Abstract: A method of forming fiber reinforced aluminum phosphate bonded material having improved strength at elevated temperatures. The method comprises the steps of: (a) preparing a slurry by blending alumina and aluminum phosphate solution, the slurry being substantially free of silica; (b) providing a fiber substrate coated with a metal selected from the group consisting of nickel, tungsten, molybdenum, platinum, copper, silver, gold, palladium, cobalt, chromium and titanium; (c) infiltrating the slurry into the fiber substrate; and (d) curing the infiltrated substrate to form a fiber reinforced aluminum phosphate bonded composite material. In a preferred embodiment of the present invention, the fiber substrate is made from SiC fibers and the refractory metal is electrolessly coated nickel.

Abstract: Disclosed is a large alloy forging and method for making it. 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 and having a grain size of ASTM grain size 4 or finer, as measured by ASTM method E112 and having a tensile strength in the range of 135 to 175 KSI. The process includes: (1) four upset forgings, (2) a rapid cooling after the final upset cooling, (3) a first and second upset forging with a reduction greater than 50%, (4) a third upset forging with a reduction greater than 25.%, and (5) a forging process with a fourth upset forging with a reduction greater than 50%.

Abstract: A method of reducing the agglomeration of ceramic powder materials, the method comprising: (a) providing a ceramic powder 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 structureSi(OR').sub.3wherein R' represents a lower C.sub.1 -C.sub.4 alkoxy group selected from the group consisting of methoxy, ethoxy, isopropoxy and n-butoxy 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 that near the gel point; and (c) drying the ceramic powder.

Abstract: Molten metal containing suspended liquid 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 ceramic composition for forming a ceramic dielectric body having a dielectric constant of less than about 5.0 and a TCE of 2.0-4.0 ppm/c. The composition is formed from a mixture comprising 25-50 weight percent of a low temperature glass selected from the group consisting of borosilicate glass, zinc borate glass and combinations thereof, 50-75 weight percent of a high temperature glass selected from the group consisting of high silica glass, titanium silicate glass and combinations thereof, and 1-10 weight percent of ceramic material having a particle size of less than about 3 microns. The mixture can be combined with a polymeric binder to produce an unfired green tape which is co-fireable with high conductivity metallurgies such as gold, silver and silver/palladium. A preferred ceramic material is colloidal alumina.

Abstract: A ceramic composition for forming ceramic dielectric body having a dielectric constant of less than about 5.5 and a TCE of less than about 5.0 ppm/.degree.C. The composition comprises a mixture of finely divided particles of 10-90 vol. % borosilicate glass and 10-90 vol. % of a material selected from the group consisting of Ga.sub.2 O.sub.3, Ga.sub.2 SiO.sub.5, Ga.sub.2 TiO.sub.5, GaAs, GaPO.sub.4 and any gallium-contained compounds to inhibit the formation of crystalline forms of silica. The composition can be used with a polymeric binder to produce an unfired green tape which is co-fireable with high conductivity metallurgies such as gold, silver and silver/palladium.

Abstract: A continuous block caster is provided with a mold block assembly having an internal anchor pin which is insulated. One end of a support pin, many of which are used to support each block, is threaded into the anchor pin, the other end is demountably secured in a fastening member in turn fastened to a carriage block. All the fastening members except only one at the center, are y- or x-y slides, so termed because they permit lateral movement of the support pin. A stepped lock-down key which provides a camming means, allows an entire mold block assembly and supporting pin assembly to be connected and disconnected quickly from the carriage block by rotating the key. Insulating the support pin in this manner allows the planarity of a casting face to be maintained in a lateral plane within 5 mils (127 micrometers) of vertical movement. Such limited distortion does not adversely affect the planarity of the upper and lower faces of the cast slab.

Abstract: Apparatus and process are disclosed for providing, and continuously monitoring and controlling, a tapered temperature profile in solid metal first heated to a specified initial temperature. Temperatures are monitored at a plurality of locations along the length of the metal and are adjusted by successively withdrawing and returning a portion to a heating source through physical movementIn one aspect, apparatus and process continuously monitor and control a tapered temperature profile in a billet of aluminum alloy through a first step of rapid heating in a single-zone electric induction furnace to a temperature sufficient to bring the billet to its cold end set point while not exceeding its maximum skin temperature. The temperatures of the billet are monitored at its die end and its ram end and are adjusted by successively withdrawing and returning the billet to the induction furnace to reduce the heat in the ram end relative to the die end.

Abstract: An aluminum alloy matrix composite containing alumina or aluminum silicate reinforcement whereby said composite material exhibits wetting between said reinforcement and said aluminum alloy. The composite comprises (a) alumina or aluminosilicate reinforcement; (b) a matrix of aluminum or aluminum alloy; and (c) an intelayer of mixed oxides of aluminum and boron wherein the interlayer of mixed oxides of aluminum and boron includes but is not limited to the following oxides, B.sub.2 O.sub.3, Al.sub.2 O.sub.3, 2Al.sub.2 O.sub.3.B.sub.2 O.sub.3 and 9Al.sub.2 O.sub.3 2B.sub.2 O.sub.3 at the interface between said reinforcement and said matrix.

Abstract: A ceramic composition for forming a ceramic dielectric body having a dielectric constant of less than about 5.5 and a TCE of less than about 3.5 ppm/.degree.C. The composition comprises a mixture of finely divided particles of 20-80 vol. % borosilicate glass and 20-80 vol. % of Al.sub.x B.sub.y O.sub.z wherein x is in the range of 4 to 22, y is in the range of 2 to 5, and z is in the range of 9 to 36. The Al.sub.x B.sub.y O.sub.z inhibits the formation of crystalline forms of silica. The composition can be used with a polymeric binder to produce an unfired green tape which is co-fireable with high conductivity metallurgies such as gold, silver and silver/palladium.

Abstract: A chain formed of links made of fiber-reinforced resin composite material. Each link has a terminal loop located at each axial end of a long strap. Loops, located at adjacent ends of successive links, are joined by relatively short connecting links that overlap bushings located within each of the loops. The bushings and connecting links are held in position at each lateral side of the links by pins and washers. A ring surrounds each link where the strap flares to form each terminal loop. The loops may be unitary or spaced laterally to receive within the space a unitary loop of an adjoining link aligned axially with the other loop. A pin located within the loops supports washers at each lateral side of the links to maintain the position of the links and to transfer load between the links.

Abstract: A ceramic composition for forming a ceramic dielectric body having a dielectric constant of less than about 4.2. The composition comprises a mixture of finely divided particles of 25-50 vol. % borosilicate glass and 50-75 vol. % high silica glass. The composition can be used with a polymeric binder to produce an unfired green tape which is co-fireable with high conductivity metallurgies such as gold, silver and silver/palladium.

Abstract: Disclosed is a method for preparing high purity alunite. In the method, a material selected from the group consisting of sodium sulfate, sodium bisulfate, ammonium sulfate, ammonium bisulfate, potassium sulfate and potassium bisulfate is provided and reacted with a source of aluminum hydroxide in a liquid. The reaction is carried out under acidic conditions, and alunite is recovered after separating, washing and drying.

Abstract: A ceramic composition for forming a ceramic dielectric body having a dielectric constant of less than about 4.2 and a TCE of less than about 4.0 ppm/c. The composition comprises a mixture of finely divided particles of 25-50 vol. % borosilicate glass and 50-75 vol. % high silica glass and sufficient amounts of crystalline ceramic material to inhibit the formation of crystalline forms of silica. The composition can be used with a polymeric binder to produce an unfired green tape which is co-fireable with high conductivity metallurgies such as gold, silver and silver/palladium.

Abstract: Controlling the linear velocity of melt discharge from the discharge outlets of a melt distribution device so as to essentially negate reverse flow from the walls of the mold has been found to produce less oxides and less surface defects in an ingot, particularly an aluminum ingot. This discharge is controlled from the outset of the casting of an ingot because it has been found most defects occur within the initial phase of a cast. A melt distribution device, referred to as a "bag-in-a-bag", is provided which is a pressureless interiorly partitioned receptacle. The partitioning of the receptacle provides an outer bag and a melt-impermeable inner bag in which a pool of melt collects. The pool is deep enough to submerge the discharge end of a spout, to dissipate the kinetic energy of the incoming melt, and to distribute melt from a central zone to discharge zones on either side of the central zone.

Abstract: When a dispersion of oxide ceramic particles in certain volatile organic solvents is mixed with less than about 2 percent by weight (based on the weight of particles) of an oligomeric polysiloxanol dispersant, and the dispersion allowed to settle, the oligomer provides a multiplicity of OH groups, many of which are available for interactive bonding to the surfaces of the particles. The net result is that the particles settle more slowly; also, the sediment has a density higher than that of sediment from a dispersion of the same particles in the same solvent mixed with the monomeric silane from which the oligomer was formed. Exceptionally dense and strong "tape", for making sintered circuitized multilayered ceramic structures, is produced by capitalizing on this phenomenon. The effectiveness of the oligomer is predicated upon the prehydrolysis of the siloxane, prior to forming the dispersion.

Abstract: A transducer unit for determining the presence of twinned columnar growth in the interior of an as-cast ingot. The transducer unit has a first means for generating and receiving ultrasonic waves and second means for rotating the direction of the wave pulse of the waves. The transducer unit detects the presence of twinned columnar growth by comparing the round trip time of flight (RTTOF) of the ultrasonic waves traveling in a first direction to ultrasonic waves of the same frequency generated in a second direction. In a preferred embodiment, a viscous liquid is used to couple the transducer unit to the ingot.

Abstract: A process of reducing macrosegregation in the casting of a metal alloy ingot is disclosed. The process includes introducing a molten metal alloy into a casting mold cavity, cooling the molten metal alloy to form a solid zone, a liquid-solid mushy zone overlying the solid zone, a liquid zone overlying the liquid-solid mushy zone and a melt surface on the liquid zone, employing during the cooling at least one substantially static magnetic field having at least two planes of symmetry which intersect on the longitudinal axis of the ingot, generating the magnetic field by at least one coil means having an inner region through which the metal alloy passes, energizing the coil means by a substantially static electrical current wherein the current follows a path defined by the coil means and passes around at least one of the molten metal alloy and the zones, and dampening convection flows of the molten metal alloy which cause macrosegregation by means of the magnetic field.

Abstract: A squeeze-casting method is taught for manufacturing metal matrix composites which require little or no finishing operations. This method utilizes a combination of techniques, fundamentals of which are found in the investment casting, die casting and metal matrix composite-making arts. The method comprises, forming a wax pattern around the preform and investing the pattern to form a melt-impermeable shell-mold around it. The shell-mold is dewaxed leaving the preform positioned within it. The shell-mold is heated before it is placed in a die cavity of a conventional die caster for high pressure injection of molten metal. Molten metal is poured into the die cavity and pressurized with sufficient pressure and for long enough to impregnate the preform. The metal encapsulates the shell-mold which allows for equilibrated pressures within said die. The pressure is released and the shell-mold is removed from the die cavity before the molten metal in the shell-mold solidifies.

Abstract: A ceramic composition for forming a ceramic dielectric body having a dielectric constant of less than about 5.5 and a TCE of less than about 4.5 ppm/.degree. C. The composition comprises a mixture of finely divided particles of 25-50 vol. % borosilicate glass 40-75 vol. % silica glass and 1-40 wt. % of a material selected from the group consisting of Ga.sub.2 O.sub.3, Ga.sub.2 SiO.sub.5, Ga.sub.2 TiO.sub.5, GaAs, GaPO.sub.4 and any gallium-contained compounds to inhibit the formation of crystalline forms of silica. The composition can be used with a polymeric binder to produce an unfired green tape which is co-fireable with high conductivity metallurgies such as gold, silver and silver/palladium.