Abstract: A thin, forged magnesium alloy casing is integrally constituted by a thin plate with projections on either or both surfaces, and the thin plate is as thin as about 1.5 mm or less. The thin forged casing can be produced by (a) carrying out a first forging step for roughly forging a magnesium alloy plate to form an intermediate forged product under the conditions of a preheating temperature of the magnesium alloy plate of 350-500° C., a die temperature of 350-450° C., a compression pressure of 3-30 tons/cm2, a compressing speed of 10‥500 mm/sec. and a compression ratio of 75% or less; and (b) carrying out a second forging step for precisely forging the intermediate forged product under the conditions of a preheating temperature of the intermediate forged product of 300-500° C., a die temperature of 300-400° C., a compression pressure of 1-20 tons/cm2, a compressing speed of 1-200 mm/sec., and a compression ratio of 30% or less.

Abstract: An aluminum extruded door beam includes an outer flange, an inner flange, and at least one web for connecting the outer flange and the inner flange. The outer corners at the extended ends of the outer flange have a radius R of 2.5 mm or less. The outward corners at the connections between the web and the inner flange and between the web and the outer flange have a radius R of 2 mm to 4 mm. The radius of the outward corners at the connections between the web and the inner flange and between the web and the outer flange is 1.5 to 2 times the width of the web. The length of the extended ends of the outer flange is 1 to 2 times the radius R of the outward corner at the connections between the web and the outer and inner flanges. The aluminum alloy extruded door beam material contains 0.8 to 1.5% by weight (hereinafter the same) of Mg and 4 to 7% of Zn, and the recrystallization surface layer has a thickness of 50 &mgr;m or less.

Abstract: A component, particularly for land vehicles, preferably a car body component for motor vehicles, consists of a metallic foam material with a foamed porous layer comprising a metal powder and a blowing agent and possibly at least one solid metal sheet, there being metallic bonds between the solid metal sheet and the foamed porous layer. The component has at least one stamped contour which is raised from its surface, the angles, occurring in the region of the transitions between the three-dimensionally molded contour and the surface region being of the order of 100° to 180°. To produce the component, an essentially flat, metallic foam material, which is provided with solid metal sheets as covering layers, is initially shaped into a semi-finished molded product, which is end-contoured on one side, and the semi-finished molded product, so formed, is placed into a foaming mold, one wall of which is adapted to the end-contoured side of the semi-finished molded product and foamed therein.

Abstract: A method for corrugating a metal foil (11), which together with a longitudinally flat foil (12) is intended to form a foil package pervious to liquid or gas, where the folds are made with a very small fold radius by rolling in at least two steps between rollers (42, 43) disposed in pairs, the fold radius (51) being large and the fold height (52) low in a first step, and after the final step, the fold radius (53) is less than 10%, preferably 2 to 5% of the fold distance (55), and the fold height (54) is greater than after the first step.

Abstract: Solder paste is deposited using a solder stencil with an aperture having a concave edge in order to reduce the formation of solder balls. The solder deposit may be formed on a pad such that the paste has a concave edge. Solder paste deposits may be made on adjacent pads with the concave surfaces facing one another.

Abstract: A weldment of a welding construction has a first member formed with a curved face, and a second member welded to the curved face of the first member. The second member has an inner conical face overlying the curved face of the first member and extending to a first end of the second member, and an oblique face extending toward the first end of the second member so that a distance between the oblique face and the inner conical face becomes smaller gradually toward the first end of the second member.

Abstract: Provided is an energy absorbing member which makes it possible to induce contraction and deformation into a form of bellows, with Euler's buckle being restrained. An energy absorbing member comprises a hollow extrusion which is made of an aluminum alloy and has an outer portion and an inner rib connected to the outer portion, and the radius of the corner where the rib and the outer portion are connected to each other is not more than a half of the thickness of the rib. A similar energy absorbing member has plural inner ribs which are connected to the outer portion and cross each other, and the radius of the corner where the ribs cross each other is 1 mm or less.

Abstract: Solder paste is deposited using a solder stencil with an aperture having a concave edge in order to reduce the formation of solder balls. The solder deposit may be formed on a pad such that the paste has a concave edge. Solder paste deposits may be made on adjacent pads with the concave surfaces facing one another.

Abstract: An aluminum extruded door beam includes an outer flange, an inner flange, and at least one web for connecting the outer flange and the inner flange. The outer corners at the extended ends of the outer flange have a radius R of 2.5 mm or less. The outward corners at the connections between the web and the inner flange and between the web and the outer flange have a radius R of 2 mm to 4 mm. The radius of the outward corners at the connections between the web and the inner flange and between the web and the outer flange is 1.5 to 2 times the width of the web. The length of the extended ends of the outer flange is 1 to 2 times the radius R of the outward corner at the connections between the web and the outer and inner flanges. The aluminum alloy extruded door beam material contains 0.8 to 1.5% by weight (hereinafter the same) of Mg and 4 to 7% of Zn, and the recrystallization surface layer has a thickness of 50 &mgr;m or less.

Abstract: This invention relates generally to a structure and process for thin film interconnect, and more particularly to a structure and process for a multilayer thin film interconnect structure with improved dimensional stability and electrical performance. The invention further relates to a process of fabrication of the multilayer thin film structures. The individual thin film structure is termed a compensator, and functions as both a ground/reference plane and as a stabilizing entity with regard to dimensional integrity. The compensator is comprised primarily of a metal sheet having a metallized via pattern and high-temperature stable polymer as an insulator.

Abstract: A first member and a second member have end portions overlapped and welded by irradiating a laser beam on an outer surface of a lap portion. A front end surface of a fused portion slants at an obtuse angle larger than 90° with respect to a naked outer surface of the second member. A dilution rate S=B/(A+B) is equal to or less than 45%, where “A” represents a cross-sectional area of the fused portion merging into the first member and “B” represents a cross-sectional area of the fused portion merging into the second member.

Abstract: A welded joint suitable for connecting armor plates in armored vehicles obtained by providing one of the armor plates, or an interconnecting element, with a semi-circular rounded lobe; and welding the lobe to the plate to be joined to form a U-shaped welded region such that the ends thereof are directed to the outside edge of the plate so that a crack formed in the weld will tend to propagate along the weld to the outside of the plate. The joint can be used for lap joints, angled joints, and joints involving multi-layers of plates. The joints facilitate utilizing the armor plates to provide a unitary mechanical structure for the vehicle.

Abstract: An expanded metal with an aerodynamic cross-section for use in high velocity fluid flows to decrease pressure drop. The expanded metal has a rhomboid cross-section with the acute angle of oriented into the flow. Also disclosed is a method of making the expanded metal.

Abstract: A method of overlaying by a laser beam, comprises the steps of: relatively moving and irradiating a laser beam with respect to a base metal and simultaneously putting an other metal material than the base metal material on the base metal surface; and forming an overlay layer by melting the other metal material, wherein the overlay operation is performed in such a manner that an inclined angle .theta. with respect to the base metal surface of the beginning end portion surface becomes a range of 8.degree.<.theta.<27.degree..

Abstract: A base plate wherein the inner barrel of the base plate hub is comprised of two distinct zones. The first zone is an inner diameter sized for use with standard tooling pins in an assembly process as a metric for size control. The second zone is a taper for distributing tension swage force and plastic strain toward the rear part of the hub by making the hub stiffer as the swage ball proceeds downward through the barrel, and for distributing compression swage force and plastic strain toward the rear of the hub by relieving stiffness as the swage ball proceeds upward. A back side slope is provided to prevent washed metal from creating added swage force and plastic strain during swaging in the compression direction. The base plate has a minimal counter bore, a lead-in chamfer which is shallower than typical, a second lead-in chamfer which is very steep and upon which the ball begins to swage, a small inner diameter region to allow for tooling during assembly, and a tapered backside to reduce unneeded material.

Abstract: An edge prepared with a groove face leaving a vertical root face is combined with another edge prepared with an opposing groove face, a step for receiving a bottom of that edge to be welded thereto, and another step defined by a vertical abutment face for abutting on the root face and a horizontal flat surface, so that a weld groove is continuously defined by the groove faces and the flat surface.

Abstract: An informative card, such as a baseball trading card, has a rectangular shape and is made of a single thin sheet of metal in such a way that it is free of pointed corners or exposed raw edges. The informative card has four rounded corners and a double-thickness frame defined by a folded lip which has four straight edges and four rounded connectors joining the straight edges at the corners. The folded lip provides an unbroken radiused peripheral edge bordering the card. A central display panel of the card is offset rearwardly to form a raised ledge on the front side of the card surrounding the central display panel.

Abstract: A process resulting in enhanced pole performance, relative to permalloy poles, in narrow track magnetic devices. A preferred process includes increasing the anisotropy field of the pole material while maintaining an acceptable coercivity level and near zero magnetostriction. One embodiment utilizes a NiCoFe alloy containing 22% cobalt by weight, heat treated in an easy axis magnetic field in a non-oxidizing atmosphere. This process achieves favorable domain structures at narrow pole tip widths.

Abstract: A method and apparatus are provided for reducing or eliminating sliver formation during aluminum sheet trimming operations. By controlling parameters such as trimming angle and cutting blade clearance, aluminum sheet can be trimmed while substantially eliminating the formation of slivers which damage the surface finish of the part. Cutting angle and clearance are preferably selected such that a wide range of cutting blade sharpnesses produce satisfactory cuts. The method and apparatus are particularly useful for trimming aluminum autobody sheet.

Abstract: The workpiece is obtained by cutting a metal product by oxygen cutting. An oxygen cutting jet is sent onto a preheated cutting zone of the product. A peripheral sleeve of additional gas is formed around the oxygen cutting jet so as to send, into the cutting zone, a coaxial double jet constituted by the oxygen jet surrounded by the sleeve of gas at a pressure of less than 1 bar. The flow rate and the pressure of the cutting oxygen and of the additional gas are regulated separately. The invention also relates to an oxygen-cutting device for implementing the method and to the metal part obtained.

Abstract: A highly efficient impact absorber for protecting articles against destructive mechanical impact. The invention has special applicability to containers for flammable materials, scientific instruments, or other fragile mechanisms or articles which may be damaged or become hazardous when ruptured. The impact absorber comprises a layer or layers of expanded metal net made from magnesium alloy foil having a thickness in the range from about 0.02 to 0.50 mm. A preferred embodiment comprises a contained layer or layers of nested spheroids formed from expanded metal sheets made from magnesium foil.

Abstract: An antitheft label composed of a soft magnetic metal strip permanently applied to an electroconductive nonmagnetic metal member. The label is attached to an object to prevent the object from being stolen or taken without permission. An object, such as food goods, having such an antitheft label can be thawed or heated in a high-frequency heater such as a microwave oven without developing spark discharge at edges of the soft magnetic metal strip of the label, thereby preventing the occurrence of fire damage to the food product.

Abstract: An antitheft label composed of a soft magnetic metal strip permanently applied to an electroconductive nonmagnetic metal member. The label is attached to an object to prevent the object from being stolen or taken without permission. An object, such as food goods, having such an antitheft label can be thawed or heated in a high-frequency heater such as a microwave oven without developing spark discharge at edges of the soft magnetic metal strip of the label, thereby preventing the occurrence of fire damage to the food product.

Abstract: A method of brazing and apparatus therefor wherein two elements are bonded together using pre-formed fillet material. In accordance with a first alternative embodiment, the pre-formed fillet material comprises a depression formed on a first surface of one of the elements by a punching operation. The preformed fillet material also comprises a protrusion formed on a second surface opposite the depression formed by the punching operation. The invention also comprises a method of reducing bending stress in a Coriolis flow tube by bonding the flow tube and a brace bar with preformed fillet material.

Abstract: A honeycomb structure includes at least two corrugated strips having major flat surfaces extending angularly between opposed strip edges. The strips are offset relative to each other and joined together to define a series of cells extending between the strip edges along axes which are oriented at an angle other than normal to the strip edges. Each of the major flat surfaces includes a central depressed portion forming a matching sub-flat surface which is parallel to and connected to the major flat surface by sidewalls which may be substantially perpendicular to the major flat surface. Abutting undepressed portions of the major flat surfaces of adjacent strips and abutting sub-flat surfaces of adjacent strips are joined together so that the strips form a series of I-beams disposed one to a cell.

Abstract: A novel method is disclosed for producing honeycomb structures with a virtually non-abrasive smoothly rounded edge between opposed end surfaces of the honeycomb structure and a peripheral bounding wall, so as to avoid detrimental cutting and abrading of surrounding supporting and insulating material utilized in vehicular applications.

Abstract: Non-spherical bodies having a circular cross-section that is 0.5-200 microns in diameter and that are longer than the cross-sectional diameter, and a method of making such bodies by reshaping non-spherical bodies. The method comprises positioning a monolayer of unsintered, deformable, spherical bodies between smooth facing surfaces on two flat formers, and applying a mild shearing force to at least one of the formers.

Abstract: The metal core used for reinforcing tire beads is constituted by a plurality of coils of wire (16), (17), (18), axially arranged side-by-side and radially superimposed, in which the wire has a cross section of modular shape with two equal and parallel opposite sides (1), (2), the profiles (15) of the corresponding ends of the opposite sides having a distance, from the axis of said pair of sides, whose value varies from one side to the other, said variation comprising at least one symmetrical deviation along, the development of its cross sectional profile.

Abstract: The present invention relates to a pattern for castings and the castings produced from the pattern. The pattern comprises a pattern plate including a parting plane, at least one multistage draft and at least one substantial draft extending from the parting plane. A casting having a suitable draft includes corner portions formed by the parting plane.

Abstract: A composite bar structure is composed of at least outer and inner members extending parallelly in the longitudinal direction of the structure and joined mechanically at an interface therebetween in an interlocked. The structure is fabricated by forming a plurality of projections on the inner member over the entire interface, preparing the outer member in a tubular shape to readily encompass the inner member, relatively positioning the members to place the inner member within the outer member in telescoped state, and applying a constrictive compression force on the outer member so that it undergoes plastic deformation and reduction in diameter, whereby the projections bite into the inner surface of the outer member. The members are thus joined tightly to form the integral composite bar structure.

Abstract: Butt joints between materials having different coefficients of thermal expansion are prepared having a reduced probability of failure of stress facture. This is accomplished by narrowing/tapering the material having the lower coefficient of thermal expansion in a direction away from the joint interface and not joining the narrow-tapered surface to the material having the higher coefficient of thermal expansion.

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 corrugated metal decking having alternating crests and troughs and interconnecting therebetween a decking web that is characterized by improved stiffening means, in particular in the form of embossments or indentations. There are provided a plurality of linear indentations, each extending across the decking web between the crest and trough walls. These indentations include inner and outer formed indentations, formed symmetrically about the web center plane with the length of each indentation being in the range of 70%-90% of the web cross-dimension and with the indentations being closely spaced. This arrangement provides for superior web stiffening and also provides improved composite action for interlocking between the metal decking and the concrete.

Abstract: Produced flake like metal chip has a shape being convexed in one side and concaved in the other side in its cross section.These metal chips are produced by dipping spherical or cone shaped projections provided on an outer surface of a rotary drum into molten metal contained in a molten metal reservoir, the molten metal adheres to each projections being dipped then the adhered molten metal is stripped off of each projection after at least a part of the molten metal has solidified.The apparatus for working the above-mentioned method includes, a molten metal reservoir, a rotary drum carrying on its outer surface a number of aforesaid projections, to the tip end of which the molten metal is adhered, and a means for stripping off the adhered molten metal after at least a part of the adhered molten metal has solidified.

Abstract: A corrugated metal decking having alternating crests and troughs and a decking web disposed angularly out of the vertical, a plurality of linear indentations each extending across the decking web in a direction between the crest and trough walls, said indentations being disposed in a parallel array, the length of each indentation being less than the full width of the decking web but extending over a substantial major fraction of the web width, said indentations being provided in contiguous alternating inner and outer formed indentations substantially symmetrical about the web plane, the length of each indentation being in the range of 70% to 95% of the web width, said web being joined to the crest and trough walls by a radius bend, the indentation length being on the order of but less than the dimension a-2R, where a is the web width and R is the radius of the bend and said indentations do not extend into crest walls, trough walls or radius bends.

Abstract: The present invention is concerned with a steel fiber for reinforcing concrete. The steel fiber according to the present invention is a needle-shaped chip resulting from directly machining a steel ingot material. The fiber has a wrinkled surface with a plurality of rugged waves along the length of the fiber. This new production employs a plain milling cutter having a plurality of cutting edges of negative rake angle and twist angle with respect to an axis of the cutter for machining the ingot material by a down-cut milling under conditions of high speed and short depth of cut.

Abstract: Steel block is directly subjected to cutting to produce steel fibers for reinforcing concrete, which are flat within determined conditions that if length of the steel fiber is L, width is W, thickness is t and flat index is N, and if L is 20 to 40 mm, N=W/t=7 to 9, wherein W=1.5 to 2.5 and t=0.2 to 0.3 mm.

Abstract: An improved ingot shape which when rolled to sheet or plate does not form laminated edges which must be trimmed. The narrow faces of the generally rectangularly shaped ingot have recesses along the length of the upper and lower portions thereof. The land area between the two recesses on each narrow face extends outwardly beyond the top and bottom edges of the ingot.

Abstract: An extruded section bar member for use as a vertical support in furniture, particularly in industrial and office furniture, comprising a cross section corresponding to an elongated rectangle with rounded edges and including T-grooves recessed into its long sides for receiving fastening elements.

Abstract: The method and apparatus for forming flanged holes and a resulting plate and tube assembly of the type used in fluid-to-fluid, such as gas-to-gas, liquid-to-liquid and liquid-to-gas, heat exchangers. A depression is formed with the aid of a punch in a plastically deformable metal sheet such as steel, aluminum, copper and the like, while applying controlled counterpressure with the aid of a larger counterpunch so that material displaced from the space between the punches is laid upon the inner bore of a constraining die. Thus the wall of the depression is formed by purely compressive means. The base of the depression may then be removed to provide deep flanges of controlled dimensions free of cracks or splits.

Abstract: An improved magnetic disk recording device having a smooth recording medium layer covered with a protective film layer whose surface is formed with radially extending sinusoidal jogs or undulations defining a surface roughness greater than that of the underlying recording medium. These jogs act to avoid wear due to the adhesiveness between the device and a recording or reproducing head. The jogged protective film layer is formed by using a solvent of specified boiling point in a spin-coating process.

Abstract: This invention is concerned with the production of steel fiber by machining a thick steel plate or block for reinforced concrete, where a milling cutter having a plurality of cutting edges is positioned on the steel plate or block and is moved relatively in the horizontal direction. A surface of said plate or block is machined by the rotating cutting edges to chop steel fibers of approximate triangular in cross section. According to this method, steel fibers of high quality may be economically produced.

Abstract: A blank for a stone setting comprising a base and prongs extending radially therefrom, said blank having a planar lower side and a notched upper side, the notches at the upper side defining at the junctions of the prongs with the base hinges which enable bending the prongs upwardly relative to the base to form a stone cage and at the distal ends thereof a seat for the stone and tangs for fixing the stone against the seat. A method of making a setting including making the blank by striking it from malleable sheet metal, removing parts of the sheet metal from around the bank, stripping the blank from the sheet metal, using a punch to force it into a die for bending the prongs and tangs at their notched areas to shape it into a cage. A further method of setting a stone by seating a stone against the seat at the top of the cage and bending the tangs against the stone.