Abstract: A very high gravimetric energy and power density hydrogen ion based rechargeable battery, which stores hydrogen and oxygen in lightweight porous carbon electrodes with metalized current collectors, and which are separated by ionically permeable polymeric membranes containing a liquid electrolyte. The hydrogen and oxygen are produced by electrolysis of water in the battery during charging and the battery cells are enclosed in lightweight, metalized polymer housings of honeycomb construction. The battery is also very highly rechargeable due to the use of carbon and hydrogen.

Abstract: A long continuous tube, strip or like material has a coating of brazing powders applied and formed thereon. It may be cut to sections of specific length when actually used. A uniform coating of brazing powders is applied in specific quantities and fixed onto the long continuous tube, strip or like material. A travel path has a tube made from aluminum or aluminum alloy running therealong. At least one spray gun section projects a coating mixture of brazing powders toward the travel path. A pressurized air supply section supplies pressurized air to the spray gun section, and a coating mixture supply section includes a coating mixture circulating arrangement and a feed line. A drying section is provided downstream of each respective spray gun section, and a rewinding section is provided at the end of the travel path.

Abstract: A hermetically sealed electromagnetic window is formed by butt end brazing an overhanging dielectric window between first and second waveguide segments. The waveguide segments have opposed knife edges with a dielectric insert positioned between the knife edges. A pair of brazing forms are inserted between the insert and the two knife edges. The window is heated, causing the brazing material to reflow and provide a hermetic seal between the insert and the waveguide segments, and a conductive path between the waveguide segments.

Abstract: A catalytic air cleaner purifies air in enclosed spaces, such as in an aircraft or spacecraft. The air cleaner includes a pair of metal strips, wound into a double spiral. The strips have projections, affixed to the strips, to maintain the spacing between turns of the spiral. The spiral defines a core which accommodates an electrically heated catalytic converter. The strips themselves have no catalyst coating. A pair of ports at the periphery of the spiral allows air to enter and leave the spiral through inlet and outlet channels. Air entering the spiral through the inlet channel receives heat, by heat exchange, from air leaving the spiral, and then enters the core, where the electrically heated catalytic converter burns off various impurities. The air then leaves the spiral through the outlet channel, and becomes cooled by transferring its heat to the incoming air.

Abstract: A method for producing a copper brazed hose coupling assembly from a plurality of members in which one of the members is electroplated with copper is provided. A stem member is press fitted to a collet member and subsequently brazed together in a furnace. The copper material being located adjacent the joint between the stem and collet members results in a high quality braze joint to be provided with a predetermined minimum amount of copper. The copper brazed hose coupling is particularly suited for use in a fluid operated system.

Abstract: A process for producing an intake manifold having a main pipe made of wrought aluminum material and having an open end, a closed end opposite to the open end, a plurality of holes formed in its peripheral wall and outward tubular projections integral with the peripheral wall and each formed around each of the holes, and a plurality of branch pipes made of wrought aluminum material and each having one end fitting in and joined to each of the tubular projections. The manifold is smooth-surfaced in its interior, diminished in resistance to air and improved in air intake efficiency. The manifold requires no finishing procedure unlike those prepared by casting.

Abstract: Slow-wave structures are formed by the method of this invention in the form of helical or coupled-cavity structures. A helical waveguide form of slow-wave structure is formed of a solid rod of copper machined with a deep, narrow helical groove. A copper sleeve is brazed to the periphery of the resulting helical thread to form a helically spiraling pathway about a solid axially centered and axially extending center portion. The center portion is then totally eroded away to form a slow wave structure having a helical radially-extending portion, or if only partially eroded with an inner helical axially-extending ridge to provide a helical axially-centered gap between adjacent ridges. The coupled-cavity forms of waveguide slow-wave structures are formed by machining disks from a solid rod of copper. The disks are supported in their desired positions by an axial retained portion of the rod until the disks are brazed inside a cylindrical shell of copper.

Abstract: An apparatus and method for forming an integral three-dimensional object from laminations of the same or gradually varying shape. The apparatus includes a supply station, a work station for forming a material into a plurality of laminations for the three-dimensional object, a control station for directing the operation of the work station, an assembling station for stacking the laminations in sequence into the three-dimensional object, and bonding the laminations to complete the formation of the three-dimensional object.

Abstract: A waveguide filter (43) comprising a series of resonant cavities (45) separated by walls (47) each formed with an iris opening (49) is assembled from two complementary box-like bodies (25) each having an open side (31) and internal partitions forming portions of the walls (47) between the cavities. Each box-like body is manufactured by impact extrusion using an open-topped box-like die (1) in which a slug of material (5) is placed, and a punch (7) which has smaller dimensions than the die and slots (11) for forming the respective partitions. The punch is driven into the die with a force such that the material of the slug is displaced into the slots in the punch and into the space between the punch and the die.

Abstract: An aperture plate for an ink jet head is formed by micro electrical discharge machining one surface of the plate to form a dimple-like recess with a relatively wide flat base. An aperture is then formed through the plate in the region of the dimple, as by micro electrical discharge machining. In one method of the invention, recesses are formed in two plates which are then mounted to the body of an ink jet head. A third plate with a formed third aperture is then mounted to the body such that the first, second and third plates overly one another and the third aperture is aligned with the recesses. Apertures of a smaller cross-section than the third aperture are then formed in the first two plates by drilling through the third aperture. The aperture through the first plate is then enlarged.

Abstract: A method for manufacturing the guide base of a valve and assembly of that valve is disclosed. The guide base is made from flat plate. Two similar workpieces are stamped out of plate. Each workpiece comprises two leg members joined by a central portion. The workpieces are engaged at their central portions and inserted into an upper valve body having at least one insert slot. The final assembly is permanently joined together.

Abstract: An aluminum cylinder for a two-stroke engine is die cast in two separate parts which are subsequently press-fitted together by differential heating. The parts are joined along a line which intersects the cylinder's inlet and exhaust ports. Thus, the port sections on the respective parts can be readily machined before the parts are fitted together.

Abstract: A process is set forth for making a structure formed of at least two metallic workpiece sections each formed of a reactive metal. A mandrel having a nonreactive surface is sandwiched between the workpiece sections thereby preventing them from being in contact over a first selected area and allowing them to be in facing relation over a second selected area. A reactive metal contact is formed of the workpiece sections over the second selected area. The workpiece sections are maintained under coordinated temperature-pressure-time duration conditions to diffusion bond them at the second selected area. A gas pressure differential is applied between intermediate the workpiece sections and external of the workpiece sections to cause breakthrough at the first selected area and superplastic forming of at least one of the workpiece sections causing it to stretch in excess of its original surface area. The mandrel is removed from between the workpiece sections.

Abstract: A belleville seal for a sealed bearing rotary cone rock bit. The inner static ring portion of the annular belleville seal is metal and is interference fitted over the base of a journal bearing. The separation joint formed between the inner diameter of the static ring portion of the belleville seal and the outside diameter of the journal bearing is circumferentially welded using a high-energy beam source to form a hermetically sealed metallurgical bond therebetween.

Abstract: A brazing method is disclosed which provides superior strength in the brazed joint formed. The brazed structure is subjected to a heat treatment after brazing, which improves the strength of the joint even if Magnesium compounds are employed.

Abstract: A method of forming thin, uniform braze joints is effected through the use of curtain coating. Braze powder is admixed with a liquid polymeric binder to form a slurry. The slurry is forced through the slots in a curtain coating head and deposited on at least one of the metal surfaces to be bonded together. The method has particular utility for bonding fin/plate sections of a heat exchanger where the fins have a U-shaped cross section. The slurry is deposited on the top portion of the fin and the side portion of the fin and wiped from the top portion leaving braze material primarily on the side wall portion. When the plates are contacted to the fins and heating performed, a bond is effected with maximum plate-to-fin contact for high heat transfer and a strong braze joint.

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 millimeter coupled cavity travelling wave tube has its slow wave structures formed by a hobbing process. In a preferred construction, each slow wave structure is made of two individual halves each extending for the length of the structure. Each half contains one half of each cavity and one half of each beam hole and all of the portions of cavity and portions of beam hole in each half are formed in one hobbing operating. Coupling holes between cavities are formed where required by a process (e.g. spark erosion) separate from hobbing and if ferrules or drift tubes are required to extend out of the cavity separating walls in the finished tube, the beam coupling holes are made oversized and individual ferrules are brazed into position. The two halves of the slow wave structure are united by furnace brazing.

Abstract: The method of providing an order of magnitude manufacturing cost reduction in the manufacture of fluid flow restrictors by employing components produced by punch press stamping operations. The flow restrictor is formed of a plurality of annular plates. Half of the plates are punched to form concentric rings of tabs at right angles to one surface thereof. The plates with and without the tabs are alternately stacked concentrically and brazed together to form the fluid flow restrictor having a central core communicating with the exterior surface through a plurality of tortuous paths.

Abstract: The disclosure relates to a process for the fabrication of low cost dual property turbine rotors having blades that are diffusion bonded to a blade ring that is simultaneously diffusion bonded to a central hub.

Abstract: An improved method of producing a scroll type compressor having an orbital scroll member and a stationary scroll member. The orbital scroll member is fabricated by a process comprising the steps of: forming an end plate and a spiral wrap separately, the end plate being composed of an upper half part having a discontinuous joining portion for joining the spiral wrap and a lower half part having an oil passage. The upper half part and the lower half part of the end plate are fixed to each other through mutual engagement between locating projections formed by a plastic work on one of the half parts and mating holes formed in the other of the half parts.

Abstract: A carrier matrix for use in the manufacture of a catalytic reactor for the purification of exhaust gases in an internal combustion engine of a motor vehicle is prepared by joining in wound form a corrugated steel sheet and a generally flat steel sheet, the sheets being joined in locations where they contact one another by the use of solder or brazing material. In one embodiment solder is applied in spots along the tops of the arches of the corrugated sheet, and after coiling the solder is activated by heating. In another embodiment, coiling is first carried out and then soldering is accomplished by the application of solder into one or both end faces of the coil.

Abstract: A segment is cut off a rotating hexagonal bar by opposed cutting tools which form a raised seat for a sealing gasket. The segment defines a hexagonal valve body into which coaxial larger-diameter and smaller-diameter holes are drilled from oppositely facing walls of the six walls of the body, respectively, and a round distribution chamber or port is drilled through the seat centrally thereof and into one side of the body. An internally threaded sleeve is tightly fitted into the smaller-diameter hole and extends toward the chamber to define a back seat. A charging port is drilled through the opposite side of the body and into the sleeve inwardly of its threads. A valve stem with a head at one end having a smaller diameter than the larger-diameter hole is inserted therethrough and is threaded into said sleeve until the head is in the chamber and the opposite end of the stem projects externally of the sleeve for actuation of the head.

Abstract: A vane compressor is provided which has a rotor formed therein with a plurality of axial slits opening in its outer peripheral surface in a circumferentially spaced arrangement, and in each of which a vane is received, and a plurality of cavities located between adjacent ones of the axial slits. The rotor is formed of at least two rotor elements integrally joined in an axial alignment, each rotor element being formed of a sintered alloy compact. The rotor elements are brazed along their end faces abutting against each other.

Abstract: A process for manufacturing a piston ring is disclosed wherein web-like first metal member which will form a base of a piston ring and web-like second metal member which will form a wear resistant layer of the piston ring are separately fed and joined together. The joined web is subject to curving to gradually decrease a radius of curvature.

Abstract: The disclosure relates to a process for the fabrication of low cost dual property turbine rotors having blades that are mechanically retained and a blade ring that is permanently bonded to a central hub.

Abstract: A method of mounting a hard, wear-resistant insert for use as a core tube, wire drawing die, and the like in which a cylindrical metal casing is provided with opposite front and back sides, the casing having a cylindrical cavity formed in the front side with a flat bottom spaced from the back side. A cylindrical plug is provided having top and bottom ends, the plug being proportioned to have a close fit in the casing cavity. The casing-plug assembly has a reference position with the casing cavity bottom facing upwardly and the plug bottom end facing downwardly. Prior to insertion of the plug in the cavity, either the plug or the casing is inverted from its reference position. A hard insert element is centered with respect to either the inverted end of the plug bottom or the casing cavity bottom and is adhered thereto. Either the plug or the casing is again inverted to the reference position, and the plug is inserted in the casing cavity with the bottom end and insert element facing the cavity bottom.

Abstract: Honeycomb structures, such as those used in turbine engine abradable seals, are provided with a uniform density filling of a suitable abradable material. The abradable material is prepared as a tape preform using an organic binder. The preform is forced into the honeycomb using a rubber tool.

Abstract: A brazed joint between a beryllium-base part and a copper-base part comprises a first layer of brazing material in contact with the beryllium-base part. This brazing material is an alloy that just prior to brazing consists essentially of silver and a minor constituent of either: (a) tin in a percentage of 4% to 15% by weight of the alloy, (b) silicon in a percentage of 1% to 5% by weight of the alloy, or (c) indium in a percentage of 6% to 25% by weight of the alloy. Contacting this first layer and brazed thereto is a second layer of a material that just prior to brazing consists essentially of silver. Between the second layer and the copper-base part, there is another brazed connection, which is formed at temperatures exceeding 600.degree. C.

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.