Abstract: A metal-coated particle is prepared by providing a disintegrator apparatus with a working chamber containing counter-rotating disks equipped with teeth design to accelerate particles towards one another, providing a first material and a second metal as powders, such that the first material is harder than the second metal and introducing the first material and second metal powders into the working chamber of the disintegrator apparatus, whereby the soft second metal collides with the hard material and is coated onto the surface of the hard first material. A metal-coated metal with an intermetallic interface is prepared by introducing a first material and a second metal as powders into a disintegrator working chamber containing counter-rotating disks and teeth designed to accelerate particles towards one another. The first material harder than the second metal and is capable of reacting with the second metal to form an intermetallic compound.

Abstract: A cold gas-dynamic spraying method for applying a coating to an article introduces into a gas particles of a powder of a metal, alloy, polymer or mechanical mixture of a metal and an alloy, the particles having a particle size of from about 1 to about 50 microns. The gas and particles are formed into a supersonic jet having a temperature considerably below a fusing temperature of the powder material and a velocity of from about 300 to about 1,200 m/sec. The jet is directed against an article of a metal, alloy or dielectric, thereby coating the article with the particles.

Abstract: A process for making an electrically conductive pattern on a substrate comprising coating the substrate with a solution of salts containing at least one supplementary element, drying and heat treating the salt coating at a temperature lower than the temperature at which oxides form from the salts, then forming a metal conductive pattern on the heat treated supplementary element coating. This process can be used to make printed circuits on ceramic substrates which are useful in hybrid circuits, for example.

Abstract: Powder-content of a powder-coating is enhauced. Powder material forms a skeleton structure. The clearances are filled with resin. The coating comprises a resin layer which bonds the power-compacted layer to the parts or any underlying powder-compacted layer. The work pieces on which a resin film may be preliminarily formed, is subjected to vibration or stirring together with the powder material and means for mediating the formation of the coating, which eans is of substantially smaller size than said work pieces and greater size than said powder material, as well as with or without the resin, to vibration or stirring in a container.

Abstract: A moving bed reactor for the treatment of fluid in a countercurrent process includes a reactor vessel having, in an upper region thereof, an inlet for receiving particulate material and an outlet for discharging treated fluid, the reactor vessel also having, in a lower region thereof, a downward tapering first funnel leading to an outlet, the first funnel guiding the particulate material to the outlet for discharge from the reactor vessel, the first funnel being formed by wall sections which mutually overlap in louvre fashion to create slot-shaped passages for the fluid to be treated to enter the vessel.

Abstract: Finely divided silicon carbide materials, particularly powders, whiskers and short fibers, are provided with a titanium nitride surface coating by the process of (i) placing a low carbon diffusivity layer atop the silicon carbon, (ii) placing a titanium metal coating atop the low carbon diffusivity layer, and (iii) nitriding the titanium metal.

Abstract: A conductive metal layer is formed on a substrate having a softening point above about 200.degree. C. by depositing copper and nickel particles having a substantially continuous oxide coating thereon on the substrate, and heating and pressing the metal particles at a temperature of at least 200.degree. C. Unlike similar methods wherein oxide coated metal particles are used, no developing agent is required to render the metal layer conductive. The coated substrates are useful for a variety of uses such as EMI shielding and printed circuit boards.

Abstract: Fine copper and nickel powders are well mixed in a preselected ratio with bonding agents and carriers as appropriate. The composition then may be patterned upon a substrate by screen printing and subsequent firing in a nitrogen atmosphere to produce a low sheet resistance, low TCR electrical resistor. Various alloy powders, inert materials, and glass frits may be used depending upon the desired characteristics.

Abstract: Manufacture of glass mold plungers utilizes a thermal spray gun having combustion chamber with an open channel for propelling combustion products into the ambient atmosphere at supersonic velocity. The method comprises injecting into the chamber a combustible mixture of combustion gas and oxygen at a pressure in the chamber of at least two atmospheres above ambient atmospheric pressure, feeding into the chamber a powder comprising self-fluxing alloy particles, and combusting the combustible mixture in the chamber means whereby a supersonic spray stream containing the powder is propelled through the open channel. The spray stream is directed toward a glass mold plunger substrate such as to produce a coating thereon which is ground and polished. The coating may be fused prior to grinding.

Abstract: A method for producing a dense and tenacious coating with a thermal spray gun including a nozzle member and a gas cap. The gas cap extends from the nozzle and has an inwardly facing cylindrical wall defining a combustion chamber with an open end and an opposite end bounded by the nozzle. An annular flow of a combustible mixture is injected at a pressure of at least two bar above atmospheric pressure from the nozzle coaxially into the combustion chamber. An annular outer flow of pressurized air is injected from the nozzle adjacent to the cylindrical wall. Powder particles having a heat-stable, non-fusible component and a heat-softenable component, and entrained in a carrier gas, are fed axially from the nozzle into the combustion chamber. An annular inner flow of pressurized air is injected from the nozzle into the combustion chamber coaxially between the combustible mixture and the powder-carrier gas.

Abstract: Method and apparatus for gas-metal arc deposition of metal, metal alloys, and metal matrix composites. The apparatus contains an arc chamber for confining a D.C. electrical arc discharge, the arc chamber containing an outlet orifice in fluid communication with a deposition chamber having a deposition opening in alignment wiht the orifice for depositing metal droplets on a coatable substrate. Metal wire is passed continuously into the arc chamber in alignment with the orifice. Electric arcing between the metal wire anode and the orifice cathode produces droplets of molten metal from the wire which pass through the orifice and into the deposition chamber for coating a substrate exposed at the deposition opening.

Abstract: A process for applying and bonding a solid lubricant on a substrate whose surface has depressions and pores. The process comprises depositing fine solid lubricant particles on the surface of a substrate to be lubricated in excess of a quantity sufficient to fill essentially all depressions and pores on the substrate surface, and thereafter burnishing the substrate to distribute and bond the lubricant particles on the substrate. Such burnishing of the substrate can be accomplished during its moving contact with another substrate during intended use. Maintenance of lubricity can be accomplished by depositing additional lubricant particles on the substrate and thereafter burnishing, and can be performed while the substrate is in moving contact with another substrate whereby this moving contact performs the burnishing operation.

Abstract: A method for producing consecutive layers of titanium and titanium nitride on a substrate to produce a contact and barrier layer between, for example, aluminum and silicon surfaces or silicide surfaces utilizing cathode sputtering in a one chamber magnetron sputtering system. The titanium and titanium nitride layers each occur as a plurality of individual layers formed in a cyclical process with temperature treatments being carried out between the deposition of the individual layers. During the deposition of the titanium nitride layer, the nitrogen concentration in the reaction gas is adjusted higher than that stoichiometrically required for production of titanium nitride. The resulting combined layers provide low mechanical stressing, good thermal stability, low contact resistance and similar advantages. The method may be employed for the production of megabit-DRAM cells and logic circuits.

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: To coat metallic or ceramic surfaces with hard substances by means of brazing, a powder mixture of 60 to 90% silver, 2 to 35% copper, 2 to 30% tin and/or indium and 2 to 20% titanium, zirconium, hafnium, chromium, vanadium, tantalum, niobium, titanium hydride, zirconium hydride and/or hafnium hydride together with an organic binder and then the hard-substance powder are deposited on the surface and heated to 900.degree. to 1200.degree. C. The particle sizes of the metallic powders must be less than the particle size of the hard-substance powder.

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: The process for optimizing the solidification of zinc on a steel strip (2) under the action of germs of crystallization constituted by zinc in the form of a fine powder, which are projected by a conveying fluid inside a case (1) onto the two sides of the strip (2), is characterized in that the temperature of the strip at the exit of the case (1) is measured and this temperature is maintained at an optimal value by regulating the flow of air blown into the case as a function of the difference between the measurement obtained and the optimal temperature.

Abstract: A method of bonding a metallic object to another object includes scatter coating an aluminum containing metal on the surface of the metallic object, after cleaning the surface, and bonding the metallic object to the other object with an adhesive. Where both objects are metallic, the surfaces to be bonded are each scatter coated with aluminum. The scatter coating can be formed by friction coating aluminum containing metal onto each metal surface to be bonded.

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 installation for the continuous coating of a strip, especially for the galvanizing of sheet steel.The object of the invention is to improve the quality of the coating and the uniformity of its crystallization, especially for thin sheets with low coating thicknesses. To achieve this result, the minimized flouring nozzle or nozzles are placed in an enclosure from which the strip leaves through a narrow slit and in which is provided means for maintaining a protective atmosphere inside this enclosure.Preferably, this enclosure is one with an enclosure surrounding the draining means, and means for recycling the protective atmosphere and for purifying it with respect to oxygen are provided.

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 manufacturing nuclear radiation shields consisting of neutron-absorbing boron carbide particles embedded in a heat-dissipating copper matrix. Copper is electroplated through a layer of loose, electrically nonconductive boron carbide particles on a metal substrate. The carbide particles may be deposited on the substrate while electroplating, and heat exchanger ductwork may be incorporated. To make cylindrical shields, a cylindrical metal substrate is rotated about its axis giving rise to centrifugal forces which hold the carbide particles on the inner surface and aid electrodeposition. A thermo-mechanical process is described in which boron carbide particles pre-encapsulated with copper are consolidated into a unitary mass on the inner surface of a heated cylindrical substrate with or without the aid of a roller within the cylinder.

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: In the manufacture of a bearing material containing an aluminum base alloy, one surface of a steel strip is washed and roughened; the aluminum base alloy is spread on the surface of the steel strip; and the aluminum base alloy and the steel strip are hot-rolled in the air to pressure-bond the former to the latter into a unitary structure. Prior to spreading the aluminum base alloy, an aluminum powder which well adheres to the steel strip may also be spread on the surface of the steel strip.

Abstract: A device is described for filtering zinc powder from an airstream which is exhausted from a galvanizing process. The device comprises an enclosed chamber to which the airstream is circulated for removal of zinc powder. The chamber has a horizontally disposed bottom surface in which there is a plurality of circular openings which are equally spaced about a vertical center axis and which lead to vertically disposed bag-type filters. An arm is coupled to a vertical drive shaft which is rotatable about the center axis. The arm is designed to move a circular cover from opening-to-opening to individually seal the openings from the chamber, so that the filters can be cleaned of zinc powder. The cover is freely mounted on the distal end of the arm such that the cover is supported on the bottom surface of the chamber as it moves in an arcuate pathway between the filter openings.

Abstract: An aluminide coating for a fuel cladding tube for LMFBRs (liquid metal fast breeder reactors) such as those using liquid sodium as a heat transfer agent. The coating comprises a mixture of nickel-aluminum intermetallic phases and presents good corrosion resistance to liquid sodium at temperatures up to 700.degree. C. while additionally presenting a barrier to outward diffusion of .sup.54 Mn.

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: The loss of zinc by vaporization when heating a zinc-aluminum coating to a temperature between about 427.degree. C. and 816.degree. C. (800.degree. F. and 1500.degree. F.) is significantly reduced by applying a zinc-aluminum coating containing about 30 to 75 weight percent zinc and the balance essentially aluminum to a mild carbon steel base which contains titanium in an amount sufficient to combine with all of the carbon in the steel and provide a small excess of uncombined titanium in the steel base, thereby providing a zinc-aluminum coated steel article which has improved corrosion and oxidation resistance when heated at temperatures between about 427.degree. C. and 816.degree. C. (800.degree. F. and 1500.degree. F.).

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 hydrogen permeation resistant barrier is formed by diffusing aluminum into an iron or nickel alloy and forming an intermetallic aluminide layer.

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: 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: 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: 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: 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: A process is disclosed for the production of a sun heat energy absorbing coating on a metallic substrate. The metallic substrate is pretreated for subsequent coating with a film of powder varnish and thereafter a coating based on a solid synthetic resin is deposited electrostatically or in a whirl sintering procedure. The coating consists of an inner brightening layer containing a metallic powder and an outer colored second layer absorbing the sun energy.

Abstract: A mechanical plating process in which a work piece is plated without the necessity of tumbling the work piece in a barrel. A plating member having a plurality of plating elements is positioned with the plating elements adjacent a surface to be plated. Void spaces between the plating elements form reservoirs for liquid plating medium, containing a carrier liquid and plating metal particles. The liquid plating medium is supplied to the work area and to the reservoirs formed by the void spaces. A mechanical plating layer is formed by the plating metal particles by moving the plating member over the work surface with the plating elements, such as bronze wire elements, urged against the work surface. Additional plating medium is supplied to the work area and to the reservoirs during the plating operation to build up an adherent, mechanically applied, metal coating. The plated metal particles are preferably supplied to the work zone in flocculated form.

Abstract: Aluminum diffusion can be effected from continuous coatings of leafing-type aluminum particles and such leafing coatings in very thin layers are more effective than coatings of non-leafing aluminum, with or without diffusion. Other protective metals in flake or leaf form can be substituted for or added to the leafing aluminum. Adhesion of the flakes to the substrate is greatly improved and can be effected at lower temperatures if the flakes are applied from a dispersion containing a volatilizable halogen-type carrier or an ammonium chromate. The leafing coatings can be sprayed on from aqueous dispersion containing wetting agents and if desired a polyethylenetrtrafluoroethylene and/or mixtures of phosphoric acid, chromic acid and magnesium, aluminum, calcium or zinc salts of these acids.

Abstract: A method of forming a high-temperature abrasion-resistant hard facing or coating on a ferrous metal substrate by employing an aluminothermic reduction reaction. The resultant article has a hard facing layer containing from 2 to 8 percent boron. Hard faced composite articles made by the invented method, such as sintering machine crash decks, coke pusher ram shoes and grizzly bars are also disclosed.

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.