Abstract: An apparatus and process for casting metals wherein the molten metal is contained and formed into a desired shape by the application of an electromagnetic field produced by a multi-turn inductor. The pitch or spacing of individual turns of the inductor is controlled to provide accurately varied electromagnetic pressure. The process includes the step of varying the distance between turns and/or the height of the individual turns to control the electromagnetic forces and balance the metallostatic pressure within the molten metal being cast.

Abstract: An apparatus and process for casting metals wherein the molten metal is contained and formed into a desired shape by the application of an electromagnetic field produced by a multi-turn inductor. The pitch or spacing of individual turns of the inductor is controlled to provide accurately varied electromagnetic pressure. The process includes the step of varying the distance between turns and/or the height of the individual turns to control the electromagnetic forces and balance the metallostatic pressure within the molten metal being cast.

Abstract: An apparatus and process electromagnetically forms feed ribbon or rod material into a desired thin strip shape. Inductors contain and form the material in molten form into the desired shape. There are at least an upstream and downstream inductor for applying the magnetic field to the molten material. Both the upstream and downstream inductors may be jointly used to contain and form the molten material into the thin strip shape. An alternating current is applied to the inductors to generate the magnetic field. This magnetic field defines a containment zone for the molten material and a gap between the molten material and the inductors. The current is applied to the inductors so that the gap remains substantially constant. The feed material has an upstream and a downstream liquid-solid interface adjacent the upstream and downstream inductors, respectively, which define the molten material head and solid material portions of the material.

Abstract: A process and apparatus for treating a metal foil to enhance its ability to be bonded to a substrate comprise immersing the metal foil in an electrolytic cell having an electrolyte bath solution containing copper and applying a current having regularly recurring pulses and preferably flowing in only one direction to the cell. The current causes a dendritic layer of copper to be deposited on at least one surface of the metal foil at a first current density and bonded thereto at a second current density. The process and apparatus are particularly suited for treating copper foil.

Abstract: A process for continuously treating a ferrous or non-ferrous alloy melt is disclosed. The melt is transferred through a plurality of interconnected zones. The carbon content of the melt is lowered in a first treatment zone. Then, the residual oxygen content of the melt is lowered in a second treatment zone by adding a deoxidizing agent to the melt. Active sulfide forming agents are added to the melt in the third treatment zone to lower the sulfur content of the deoxidized melt. The dissolved gas content of the desulfurized melt is lowered by flushing the melt with a gas in a fourth treatment zone. Next, the remaining particulates and films are removed from the melt by filtering the degassed melt in a fifth treatment zone.

Abstract: A copper-tin alloy having improved wear performance and a process for forming the alloy is described herein. The alloy consists essentially of about 2% to about 11%, preferably about 3.5% to about 9% tin, about 0.03% to about 0.75%, preferably about 0.08% to about 0.5% phosphorous and the balance essentially copper. The processing for improving the wear performance includes a final heat treatment at a temperature in the range of about 400.degree. C. to about 650.degree. C., preferably about 500.degree. C. to about 600.degree. C. in an atmosphere having a dew point in the range of about -75.degree. C. to about +95.degree. C., preferably -57.degree. C. to +21.degree. C. and an oxygen level in the range of about 0.001 ppm to about 225 ppm.

Abstract: A method and apparatus for assembling an optical fiber communication cable comprises forming a tubular member out of a strip of metal or metal alloy and sealing the tubular member. After the tubular member has been sealed, at least one optical fiber and a cushioning material are deposited into the member.

Abstract: A process and apparatus for continuously casting molten metal is described. To substantially reduce the risk of tearing the forming metal shell and adversely affecting the casting process and ingot quality, lubricant is supplied to the casting mold and at least that portion of the molten metal supply system where freeze-back is most likely to occur. In a preferred embodiment, a system for delivering cooled lubricant is embedded within the material forming the outlet portion of the molten metal supply system.

Abstract: A composite material having improved bond strength and a substantially smooth external surface comprises a deoxidized copper alloy core material and a copper-aluminum-silicon clad material. The composite is formed by rolling together the core and clad, preferably in an unheated condition, in a single pass with a reduction of about 50% to 75% to form a metallurgical bond between the core and clad and thereafter enhancing the bond strength by heating the bonded core and cladding to a temperature in the range of about 200.degree. C. to about 750.degree. C. for a time period of about 5 minutes to about 24 hours.

Abstract: The process of forming a composite with an alloy having an alloy component of about 0.5 to 12% aluminum and a matrix selected from a material of the group consisting of copper, iron or nickel. The alloy is heated in an oxygen-rich atmosphere to form a material oxide-rich layer on a surface of the alloy. The alloy is then heated in a reducing atmosphere to reduce the material oxide-rich layer to form an aluminum oxide on the surface of the alloy and a material-rich layer on the aluminum oxide layer.

Abstract: A system for machining and sizing optical fibers is described herein. The system uses a laser beam to machine oversized regions of a buffer material surrounding an optical fiber to create a coated optical fiber having a substantially uniform maximum outer dimension that is within a desired tolerance. The machining of the buffer material is accomplished by forming a substantially cylindrical laser beam having a hollow central portion and passing the optical fiber to be sized through the hollow central portion. The hollow central portion has a dimension or diameter substantially equal to a desired outer dimension or diameter for the optical fiber. Any discontinuities or oversized regions of buffer material outside the hollow central portion diameter will be contacted and vaporized by the substantially cylindrical laser beam.

Abstract: Copper alloys are disclosed which may be bonded to aluminum containing members with reduced formation of undesirable copper-aluminum intermetallic compounds. The copper alloys consist essentially of about 15% to about 30% nickel and the balance essentially copper. The nickel addition in the alloys suppresses the nucleation rate and the subsequent growth rate of copper-aluminum intermetallic compounds. The copper alloys of the instant invention have particular utility in integrated circuit assemblies as lead frames, lead wires and beam lead tapes.

Abstract: An apparatus and process for casting metals wherein the molten metal is contained and formed into a desired shape by the application of an electromagnetic field established by an inductor. The height of the liquid metal head, the location of the liquid-solid interface at the periphery of the forming ingot, and/or variations in the values of these parameters is displayed during the casting run by a system which monitors the in-phase component of the voltage across the inductor to determine variations in the total equivalent series resistance of the electromagnetic casting system as seen by the inductor.

Abstract: A multi-strand apparatus and process is provided for casting molten materials into ingots of desired shape. The apparatus comprises a plurality of devices for receiving and electromagnetically forming the molten material into desired shape. Each of the receiving and forming devices includes an inductor for applying a magnetic force field to the molten material. The inductor in operation is spaced from the molten material by a gap extending from the surface of the molten material to the opposing surface of the inductor. An alternating current applying device sends current to its associated inductor to generate the magnetic force field. Circuitry associated with each of the inductors senses variations in their respective gaps. The improvement comprises a pulse width modulating circuit associated with said gap variation sensing circuitry being connected to the alternating current applying device for controlling the application of alternating current to the inductor.

Abstract: A process and apparatus for forming a thin-walled, elongated member having superior strength properties from an age hardenable copper base alloy is described herein. A slug or billet of a slurry cast, age hardenable copper base alloy is formed into a semi-solid slurry having about 10% to about 30% of the alloy in a liquid phase. The semi-solid slurry is then thixoforged to form the thin-walled, elongated member. Thereafter, the member is age hardened to provide a product having desired strength properties. The process and apparatus of the instant invention may be utilized to form cartridge casings.

Abstract: A system for machining and sizing optical fibers is described herein. The system uses a laser beam to machine oversized regions of a buffer material surrounding an optical fiber to create a coated optical fiber having a substantially uniform maximum outer dimension that is within a desired tolerance specification. The machining of the buffer material to size the optical fiber is accomplished by generating at least one laser beam transverse to the buffer material, rotating the beam or beams about an axis coaxial with the optical axis of the optical fiber, and moving the fiber past the rotating laser beam or beams. The rotating laser beam or beams vaporize any excess or oversized regions of buffer material and substantially provide the optical fiber with the desired outer dimension or diameter.

Abstract: A composite comprises a first metal or alloy component having a thin refractory oxide layer on a first surface thereof. A second metal or alloy component has a second thin refractory oxide on the first surface thereof. Means are provided having a closely matched coefficient of thermal expansion to the first and second metal or alloy components for bonding the first and second thin refractory oxide layers and for electrically insulating the first component from the second component whereby thermal stress between the metal or alloy components and the bonding means is substantially eliminated.

Abstract: A process and apparatus for producing surface treated metal foil is described. The process comprises plating a relatively smooth metal foil onto a cathodic surface and thereafter forming a dendritic layer on the foil and firmly bonding it thereto while the foil is still on the cathodic surface. In one embodiment, the apparatus comprises an electrolytic cell containing an electrolyte, a rotating drum cathode at least partially immersed in the electrolyte, at least two primary anodes and a plurality of treatment anodes embedded in one of the primary anodes.

Abstract: An electrochemical cell for regenerating temperature sensitive solutions is described. In a preferred construction, the cell comprises a central electrode chamber and two counterelectrode chambers. To maintain the temperature of the electrolyte within a desired temperature range, the electrode in the electrode chamber is formed from at least one hollow tube through which a heat exchange medium flows. In a preferred construction, the electrode comprises a plurality of hollow tubes and a plurality of current collectors bonded to the tubes to form a grid-like structure.

Abstract: A casing for an electrical component comprises a metal lead frame having the electrical component connected thereto. A metal base member is bonded to one surface of the lead frame. A plastic housing member is bonded to a second surface of the lead frame. An adhesive seals and bonds the metal base member and plastic housing member to the lead frame so as to enclose the electrical component.