Abstract: A sacrificial anode and method of making a sacrificial anode are provided. The anode includes an extruded galvanically active metal rod and integrally formed end cap which has a cylindrically shaped portion with a threaded exterior surface. The anode is formed by extruding the rod, forging the end cap from the anchoring end portion of the rod, and machining the outer surface of the end cap to provide threads.

Abstract: A yoke of a universal joint is substantially U-shaped and includes a base portion and first and second arm portions. A method of producing the yoke includes the sequential steps of: (a) shearing a metal plate which is rectangular in shape and has certain uniform width and thickness so as to form a blank which is rectangular in shape and consists of a middle portion and first and second end portions; (b) squeezing the middle portion of the blank by cold forging so that the middle portion is expanded to have first and second peripheral bulge portions which are opposed to each other and that the expanded middle portion becoming substantially oval in shape and thinner than the first and second end portions in thickness; and (c) pressing the blank with a press machine to produce the yoke so that the expanded middle portion and the first and second end portions of the blank are turned into the base portion and the first and second arm portions of the yoke, respectively.

Abstract: A method of manufacturing a roller cone type drill bit, or main body thereof, includes forging a monolithic main body forging comprising a shank blank extending longitudinally at one end and a plurality of circumferentially spaced leg stubs at the other end; turning the shank blank to form a threaded section; rotatably mounting a respective roller cone on each of a plurality of journal members, each journal member being carried at one end of a respective leg extension; and welding a respective one of the leg extensions to each of the leg stubs. The main body is forged with its longitudinal centerline perpendicular to its flash line, the latter being located well inward of the leg end of the forging.

Abstract: A pair of truss brackets are secured to the roof of an underground passage adjacent to opposing ribs of the passage. The truss brackets each include a roof engaging surface and a truss supporting arm member extending from the roof engaging surface. A pair of U-bolts are supported by the arm members of the truss brackets. Each arm member extends horizontally from the truss bracket to an enlarged end portion of the arm member. The U-bolt is horizontally movable in a vertically hanging position on the arm member and is restrained by the enlarged end portion from disengagement from the arm member. The U-bolts are pivoted on the truss brackets to a horizontal position for connection to truss members which are connected to each other and tensioned to apply an uplifting force to the roof. As the truss members are connected and tensioned, the U-bolts are retained for a range of horizontal movement on the arm members to facilitate adjustments in the position of the U-bolts on the truss brackets.

Abstract: A method of manufacturing a scroll member for use in a rotary compressor has the steps of heating a material which has been preformed into a substantially frusta-conical body consisting of a flat upper surface portion provided with a cylindrical projection integrally formed in the center portion thereof and a lower surface portion having a conical surface and a flat projecting surface, and forging the material by a forging apparatus. The heating step compriss a first heating at a temperature in the range from 100.degree. to 200.degree. C. and a second heating at a temperature of 440.degree. C. which is carried out after coating the material with graphite, the coating being applied to the material between the first and the second heatings.

Abstract: A carbon steel with at least 1% by weight carbon and at least one carbide-forming alloying element such as chromium is forged into a construction machine-tool part for engagement with abrasive material, the forging provides a fiber extension direction which coincides with the principal direction of abrasive action.

Abstract: A substantially homogeneous heavy wall drill pipe and its method of manufacture are disclosed. A cylindrical ingot is placed in a multi-hammer forging press to form the ingot into a drill pipe bar having a central protector portion and upper and lower connector sections each of larger diameter than cylindrical body sections of the drill pipe. Thereafter, the bar is straightened and upper and lower end connectors are machined. Threaded end portions are machined on the connectors and a bore is drilled through the drill pipe bar.

Abstract: An apparatus and method of hot-forging in a forging press a cylindrical powdered metal preform to substantially full theoretical density to thereby produce a powdered metal part having a small inner bore wherein the core rod defining such bore is constructed so as to allow a continuous flow of a highly vaporizable liquid coolant such as nitrogen to the metal forming portion of the core rod and to thermally insulate the incoming coolant to assure its being maintained substantially unvaporized until being expelled to the core rod cooling chamber.

Abstract: A one-piece piston is produced by die pressing in a single step, a previously forged blank to bend an annular cylindrical collar thereon and at the same time form a fire rib between two lugs which are pierced in the die-pressing tool so that eyes are formed in the lugs and the latter are calibrated by the piercing operation.

Abstract: A helical baffle for shell and tube type heat exchangers is fabricated by stamp forming a plate in the form of a partial circular section into a helical section between opposed, mating helically-shaped faces of two forming dies. The plate contains a series of apertures in the form of a pattern for receiving heat exchanger tubes. The dies contain sleeves and opposed reaming rods which form lips on the apertures during stamping of the plate. Lips can also be formed on the outer edge of the plate and the edge of a central passage during stamping. The lips prevent the helical plate from twisting or returning to a flat configuration. The leading and trailing edge of the helical plates are then joined such as by riveting or welding into a continuous helical baffle with sets of heat exchanger tube apertures aligned along a common axis.

Abstract: A rotor for a rotary compressor having a metal central portion integral with two opposite end portions that are fiber-reinforced metal matrix composites having a matrix metal common to the central portion. Such rotors may be made by pressing inorganic fibers to form the end portions of the rotor, arranging the end portions in an opposing relationship in a mold to form the central portion between the end portions. Molten metal is placed into the mold such that it infiltrates the porous end portions while forming the central portion. Solidification of the metal forms fiber-reinforced metal-matrix composite end portions integral with the central portion.

Abstract: A method is provided for the fabrication of a steel propeller which is designed to have a final shape and size consistent with a conventional propeller design. The resultant formed propeller includes n individual blades, each having boss segments. When the boss segments of the individual blades are joined together they form a propeller having a center boss portion. A center aperture may thereupon be drilled or bored in the boss for mounting the propeller on the shaft of a marine engine. The propeller is formed, in accordance with the method of the present invention, by individually press-forging n steel blanks into individual blade portions which include boss segments. The press-forged blades are then ground with their lateral surfaces beveled to permit them to be welded together into a whole propeller. The center aperture is then formed and the propeller finally heat treated and finally ground.

Abstract: A piston bottom for large capacity internal-combustion engines is made by forging a saucer-shaped blank from refractory-forging steel and then in a second forging step transforming the saucer-shaped blank into a cup configuration with a planar rim of the blank being transformed into a cylindrical shoulder and an annular bulge of the blank being transformed into an annular boss for connecting the piston bottom of the cylindrical body of the piston. The blank has a convexity projecting on one side of the blank opposite that formed with the bulge.

Abstract: A hip prosthesis comprises a one piece element including a head, a plate portion, a neck interconnecting the head and plate portion, and a flexible femoral rod which includes thin longitudinal elements extending away from the head in opposition to one another. The longitudinal elements are obtained by providing at least a longitudinal cutting in the rod which extends to its end opposite the head. A slot in each end coincident with the cutting houses a linking part for holding the elements together in one plane while permitting their relative movements in a second substantially orthogonal plane. The elements are made in one piece with the head, the neck and the plate of the prosthesis, with the rod itself being forged from a single piece.

Abstract: The invention concerns welded turbine rotors. It is characterized in that, n the elements constituting a welded rotor which consist of a blade bearing block having at least one axial protuberance, that axial protuberance is made of steel having a lower carbon and nickel content than the remainder of the element and is joined thereto by a transition zone also made of steel. The invention applies more particularly to high-power steam turbines.

Abstract: Helical or spiral bevel gears are forged from powdered material in a mold ving a stationary die in which a cavity is provided with an interior gear configuration conforming to the desired gear blank to be forged. An ejector rod is movably mounted within the stationary die along its central axis and is provided with means which cause its stroke to have an axial and rotary movement corresponding to the pitch of the teeth on the gear. The front edge of the ejector rod is provided with means forming a key-lock arrangement with the gear blank, thereby simultaneously rotating the gear out of the die on its ejection stroke.

Abstract: A method for treating investment cast superalloy castings wherein the portions of the castings which solidify directly against the mold walls comprise a substantially continuous or encapsulating skin of a metallic and/or nonmetallic composition. In such castings, defects in the form of material voids, including defects present immediately beneath the skin, are eliminated by the application of heat and pressure. The castings are heated to temperatures sufficient to achieve metal movement in the form of yield or creep, and a pressure of at least about 10,000 psi is applied by means of a surrounding gaseous atmosphere. The heat and pressure application deforms the material in the area of the voids and consolidates this material to substantially remove the voids and to thereby improve the performance characteristics of the castings.

Abstract: Gas carburizing of a briquetted powder metal preform prior to hot forging of the preform to acquire a fully dense, carburized powdered metal part.

Abstract: A machine element consisting of a shaft having thereon an enlargement such as a gear or cam is made in composite form at a much lower cost in labor and materials than in one-piece form by providing a solid metal supporting shaft of the desired dimensions with a roughened zone, as by coarse-knurling it. A sintered powdered metal preform of suitable metal for the enlargement is prepared in a conventional manner of slightly smaller diameter and of slightly greater length than the finally-desired configuration, and with a central longitudinal bore of slightly larger diameter than the shaft, to allow for expansion of both preform and shaft when both are heated to a forging temperature of 1800.degree. F. to 2000.degree. F.