Abstract: A method of making stock for fabricating a hollow metal ball bat, the stock having a barrel section, a handle section and a tapered section connecting the barrel section and handle section. The barrel section has a first inner and outer diameter. The handle section has a second outer and inner diameter. The second outer and inner diameters are smaller than the first outer and inner diameters. The tapered section has a variable inner and outer diameter along its length and a substantially uniform wall thickness.

Abstract: A method of fabricating a metal matrix composite containing electrically isolated areas and the MMC formed from the method. The method comprises: (a) providing a liquid pool of unreinforced aluminum alloy; (b) infiltrating the unreinforced aluminum alloy into a stack comprising upper and lower porous preforms and an electrical insulator material placed between the preforms; (c) solidifying the liquid-phase metal to form a metal matrix composite product that completely surrounds the stack; and (d) forming at least one groove in the solidified metal, the groove extending downward to the insulating substrate so as to electrically isolate at least one region on the surface of the metal matrix composite.

Abstract: An alumina multilayer wiring substrate having a high capacitance in the substrate on which a VLSI is to be mounted to effectively eliminate electrical noise(s) which may hinder the operation of the VLSI at high speed (frequency). The wiring substrate comprises: (a) a first alumina layer; (b) a first metallized layer on the first alumina layer; (c) a dielectric material layer on the first metallized layer; (d) a cermet layer on the dielectric material layer; (e) a second metallization layer on the cermet layer; (f) a second alumina layer on the second metallization layer; (g) a first conductor electrically connecting to and extending from the second metallized layer through the second alumina layer; and (h) a second conductor electrically extending from the first metallized layer through the cermet layer and dielectric material layer, through but not electrically connecting the first metallized layer, and through the second alumina layer.

Abstract: A process for fabricating an aluminum alloy rolled sheet particularly suitable for use for an automotive body, the process comprising: (a) providing a body of an alloy comprising about 0.8 to about 1.3 wt. % silicon, about 0.2 to about 0.6 wt. % magnesium, about 0.5 to about 1.8 wt. % copper, about 0.01 to about 0.1 wt. % manganese, about 0.01 to about 0.2 wt. % iron, the balance being substantially aluminum and incidental elements and impurities: (b) working the body to produce a sheet; (c) solution heat treating the sheet; and (d) rapidly quenching the sheet. In a preferred embodiment, the solution heat treat is performed at a temperature greater than 840.degree. F. and the sheet is rapidly quenched. The resulting sheet has an improved combination of excellent formability and good strength.

Abstract: A method of fabricating a plurality of multilayer structures which includes at least one recess defined by a nonplanar surface. The method comprising the step of: (a) providing a resilient, compliant material on over one or more stacks of layers including the area over the recess; (b) applying sufficient pressure to the stacks to cause the resilient, compliant material to fill the recess and laminate said stacks; (c) lifting the resilient, compliant material off the stack subsequent to the application of pressure; (d) providing one or more stacks of layers that have not been subjected to step (b); and (e) repeating steps (a)-(d). In a preferred embodiment of the invention steps (a)-(d) are repeated at least ten times without the need to change the resilient compliant material. In a most preferred embodiment of the invention steps (a)-(d) are repeated at least one hundred times.

Abstract: A method of fabricating a metal matrix composite containing electrically isolated areas and the MMC formed from the method. The method comprises: (a) providing a liquid pool of unreinforced aluminum alloy; (b) infiltrating the unreinforced aluminum alloy into a stack comprising upper and lower porous preforms and an electrical insulator material placed between the preforms; (c) solidifying the liquid-phase metal to form a metal matrix composite product that completely surrounds the stack; and (d) forming at least one groove in the solidified metal, the groove extending downward to at least one insulating substrate so as to electrically isolate at least one region on the surface of the metal matrix composite.

Abstract: A method of preparing a metal alloy product from a powder blend. The method comprising: (a) cold pressing a blend to form a compact, the metal blend comprising a metal powder phase and at least one reinforcement phase having a hardness greater than the metal phase; (b) heating the compact to form a preheated compact; and (c) hot working the heated compact. In a preferred method, the powder metal blend comprises 50 to 90 vol. % of an aluminum alloy powder and 10 to 50 vol. % of silicon carbide; the heating of the compact perforated in a nitrogen atmosphere to form a preheated compact; and the extruded hot compact is hot worked. Hot working may take the form of forging, rolling, upset forging, exuding, compacting or other processes known in the art.

Abstract: A method for reducing the coefficient of friction and wear at the interface of two ceramic surfaces at temperatures above approximately 600.degree. F. The method comprising the steps of: a) providing a first and second ceramic surface; b) providing a lubricant selected from the group consisting of p-dodecylphenol, C26 and organophosphorus compounds; and c) applying the lubricant to the interface of the first and second ceramic surfaces at temperatures above approximately 600.degree. F. to reduce the coefficient of friction at the interface.

Abstract: A method of reducing the agglomeration of inorganic powdered material, the method comprising: (a) providing an inorganic powdered material comprising ceramic particles; (b) coating the ceramic particles with a solution containing from 0.05-0.5 wt. % of a polysiloxanol oligomer of a trialkoxysiloxane monomer having the structure Si(OR').sub.3 wherein R' represents a C.sub.1 -C.sub.4 alkoxy group selected from the group consisting of methyl, ethyl, isopropyl and n-butyl and wherein the oligomer has chains having a number average distribution with a number average degree of polymerization X.sub.n in the range above 2 but below the gel point; and (c) drying the inorganic powdered material.

Abstract: A method of forming a highly-deflective surface on aluminum alloys. The, the composition comprising: cleaning a body formed from an aluminum alloy; electrobrightening the body; and desmutting the surface of the freshly-brightened body without etching. The bath comprises: 15-95 vol. % nitric acid and 1-85 vol. % acetic acid; 1-40 vol. % total water; and a source of fluoride ion supplying at least 35 grams per liter of fluoride. Ammonium bifluoride is the preferred source of fluoride.

Abstract: A process for fabricating an aluminum alloy rolled sheet particularly suitable for use for an automotive body, the process comprising: (a) providing a body of an alloy comprising: about 0.8 to about 1.5 wt. % silicon, about 0.2 to about 0.65 wt. % magnesium, about 0.02 to about 0.1 wt. % copper, about 0.01 to about 0.1 wt. % manganese, about 0.05 to about 0.2 wt. % iron; and the balance being substantially aluminum and incidental elements and impurities; (b) working the body to produce a the sheet; (c) solution heat treating the sheet; and (d) rapidly quenching the sheet. In a preferred embodiment, the solution heat treat is preformed at a temperature greater than 860.degree. F. and the sheet is quenched by a water spray. The resulting sheet has an improved combination of formability, strength and corrosion resistance.

Abstract: An anion intercalated hydrotalcite filler material for polymer and paper systems. The filler material is formed by a method which includes reacting an activated magnesia with an aqueous solution of aluminate, anion, such as bromide, chloride, sulfate, borate and combinations thereof and hydroxyl ions. The method can be carried out at atmospheric pressure to form hydrotalcite in high purity and high yield. In a preferred embodiment of the invention, the aluminate solution is formed from sodium aluminate, sodium bromide and sodium hydroxide and the aqueous solution is substantially carbonate free. Other anion intercalated hydrotalcites can also be produced by the method of the present invention.

Abstract: A method of modifying an inorganic material which evolves gases and/or vapors at a temperature which is detrimental to the processing temperature of polymer or paper systems so that the modified material can be used as a fire retardant additive with that polymer or paper system. The method comprises the steps of: (1) providing a first material; (2) treating the first material to remove the portion which evolves gas which is detrimental to the processing of the polymer or paper system; and (3) combining a second material with the first material to create a modified material which does not evolve gas at a temperature which is detrimental to the processing of the paper or polymer system.

Abstract: An essentially flat "arc-grained" surface of a sheet of aluminum alloy is produced with a coarse and non-uniform microstructure which, after it is coated with a durable phosphate-free coating, provides excellent lithoplate. Though such arc-grained microstructure is much coarser than an electrochemically etched surface typically used on lithoplate, the very coarse surface is peculiarly well-adapted to provide durable lithoplate after it is coated with a phosphate-free protective surface. After the coated surface is coated with a photoresist the excellent resolution of prints is maintained over a large number of repeated uses in an off-set printing press.

Abstract: A method for wetting and bonding refractory alumina or aluminosilicate fibers or particles with molten aluminum or aluminum alloys by forming a boron oxidized interface between the fiber and the metal is exists. The method comprises the steps of (a) coating alumina fibers with an effective amount of a thermally decomposable precursor of boron oxide; (b) heating the coated fiber sufficiently to form a boron oxide; and (c) forming a composite with aluminum metal or an aluminum alloy. Thermally decomposable precursors of boron oxide include ammonium pentaborate, ammonium diborate and orthoboric acid.

Abstract: A method of extruding a plurality of billets. The method includes (a) preheating a billet to a preheat temperature; (b) extruding the billet so that the exit temperature of the extrusion is within a predetermined temperature range; (c) measuring the extrusion pressure during (b); (d) comparing the measured extrusion pressure to a reference pressure range; (e) if the extrusion pressure was below said reference pressure range, resetting the preheat temperature so that it is lowered by a predetermined increment; (f) if the extrusion pressure climbed above the reference pressure range, resetting the preheat temperature so that it is raised by a predetermined increment; (g) preheating another billet to the preheat temperature; and (h) repeating (b)-(g) until all the billets have been extruded. In a preferred embodiment, the billet is formed form an aluminum alloy.

Abstract: Molten metal containing suspended liquid and solid particles is passed preferably generally upwardly through a porous media so constructed and arranged such that the movement of the molten metal therethrough renders the suspended liquid particles gravity separable. The gravity separable liquid particles rise upwardly or settle downwardly so as to be removable from said molten metal for subsequent removal therefrom. An associated apparatus is also provided.

Abstract: A method of forming a highly reflective surface on aluminum alloys, the composition comprising (a) brightening the surface of a body formed from an aluminum alloy; and (b) desmutting the freshly brightened body in a bath. The desmutting bath comprises 10-100 volume percent nitric acid; 0-60 volume percent sulfuric acid; 0-50 volume percent water; and at least 15 grams per liter of a source of bifluoride. Ammonium fluoride is the preferred source of fluoride.

Abstract: A process of reducing macrosegregation in the casting of a metal alloy ingot is disclosed.

Abstract: Disclosed is a large alloy forging, the forging having an alloy composition selected from one of a nickel base alloy, a cobalt-chromium-nickel base alloy, a nickel-cobalt base alloy and an iron-nickel-chromium-molybdenum alloy, the forging having a grain size of ASTM grain size 3 or finer, as measured by ASTM method E112 and having a tensile strength in the range of 135 to 175 KSI.