Abstract: A preform and method for forming a structural assembly are provided. The preform can be formed by friction welding structural members to a base member and subsequently providing a connection material to join the structural members. The resulting preform can be formed with dimensions and a configuration that approximate the dimensions and configuration of the structural assembly. Thus, the structural assembly can be formed by joining multiple members that are generally smaller than the finished assembly.

Abstract: A method an apparatus for a gas turbine compressor rotor is provided which offers improved characteristics to the rotor when used with at least titanium IMI 834. Mechanical work is optimized through forging to provide at least improved low cycle fatigue life to the part.

Abstract: A method and apparatus are described for making a coldplate. A first component of, for example copper, is explosion welded to a second component of, for example aluminum. The first metal component has a top surface opposite the second metal component and at least one channel proximate the top surface adapted to carry a cooling fluid. The coldplate can be used as an interior wall for a plasma chamber.

Abstract: After copper plates 14 are bonded to both sides of a ceramic substrate 10 via a brazing filler metal 12, UV curing alkali peeling type resists 16 are applied on predetermined portions of the surfaces of the copper plates 14 to etch undesired portions of the copper plates 14 to form a metal circuit portion. While the resists 16 are maintained, undesired portions of the brazing filler metal 12 and a reaction product, which is produced by a reaction of the brazing filler metal 12 with the ceramic substrate 10, are removed (or undesired portions of the brazing filler metal 12 and a reaction product, which is produced by a reaction of the brazing filler metal 12 with the ceramic substrate 10, are removed, and the side portion of the metal circuit portion is etched). Thereafter, the resists 16 are peeled off, and an Ni—P electroless plating 18 is carried out.

Abstract: A method of forming a sputtering target is described that involves bonding a backing plate onto a casement having one or more recesses that contain target material to form a bonded target. During the bonding process, the bonded target is optionally vacuum sealed within the recess. The bonded target is then optionally annealed while under vacuum to form an annealed sputtering target. The sputtering target can then be retrieved by removing at least a portion of the casement from the sputtering target in one or several steps. Also described is a casement having one or more recesses containing bonded target material that is optionally vacuum sealed in the casement. The casement, as well as the backing plate that is optionally bonded onto the casement, are further described as well as other options and methods.

Abstract: A method for fabricating devices in a pre-assembled state comprising forming plural laminae, registering the laminae, and bonding the laminae one to another is described. The plural laminae contain the substructures and structures of the device. The substructures are coupled to structures and other substructures by fixture bridges in the pre-assembled state. The substructures of the device are dissociated by eliminating the fixture bridges. The plural laminae are registered and bonded to form the device either before or after the fixture bridges are eliminated. The fixture bridges can be eliminated in a variety of ways, including vaporization by electrical current, chemical dissolution, or thermochemical dissociation. One method to selectively bond the laminae together is by microprojection welding. Microprojection welding comprises forming laminae with projections that extend from at least one planar surface of the lamina.

Abstract: A method of constructing a preform for use in forming a machined structural assembly is provided. The method includes determining the dimensions of the machined structural assembly. First and second structural members are selected based on the predetermined dimensions of the machined structural assembly. The first structural member is positioned adjacent the second structural member so as to define at least two contact surfaces. The contact surfaces of the first and second structural members are friction welded to construct the preform such that the preform has dimensions approximating the dimensions of the machined structural assembly to thereby reduce material waste when forming the machined structural assembly. A machined structural assembly having predetermined dimensions is formed from the preform by machining away excess material.

Abstract: The invention relates to a method of connecting workpieces which is suitable notably for connecting an anode rod (5) to an end plate (6) of a rotor sleeve (7) in a rotary anode X-ray tube where on the one hand adequate strength is required and on the other hand an as small as possible cross-section of the anode rod so as to realize a heat barrier. The method is characterized mainly in that the objects are connected to one another by friction welding and that the cross-section is reduced, that is, outside a connecting zone in which the friction weld is situated, in such a manner that the strength of the connecting zone is at least slightly greater than that of the segment of reduced cross-section.

Abstract: By pressing a wiping member 37 of a wiper 33 onto a concave curved surface 28 and an upper side flange portion 30 of a squeeze roll 8, spatter is wiped off by the rotation of the squeeze roll. In the wiper 33, the wiping member 37 is fixed to a base plate 36 that is linked via a rotatable arm 35 to a shaft body 34. The wiping member 37 is formed from flannel and an anchor member 39 is provided on the base plate 36 on which the wiping member 37 is fixed. The anchor members 39 of a pair of squeeze rolls are linked under tension by a coil spring 40 so as to press the wiping members 37 against the concave curved surfaces 28. A cooling tube 42 for discharging cooling water is provided to the rear of the squeeze roll in the rotation direction of the squeeze roll.

Abstract: A wire bonding technique applied to wafer bump and wafer level chip size package structure and the method of manufacturing thereof comprising under no repassivation layer and without an under bump metallurgy layer, direct forming metal bump on a metal pad of a wafer surface, ball bump, method being employed to form metal bump, and wire bonding of ultrasonic vibration being used to join a suitable metal wire on the metal pad, next pulling off the metal wire and leaving the metal bump, the height of the metal bump is controlled by the parameters of the type, diameter and wire bonding of the metal wire; planarizing the metal bump of all wire bonding to an appropriate height using metallurgical tools; implanting solder bump by means of implant ball or solder printing technology on the metal bump, and an under bump metallurgy layer being formed on the top face of the metal block by means of metal deposition method in case an unfavorable intermetallic compound is formed between the metal (used for the metal bump) a

Abstract: A solder ball arrangement device has a thin arrangement plate having a plurality of through-holes of a truncated pyramid shape, a porous member bonded to the arrangement plate, and a housing member for receiving the arrangement plate and the porous member for defining an air space inside the housing member. A suction pump is provided to evacuate the air space and to receive an array of solder balls in the through-holes by suction. The through-holes are formed by etching, and the porous member reinforces the thin arrangement plate.

Abstract: In the present invention, by the method using a backing material such as copper, which is not melted by a welding heat source, in an end face of a member without using a backing metal or consumable backing material at a joint welding time, overlay welding is performed to increase a plate thickness and a plate width. Thereafter, edge preparation including a member of a designed joint weld location and an overlay weld is performed, and the groove processed portion is placed to an opponent member to provide joint welding in order to obtain an effective throat depth more than a plate thickness and a plate width of the member.

Abstract: A method and assembly useful in metal joining processes is disclosed which blocks the deposition of molten metal in openings. The method and assembly employs mica material with a binder to block the flow of molten metal. In one detailed embodiment, the mica material supports elements of the articles being brazed.

Abstract: A weld bead chopper is provided, for use in combination with a scarfing tool which is intended to scarf a longitudinal weld bead from a tube. The chopper has a) a chopper blade which is rotatable about an axis which is substantially perpendicular to a longitudinal axis of the tube, and b) a stationary blade which is cooperable with the rotatable blade. The cooperating chopping surfaces of the rotatable and stationary blades are at a short distance from the weld bead, e.g. less than 100 mm, and preferably from 20 to 50 mm. The scarfed weld bead enters an enclosed throat which has walls to guide a scarfed weld bead towards the cooperating chopping surfaces. The throat has a first guide adjacent to the scarfing tool which directs the scarfed weld bead towards a second guide. The second guide faces the scarfing tool, and is adapted to guide the scarfed weld bead towards the cooperating chopping surfaces.

Abstract: The present invention relates to a method for manufacturing a tubular medical device for insertion in a body. The method includes the step cutting a plurality of cross-sectional pieces or layers from a flat sheet. The pieces are cut so as to define inner apertures. The pieces are then aligned generally along an axis such that the pieces are arranged to form an elongated structure having an interior lumen extending longitudinally therethrough. Finally, the aligned pieces of the elongated structure are connected together such that each interconnected piece forms a layer of the tubular medical device.

Abstract: Platelet assemblies are formed from bondable platelets, such as diffusion-bondable, brazable, or adhesive-bondable platelets, with void regions in the platelets to form channels or open spaces in the finished platelet assembly. To improve the response of the platelet assembly to pressure bonding as well as to post-bonding fabrication processes such as forming, machining and welding, the void regions are filled with a sacrificial material which transmits the load of the applied pressure in the same manner as the remainder of the platelet, and yet which is removable from the finished platelet assembly by either thermal or chemical liquefaction after all potentially damaging fabrication procedures have been performed on the platelet assembly.

Abstract: A method of producing a leadframe for use in semiconductor devices, comprises the steps of forming a space between leads 1a and 1b which are to be overlapped and welded each other, and welding the leads at a region including the space and melting and cutting off one of the leads. In one of the leads which is melted, cohesion and separation of molten metal occur in the region around the space. As a result, unnecessary portions such as an outer frame used for positioning can be cut off at the same time when the leads are connected by welding. Thus, high precision positioning of a plurality of element leadframes as well as high assembling productivity are achieved.

Abstract: In a method and apparatus for forming a three-dimensional object, successive layers of metal are welded together to build the object. After each layer is formed a complementary material is placed adjacent the layer. In this manner, layers of material form a block of welded metal and complementary material. Then, all or a portion of the complementary material which serves as a support structure during forming can be removed. The welded layers are milled to a final shape either after each layer is formed or after all layers have been made. Existing CNG machines can be easily modified to practice the method.

Abstract: A method of mounting an integrated circuit carrier (10) having a plurality of straight leads (12) retained by an integral frame (16) is provided. The plurality of straight leads (12) of the carrier (10) is bent to form a plurality of bent leads (12) still retained by the frame (16). The plurality of bent leads are then scored to form a notch (32) on each bent lead. Solder fluxing, placing, and reflowing the plurality of bent leads of the integrated circuit carrier against corresponding printed lines of the printed circuit (26) surface before each notch follow. Finally, a remainder portion of the plurality of leads from and including the frame (16) to the notch (32) on each lead (12) is removed.

Abstract: A connector (10) having one or more arrays of elongate arms (22) of contacts (20) having contact sections (26) on free ends (24) thereof to be soldered to respective traces (94) of a circuit element (90), facilitated by securing a soldering component (40) to free ends (24). Component (40) includes a block member (42) along the outer surface of which is secured a lead frame (60) which includes a corresponding plurality of fingers (66) extending transversely from an elongate body section (62). Block (42) is of thermally insulative material having solder resistive surfaces. On the finger ends (68) are affixed preforms (88) of solder; on body section (62) is defined a thin magnetic layer, transforming the brass carrier strip into a Curie point heater.

Abstract: The present invention provides an improvement in a color picture tube having an inline electron gun with coma correction members therein. The gun includes at least two electrodes that form a main focusing lens and a shield cup interconnected to one of the main focus electrodes. The improvement comprises the coma correction members being attached to the outside surface of the shield cup facing the main focusing lens electrodes. In a method of attaching the coma correction members to the shield cup, the members are provided as one of a plurality of sets of members in a continuous strip. One set of members are placed against the outside surface of the bottom of the cup and welded thereto. Portions of the strip that are not part of the welded members are broken-away from the welded members.

Abstract: A method of manufacturing a color screen structure for a CRT. The color screen structure comprises a frame consisting of a pair of parallel supporting members and a pair of connecting members interconnecting the pair of supporting members at the opposite ends thereof, and a color screen member provided with a plurality of parallel slits in the color screening region thereof, a pair of slots formed outside the color screening region respectively alongside the opposite outermost slits, and a pair of grooves previously formed respectively along lines corresponding to the outer upper edges of the supporting members of the frame. The color screen member is welded to the supporting members of the frame so that the grooves extend respectively alongisde the outer upper edges of the supporting members, and then the unnecessary portions of the color screening member are torn off along the grooves.

Abstract: The front of a new steel strip is welded to the tail of a strip being formed in a continuous pipe mill or the like at an improved splice station. The ends of the strips are sheared to match and are clamped on a carriage movable in the longitudinal direction of the strips. A pair of pinch rolls downstream from the carriage for holding the tail of the strip in the mill can be translated in a direction transverse to the strip for aligning the tail with the front of the new strip of metal. Movement of the pinch rolls and carriage bring the ends of the strips into alignment and abutment. An automatic welder on the carriage butt welds the seam between the ends of the strips. A milling cutter traverses across the welded seam for removing excess weld bead to prevent damage to rolls in the forming mill.

Abstract: In a method for producing a clad plate by rolling an improvement comprises: a base material, a cladding material, and a cover material overlaid one on another to form a multi-layer structure, and after cleaning joining surfaces of the materials, the cover material is welded to the base material along the periphery thereof, thereby sealing and fixing the cladding material between the cover material and base material, and forming a multi-layer assembly. A member for preventing warp is overlaid over an outer surface of the cover material via a separating agent, and the member for preventing warp and the base material are fixed to one another by welding along the periphery thereof, thereby forming a blank for rolling. The blank is hot-rolled, a rolled article is cut along its periphery to separate the means for preventing warp, and subsequently, the cover material is removed by machining, grinding, or pickling.

Abstract: A method of manufacturing a fluidic angular rate sensor of the type wherein fine wires, such as tungsten wires, are mounted in tension over the heads of two pairs of spaced apart metal supports which are mounted on a ceramic disc having fluid passage apertures therein, comprising plating gold on the wires; fixedly mounting the wires between the spread apart metal supports by means of thermocompression bonding or the like; and heating the mounted gold plated wires in a predetermined atmosphere for removing the plated gold from the wires and to recrystallize the wires.

Abstract: A method and apparatus for constructing an electrical contact including welding means for welding a base element to a blank comprised of contact facing material, separating means for separating finished electrodes from the balance of the contact facing material, examining means for examining an aperture formed within the contact material blank when the finished electrode is separated from the blank, and classifying means for classifying the finished electrode as acceptable or unacceptable depending upon the examination.

Abstract: The invention concerns a process for assembly of the end of a girder (16,18',18",20', 20"and the associated region of a crossbrace (10,12), constituting components of the chassis end of a railway vehicle, with the girder and crossbrace each comprising at least one vertical web and upper and lower flanges. According to the invention, the flanges of the girder are cut away such that its web extends longitudinally beyong the edges of the flanges. Then the flanges of the crossbrace are cut so as to form attachment journals with free edges adapted to the respective free edges of the flanges of the girder, at the same time, forming in the region of the free edges, hook-shaped lateral appendages. The crossbrace and girder are positioned so that the respective free edges of the flanges of the crossbrace and the girder essentially abut one another, and the girder and crossbrace are welded together in the regions of mutual contact.

Abstract: A turbine blade spar wall surrounds a coolant plenum of the blade and is cast with an intermediate thickness exceeding its final or design thickness. The outer surface of the spar wall is machined to form a plurality of incomplete holes extending to bottoms located at the final thickness dimension of the spar wall. A pre-formed sheath of porous metal is fit closely around the spar wall outer surface with coolant pores in the sheath communicating with the incomplete holes. A high pressure inert gas is introduced into the coolant plenum concurrently with application of compressive forces to the sheath as both the sheath and the spar wall are raised to a high temperature whereby the sheath is diffusion bonded to the spar wall. The inert gas pressure in the coolant plenum reinforces the spar wall against the compressive forces.

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: 1. A method of making a fuel-containing structure for nuclear reactors, comprising providing an assembly comprising a plurality of fuel units; each fuel unit consisting of a core plate containing thermal-neutron-fissionable material, sheets of cladding metal on its bottom and top surfaces, said cladding sheets being of greater width and length than said core plates whereby recesses are formed at the ends and sides of said core plate, and end pieces and first side pieces of cladding metal of the same thickness as the core plate positioned in said recesses, the assembly further comprising a plurality of second side pieces of cladding metal engaging the cladding sheets so as to space the fuel units from one another, and a plurality of filler plates of an acid-dissolvable nonresilient material whose melting point is above 2000.degree. F.

Abstract: The novel electron gun comprises, as in prior guns, a plurality of cathode assemblies and at least two spaced successive electrodes having aligned apertures therethrough for passage of a plurality of electron beams. The cathode assemblies and the electrodes are individually held in position from a common ceramic member. The ceramic member has a first major surface and an oppositely disposed second major surface with a metallized pattern formed on at least a portion of each major surface. The electrodes are attached to the first major surface, and the cathode assemblies are attached to the second major surface. Unlike prior guns, a first transition member is attached to the metallized pattern on the first major surface. At least one of the electrodes is attached to the first transition member.

Abstract: It is known to apply coatings which have desired characteristics, e.g., wear resistance, thermal barrier capabilities anti-oxidation, to articles the material of which does not have the desired characteristic, wherein the coating is applied directly to the article. Some article materials, e.g. titanium are highly reactive which immediately obviates several known methods of applying coatings. The invention uses a member (12) which would normally be preformed to mate with the article surface to be coated. The member (12) is manufactured from cheap, non-reactive material, as a base to which the coating (14) is applied by the most suitable of any of the known means. The member (12) is then placed against the article with the coating (14) therebetween and the whole hot isostatically pressed. The member (12) is afterwards removed, e.g. by machining or etching.

Abstract: Methods for manufacturing components having internal flow passages in which an insert composed of a carrier and passage-forming and/or flow controlling elements is sandwiched between or installed in elements of the component. The insert associated and component elements are then bonded together and the carrier subsequently leached away to complete the formation of the flow passages.

Abstract: A heat exchanger such as a radiator for an automotive engine is produced by fixing lengths of flattened tubes and corrugated fins to each other by brazing within a furnace. The flattened tube is formed by bending a strip and welding the opposing edges of the bent strip to each other to form a tube of a substantially circular cross-section, and applying pressure to the tube along the weld line to form the flattened tube while depressing the tube wall along the weld line to form an elongated recess or groove along the weld line. Then, a brazing material is applied to the outer surfaces of the flattened tube to cover and fill up any minute weld defects which may exist in the flattened tube whereby the weld defects are repaired.

Abstract: A connecting rod for a radial piston motor including a spherical surface portion, a rod portion and a pad portion having a sliding surface. The spherical surface portion, rod portion and pad portion are formed integrally, and the sliding surface has a bearing alloy attached to its surface by centrifugal casting. An overlay may be provided on the bearing alloy. The connecting rod is produced in a mass production basis by a method including the steps of integrally forming a star-shape cylindrical monolithic blank (18) having a single cylindrical centrally located axial opening and bearing six equally spaced outwardly radiating rod portions (2), each rod portion bearing an integral, substantially spherical surface portion (1) on its distal end; attaching a bearing alloy by centrifugal casting, to the centrally located axial opening in said blank (18); machining the surface of the bearing alloy; and dividing the blank into six pieces constituting six connecting rods.

Abstract: An electrical assembly includes a conductor pattern, a non-metallic substrate, and a eutectic alloy situated between and bonding together the conductor pattern and the substrate. The conductor pattern includes an area with a surface facing the non-metallic substrate but spaced from the substrate. A method of fabricating such assembly includes, prior to bonding, the step of partially penetrating through the side of the metallic sheet to be bonded to the substrate in selected areas of the sheet. The remaining metal of the sheet in each selected area does not bond to the substrate during a eutectic bonding procedure.

Abstract: Applicant's invention relates to a process and apparatus for the high speed welding in large quantities of various geometric shaped jump rings to buttons, pendants and other jewelry by utilizing composite jump ring apparatus having first and second projections extending from the jump rings at different locations so that they may function in automatic welding machines.

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 method of providing a raised contact portion on a contact area of an electronic microcircuit in which a ball is formed at one end of a metal wire by means of thermal energy, the ball is pressed against a contact area of the electronic microcircuit and is connected to said contact area. A weakening is created in the wire near the ball and the wire is then severed at the area of the weakening to provide the desired raised contact portion.

Abstract: To permit accomplishment of wire bonding at a depth that precludes the use of the conventional clamp adjacent to the bonding tool, a new tool is provided which includes a means for preventing bowing of the wire and a method of using such a tool which substantially obviates any need to feed wire by pushing. The bond is completed at the second circuit point after a special motion which pays out a length of wire sufficient to maintain a loop of wire between the first and second bond points. Another special motion breaks the wire after the second bond and positions and shapes the wire end for making another initial bond.

Abstract: Methods of forming a conductor pattern including fine conductor runs direct bonded, using a eutectic composition, to a ceramic substrate are disclosed. These methods provide grooves in the side of a metallic sheet to be bonded to the ceramic substrate, the grooves serving as vent passages for any otherwise entrapped gas between the metallic sheet and the ceramic substrate.

Abstract: A method of manufacturing metallic objects having thin walls and comprised of corrosion resistant materials. The method has the consecutive steps of forming a workpiece in the shape of the desired end product from a metal having a low resistance to an etchant, forming within a surface of the workpiece a metallic alloy case resistant to the etchant and etching the workpiece with the etchant.

Abstract: Method for welding fine wires to connecting terminations born by the base of a semiconductor device, using a tool for welding and cutting the wire in the form of a tube (9) which acts by its end face (11) containing the wire (12) to be welded, of which the outer strand (13) is to be welded to the termination (6), an incipient rupture (16) being formed by the inner angle (17) of the tube, and a limited flattening (H) being obtained by contact (40) between part of the end face of the tube and the termination, the value (H) being determined by the choice of an angle (P) created between the termination (6) and the end face (11) of the tube.

Abstract: A method of fabricating an improved multiple grid electrode having a plurality of discs by simultaneously forming a dimpled segment in a sandwich structure consisting of metallic discs separated by spacer material. The dimpled sandwich structure is then machined, forming a series of vanes on the dimpled portion by an appropriate method, such as electrical discharge. After machining, the spacer material is etched away, leaving only the vaned discs, forming grid electrodes.

Abstract: A method of making rotor blades of radial-axial hydraulic machines, wherein a plain blade blank is obtained by welding together at least two sheet pieces that compose the blank in the direction of principal variation of the cross-sectional thickness thereof. The thickness of each of said sheet pieces is selected to be not less than a maximum cross-sectional thickness of the blank at its portion defined by said sheet piece. Then the blank is machined until the required blade outline is obtained, after which the blade blank bent to obtain the desired blade shape.

Abstract: A process is disclosed for the manufacture of solid electrolytic capacitors wherein sintered anode elements with their anode wires are attached to a clamping fixture. In a further step a notch is formed in the anode wires. After bending of the anode wires the anode input wires which are held in an additional fixture are welded on in overlapping fashion. The notch acts as a designed fracturing or breaking point for the final separation of the capacitor elements. It is expedient to design the anode input wires to have a section expanded to form a roof like shovel.

Abstract: A process for producing articles of jewelry, trinketry and the like, such as rings, necklaces, bracelets and the like starting from a composite tubular element made of different elements, characterized by the fact that it comprises the following steps of:Drawing a plurality of hollow tubular elements, each made of a metal of a different color or color tonality and each having an outer diameter slightly less than the inner diameter of another of said elements, while the element of the smallest outer diameter has a solid cross section;Inserting said tubular elements into each other in order to obtain a multi-layer composite tubular element having adjacent layers of different colors or color tonalities;Drawing said composite multi-layer element until the various adjacent tubular components perfectly adhere to each other;Cutting sections of the desired lengths from the composite elements obtained in preceding the step;Shaping each length of said composite element according to the desired configuration, optionally

Abstract: The wire, ribbon, or the like, is repetitively bent back and forth until it breaks, the bending being, preferably, effected rapidly, for example by means of an electromagnet fed, for example, with line frequency alternating current. The wire is guided in a guide tool which deflects the wire transversely to its axis rapidly back and forth, thus effecting breaking within about one second of application of bending stresses. This is particularly useful to sever tiny wires, in the order of 100 .mu.m diameter, as connecting leads in semiconductor and thin film technology.

Abstract: A process for thermocompression bonding a copper wire lead to gold film on alumina ceramic substrate by use of a gold interface. The three step process involves: (1) thermocompressing a gold lead with a die-formed head to the gold film, (2) removing the gold lead to form a gold die-formed head bonding pad, and (3) thermocompressing the copper lead to the gold die-formed head bonding pad.

Abstract: A method of manufacture of an annular seal element comprises the steps of providing an apertured backing ring with closely packed bristles extending radially outwardly from the circumference thereof, clamping the free ends of the bristle between a pair of co-axial rings and welding the rings and the outermost tips of the bristles into a unitary structure and subsequently machining away the original backing ring to leave the rings with radially inwardly extending bristles.The invention also includes a sealing element made by the method.