during the process, which permits molten matrix metal to spontaneously infiltrate the filler material or preform. Moreover, prior to infiltration, the filler material or preform is placed into contact with at least a portion of a second material such that after infiltration of the filler material or preform, the infiltrated material is bonded to the second material, thereby forming a sealable electronic package.

Abstract: An improved method for repairing a damaged portion of a glass layer of glass-lined equipment. In the method, a metallic fiber-containing sheet made of a metallic fiber-containing web, a metallic woven fabric sheet or a metallic nonwoven fabric sheet is disposed on the metal substrate of the damaged portion exposed by grinding, and the metallic sheet is welded partially to the metal substrate underlying the glass layer by a resistance or spot weld. After solidification of the repairing agent, e.g., of a sol-gel solution containing a metallic alkoxide which has been applied onto the partially welded sheet(s) and the sol-gel solution impregnated therein, the reapiring glass layer is formed integrally together with the sheet(s) by heating the damaged portion at a temperature from about 300.degree. to about 350.degree. to avoid the occurence of cracks on the glass layer surrounding the damaged portion.

Abstract: A metal matrix composite is produced by forming a rapidly solidified aluminum base alloy into wire. The wire is arc sprayed onto at least one substrate having thereon a fiber reinforcing material to form a plurality of preforms. Each of the preforms has a layer of the alloy deposited thereon, and the fiber reinforcing material is present in an amount ranging from about 0.1 to 75 percent by volume thereof. The preforms are bonded together to form an engineering shape.

Abstract: A method of forming enclosures for microwave and hybrid devices and the enclosure itself wherein the metals to be joined are thin (i.e., less than 40 mils thick) and/or thick (up to several inches) and wherein metallurgical hermetic bonds are provided between adjacent metals which are generally difficult to bond to each other and may be bonded by a select number of bonding processes.

Abstract: Methods are described for attaching ceramic fibrous bodies to metallic substrates. Metal fibers or metal wires are woven into the ceramic fibrous body which is to be adjacent the substrate and the exposed portion of these fibers or wires is attached by brazing to the substrate.

Abstract: A method of bonding a metal connection onto an electrode for an electrochemical cell including a foam type substrate (2), which substrate has been filled with active material and then compressed, the method being characterized by the facts that: at least one perforation (3, 4) is formed through said electrode; a metal tongue (5) is compressed against said performation and the surrounding zone, which tongue penetrates superficially into a first face of the electrode; and said connection (11) is welded onto said metal tongue (5) through said perforation (3, 4).

Abstract: This invention is directed to a novel method of removably securing a sight glass member to a refrigeration vessel in hermetically sealed relation therewith. In accordance with the method concept, a ferrule or like tubular mounting means is fixedly attached to the vessel through an opening therein, and one end of the sight glass is located within the ferrule. Brazing metal is then positioned in contact with the sight glass member and ferrule, and the metal, member, and ferrule are heated by electromagnetic induction to melt the brazing metal and form a hermetic bond between the ferrule and sight glass member. By this method, leakage associated with threaded connections, and damage to the sight glass and extreme difficulty of removing the sight glass member when resistance or arc welding methods are used, are herein substantially entirely eliminated.

Abstract: Metal-ceramic interfaces of enhanced strength are produced by positioning bodies of ceramic oxides and transition element metals or alloys containing such in abutting relationship, and heating in air at a temperature ranging from 500.degree. C. to just below the melting point of the metal of the metal body to join said bodies and then subsequently heat treating said joined bodies in a reducing atmosphere at a temperature in the range of 300.degree. C. to 1200.degree. C. to form intermetallic compound layer at the interface.

Abstract: A cochlear prosthetic package having a cup-shaped titanium case with a ceramic plate; a plurality of hermetically-sealed feedthroughs are formed in the plate by sintering the plate with hollow metallic tubes located in plate holes and then sealing at least one end of each tube. An electrode cable connector is provided which allows removal and replacement of a case even in the presence of body fluids. A telemetry coil is contained in a metallic tube which extends out of the case; the coil-containing tube has its two ends hermetically-sealed to the case by ceramic insulating bushings.

Abstract: An actively cooled device, such as a heat shield for a fusion reactor, includes elements (10) of a heat-resistant material, particularly graphite, each being provided with at least one recess having a circular cross section, particularly a groove (14), into which a cooling pipe (16) conducting a coolant is brazed directly and with surface contact. This produces an effective dissipation of heat from the elements and a more durable connection of the elements with the cooling pipe or pipes.

Abstract: A composite target for an x-ray tube has a graphite substrate portion and a metal portion, the two portions being bonded together by platinum and platinum alloying materials. The preferred alloying materials are tungsten and nickel which act in conjunction with the platinum to improve the bond resulting in an x-ray tube having a longer life span.

Abstract: A method for forming metallized coatings on ceramics for high-temperature uses above about 630.degree. C. comprising the steps of: preparing a metallizing composition of mixed ingredients of differing sizes, proportioning the differing sizes to have nonsegregating qualities when applied onto the ceramics, coating the metallizing composition on the ceramics; and heating to form the desired metallized layer.

Abstract: This invention is directed to a novel method of removably securing a sight glass member to a refrigeration vessel in hermetically sealed relation therewith. In accordance with the method concept, a ferrule or like tubular mounting means is fixedly attached to the vessel through an opening therein, and one end of the sight glass is located within the ferrule. Brazing metal is then positioned in contact with the sight glass member and ferrule, and the metal, member and ferrule are heated by electromagnetic induction to melt the brazing metal and form a hermetic bond between the ferrule and sight glass member. By this method, leakage associated with threaded connections, and damage to the sight glass and extreme difficulty of removing the sight glass member when resistance or arc welding methods are used, are herein substantially entirely eliminated.

Abstract: A method of forming diffusion bonds between aluminum and aluminum alloy saces by coating the surfaces with molten AgNO.sub.3 and then decomposing the AgNO.sub.3 to form a thin uniform layer of silver on the surfaces before forming the diffusion bond. The AgNO.sub.3 coating and decomposition in treatment permanently breaks up the Al.sub.2 O.sub.3 coatings on the aluminum or aluminum alloy surfaces, making diffusion bonding possible.

Abstract: A connector for a concrete structure including two generally flat plates connected together along one edge to form an elongated structure having substantially an L-shaped cross section. One plate has an opening sized to allow unset concrete to flow through the opening and to hold the plate firmly within the concrete when it is set. When this plate is held within the concrete, the other plate protrudes from the concrete and is available for connection with another such connector by direct welding or clamping of the two plates together.

Abstract: A combination of unique properties of (i) high strength and stiffness at temperatures up to about 1500.degree. F., (ii) good room temperature mechanical properties including good ductility and (iii) improved resistance to matrix cracking is achieved in a titanium structure by forming a hybrid titanium alloy matrix composite in which the matrix consists of layers of at least two alloys, i.e. a high temperature-resistant titanium aluminide alloy and a ductile, lower modulus titanium alloy, that are bonded metallurgically to each other in various embodiments. A reinforcing material in the form of filaments, fibers or whiskers, e.g. silicon carbide, can be embedded within either or both types of the titanium layers.

Abstract: A method of fabricating irregular shapes wrapped with metal matrix composite monotape utilizing a cylindrical deposition drum wrapped with a spiraling array of evenly spaced strands of high strength fibers and overlaid with a metal matrix, which is cut into a narrow ribbon which is transferred to a spool and then wound on the irregular shape in a helical manner so that the opposite side margins are adjacent each other in adjacent turns.

Abstract: A method for producing a high temperature, high strength bond between a ceramic shape and a metal substrate, such as joining a ceramic cap to a piston for an internal combustion engine. The composite joint is effected through the use of a ceramic preform fabricated using fibers, whiskers, platelets or sponge-like particles having the same composition as the ceramic body. The preform is joined to the ceramic shape by using a ceramic slip having a ceramic corresponding in composition with the ceramic body, with this juncture being heated to achieve a secure bond. The preform is joined to the metal substrate by first infiltrating the preform with molten material corresponding to the substrate, and then pressure bonding the infiltrated preform to the substrate after the molten material has solidified. The substrate can be metal or metal alloys. An example is given for the bonding of silicon carbide to a 300 series aluminum.

Abstract: Abradable coatings are applied to turbine or compressor shroud structures to facilitate reductions in blade tip-to-shroud clearances for improved engine performance or airfoil durability. Coating compositions include a chemically table, soft, burnishable ceramic material (such as CaF.sub.2 or BaF.sub.2) in a ceramic or metallic matrix or honeycomb structure.

Abstract: To alter the surface qualities of nonreactive materials, such as polypropylene and polyethylene in order to provide a means for bonding the plastic to metal, hard granular materials of oxides or carbides are partially impregnated into the surface of the plastic by application of heat and pressure so that granular edges remain exposed. Thereafter, a silver coating is applied over the impregnated plastic to interlock with the granules. The composite layered plastic then provides a means for soldering or bonding the plastic to a metallic coupling using either a bonding cement or a low temperature solder such as bismuth, lead, or tin based solder. Abrasion-resistant qualities also are improved by impregnating the internal surfaces of a plastic tube in order to improve its wear-resistance during transporting abrasive slurries of sand, coal, and the like.

Abstract: In order to secure electronic components, and particularly large-area power semiconductors, to a substrate, first a paste formed of metal powder and a solvent is applied in the form of a layer to a contacting layer of the component and/or a contact surface of the substrate. The layer of paste is then dried. When the paste has dried, the component is placed onto the substrate, whereupon the entire arrangement is heated to a relatively low sintering temperature preferably between 180.degree. C. and 250.degree. C., and with simultaneous application of a mechanical pressure of at least 900 N/cm.sup.2. A connection which is thus achieved by such a pressure sintering at relatively low sintering temperatures is particularly suitable for securing power semiconductors produced in MOS-technology to a substrate.

Abstract: The invention relates to a method of securing a first part made of a thermoplastic material to a second part made of an electrically conductive material, a connector means of an electrically conductive material being placed in the part made of a thermoplastic material and subsequently being welded to the part made of an electrically conductive material. A metal ball is used for the connector, which ball is inserted into an opening in the first part and is brought into contact with the second part, after which the ball is welded to the second part by means of a welding electrode.

Abstract: A method of sculpting in metal is disclosed in which the artist first sculpts or otherwise forms a core in a desired, artistic, aesthetically pleasing shape. The core is formed of a material which is at least meltable, and in most instances capable of being completely destroyed, as for example by being burned. In carrying out the process, the artist applies pin-like elements to the entire surface of the core, having large flattened heads flush with the core surface and at some locations, from one another. Thereafter, a brazing rod is applied to the heads of the nails, using conventional welding methods, forming a metallic sheath that follows the surface of the sculptured core and which is formed throughout with irregularly shaped openings occurring between the heads of the pin elements. The core is then burned out or otherwise destroyed without affecting the metallic sheath, leaving the hollow metallic sheath as the end sculpture.

Abstract: A method for the adhesion of oxide type ceramics and copper or a copper alloy is provided by this invention, which method comprises placing the oxide type ceramics and the copper or copper alloy in mutual contact, heating them in an oxidative atmosphere thereby effecting adhesion thereof, and rapidly cooling the resultant composite of adhesion. The adhesive strength of the composite of adhesion so produced is about 40% higher than the adhesive strength of a similar composite of adhesion obtained by the conventional method involving gradual cooling.

Abstract: A method and associated device for forming reinforced panels including providing a first panel of insulation having two major surfaces, piercing the insulation panel with rod like members so that portions of the rod members extend out from both major surfaces, superimposing on each major surface a grid formed from a plurality of longitudinally and latitudinally extending bar members which are formed by attaching the bar like members at intersections thereof and orienting the grid and additionally the rod like members so that some of the rod like members contact different bar like members which are thereafter welded to form a reinforced panel.

Abstract: A composite laminate capable of exposure to high temperature differentials without damage, comprising a first layer, a second layer and an intermediate web interface layer of a low modulus metallic low density structure having a high melting point. The first layer is secured to the low modulus structure directly or through an intermediate composite layer, and the second layer is bonded or secured to the intermediate low modulus layer. The thermal strains caused by a temperature differential between the first and second layers are taken up without harmful effect by the intermediate low modulus web layer.

Abstract: Decorative leaded panels of translucent or transparent thermoplastic material, such as windows, lampshades, or illuminated signs, are made by affixing metallic lead strips to the surface of a thermoplastic sheet by means of solderable securing means such as lead bolts, lead rivets or molten lead inserted through an aperture drilled through the lead strip and at least part way into the body of the thermoplastic sheet, and then soldering to complete the joint. The lead strip may delineate and surround portions of a decoration such as a painting applied to one surface of the thermoplastic sheet so that the finished article may have the appearance of a leaded stained glass window. An additional sheet of transparent or translucent thermoplastic may be applied to the decorated surface so as to protect the decoration.

Abstract: A ceramic fiber module, suitable for lining furnaces, comprises a weldable (metallic or perforate refractory) backing and a number of ceramic fiber mats cemented to the backing by the edge of the mat, so as to leave a portion of the backing accessible between mats or on their perimeter, for welding. The weldable backing is welded to a metallic substrate, preferably by use of spherical attachments, to provide thermal protection to the metallic substrate.

Abstract: A ceramic-metal composite laminate capable of exposure to high temperature differentials without damage, consisting of an inner ceramic layer, an outer metal layer and an intermediate interface layer of a low modulus metallic low density structure having a high melting point. The ceramic layer is secured to the low modulus structure directly or through an intermediate ceramic-metal composite, and the outer metal layer is brazed to the intermediate low modulus layer. Thermal strains caused by a temperature differential between the inner and outer layers are taken up without harmful effect by the intermediate low modulus layer.

Abstract: An evacuated envelope having at least one ceramic component and one aluminum component sealed to one another along a common interface. A metallized layer is on said ceramic component along said interface and a fused solder having an Al-Si eutectic structure with 89% aluminum and 11% silicon is along said interface.

Abstract: A composite target for an X-ray tube has a graphite substrate portion and a metal portion, the two portions being bonded together by successive interspersed layers of platinum and tantalum. The platinum layer is disposed between the graphite substrate portion and the tantalum layer. The tantalum layer acts to bond the metal portion to the platinum layer and also acts as an isolator to prevent the formation of carbides by migration through the bonding layers.