Abstract: A fusible link has two generally oval members in overlying relationship, the two members having relatively flat surfaces confronting one another. One member has a quadrangular slot therein having tapered surfaces and the second member has a quadrangular projection having beveled sides complementing the tapered surfaces. The projection is accommodated in the slot and seats on the tapered surfaces of the latter to provide a space between the confront surfaces. The space is filled with a eutectic alloy which secures the members together. Pins on the members maintain the thickness of the space uniform. When the alloy is heated to a predetermined temperature it melts, thereby enabling the members to separate.

Abstract: An adapter element that allows machine elements to be accommodated in a centered manner with zero play, with these machine elements having different thermal expansions over broad temperature ranges. The adapter element has a sleeve-like portion that has tongue-like regions defined therefrom. Flattened or planar regions are provided on the inner and/or outer surface of the sleeve-like portion, with these planar regions at least partially overlapping the tongue-like regions.

Abstract: A thermal stress-free joint assembly for joining a low thermal expansion member and a high thermal expansion member uses a fastener and a bushing fitted within a bore in the low thermal expansion member, wherein the fastener and bushing materials are selected to have predetermined coefficients of thermal expansion. The fastener includes a shank which passes through the bore in the low thermal expansion member. The bushing, bore and shank are dimensioned according to a mathematical relationship to maintain a predetermined clearance or preload as the joint undergoes changes in temperature, without damage to either joined member from thermally induced stress.

Abstract: A method of securing a window of crumbly material in the end of a tube so as to effectively prevent leakage during temperature cycling, first involving the step of selecting a window having a small clearance when placed inside the end of the tube. Any contamination is removed from the periphery of the window, and then a thin metallic layer that will accept nickel plate is vapor deposited around the periphery of the window. Subsequently, a hoop of tensilely stressed nickel plate is applied over the thin metallic layer, after which the window and tube are sweated together by the application of suitable amounts of solder and heat. Significantly, the hoop of nickel serves to keep the window in continuous compression, such that leakage between the window and tube is effectively prevented.

Abstract: A metal housing is provided with lead in members by way of a compression seal using a glass that can be worked below about 480.degree. C. The housing and lead in members can be preplated in a low cost process to provide a suitable protective coating that is present under the glass after the seal is made. This obviates a post seal plating and therefore avoids the related problems. It also permits using aluminum as the housing material.

Abstract: A method of securing a window of crumbly material in the end of a tube so as to effectively prevent leakage during temperature cycling, first involving the step of selecting a window having a small clearance when placed inside the end of the tube. Any contamination is removed from the periphery of the window, and then a thin metallic layer that will accept nickel plate is vapor deposited around the periphery of the window. Subsequently, a hoop of tensilly stressed nickel plate is applied over the thin metallic layer, after which the window and tube are sweated together by the application of suitable amounts of solder and heat. Significantly, the hoop of nickel serves to keep the window in continuous compression, such that leakage between the window and tube is effectively prevented.

Abstract: A connecting structure for connecting a ceramic shaft to a metallic shaft comprises an arc body having a tapered portion in cross section, the arc body being fitted around a ceramic shaft, a member inserted by the ceramic shaft and placed adjacent the arc body at its one side, a metallic shaft placed adjacent the arc body at its other side, at least one of the member inserted by the ceramic shaft and the metallic shaft being in contact with the tapered portion and a fastening means for fastening the member and the metallic shaft to clamp the arc body.

Abstract: A strong transition joint between an aluminum plate and a steel object includes an aluminum sleeve adapted to be fusion-welded to the aluminum plate and a titanium core explosion-welded to the aluminum sleeve in the center thereof with the titanium core having an internally threaded hole adapted to receive a steel bolt so that the occurance and economic consequences of corrosion are minimized.

Abstract: An insulating member formed from a suitable hydrocarbon such as polyether ether ketone may be molded into any desired shape at a temperature of approximately 700.degree. F. and a suitable pressure of approximately 10,000-12,000 psi. An epoxy insulating material hermetically seals the insulating member to an electrically conductive member and a metallic housing. The insulating member and the epoxy insulating material maintain the hermetic seal through a suitable range of temperatures such as between ambient and approximately 400.degree. F. and through a suitable range of pressures such as between atmospheric and approximately 60,000 psi. The epoxy insulating material is first applied to the surfaces of the conductive member and the metallic housing, one of these surfaces being preferably flat, and the insulating member is then inserted into the space between the conductive member and the metallic housing.

Abstract: A very high hermeticity glass to metal seal comprising a round cylindrically shaped glass member having an outside diameter; a tubular sleeve of resilient metal having (i) a first end with an inside diameter slightly larger than said outside diameter of said glass member, and (ii) a reduced diameter portion adjacent to said first end thereof with the diameter of said reduced diameter portion being slightly smaller than the outside diameter of the glass member; a thin metalized layer on a first end of the glass member adapted to be inserted into said first end of the tubular metal sleeve so as to define an annular gap therebetween, the glass member being inserted as far as possible into the sleeve so that the end thereof is into abutting relation with said reduced diameter portion of said sleeve so as to form a capillary gap therebetween.

Abstract: Galvanically incompatible materials are isolated from each other to prevent galvanic corrosion while providing for electrical conductivity therebetween. A two-sided shim is interposed between the galvanically incompatible materials and each side of the shim is galvanically compatible and placed in contact with one of the galvanically incompatible materials. The shim itself is sealed against moisture to prevent galvanic corrosion in a central contact area between the two sides. Holes through the shim to permit the insertion of fasteners therethrough must similarly be sealed.

Abstract: A seal between a metal surface and a surface of glass or glass-like ceramic having, in juxtaposition, the metal, gold, an indium-gold alloy, indium, and either glass or a glass-like ceramic.

Abstract: A glass-to-metal compression sealed lead-in structure for electronic devices. The structure is constituted by an outer metal case having a high coefficient of thermal expansion (CTE), a lead-in conductor extending through the opening in the case and having a relatively low CTE, and a glass seal filling the space between the conductor and the case and having a relatively low or intermediate CTE. The conductor is fabricated of a machinable metal whose normal CTE is higher than required, the surface of the metal after the conductor is machined to specification, being treated with a substance that acts to reduce the CTE of the conductor to render it compatible with the CTE of the glass seal.

Abstract: A ferrule is provided with an opening extending through the ferrule and a terminal pin is disposed in the opening in spaced relationship to the ferrule. A plurality of insulating members are disposed on the terminal pin in the opening in a stacked relationship. Each of the insulating members is fused to the terminal pin and the ferrule. Each of the insulating members in the stack has a higher temperature of fusion than the preceding members in the stack. The insulating members in the stack are progressively fused to the ferrule and the terminal pin by the application of progressive temperatures to the terminal pin, the ferrule and the insulating members.The insulating members having the highest temperature of fusion are provided with properties of being able to withstand large forces without any degradation of the fusion with the terminal pin and the ferrule. The insulating members of the reduced temperatures of fusion are able to withstand other types of shock such as sudden changes in temperature.

Abstract: A vacuum-tight assembly, such as a discharge tube for a sodium vapor arc lamp, includes a high density polycrystalline ceramic body, such as alumina or yttria, having a cavity, at least one closure member, and a sealing material. The closure member is formed from a molybdenum-titanium alloy containing a small amount of nickel, cobalt, or copper. The nickel, cobalt, or copper forms a relatively low melting eutectic with titanium, thereby facilitating fabrication of closure members by sintering. The closure member and the sealing material have thermal coefficients of expansion closely matched to the thermal coefficient of expansion of the ceramic body over a wide temperature range.

Abstract: Disclosed are means and method for forming elastic connection between ceramic and metallic structural elements. The means comprises a ceramic structural element; a metallic structural element having thermal and elastic properties different from those of the ceramic structural element; and a connecting element connecting the ceramic and metallic structural elements and comprising an insulating resilient body of ceramic material having a thermal conductivity of between about 0.02 and 0.25 W/cmK at a temperature difference between the ceramic and metallic structural elements of from about 100 to 1500 Centigrade degrees, an elastic modulus of between about 5000 and 150,000 N/mm.sup.2 and being substantially free of plastic deformation.

Abstract: An aluminum electrical conductor is electrically joined to a copper electrical conductor by a cold weld lap joint which is substantially free of copper-aluminum intermetallic compounds. The overlapped portions of the conductors are deformed at least 74% and no greater than 82% to achieve a weld joint which has both excellent physical properties and excellent electrical properties. The cold weld lap joint is a reliable electrical connection for electrical circuits experiencing current densities of more than 1000 amperes per square inch and a sustained high temperature of 125.degree. C. and above.

Abstract: A roll for use under high or low temperature conditions, for example a conveyor roll in a flat glass annealing lehr, comprises a tire of a different material from collars on the roll between which the tire is held. The tire and at least one collar have matching frusto-conical surfaces which are designed so that differential thermal expansion between the tire and the retaining collars causes sliding movement only of frusto-conical surfaces relative to each other.

Abstract: An improvement in a high thermal stress connection between a rotationally symmetrical component made of ceramic material and a component made of metallic material is provided in which a connecting part which is elastic and radially and axially resilient connects the ceramic part and the metallic part by means of high temperature soldering. The stresses normally produced by differential expansion of the ceramic part and the metallic part are substantially absorbed by elastic deformation of the connecting part.

Abstract: A method is provided for inhibiting the development of friction fatigue stress between the mating surfaces of paired machine parts, and particularly those subject to oscillatory loads. This is achieved by maintaining the mating surfaces separated by placing between them a material either of a different crystal structure than the parts separated, or a material of a greater hardness. The separating material may be in the form of a connecting element, or it may be coated onto one of the mating surfaces.

Abstract: A process for hermetically sealing an optical fiber to a metal housing is described. An optical fiber 12 is threaded through a thick-walled metal tube 10 which has a bore 11 of slightly larger diameter than the fiber. The tube and fiber are inserted in a pneumatically operated collet and uniform radial pressure is applied to the tube to form a unitary hermetic assembly. Metal tube 10 is characterized in that it has or, prior to forming the assembly, is annealed to have a Rockwell hardness of less that 15 T 15. At this value the metal is soft and the pressure required to cause the metal to cold flow around the fiber is less than that required to break the fiber. The tube is then soldered or otherwise secured in a hole in the housing, thus completing the hermetic seal. Such a seal is useful in hermetic packaging of optical devices. It is advantageous over the prior art for its simplicity and inexpensiveness. The technique is suited to high yield mass production of reliable seals.

Abstract: A semiconductor device subassembly of an elongated conductive lead member, a refractory metal slug and a brazing disk is constructed by mechanically securing the slug to the lead member, assembling the brazing disc to contact both the slug and the lead member and thereafter brazing the slug and the lead member together.

Abstract: New alloys containing gold, vanadium, yttrium and/or scandium, optionally including niobium. The alloys are particularly suitable for brazing and for metallizing, most particularly for brazing hermetic ceramic-metal seals. Unique brazing structures and methods are also disclosed.

Abstract: For sealing metal annular elements on to a cylindrical ceramic member, e.g. a ceramic electrolyte tube in a sodium-sulphur cell without causing excessive hoop stress in the ceramic, the ceramic tube is formed with tapered inner and outer surfaces at one end, correspondingly tapered inner and outer annular elements are put over these surfaces with a soft metal, e.g. aluminium interface layer, the inner and outer annular elements having coefficients of thermal expansion respectively less than and greater than that of the ceramic, the assembly is then heated and the annular elements forced in the axial direction onto the ceramic whereby the ceramic material, on cooling, is tightly secured between the annular members.

Abstract: A feedthrough connector for use on an implantable electronic cardiac pacer. A single structure provides a means for connecting a heart lead to the pacer and feedthrough into the body of the pacer. The feedthrough may include filtering means to protect against external interferences. The entire structure has provisions for physical compliance to absorb stresses due to different heat coefficients and as may be caused during assembly and use. Also disclosed is a method for making the feedthrough connector.

Abstract: A self-clinching stand-off to be embedded into thin sheeted material. The stand-off comprises a base produced on a "screw machine" and an extension molded thereto. The extension is formed from a material which is softer than that of the base. Further, the extension may vary in length for a given base.

Abstract: A novel flexible ferrule is provided. The ferrule is a hollow tapered tube having walls formed from a plurality of layers of continuous graphite fiber-reinforced plastic sheet material in which the graphite fibers of one layer of sheet material are at an obtuse angle ranging from about 110.degree. to about 140.degree. relative to the fibers in the next superimposed graphite layer of sheet material. Interposed between and alternating with the graphite layers are layers of woven fiberglass material, the glass fibers of which are at right angles to each other.

Abstract: Hermetic glass seals of high electrical resistivity are provided. Glass compositions suitable for use in such seals and based on lead-silica glasses are described. Glass compositions having particular efficacy in a nuclear reactor environment also are described.

Abstract: An improved energy conversion device of the type comprising: (A) an anodic reaction zone, (i) which contains a molten alkali metal anode-reactant in electrical contact with an external circuit, and (ii) which is disposed interiorly of a tubular cation-permeable barrier to mass liquid transfer; (B) a cathodic reaction zone (i) which is disposed exteriorly of said tubular cation-permeable barrier, and (ii) which contains an electrode which is in electrical contact with both said tubular cation-permeable barrier and said external circuit; (C) a reservoir for said molten alkali metal which is adapted to supply said anode-reactant to said anodic reaction zone; and (D) a tubular ceramic header (i) which connects said reservoir with said anodic reaction zone so as to allow molten alkali metal to flow from said reservoir to said anodic reaction zone, (ii) which is sealed to said tubular cation-permeable barrier, and (iii) which is impervious and nonconductive so as to preclude both ionic and electronic current leakag

Abstract: Novel header for use in nuclear applications comprised of a base containing at least one bore, a niobium terminal passing through said bore sealed in an alumina plug which, in turn, is sealed in a bore defined in the base.