Abstract: The present invention relates to a method for making an array of metal balls. The method includes the step of generating a first pattern on a metal foil which includes a plurality of foil projections. The method also includes the step of generating a second pattern on a carrier substrate. The second pattern includes a plurality of carrier recesses that are arranged and configured to correspond with the foil projections of the first pattern. The method further includes the steps of placing the metal foil and the carrier substrate together such that the foil projections of the metal foil fit within the carrier recesses of the carrier substrate, and melting the metal foil such that the foil projections form metal balls positioned within the carrier recesses of the carrier substrate. The invention also relates to metal ball arrays constructed via the above method.

Abstract: At the step of printing a wiring portion of a ceramic substrate with a conductive adhesive for mounting an IC chip or a part such as a capacitor other than the IC chip, a wire bonding pad made of gold is formed by the ball bonding method or the like at the portion of the wiring portion to be wire-bonded. After the pad was formed and before the conductive adhesive is printed, a heat treatment is performed to cause a thermal diffusion between the wiring portion and the pad to improve the jointability therebetween.

Abstract: Means of implementing production of an oxide superconductor joined member, excellent in electric current transmission performance, without a need of going through particularly complex steps, are provided. When joining together oxide superconductors by use of a solder composed of an oxide superconducting material, a finally solidified portion of the solder is positioned in a region where a transmission path of electric current flowing between oxide superconductor base materials as joined together is not obstructed by, for example, disposing the solder on a face of the oxide superconductor base materials, other than butting surfaces of the oxide superconductor base materials, so as to straddle both the base materials like bridge-building, or by, for example, shaping junction faces of the oxide superconductor base materials such that at least portions of the butting surfaces thereof are in the shape of sloped open faces, parting from each other.

Abstract: In a method for manufacturing a metallic or ceramic body constructed in layers from a real body elements, the a real body elements are cut out of a body material connected to a support material. Subsequently, the a real body elements are sequentially connected to a respective last applied layer of a real body elements of the body to be manufactured by a physical or chemical connecting process. After connection with the last applied layer, the support material is removed from the a real body elements.

Abstract: An apparatus and method for positioning a first piece relative to a second piece in a predefined position is disclosed. This apparatus has a tab and a slot. The tab projects from one of the first piece and the second piece and defines a preestablished configuration having a plurality of surfaces. The slot is positioned in the other one of the first piece and the second piece and defines a preestablished configuration having a plurality of surfaces. At least one of the plurality of surfaces of the tab and of the slot is defined by a generally arcuate configuration. At least one of the plurality of surfaces of the tab is in a frictional contacting relationship with at least one of the plurality of surfaces of the slot.

Abstract: A process for the production of a homogenized material of metals and alloys from a slab, and the material has a fine microstructure or fine nonmetallic inclusions and has less segregation of alloying elements.

Abstract: An explosive laminated cutting tool which provides a self sharpening edge. The improved cutting tool s preferably comprised of two softer metals adhered to a hard central layer forming the cutting edge, with the central layer being made of such a material as tungsten carbide. The central laminate layer is preferably perforated to allow the outer layers to fuse through the perforations to adhere to one another, thus creating a strongly bonded laminated cutting structure which may be self sharpening. A method for manufacturing the cutting tool is also described. Another embodiment comprises a laminate wherein one of the layers has a plurality of recesses in the surface facing another layer. The recesses are filled with particles such as tungsten carbide or diamond. When the layers are explosively welded together, the particles are fused in the weld area.

Abstract: A method for making a spacer assembly comprises: forming a plurality of projections along an edge of a portion of sheet metal; roll forming the portion of sheet metal into a tubular configuration; positioning the roll formed portion of sheet metal and a metal base member to which the roll formed portion of sheet metal is to be welded in a discharge welding apparatus having a pair of electrodes so that the projections of the roll formed portion of sheet metal contact a surface of the metal base member; providing a force so that the projections are disposed in forcible engagement with the surface of the metal base member; and supplying an electrical current between the pair of electrodes and through the roll formed portion of sheet metal and the metal base member so that the projections reach a molten metal stage and are subsequently solidified to enable the roll formed portion of sheet metal to be welded to the metal base member.

Abstract: The present invention relates to vibration damped laminate articles having improved force (torque and/or pressure and/or stress) retention and decreased or eliminated spring back. An area defining a through hole and/or the periphery of the article is welded. Methods of making the articles and fastening assemblies including the articles are provided.

Abstract: A method of metallurgically joining dissimilar metal tubes using a connecting member clad metal tube in which the clad metal is the same or similar metal to a metal of one of the dissimilar tubes to be joined and is susceptible to bonding by welding. The underlying clad metal connecting member metal is a dissimilar metal which is susceptible to bonding by soldering.

Abstract: Sections 1 and 2 each in the form of a welded pipe (square pipe) are provided. The sections 1 and 2 are brought into abutment with each other so that the respective end faces 3a and 3b abut each other at a predetermined angle .beta. between each section and its axial direction. The sections 1 and 2 are arranged symmetrically with respect to each other. Acute end portions of the abutted portion are chamfered to from a plane part. Corners of the sections 1 and 2 are rounded. In such a combined state of both sections, the abutted portion is welded in the circumferential direction to form a weld bead. As a result, penetration of weld metal to the section 1 and that to the section 2 become equal to each other. Thus, it becomes possible to fabricate a welded structure having a uniform weld bead and having improved strength and reliability of welded portions.

Abstract: This invention is directed to an improved bonded sputter target/backing plate assembly and a method of making these assemblies. The assembly includes a sputter target having side and bottom bonding surfaces bonded within a recess in an underlying backing plate, the recess having top and side bonding surfaces. The method of forming the bonded assembly includes treating the bonding surfaces of either the sputter target or backing plate recess by roughening at least a portion of the bonding surfaces so as to produce a roughened portion having a surface roughness (R.sub.a) of at least about 120 micro-inches. The method further includes orienting the sputter target within the backing plate recess to form one assembly having a parallel interface defined by the top and bottom bonding surfaces and a side interface defined by the side bonding surfaces, subjecting the assembly to a controlled atmosphere, heating the assembly, and pressing the assembly so as to bond the bonding surfaces.

Abstract: A chip component is manufactured through a step of burning a unburned unit element made of ceramics having prism-shaped parts at its ends, a step of polishing the edges of the burned unit element, and a step of forming a resistor conductor, an electrode conductor and a armor on the polished unit element.

Abstract: A fabricated gas turbine engine component and method of manufacturing. In one embodiment the component having a structural member with a cover member metalurgically bonded thereto. The bonding of the cover member being controlled by an apparatus that sequentially applies a substantially non-unifrom bonding load across the components radius of curvature. The patterns utilized in the casting process are formed in one embodiment to a precision preformed geometry by a closed die forming operation.

Abstract: The present invention relates to a method for making an array of metal balls. The method includes the step of generating a first pattern on a metal foil which includes a plurality of foil projections. The method also includes the step of generating a second pattern on a carrier substrate. The second pattern includes a plurality of carrier recesses that are arranged and configured to correspond with the foil projections of the first pattern. The method further includes the steps of placing the metal foil and the carrier substrate together such that the foil projections of the metal foil fit within the carrier recesses of the carrier substrate, and melting the metal foil such that the foil projections form metal balls positioned within the carrier recesses of the carrier substrate. The invention also relates to metal ball arrays constructed via the above method.

Abstract: A continuous hot rolling method is available for continuously hot finish rolling steel pieces. The trailing end of a preceding steel piece and the leading end of a succeeding steel piece are cut by a drum shear which sandwiches the steel piece between its upper drum and lower drum, having cutting blades on the peripheries of the drums. The cut ends are heated to raise the temperatures thereof by high-frequency induction heating, pressed against each other to butt-join the cut ends. The joined steel pieces are then supplied to a rolling equipment. The trailing end of the preceding steel piece and the leading end of the succeeding steel piece are cut individually by two pairs of the cutting blades. One pair of the cutting blades has the obverses of the blades oriented in opposite directions in the obverse side and the reverse side of the steel piece.

Abstract: This invention is directed to an improved method for making a bonded sputter target/backing plate assembly as well as assemblies produced therefrom. The assembly includes a sputter target having a bonding surface which is bonded to the bonding surface of an underlying backing plate. The method of forming the bonded assembly includes treating one of the bonding surfaces, either by roughening at least a portion of one of the bonding surfaces so as to produce a roughened portion having a surface roughness (R.sub.a) of at least about 120 micro inches, or by drilling a plurality of holes in one of the bonding surfaces. The method further includes orienting the sputter target and backing plate to form an assembly having an interface defined by the bonding surfaces, subjecting the assembly to a controlled atmosphere, heating the assembly, and pressing the assembly so as to bond the bonding surfaces.

Abstract: The invention features a method for flowing solder in a gap between two surfaces. A supply of solder is heated to cause it to reflow and flow in the gap. The solder is directed to flow as a main stream in the gap and to flow as peripheral streams from the main stream toward edges of the gap to reduce formation of voids.

Abstract: A composite thermal insulation structure particularly suited for gas turbine engine applications is disclosed. An aspect of the present invention includes a composite thermal insulation structure having a backing, a ceramic pile woven substantially perpendicular into the backing, and a ceramic matrix material infiltrated in the ceramic fiber pile.

Abstract: A method for manufacturing a large basically spherical vessel from plane aluminum plates having a thickness in the range from about 20 mm to about 70 mm, comprises (a) forming at least first and second plane plate assemblies by downhand welding together plane plates controlled by a welding device including an adjustably lockable portal, (b) cutting each welded plane plate assembly to a peripheral shape that fits into the structural pattern of the vessel except for an allowance for machining in step (d), (c) bending each plate assembly to part-spherical configuration, (d) machining respective edges of the first and second bent plate assemblies to a profile suitable for welding in step (e), and (e) downhand welding the first and second plate assemblies together along the machined edges using a manipulator device that includes a tiltable support.

Abstract: A method of repairing a joint between conductor elements of a stator winding bar of an electrical machine and a connecting device connected to an end of the stator winding bar for providing electrical connection and coolant flow for the conductor elements includes the steps of removing an existing connecting device from the end of the stator winding bar; aligning the conductors of the end of the stator winding bar by heating the bar end to above the flow point of the braze holding the conductors in position while simultaneously holding the conductors of the end of the stator winding bar under compression in two orthogonal directions perpendicular to the length of the stator winding bar; forming slots in the end of the stator winding bar and at locations such that the slots extend to locations where the conductor elements abut one another; applying an electrically conductive first connecting part onto the end of the stator winding bar such that the first connecting part substantially surrounds the end of the s

Abstract: A method of making an integral solder and plated cover for an electronic package is described which involves applying a corrosion resistant material onto a metal strip and a solderable material on the corrosion resistant material. A solder material is then roll clad over the solderable material after which it is stamped to covers which are then coated with gold.

Abstract: A method of manufacturing structural sheet metal products whereby a number of portions of sheet metal are fed simultaneously along concurrent planes so that the leading edge of one portion cooperates with a face of an adjacent portion along the plane of contact between the two portions; respective sheets are cut simultaneously off the portions; and the sheets are welded together along the respective planes of contact; cutting and welding being performed using laser heads.

Abstract: The method for repairing a connecting device for the electrical connection and for supplying and carrying away the coolant to and from the hollow conductor elements of the stator winding bars of electrical machines includes removal of the existing connecting device (2) from the bar end by inductive heating; cleaning the bar end in the region where the new connecting device is intended to be mounted; material-cutting machining the end surface of the bar end; introducing narrow slots (7) between adjacent conductor elements (1) into the end of the bar in the transverse and vertical directions; pushing on a first connecting part (2a) which is made of copper and completely surrounds the bar end; filling remaining gaps between the first connecting part (2a) and the outer surfaces of the bar end with copper foil and/or solder foil; filling the narrow slots (7) with copper foil and/or solder foil (10) or a combination of both; inductive heating of the first connecting part (2a) and of the bar end and soldering with t

Abstract: A process and apparatus for manufacturing structural steel metal products in which a strip of sheet metal is fed along a plane and cut by a laser into a number of sheets with each sheet secured to a respective supporting surface of a rotary work holder and welded by an additional laser to the previous sheet along a common edge.

Abstract: A method for the manufacture of a helix-coupled vane line consists in cutting out, in a part comprising at least one channel, successive slots through the channel that extend beyond the channel so as to obtain portions of turns each fixedly joined to a vane; cutting out, in another part, a succession of fingers that are all fixedly joined to each other; connecting the turn portions to the fingers so that one end of a turn portion is connected to one end of a first finger and the other end of the turn portion is connected to the base of a second finger adjacent to the first finger; and separating the fingers from one another at their bases. Application of helix-coupled vane lines. Is most notably for crossed-field amplifiers.

Abstract: In a method for making a joined pipe, a main pipe is cut so that two V-shaped edges of a right angle are formed in the diametrical positions on the periphery of the main pipe, and a branch pipe is cut so that two peaked edges of a right angle are formed in the diametrical positions on the periphery of the branch pipe. Then, the facets of the V-shaped edges and the peaked edges are fused by heating, and butt-welded under pressure.

Abstract: Method to implant defects in a metallic component, for the retraining and qualification of operators and in non-destructive test techniques. This method is characterized by the implantation of non-homogenious material directly in the model item and to do so excavations are made that, following implantation of the defects, are filled by a welding process.

Abstract: As preparation for the seam welding of different thickness sheet metal blanks (10 and 12), at least the thicker (10) of the two blanks is reduced in thickness, preferably by chip machining, in its edge region (11) which is intended for welding. Since the edge regions (11 and 13) which are to be welded then approximate to each other in their thicknesses (t1+t2), practically symmetrical conditions with regard to the joint plane exist for the welding operation, so that the welding can proceed with substantially the same controllable welding parameters as in the seam welding of sheet metal blanks of equal thickness. The process is suitable mainly for use in mash seam welding, but also in other seam welding processes, such as for example, in laser welding.

Abstract: In this invention, a back end portion of a preceding sheet bar and a front end of a succeeding sheet bar are cut in a transfer line at an entrance side of a finish rolling mill so that at least both side edge regions of these sheet bars are contacted with each other at a butted contact state thereof and a gap is formed between both end portions and then portions to be joined int he preceding and succeeding sheet bars are locally heated and pushed to join them while gradually enlarging a joining area, whereby the required time is largely reduced as compared with the conventional technique and also it is attempted to miniaturize the heating apparatus and shorten the length of the apparatus.

Abstract: In the continuously hot rolling of plural sheet bars, in order to simply and surely join the sheet bars to the back end portion of the preceding sheet bar and the front end portion of the succeeding sheet bar are prejoined by butting to each other at an entrance side of a finish rolling mill and then bitten into the finish rolling mill, during which the joining of the sheet bars are promoted to conduct the continuous rolling.

Abstract: A compact multilayer ceramic-to-metal seal structure, and method for manufacture, includes a ceramic core with opposed metallic surface layers. Between the ceramic core and each of the metallic surface layers is a transition zone which is made from graded layers of metallic and ceramic powders. These layers have progressively greater concentrations of metallic constituents than ceramic constituents the nearer the layer is to the metallic surface layer. Conversely, within the transition zone, the nearer a layer is to the ceramic core, the greater is its concentration of ceramic constituents. This seal is manufactured by simultaneously sintering a multilayer structure of compressed ceramic and metallic powders.

Abstract: A method of repairing a turbine blade comprising the steps of ascertaining a normal vibration characteristic of the blade, separating an outer end part of the blade from a residual inner part of the blade and subsequently securing a new end part to the residual part so that a joint between the new end part and the residual part is positioned in a predetermined relationship to said vibration characteristic.

Abstract: An improved method for making a composite tube (10) to a carbon steel tube (16) joint or a composite tube (10) to a carbon steel header (50) joint is achieved by specially preparing the composite tube (10) by removing the cladding (12) from one end (24) to a predetermined length to provide base carbon steel material (14). The end (24) of the composite tube has cladding (12) tapered at a predetermined angle. This end (24) is then expanded. The composite tube (10) is then welded to the carbon steel tube (16) with fewer weld passes while also eliminating the stainless steel weld pass.

Abstract: For a torsional vibration damper, whose working chamber, formed by an inner shell (17), an outer shell (19), a rear wall (15) and a cover (13) is provided to receive a seismic ring and viscous damping liquid (1), the housing body (1) bearing the working chamber is made by a metal forming process in a spinning lathe, starting from a round steel blank (17), which is clamped between mandrel bodies within the spinning lathe, and is split into two blank sections (31, 33) which receive the contour of the cylindrical inner and outer shell (17, 19) defining the working chamber (5) of the damper by subsequent forming.

Abstract: The present invention relates to a method of efficiently manufacturing a spotwise partial clad material, which is used for a lead frame of a semiconductor integrated circuit such as a flat package. According to the method, a substrate material to which metal foil pieces having a determined size have been tacked at a highly accurate pitch is prepared by continuously pre-tacking a metal foil as fed at a constant feeding rate to a substrate material as fed also at a constant feeding rate at determined intervals by spot-welding by any of resistance welding, ultrasonic welding or laser welding or thereafter cutting and removing the unnecessary parts by laser-cutting or by the use of rotary cutters, or alternatively, it is prepared by cutting a metal foil as fed at a constant feeding rate with a punch with simultaneously tacking the resulting metal foil piece to a substrate material as fed also at a constant feeding rate by spot-welding of using the punch as an electroconductive material part.

Abstract: A method is described for manufacturing a built-up sheet panel by forming a double flanged joint with raised flange edges between sheets arranged alongside of each other, which are then welded together by means of a driven welding carriage, the raised flange edges being shortened in accordance with the invention shortly in front of the welding.A welding carriage suitable for this purpose is provided on its lower side, in front of a welding device as seen in the direction of travel, with a parting device which is preferably developed as driven pair of cutting rollers. In this way in particular thin sheets can be assembled with excellent quality to form a sheet panel.

Abstract: Fusible sheet edges are joined by first forming each of the edges with a laterally projecting burr and then butting the edges together at a join line with both the burrs directed in the same lateral direction adjacent each other and plastically deforming the laterally projecting burrs at the join line in the lateral direction opposite their projection direction. Finally the edges are fused together at the join line. The burrs are plastically deformed by pressing them with a barrel-shaped roller that is moved along the join line.

Abstract: A first tube of rectangular cross section is joined to a second tube by notching the first tube on two sides to assure that the top and bottom walls of the first tube touch the rounded corner of the second tube at a central location to define a weld receiving groove and to eliminate the gap between the abutted tubes for repeatable, well defined welds. To avoid large fixtures and structural locators adjacent a weld location, a small tab is provided in the notched end of the first tube. An oversized laser-cut slot in the side of the second tube receives the tab and has one slot boundary precisely located with respect to a reference point on the second tube. The first tube is urged in the direction to force the tab against the boundary and positively locate the first tube with respect to the reference point.

Abstract: A metal patio chair has a seat frame made by the steps of providing a pair of seat rails in the form of elongated metal tubes, placing a mandrel inside each tube to reinforce the wall of the tube, punching a series of spaced apart holes in the wall of the tube while the mandrel contained in the tube holds the shape of the tube while punching out the holes, removing the mandrel, providing a plurality of metal slats having a cross-sectional shape to match the shape of the holes punched in the seat rail tubes, inserting ends of the metal slats in corresponding pairs of holes formed in the tubes to form a ladder type chair frame in which opposite ends of the slats are held captive in corresponding holes in the tubes, and are rigidly securing the slats to the seat rail tubes to lock the slats in palce in the tubes to provide a rigid seat frame structure elevated above the ground by a supporting sub-structure to which the finished seat frame is attached.

Abstract: A method and apparatus for selectively removing target sections from a continuous coil of sheet metal and connecting those sections to one or more sheet metal take-up winders. Depending upon the thicknesses or amount of defects in each detected target section, the corresponding target can be connected to an appropriate continuous sheet metal winder which therein contains a specific classification of sheet metal. Defects, such as errant sheet metal thicknesses, can be removed from a continuous coil and placed on a raw sheet metal coil separate from a finished sheet metal coil containing substantially no defects.

Abstract: An upper control arm for a vehicle suspension system having a modulus section of hollow construction for reduced weight. The modulus section of the control arm is of a stamped and welded construction thereby eliminating material weight while reducing the cost of manufacturing. The modulus section has a substantially triangular configuration with a reinforced rim flange along the high compression stream area of the control arm elbow. The reinforced rim flange improves the strength of the control arm without sacrificing the weight reduction provided by the hollow construction.

Abstract: A flywheel assembly adapted to act also as a high inertia journal bearing in a canned pump or the like is composed of an annular core of heavy metal material which is hermetically sealed in a stainless steel casing formed by a number of enclosure pieces welded together along circumferential weld edges. The weld edges are specially configured by mating weld canopies provided on the respective pieces which minimize the potential for damage to the annular core during welding, and which act to minimize stress concentrations due to the welds and thermal expansion of the casing. An outer cylindrical shell of the casing is heat shrunk onto the outer core and grooves are provided in the outer surface of the annular core to axially secure the outer enclosure member to the core, and to ensure that thermal expansion of the cylindrical shell occurs substantially equally in each axial direction of the shell. The flywheel assembly includes radial and axial bearing surfaces provided on the outer casing.

Abstract: A method of manufacturing cooled aerofoil blades in which blade parts are bonded together to provide complete blades. The blade parts are provided with mating surfaces which are simultaneously spark erosion machined to match the same prior to the blade parts being brazed together. Spark erosion machining is performed by maintaining the mating surfaces to be matched at a constant distance apart from each other and translating a tensioned wire electrode along a path passing mid-way between the mating surfaces.

Abstract: A method for shear forge bonding two or more metal parts having forging compatible compositions is comprised of the steps of sizing parts to be joined across a forged bond line, disposing those parts in forging dies configured to present them in a bonding-effective orientation, shearing surfaces, one on each of the metal parts, located proximately and opposite one another across a gap, under controlled conditions of temperature and atmosphere selected to prevent the formation of any bonding disruptive surface contamination on the sheared surfaces, and then finally forging those parts to close the gap and bring the sheared surfaces into contact under controlled conditions of temperature, pressure, atmosphere, and outer diameter constraint to yield a shear forged bond between the sheared surfaces.

Abstract: The present invention provides a method and apparatus for making joists. The chord members of the joists consist of two pairs of spaced apart angle irons, and the web portion of the joists consist of a plurality of linear metal bar lengths. Under a computerized control, the pairs of angle irons are spaced from one another by a predetermined distance depending on the design characteristics of the joist to be made, and the metal bar lengths are individually selected and cut to provide a metal bar having a specified diameter and a specified length, after which each of the metal bars is selectively positioned, in sequence, between the two pairs of angle irons, and then each end of each metal bar is automatically welded to the angle irons in a predetermined sequence.

Abstract: In a continuous hot rolling system, at least one melt-cut torch is set in a predetermined positional relationship with respect to a trailing end of a preceding hot material and a leading end of an adjacent succeeding hot material. An injected flow of cutting gas from the melt-cut torch is blown against a portion of at least one of the trailing end of the preceding material and the leading end of the succeeding material to melt-cut the portion. The portion extends from an end surface of the one end over a predetermined length. The trailing end of the preceding material and the leading end of the succeeding material are forced against each other and are butt-joined to each other. By doing so, there are produced joining surfaces superior in surface accuracy and high in temperature, to allow joining to be high in accuracy and strength. This joining may be made with respect to slabs before rough rolling, or may be made with respect to bars after rough rolling.

Abstract: A method for making monobloc points for a transporation rail is disclosed. The points include a profiled body having a groove for housing a point rail. The method includes selecting a steel bloom having dimensions at least equal to the outer dimensions of the body and machining the steel bloom to define the profiled body.

Abstract: Brake shoe ribs are formed in a continuous strip stock utilizing a method to decrease the amount of trim stock. The strip stock is selected to have a width approximately equal to the maximum dimension between the ends of a rib to reduce trim stock along the edges of the strip. Each rib is formed with a pair of notches in an outer periphery and the ends of an adjacent rib extend adjacent the notches to reduce the amount of trim stock between the ribs. A brake shoe table is attached to the outer periphery of a rib by continuous welding along both sides of the rib even across the spaces defined by the notches and a brake lining is attached to an outer surface of the table.

Abstract: In a method for producing workpieces of metal having profiled outer and/or inner contours which have any desired shape contours and are or can be profiled in thickness, the workpiece (R) is to be divided in terms of construction into simple part-profiles (4, 7, 13, 14), which are then produced by precision blanking and then fitted together and joined to one another by lamination to form the finished part.