Abstract: A highly aligned rare-earth transition metal alloy magnet material such as samarium-cobalt (SmCo.sub.5). The high degree of alignment is evidenced by an isolated X-ray diffraction pattern peak for Cu.sub.k.alpha. radiation at a interplane "d" spacing of 2.0 A.degree. and is produced by very high temperature deposition of the material on a hot surface. The surface temperature is maintained well above 800 degrees centigrade and most preferably is initially set at approximately 1020 degrees centigrade or higher at which temperature the isolated diffraction pattern peak dominates. A higher temperature typically occurs during deposition. Deposition of the material on the surface typically takes place by application of the material as a fine, homogeneously sized powder to the plasma flame of a plasma torch. The surface may be preheated by the application of the plasma flame to the surface without the application of the powdered material.

Abstract: The invention relates to a process and an apparatus for the plasma deposition of protective coatings and near net shape bodies using induction plasma technology. The apparatus comprises an induction plasma torch in which the particulate material to be deposited is accelerated and injected axially into the discharge. As the particles traverse the plasma they are heated and melted before being deposited by impaction on the substrate placed at the downstream end of the plasma torch facing the plasma jet.

Abstract: Methods are described for making a mirror useful in reflecting high energy laser radiation. The mirrors are comprised of an intermediate coating layer applied to the mirror substrate and a reflective coating layer applied to the intermediate layer. Plasma spray techniques are used to apply a readily polishable intermediate coating layer at high deposition rates.

Abstract: A process is disclosed for producing discontinuous metal foils. The process involves entraining metal powder particles in a carrier gas and passing the powder particles through a high temperature zone at a temperature above the melting point of the powder particles to melt at least about 50% by weight of the powder particles and thereafter resolidifying the resulting high temperature treated material by impacting the material against a substrate to form the foils.

Abstract: A method of cladding an internal cavity surface of a metal object is disclosed. The method includes the steps:(a) applying a powder metal layer on said internal surface, the metal powder including metal oxide or oxides, borides and carbides,(b) filling a pressure transmitting and flowable grain into said cavity to contact said layer,(c) and pressurizing said grain to cause sufficient pressure transmission to the powder metal layer to consolidate same.

Abstract: The invention relates to a process and composition for trapping coloring or non-coloring liquids, in a non-woven textile consisting of fibers, characterized in that said textile is metallized under vacuum by spraying metal particles onto at least one face of the textile and along a portion of its thickness in such a way that the surface fibers, or those in the immediate vicinity of the surface, are coated with metal while remaining independent of each other.

Abstract: A blast material for the mechanical plating and a continuous mechanical plating process. The blast material comprises up to 90% by weight of steel shot not less than 10% by weight of an alloy powder which comprises 2.5-50% by weight of iron, not more than 5% by weight of at least one of aluminum, copper, tin, magnesium and silicon, the balance being zinc, and has a maximum particle size of about 0.4 mm and an average hardness of 140-450 Hv., The continuous mechanical process comprises continuing blasting, recycling the used blast material and magnetically separating the abraded fine particles of the steel shot in the course of the recycling.

Abstract: Preselected surface areas of a prosthesis are covered by a blend of matching primary metallic particles and expendable particles. The particles are compressed and heated to assure that deformation and metallurgical bonding occurs between them and between the primary particles and the surface boundaries of the prosthesis. Porosity is achieved by removal of the expendable material. The result is a coating including discrete bonded particles separated by a network of interconnected voids presenting a homogeneous porous coating about the substrate. It has strength suitable for bone implant usage without intermediate adhesives, and adequate porosity to promote subsequent bone ingrowth.

Abstract: A method of and an apparatus for supplying a powdery material to a workpiece to be processed thereby. According to the method, the powdery material is discharged from a hopper and metered, and then fed into a tube extending in the vicinity of the workpiece. Ultrasonic vibrations are imparted to the tube to supply the powdery material to a portion to be processed of the workpiece while the amount of the supplied powdery material is being detected. The apparatus includes a hopper for storing the powdery material, the hopper having an outlet, a tube extending from the outlet to a position adjacent to the workpiece for conveying the powdery material therethrough, and an ultrasonic vibrating device mounted on the tube for imparting ultrasonic vibrations to the tube, and a device mounted on the tube for detecting the amount of the powdery material supplied through the tube.

Abstract: A method for coating a surface comprises providing an electrostatically charged powder, irradiating the powder with energy until the powder or the surface melts, and allowing the surface to solidify.

Abstract: A gasket made of compressed expanded graphite particles bonded to an apertured reinforcement plate whose apertures are bridged by a relatively narrow area, as in a cylinder head gasket, is made by pressing the graphite particles onto the face of the plate without transverse support of those particles at the periphery of the plate apertures, by pressing between two compressor belts.

Abstract: Method of manufacturing a metallic composite article, with which the surface area of a base member, which surface area consists of a metallic base material, is bonded to a plating material over the entire surface. The base member is to be plated with a layer which is as far as possible homogeneous and thin and the composition of which is freely selectable. For this purpose, the plating material is placed in a sheet-metal cap which is adapted to the surface area to be plated as well as to the adjacent area of the base member surrounding this surface area and overlaps this adjacent area. Once the plating material and sheet-metal cap have been pressed against the base member the sheet-metal cap is evacuated and welded by electron beam, under vacuum, to the base member, whereupon base member, plating material and sheet-metal cap are hot-isostatically pressed. The sheet-metal cap is then removed, leaving the desired, plated base member.

Abstract: A method for coating a substrate with rapidly solidified metal which comprises spraying a mixture of rapidly solidified metal powder and small peening particles at high velocity against the substrate, said velocity being sufficient for the rapidly solidified metal powder and peening particles to impact the substrate and simultaneously bond the metal powder to the substrate. If the substrate is metallic, the method may provide the simultaneous mechanical working of the substrate surface.

Abstract: A ceramic shaped body having an improved mechanical strength which is useful for a structural material, such as engine parts, is produced by coating a slip which is substantially the same in the chemical composition as the ceramic shaped body and is very small in the difference of the thermal expansion coefficient at 800.degree. C. from the shaped body, on the surface of the shaped body, drying the coated shaped body, subjecting the thus treated shaped body to a hydrostatic press and firing such a shaped body.

Abstract: An oxidation resistant coating is produced on carbon-base materials, and the same processing step effects an infiltration of the substrate with silicon containing material. The process comprises making a slurry of nickel and silicon powders in a nitrocellulose lacquer, spraying onto the graphite or carbon-carbon substrate, and sintering in vacuum to form a fused coating that wets and covers the surface as well as penetrates into the pores of the substrate.Optimum wetting and infiltration occurs in the range of Ni-60 w/o Si to Ni-90 w/o Si with deposited thicknesses of 25-100 mg/cm.sup.2. Sintering temperatures of about 1200.degree. C. to about 1400.degree. C. are used, depending on the melting point of the specific coating composition.The sintered coating results in Ni-Si intermetallic phases and SiC, both of which are highly oxidation resistant. The final coating composition can be further controlled by the length of the sintering time.

Abstract: A reactor tube for thermally cracking or reforming hydrocarbons comprising a tube member made of Fe-Cr-Ni heat resisting material and a covering layer of self-fluxing alloy fusing to the inner surface of the tube member, the covering layer made of heat resisting material free from Ni or with a low Ni content. The tube member is manufactured by centrifugal casting, and the covering layer is formed by applying the self-fluxing alloy powder by scattering with or without thermit agent or spraying the alloy to the inner surface of the tube member.

Abstract: The surface properties of solid substrates are improved by the formation of discrete sites of inorganic materials on one surface of the substrate.

Abstract: A wear resistant coating on ceramic or metallic substrates is provided by coating the substrate with a titanium based alloy and then converting the titanium to titanium carbide, titanium nitride, titanium carboxynitride or titanium boride.

Abstract: A process for the surface treatment of inorganic fibers for reinforcing titanium or nickel, comprising the steps of coating the surface of inorganic fibers with an aqueous or organic solvent solution containing a titanate, borate, tetralkylammonium hydroxide and, if desired, dextrin and then heat treating the coated fibers at a high temperature in an inert or non-oxidizing atmosphere. In one embodiment, the heat treated inorganic fibers is further subjected to ionic or chemical plating with nickel.

Abstract: A method of forming a clinically unbreakable composite structure between a noble based metal and a ceramic comprising depositing a thin layer of a bonding material including finely divided particles of a noble metal halide alone or in combination with particles of a noble metal; sintering the layer at a predetermined temperature between 1775.degree. F. and 1975.degree. F. and firing a ceramic over the sintered coating.

Abstract: A protective sheet for a cassette holding a magnetic recording tape comprises a transparent base which is coated with a hardened surface layer formed by bonding hard fine particles with a binder.

Abstract: A method for forming an anticorrosive coating on the surface of a metal substrate, which comprises, in one embodiment, (1) coating the surface of the metal substrate with an anticorrosive metal capable of forming an alloy with the substrate metal and/or a hydride of the anticorrosive metal; (2) heating the coated surface, and then; (3) heating the coated surface in a vacuum or in an atmosphere substantially inert to the metal coating and the metal substrate by irradiating the coated surface with electron beams, laser beams or a plasma arc to sinter the coated metal and form an alloy layer in the interface between the metal substrate and the metal coating and, in another embodiment, subsequent to Step (2) and prior Step (3) above, coating the coated surface with a solution of a thermally decomposable platinum-group metal compound and then heating the resulting coated surface at about 40.degree. C. to about 600.degree. C.

Abstract: A magnetic record for use in magnetic disc or drum recording playback systems is provided with at least a solid lubricant thin-film outer surface. The lubricant is applied to the disc surface by rubbing under pressure to obtain a uniform lubricant layer of a thickness less than the particle diameter of the original lubricant. By properly selecting the material underlying the surface layer, the lubricant can be made to strongly adhere thereto such that an excellent lubricating effect is obtained between the record and the recording/playback head.

Abstract: Iron-containing refractory balls, in a retorting process for oil shale, permit effective magnetic separation of the balls from the spent shale. These ceramic balls can be made by a process such as admixing powdered alumina and water to form an extrudable mixture, extruding to form cylinders, reshaping cylinders into balls, overcoating with iron particles, further overcoating with alumina, and firing.

Abstract: A method of cladding a wire with a powdered metal includes feeding the wire in its axial direction, applying powdered metal around its surface, compacting the applied powdered layer on the surface and subsequently continuously rolling-over the applied layer on a helical path to provide a helical zone of metallurgically bonded powdered material. The device of this invention has a storage container for powdered material, a rotary shaft defining at its center a forwardly tapering passage with an internal thread acting as a worm conveyor, the shaft being terminated with an exchangeable outlet nozzle, the nozzle supporting a set of cladding rollers, the axes of rotation of which are inclined at an acute angle to the axis of the passage. The driving arrangement for the rollers is preferably driven by a separate motor.

Abstract: Printed circuits are produced by an additive technique wherein a metal-loaded resinous ink is first printed on the board, the circuit next being covered with a conductive metal powder while the ink is still wet. The powder is then pressed into the ink and the circuit cured. Next, a solder stratum is alloyed with the powder as by a solder paste printed over the circuit and the board heated to cause the solder to alloy with the ink an powder substrates. A solder resist may then be applied selectively over the circuit and multiple layers of circuits may be built up on the board. The conductive ink is an epoxy resin loaded with a metallic powder, preferably copper, with a catalyst added to the ink. The solder paste is a lead-tin alloy containing antimony suspended in a binder and a flux.The apparatus employed to carry out the procedure includes silk screens and a roller arrangement for pressing the metallic powder into the ink. The press includes a plurality of progressively harder rollers.

Abstract: The production of a continuously advancing steel strip with a protective metal coating on only one face thereof by electrolytically depositing a thin primary coating of metal from an ionized metal salt bath onto said face, which is followed by a cleansing and drying thereof. Thereafter a predetermined quantity of coating metal in minute particulate form is deposited uniformly onto the coated face and is heated in a non-oxidizing atmosphere to fuse the particulate metal particles onto the thin primary coating followed by the sudden cooling thereof, while preventing the oxidation of the uncoated face during the fusing and cooling-off stages.

Abstract: The method of applying ohmic contacts to a semiconductor, such as a silicon body or wafer used in solar cells, by the use of arc plasma spraying, and solar cells resulting therefrom.

Abstract: A novel process for fastening ceramic material such as alumina or the like to metallic material such as an electrical conductor. The process is characterized by the fact that a solder wettable, oxidation-resistant barrier is used, on metal particles printed onto the ceramic. In some advantageous processes, the carbide layer allows metallizing processes to be carried out in non-hydrogen atmospheres. The process requires no expensive noble metal; and it utilizes a barrier material which is sufficiently stable to tolerate conductive film formation at high temperatures. Nickel-carbide coated nickel is a particularly favorable material for use in the invention because it is conductive, in the ohmic sense, and is readily wetted by common solders.Also disclosed are novel articles and compositions useful in practice of the process of the invention, and novel articles produced by the process of the invention.

Abstract: A powder suitable for flame spraying comprising particles of an alumino silicate glass, each of the particles being hollow and coated with an alloy containing, by weight, 80% nickel, 2.5% aluminium, 15.7% chromium and 1.8% silicon. The resultant coating is particularly suitable for use as a thermal barrier.

Abstract: The present invention relates to bonding a coating of polyarylene sulphide, for example polyphenylene sulphide, to a steel backing by the use of a ceramic or other non-metallic inter-layer or bonding layer. In some cases the bonding layer comprises a layer of fine particles bonded to the backing followed by a layer of coarser particles to which the coating can be more effectively bonded. This results on a coated steel backing capable of being deformed without the coating becoming detached. Such a coated backing is suitable for use as a bearing material, a chemically resistant material or as cookware.

Abstract: A metallic coating is applied to a metallic substrate by directing a laser beam on to the substrate and simultaneously directing a gas stream containing entrained particles of the coating material on to the area of laser impingement on the substrate. The particles are melted by the laser beam to form a pool of molten coating metal. Relative movement is effected between the laser beam and substrate so that a pool of molten coating metal traverses the substrate to form a solidified metallic coating which is fused to the metallic substrate.

Abstract: A method of cladding a wire with a powdered metal includes feeding the wire in its axial direction, applying powdered metal around its surface, compacting the applied powdered layer on the surface and subsequently continuously rolling-over the applied layer on a helical path to provide a helical zone of metallurgically bonded powdered material. The device of this invention has a storage container for powdered material, a rotary shaft defining at its center a forwardly tapering passage with an internal thread acting as a worm conveyor, the shaft being terminated with an exchangeable outlet nozzle, the nozzle supporting a set of cladding rollers, the axes of rotation of which are inclined at an acute angle to the axis of the passage. The driving arrangement for the rollers is preferably driven by a separate motor.

Abstract: An article fabricated from a resin (e.g. ABS, polycarbonates, polyethylenes, polyaryl ether, or polypropylene of platable grades) susceptible to softening when contacted with trichloroethylene or a mixture of trichloroethylene and methylene chloride is dipped into an alkaline detergent, rinsed, and immersed in an agitated bath (by volume, 90 parts of trichloroethylene, 9 to 10 parts of ethanol, and 0 to 1 part of methylene chloride--1 part of methylene chloride if the resin is polypropylene) to which copper or nickel has been added as a powder (50 to 150 microns, 200 to 250 grams per liter) whereupon the article is drained, dipped in an agitated bath of similar composition, and dried. Alternatively, the powder may be sprayed onto the article, after the article has been immersed in such a bath. Next, the article may be dipped in dilute nitric acid, rinsed and immersed in a non-catalytic bath for deposition of nickel.

Abstract: A printed circuit board and a method of making the same is disclosed wherein a powdered conductive composition is placed on a dielectric substrate in a matrix corresponding to the desired electrical circuit pattern. The powdered conductive composition is then heated by induction so that the conductive particles are sintered to form continuous conductive pathways secured to the dielectric substrate. The use of relatively high frequency induction currents coupled with a relatively small size of the conductive particles results in rapid heating of the powdered conductive composition while leaving the underlying dielectric substrate unaffected by the induction heating.

Abstract: A metallic coating is applied to a metallic substrate by directing a laser beam on to the substrate and simultaneously directing a gas stream containing entrained particles of the coating material on to the area of laser impingement on the substrate. The particles are melted by the laser beam to form a pool of molten coating metal. Relative movement is effected between the laser beam and substrate so that a pool of molten coating metal traverses the substrate to form a solidified metallic coating which is fused to the metallic substrate.

Abstract: There is provided an improved plasma spray powder composition for producing bearing surface alloy on a metal substrate, e.g. cast iron, said powder being characterized by the presence therein of a substantial amount of iron, molybdenum and a relatively small amount of silicon. Carbon may also desirably be present in the powder. When plasma sprayed, these powders yield a coating on a metal substrate, e.g. a cast iron piston ring, which is wear and scuff resistant.

Abstract: An improved method for manufacturing a composite metal wire including a core metal wire having extruded therearound a coating metal layer which is different in material from the core metal wire, includes feeding the coating metal into a narrow passageway which is defined between a circumferential groove formed on the outer edge of a rotary wheel and a close fitting surface of a fixed shoe block, carrying the coating metal towards an outlet end of the passageway by frictional drag with the surface of the passageway in accordance with the rotation of the wheel, and passing a core metal wire harder in material than the coating metal through a covering chamber of a larger cross sectional area which is provided with a die and a nipple at the front and rear portions, respectively, whereby the core metal wire is covered with the coating metal in the covering chamber so that a predetermined construction of a composite metal wire is extruded through the die.

Abstract: A photovoltaic cell is formed by applying electrical contact material through an antireflective coating on the light receiving surface of the cell by flame, arc or plasma spraying. The cell so formed has a metal contact spaced portions of which are in electrical contact with the light-receiving surface of the cell.

Abstract: There is provided a process, and the product resulting therefrom, for coating a refractory block or substrate with a small particle size form of at least one platinum group metal whereby a fused layer of such metal is formed on the refractory and is directly and strongly adhered on a surface thereof. This technique can likewise be employed in such a manner that the layer is a bonding agent for purposes of bonding a separate sheet of a platinum group metal to the refractory which structure can then be employed as a glass contacting member in apparatus for handling molten glass.

Abstract: A thermal spray method capable of directing plasticized powders against a substrate for deposition of a protective coating thereon is disclosed. Various structural details of the apparatus described enable the attainment of high particle velocities without melting the particles. The method is built around the concept of reducing the temperature of a hot plasma stream after the hot plasma stream is generated. Coating particles are injected into the hot plasma stream only after the medium is cooled. In detailed embodiments, a generated plasma is cooled by the addition of a diluent gas or by passing the generated plasma through an elongated heat exchanger upstream of the point at which the powders are to be injected. The plasma is accelerated after the plasma is cooled to recover velocity lost in the cooling step.

Abstract: By the process of this invention, printed circuits are prepared containing an electrically conductive wiring trace from materials having adherent and non-adherent surface areas, e.g., printed circuit substrates bearing an imaged photoadhesive layer. Onto the adherent surface areas of the material are applied ductile metal or alloy particles, and any excess particles are removed from the non-adherent areas. The metallized areas are conjoined, e.g., with silicon carbide brush or rounded metal rod. The conjoined areas can be electrolessly plated, electroplated or soldered. Multilayer printed circuits can also be prepared by repeating these steps with additional layers of photoadhesive material adhered to underlying printed circuits.

Abstract: Method for hard-facing metal substrates is disclosed using a hard facing material consisting essentially of combined vanadium, tungsten and carbon and from about 5 to about 40% by weight of chromium carbide with up to 15% by weight in the aggregate of cobalt, iron, molybdenum and nickel.

Abstract: The surface of a metallic substrate is coated with wear-resistant material by depositing on the surface a layer of a mixture of a coating powder including a metallic carbide with powdery silicon and heating said layer by exposure to a source of high density energy to bring about simultaneous evaporation of said silicon and fusion of said coating powder with bonding to said substrate. A coating of high surface porosity can be obtained.The substrate may be a piston ring for heavy-duty internal combustion engines.

Abstract: There is provided a process, and the product resulting therefrom, for coating a refractory block or substrate with a small particle size form of at least one platinum group metal whereby a fused layer of such metal is formed on the refractory and is directly and strongly adhered on a surface thereof. This technique can likewise be employed in such a manner that the layer is a bonding agent for purposes of bonding a separate sheet of a platinum group metal to the refractory which structure can then be employed as a glass contacting member in apparatus for handling molten glass.

Abstract: A method for metalizing the surface walls of a printed circuit board through hole to produce an electrically conductive path from one metallic layer of the board through the insulating plate to another metallic layer. A drill bit is forced through the board and into a block of soft conductor material. While the bit is turning the conductive cuttings from the block are carried to the hole in the insulating plate and smeared on the wall surface by the bit. The smeared conductive material creates an electrically conductive path between two metallic layers of the printed circuit board.

Abstract: The corrosion resistance of a base metal article is improved by frictionally applying a metal to the article which is capable of forming an intermetallic compound with the base

Abstract: Wear and corrosion resistant coatings are obtained using the plasma or d-gun techniques and applying a coating material consisting of carbides and nickel-containing base alloy having 6-18 wt.% boron.

Abstract: Apparatus for manufacturing a composite metal wire including a core metal wire having extruded therearound a coating metal layer which is different in material from the core metal wire. The coating metal is fed into a narrow passageway which is defined between a circumferential groove formed on the outer edge of a rotary wheel and a close fitting surface of a fixed shoe block, the cross-sectional area therebetween decreasing for half the distance between entry and discharge and thereafter increasing until discharge. The coating metal is carried towards an outlet end of the passageway by frictional drag with the surface of the passageway in accordance with the rotation of the wheel.

Abstract: An improved method for manufacturing a composite metal wire including a core metal wire having extruded therearound a coating metal layer which is different in material from the core metal wire, includes feeding the coating metal into a narrow passageway which is defined between a circumferential groove formed on the outer edge of a rotary wheel and a close fitting surface of a fixed shoe block, carrying the coating metal towards an outlet end of the passageway by frictional drag with the surface of the passageway in accordance with the rotation of the wheel, and passing a core metal wire harder in material than the coating metal through a covering chamber of a larger cross sectional area which is provided with a die and a nipple at the front and rear portions, respectively, whereby the core metal wire is covered with the coating metal in the covering chamber so that a predetermined construction of a composite metal wire is extruded through the die.