Abstract: A method for wafer bumping includes the steps of spreading a layer of an electrically conductive paste on a surface having a plurality of electrical contacts and exposing a beam-paste interaction volume to a beam of energy to bond a portion of the layer of the electrically conductive paste to at least one of the plurality of electrical contacts for forming a wafer bump.

Abstract: Selectively reinforced blanks are used in a hydroforming process to produce completed components having a predetermined shape and sufficient structural integrity to perform their desired function. To reinforce those components, reinforcing patches are added to the blank prior to hydroforming. Planar patches can be bonded to planar blanks or arcuate patches can be bonded to tubular blanks. In so doing, the hydroforming process produces a complete component, which does not require additional manufacturing steps to reinforce it. Additionally, by selectively using the reinforcing patches, the overall weight of the component is not unduly increased.

Abstract: An improved method for mounting tape carrier package type integrated circuits on printed circuit boards. In the method, some of leads of the integrated circuit are preliminarily soldered with corresponding lead pattern on the printed circuit board after the integrated circuit is aligned on the printed circuit board so that the integrated circuit is prevented from being disordered while the printed circuit board including the integrated circuit aligned thereon is transferred to a soldering apparatus.

Abstract: A punching pin of a soldering apparatus cuts out a solder piece from a solder plate onto a feeder pin, and the feeder pin presses the solder piece against a predetermined junction of a conductive wiring pattern incorporated in a printed circuit board; then, an electric circuit component is mounted on the printed circuit board, and is strongly soldered to the conductive wiring pattern, because the punching pin and the feeder pin supply a fixed amount of solder to the predetermined junction.

Abstract: In a soldering method for soldering a thermit case 26 and a pair of bus bars 11a, 19a to be electrically connected to the thermit case 26, a portion to be heated P of the thermit case 26 which is spaced from the respective bus bars 11a, 19a by an approximately equal distance is heated by a gas burner 71, and solders are simultaneously supplied from solder wire supply portions 75a, 75b to a pair of solder joining faces 22 for joining the thermit case 26 and the pair of bus bars 11a, 19a, after the portion to be heated P has been heated. The temperatures of the pair of solder joining faces 22 are made substantially equal to each other by heating the portion to be heated P so that solders are simultaneously supplied to the pair of solder joining faces 22.

Abstract: A vacuum-tight cable feedthrough device includes a metallic first flange that is penetrated by a slot. Passing through the slot is a flat stripline cable that includes a plurality of conductive signal channels encompassed by a dielectric material on whose upper and lower surfaces is disposed a conductive material includes a ground. The stripline cable is sealed within the slot to provide a substantially vacuum-tight seal between the cable and the first flange. In a preferred embodiment, the cable feedthrough device includes a plurality, at least 16, of stripline cables. In a further preferred embodiment, the device includes a second flange and a bellows sealably connecting the first and second flanges, thereby providing a substantially vacuum-tight, flexible housing for the plurality of cables.

Abstract: A method of bonding two pieces of metal having a foil or layer of another metal, either of lower melting point or such that it forms a liquid layer at or near to the bonding temperature, disposed therebetween. The method comprises the steps of: bringing the pieces into contact; applying pressure across the area of contact; heating the area of contact; and providing a predetermined temperature gradient across the area of contact.

Abstract: A high strength ternary lead-free solder alloy, solder paste and method. The alloy consists essentially of a major portion of tin, from in excess of 5 wt % bismuth to 25 wt % bismuth and 2 to 5 wt % silver.

Abstract: The present invention is directed to a high density test probe which provides a means for testing a high density and high performance integrated circuits in wafer form or as discrete chips. The test probe is formed from a dense array of elongated electrical conductors which are formed by cutting with one or more blades. The shape of the blades determines the shape of the probetips. The probetips can be coated with other conductive materials to enhance the hardness and profile of protuberances formed at the probetip ends by the blade-cutting process. The wires are as dense as the contact location array. A mold is disposed surrounding the array of outwardly projecting wires. A liquid elastomer is disposed in the mold to fill the spaces between the wires. The elastomer is cured and the mold is removed, leaving an array of wires disposed in the elastomer and in electrical contact with the space transformer.

Abstract: For the manufacture of a metallic honeycomb body which is wound, layered or looped from at least partially structured sheet metal layers, it is proposed to provide at least the structured sheet metal layers with a layer of rolling oil, to the extent that this is not already present in the process for manufacturing the sheet metal layers. A step for partially thermally removing highly volatile components of the rolling oil can follow. The honeycomb body manufactured from the sheet metal layers is brought into contact with a brazing powder which remains adhered to the rolling oil in particular in the area of the contact lines between the sheets. The honeycomb body is subsequently subjected to a brazing procedure in a high temperature brazing furnace under vacuum or a protective gas.

Abstract: A method for connecting first and second bonding points with a bonding wire that passes through a capillary comprising the steps of: bonding a ball formed at the end of the wire protruding from the capillary to the first bonding point; raising the capillary; moving the capillary toward the second bonding point so that the capillary is first lowered to a point that is slightly on the first bonding point side of the second bonding point, and a portion of the wire suspended from the capillary is pressed against a horizontal surface located between the first and second bonding points; raising and moving the capillary to a point above the second bonding point, and lowering the capillary so as to bond the wire to the second bonding point.

Abstract: A method of making an electrically conductive contact on a substrate by applying a layer of solder paste to a circuitized feature on a substrate and selectively heating and melting the solder paste over the feature to form a solder bump. The excess solder paste is removed. A focused energy heat source such as a laser beam or focused Infrared heats the solder paste. In another embodiment, a reflective mask with apertures may be used to allow focused heating source to selectively melt areas of the solder paste layer applied to a circuitized feature. In yet another embodiment, a reflective mask with apertures filled with solder paste is applied onto a substrate and then heated to cause localized solder melting. The mask and excess solder paste are removed.

Abstract: In a bonding apparatus such as a bump bonding apparatus, tape bonding apparatus or the like, a positioning claw which is used for positioning a semiconductor pellet on a bonding stage of the bonding apparatus is provided on a bonding head or on an XY table on which the bonding head is installed.

Abstract: In an electrowinning anode in which a lead anode sheet is tightly fitted to a copper busbar, the anode sheet is additionally joined to the busbar by pinning to prevent damage to the joint. A lead coating is electrodeposited onto the busbar, pin and the soldered joint to provide a complete metallurgical seal and good resistance to acid corrosion.

Abstract: A method for soldering a first component having a metal surface to a second component having a metal surface includes holding the metal surface of the first component in a position above a placement area on the metal surface of the second component to establish a gap between the surfaces. The method further includes reflowing solder within the gap.A structure including a thermally conductive baseplate, an electrical insulator attached to the baseplate, and a metallic shield mounted on the insulator. The structure also includes an integrated power device having a power-dissipating electronic device, and a first metal layer connected to the shield through a solder joint. A substrate includes an aperture, and the integrated power device is mounted with the power-dissipating device sitting within the aperture. The substrate also includes a conductive run electrically connected to a second metal layer of the integrated power device.

Abstract: A wear resistant, diamond enhanced cutting tool for excavating is disclosed. The cutting tool includes a cutting insert having a diamond coated cutting tip brazed to the cutting insert. The cutting tool is formed by brazing the insert to a tool body with a braze alloy by heating the insert and tool body to a temperature at which the braze alloy melts. The insert and tool body are then cooled to solidify the braze alloy and quenched to cause a martensitic transformation. Finally, the diamond enhanced tip is brazed to the insert while the temperature of the tool body is maintained below a temperature at which the tool body would soften. According to this method, the cutting tool is formed without creating a tempered zone of reduced hardness.

Abstract: In a wire bonding method, particularly a method for forming a ball at an end of a bonding wire that has an intended ball size, a tail length of the bonding wire extending from the lower end of a capillary is determined according to the size of the intended ball and the internal shape of the lower end portion of the capillary, and the wire end having such a tail length is melted up to the lower end surface of the capillary by a discharge produced by an electric torch so as to form a ball on the wire end.

Abstract: A method for continuous rolling includes flash-butt welding to form a continuous billet by joining a rear end of a preceding billet with a front end of a succeeding billet, removing burrs from a welded portion of the joined part, and continuously rolling the joined continuous billet in a rolling mill group. The flash-butt welding step includes the use of two travelling welders arranged in series and spaced at a distance along the direction of movement of the continuous billet corresponding to the length of the billet being welded. The travelling welders synchronously move with the continuous billet, and separately and simultaneously weld the continuous billet to another billet by flash-butt welding so as to extend the length of the continuous billet.

Abstract: A trolley having an inner assembly and trolley sides is assembled by placing the components of the inner assembly in a welding fixture, welding the inner assembly components together, and welding the inner assembly to the trolley sides. The use of the fixture and the order in which the welds are carried out minimize distortion in the assembled trolley.

Abstract: Process for bonding a metal brush structure to a planar surface of a metal substrate in which an array of metal rods are retained and immobilized at their tips by a common retention layer formed of metal, and the brush structure is then joined to a planar surface of a metal substrate via the retention layer.

Abstract: A wear resistant, diamond enhanced cutting tool for excavating is disclosed. The cutting tool includes a cutting insert having a diamond coated cutting tip brazed to the cutting insert. The cutting tool is formed by brazing the insert to a tool body with a braze alloy by heating the insert and tool body to a temperature at which the braze alloy melts. The insert and tool body are then cooled to solidify the braze alloy and quenched to cause a martensitic transformation. Finally, the diamond enhanced tip is brazed to the insert while the temperature of the tool body is maintained below a temperature at which the tool body would soften. According to this method, the cutting tool is formed without creating a tempered zone of reduced hardness.

Abstract: A tube connection for a water box of a motor vehicle heat exchanger is disclosed. A connecting sleeve is provided which is a component which is separate from the water box and is provided with a connecting area which can be inserted into a corresponding opening of the water box.

Abstract: A stator vane assembly for a gas turbine engine that includes a plurality of circumferentially spaced ceramic vanes, each of which has an inner and outer ceramic shroud, and a ceramic post extending from one of the shrouds, and a metallic platform having a plurality of circumferentially spaced recesses. The posts are inserted into a metallic sleeve and then brazed. The brazed sleeves are then mounted in the recesses. A method for assembling these components to form the stator assembly is also described.

Abstract: Engine components are thermally insulated with composite layers for improved engine efficiency. A metallic insulation layer is affixed to the metallic substrate of each component, and a layer of heat and corrosion resistant metal overlies and is bonded to the insulation layer. One preferred embodiment incorporates a preformed sheet layer of stainless steel sintered to a layer of metallic insulation attached to the component body substrate. An alternate embodiment incorporates a plasma-sprayed stainless steel layer over the insulation layer. A preferred process for making the engine component includes casting the component body in a mold containing a preformed insulation composite formed of a layer of stainless steel sheet sintered to a layer of metallic insulation.

Abstract: A mounting apparatus for deploying a plurality of FPC tape carrier electronic component mounting structures having a plurality of cut out regions in a FPC tape carrier formed spatially along the length thereof, which regions define electronic component mounts. These cut out regions are contained within the confines of the FPC tape carrier and having a preformed substantially closed loop cut out boundary. Each of these cut out regions may contain at least one electronic component mount having a semiconductor integrated circuit chip electronic device electrically connected to at least one lead pattern formed on the carrier within the cut out region boundary. Slits or slit apertures are formed at one or more points along the cut out boundary. Securing attachment is provided at one or more points along the mount boundary, which are provided at the regions of the slits or slit apertures to secure the electronic component mounts with minimal connection to the body of the tape carrier.

Abstract: Engine components are thermally insulated with composite layers for improved engine efficiency. A metallic insulation layer is affixed to the metallic substrate of each component, and a layer of heat and corrosion resistant metal overlies and is bonded to the insulation layer. One preferred embodiment incorporates a preformed sheet layer of stainless steel sintered to a layer of metallic insulation attached to the component body substrate. An alternate embodiment incorporates a plasma-sprayed stainless steel layer over the insulation layer. A preferred process for making the engine component includes casting the component body in a mold containing a preformed insulation composite formed of a layer of stainless steel sheet sintered to a layer of metallic insulation.

Abstract: There is provided an improved coated composite article and an improved process for making the article. A cloth-like flexible preform is brazed to a metallic substrate to make the article. The article is then subjected to a uniform high pressure and temperature for sufficient time to remove porosity in the coating. The result is a fully dense coating, which is metallurgically bonded to the substrate without any porosity, which has improved physical properties, and which is capable of being polished to a surface finish of at least 4 RMS.

Abstract: The method and structure permit the testing of welds forming the structure. The structure comprises a base plate, a longitudinal member on the base plate, a web having an opening positioned over the longitudinal member, and a lap collar having an air hole and covering the web opening. An air channel is formed by welds formed between welded abutting surfaces of the base plate and the web, and between the web and the longitudinal member, and between the lap collar and the base plate, and between the lap collar and the longitudinal member. The air channel is continuous along the entire length of the web and base plate thereby permitting the detection of defects in the entire length of welds when the air channel is pressurized through the air hole.

Abstract: Methods and apparatus for joining conveyed steel pieces in a hot rolling mill are disclosed. A joining apparatus having a series of fusing torches extending laterally across the steel path is used, either before a rough rolling stage or between rough rolling and finish rolling. The fusing torches which operate at the side edges of the pieces to be joined are controlled to have independent movement by a controller, in such a way that the time elapsing between fusing and pressing together of portions at the lateral edges of the join line does not exceed a critical time for regrowth of oxide scale. Various mounting and control techniques for the fusing torches are proposed, including the possibility of two independently-driveable sets the controller can base its control of the torches on steel strip width information obtained from the processing path.

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: A number of rare earth-cobalt permanent magnet segments are temporarily secured together by means of a tool. Before securement the segment surfaces at each interface are pre-tinned. A solder pre-form in the shape of a "wagon wheel" rests on one transverse end of the magnet so that the spokes of the pre-form overlie the interface joints. The magnet is then lowered into a gradually heated glycerine bath until the solder melts and directly flows over each interface. Upon slow cooling of the cylinder, metallurgical bonding is effected between the various segments of the magnet.

Abstract: A tapered metal pole has at least three ribs. Each rib has two parallel spaced apart walls. The inner edges of the walls of one rib will be welded to the inner edges of the walls of another rib. The walls of adjacent ribs will be at an angle relative to each other. An outer plate extends between the outer edges of each wall. The walls taper in width from a lower end to an upper end. Each of the walls of the ribs intersect with the walls of an adjacent rib at an angle.

Abstract: Pieces of metal are joined with silver material in a two-stage heating process. In one application, a brazed porous coating of metal particles on a metal substrate of a device is formed by interposing a silver material between the substrate and the particles, and placing the particles onto the substrate. The device is heated to a first temperature slightly below the melting point of the silver material, then briefly heated to a second temperature above 1100.degree. C. to rapidly melt the silver material to wet the particles and substrate and to generate alloying among the silver material, the particles, and the substrate. The device is allowed to cool to solidify the alloy and unite the particles and substrate to form a porous coating on the device. Also disclosed are a prosthetic device having a metal shaft for insertion into a bone canal, and a porous coating of metal particles brazed to the metal shaft by a silver material.

Abstract: A process for attaching a porous layer to a substrate adapted to form the core of a hip prosthesis, the substrate is placed in a cavity in a mould. Spherules are introduced into the space between the substrate and the walls of the cavity. The mould is placed in a furnace, which is heated to a temperature at which the material of which the substrate is made is superplastic. Then a pressure of the order of 10 to 30 MPa is applied to the mould, enabling the spherules to be encrusted on the substrate at a relatively low temperature.

Abstract: Pieces of metal are joined with silver material in a two-stage heating process. In one application, a brazed porous coating of metal particles on a metal substrate of a device is formed by interposing a silver material between the substrate and the particles, and placing the particles onto the substrate. The device is heated to a first temperature slightly below the melting point of the silver material, then briefly heated to a second temperature above 1100.degree. C. to rapidly melt the silver material to wet the particles and substrate and to generate alloying among the silver material, the particles, and the substrate. The device is allowed to cool to solidify the alloy and unite the particles and substrate to form a porous coating on the device. Also disclosed are a prosthetic device having a metal shaft for insertion into a bone canal, and a porous coating of metal particles brazed to the metal shaft by a silver material.

Abstract: A method whereby a base member having a surface on which a wear-resistant layer is formed and a mold member are disposed in opposing relation so as to form a gap between the surface of the base member and the surface of the mold member opposing the surface of the base member. Sintered hard substance grains of a hard substance powder such as material selected from carbides, nitrides and borides of metals belonging to groups IV, V and VI of the periodic table are filled in the afore-mentioned gap along the wear-resistant layer forming surface of the base member. A metal of self-melting alloy is then permeated into a filling-up layer of the sintered hard substance grains. The mold member is thereafter removed and the exposed surface is polished to obtain a fine wear-resistant layer on the base member.

Abstract: A method for fabricating an improved titanium alloy composite consisting of at least one high strength/high stiffness filament or fiber embedded in an alpha-beta titanium alloy matrix which comprises the steps of providing a rapidly-solidified foil made of an alpha-beta titanium alloy, fabricating a preform consisting of alternating layers of the rapidly-solidified foil and the filamentary material, and applying heat and pressure to consolidate the preform, wherein consolidation is carried out at a temperature below the beta-transus temperature of the alloy.

Abstract: An external cavity klystron vacuum tube has a ceramic cylindrical wall surrounded by an external cavity within which is an output probe. The cylindrical wall section is sealed at its ends to other components of the tube--to enable the interior to be evacuated--by sealing means such as to avoid a sharp edge projecting inwardly towards the interior of the cavity.

Abstract: A complexly curved mold and method of fabricating same provides a highly accuate form for producing complexly curved panels such as automobile lights and the like. The mold comprises a lattice-work support or grid having one surface which conforms to the desired contour of the product. The lattice-work comprises and is assembled from a plurality of strips of a material such as stainless steel or similarly relatively high strength material which are arranged in two parallel arrays disposed normal to one another and secured together to form the lattice-work support. A plurality of plates which have been shaped by rolling, bending, or other forming means to conform to areas of the mold define the face of the mold. They are secured to the lattice-work support by suitable means such as welding. The face of the mold may also include a plurality of apertures arranged in a grid through which a vacuum may be drawn to ensure intimate contact between the product and the mold face.

Abstract: A method of manufacturing a brush seal is disclosed which comprises producing a plurality of tufts of brush material and securing the tufts between two side plates to form a seal. Each tuft is produced by forming a tape which comprises one or more layers of parallel contiguous lengths of filaments adhesively bonded together to form a self supporting body. The tape is cut into discrete portions and these constitute tufts of bonded filaments. A plurality of tufts are assembled closely adjacent to each other in a support member with a part of each tuft projecting from the support member, and the tufts are subsequently secured in the support member. Finally the adhesive is removed from at least that part of each tuft which projects from the support member.

Abstract: A method for constructing a surgical implant provides a porous layer that is metallurgically bonded to a substrate. An electrode passes current through the porous layer and through the substrate while also controlling the compaction of the porous layer relative to the substrate.

Abstract: Seal (40) between travelling-wave tube electrodes (32 and 34) includes an inner hermetic seal ring (50) for providing vacuum sealing and an outer ring (52) which shares the mechanical stresses due to changes in temperature.

Abstract: This invention relates to devices and methods of manufacturing cut glass panels which comprise a plurality of glass panes arranged in a predetermined pattern with novel came flanges that span the adjacent edges of the glass panes on both sides of the panel. In this manufacturing method, a pair of complementary came-flange gridworks that correspond to mirror images of the predetermined pattern are first constructed. The cut glass panes are then positioned between the inner surfaces of the complementary gridworks so that the edges of each pane are separated from the edges of adjacent panes by spaces that form a network of continuous interconnected channels, and so that those channels are completely spanned by and sandwiched between the inner surfaces of the complementary came-flange gridworks. In a preferred embodiment, the outer surface of one of the gridworks is then sealed to all adjacent glass surfaces with a releasable cement. The cemented came-pane assemblage so formed is detached from the other gridwork.

Abstract: Electrically conductive bodies and methods of using same are disclosed which generally incorporate the feature of wire crossing wire at multiple sites of mutual contact throughout the body with the wire interconnected at the sites by a chemical deposition of metal to yield a rigid, open metallic lattice.

Abstract: A plasma arc spray overlay of cladding metals is used over joints between clad metal pieces to provide a continuous cladding metal surface. The technique permits applying an overlay of a high melting point cladding metal to a cladding metal surface without excessive heating of the backing metal.

Abstract: A process is disclosed with which a viscous liquid vehicle is applied as a coating to strands, or fibers, of stainless steel to hold finely-divided brazing material at the surfaces of the strands. A mat of the coated strands/fibers is spread in a layer over the surface of a substrate and brought to the brazing temperature to form the desired bond. At the brazing temperature forming the bond, the viscous vehicle is evaporated, leaving no residue which deteriorates the quality of the brazing bond of the strands/fibers to each other, and the brazing bonds between the strands/fibers and the substrate.

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: A method of manufacturing a brush seal for effecting a seal between relatively moving parts. Brush elements are first made by assembling bundles of bristle elements in holding tubes therefor, the brush elements then being mounted for instance by an adhesive on a carrier, so as to lie at the required disposition. The free end portions of the bristle elements are affixed to a brush seal root member, and the bristle elements are cut off at the required position between the root member and the carrier; the carrier and holding tubes--which may be re-used--are removed to leave the brush seal. A final machining of the brush seal, such as of the bristles, may be performed.

Abstract: A hollow rectangular boom formed with four corner sections of identical cross section and plates interconnecting the corner sections is disclosed herein. Each of the corner sections is identical and is generally L-shaped in cross section with first and second legs each having a recess with adjacent pairs of corner sections being interconnected by flat plates received into the respective recesses and welded therein. The invention also resides in the method of assembling the various parts to form the hollow boom sections.

Abstract: A method of manufacture of a brush for use as a seal includes the steps of winding a filament or filaments of bristle material onto a mandrel which carries on each side thereof a side-plate of the brush so that the bristle material overlies an exposed face of each side-plate at an angle of 45.degree.. After winding, a second side-plate is made to overlie the bristle material to sandwich it between the two plates and the side-plates and bristle material are welded or fused together at one edge thereof. The bristle material is then cut and the plates removed from the mandrel to produce two brushes with bristles projecting from the other edge at an angle.