Abstract: A surface treatment, especially for titanium and aluminum alloys, forms a Si—Y sol-gel film covalently bonded on the metal surface to produce strong, durable adhesive bonds between the metal and an organic adhesive without using toxic chemicals and while significantly reducing or eliminating rinse water requirements of traditional anodizing or etching processes. The sol should produce bonds in a single application comparable in strength and performance to standard anodize controls. Parameters affecting performance include the sol composition, the ratio of silicon to yttrium in the sol, the ratio of other sol ingredients, the concentration of the sol, the carrier solvent, solution age, catalysts, surface pretreatment, application method, curing process, and primer used.

Abstract: A preferred rotary actuator includes an actuator assembly having a torque tube formed of a shape memory alloy (SMA), a superelastic NiTinol return spring associated with the torque tube and adapted to bias the torque tube toward an initial position, and a torque tube heating element, especially a thermoelectric device, for switching the SMA to cause rotation to an object connected to the actuator or to generate a torque upon that object. The torque tube (24) includes a proximal end (32) and a distal end (34). The return spring and torque tube are connected at their ends, with the torque tube being pretwisted while in a martensitic state relative to the spring. Activation of the heating element causes the torque tube to enter an austenitic state in which it returns to its previous untwisted configuration. Removal of heat allows the torque tube to return to a martensitic state, when the return spring retwists the torque tube. A unique locking assembly 22 is used with the preferred actuator assembly.

Abstract: Rare earth metal switched magnetic devices that comprise one or more magnets, a rare earth metal element positioned in the magnetic field produced by the magnet(s) and a system for controlling the temperature of the rare earth metal element are disclosed. The rare earth metal element is formed of a rare earth metal or rare earth metal alloy having magnetic properties that change from ferromagnetic to paramagnetic when heated above the Curie temperature of the chosen rare earth metal or rare earth metal alloy. Preferably the Curie temperature of the chosen rare earth metal or rare earth metal alloy is at or below the ambient temperature in which the rare earth metal switched magnetic device is to be used—approximately room temperature (70° F.) in the case of devices intended for use in a factory. Tailored Curie temperatures can be obtained by alloying rare earth metals together and/or with conventional switchable “soft” magnetic metals—iron, nickel, and cobalt.

Abstract: Thrust reverser inner wall structure comprising a thermally conductive nonmetallic carbon pitch fiber honeycomb core sandwiched between a top and bottom layer. The core is adhered by a reticulated layer of adhesive to a perforated carbon fiber top layer, and adhered to a base layer of nonmetallic, nonperforated carbon fiber reinforced fabric.

Abstract: Prefabricated composite detail parts use precured strips that include Z-pin reinforcement along the bond line. Each strip has Z-pin stubble protruding from opposed faces so that the pins are embedded into the detail parts when the joint forms.

Abstract: Electric arc furnace production of recycled steel is plagued by the formation of an iron-depleted, metal-rich electric arc flue dust (EAFD). In the present invention, we recover at least about 85 wt. % of the base metals in the EAFD (i.e., lead, cadmium, copper, and zinc) as high quality metals products without producing any solid, liquid, of gaseous wastes. We use a recyclable calcium chloride/hydrochloric acid leach mill solution to extract the base metals from the EAFD in a reactor under a controlled pH of about 2.6 at an elevated temperature and pressure in an oxygen environment wherein the solids content in the reaction slurry is about 15-30 wt. %. In this way, we place the base metals in solution while leaving the iron as a solid hematite iron complex. When separated from the metal-rich solution, the solid hematite iron complex is recycled to the electric arc furnace. The base metals are precipitated and recovered.

Abstract: A fibrous ceramic mat is molded from a slurry of ceramic fibers and/or ceramic micropartides and/or a metal. The mat is impregnated with a sol prior to drying. A catalyst for the sol is introduced into the mat to cause the sol to gel. The sol-gel binder forms bonds so that the mat is dimensionally stabilized. The mat is dried to produce the desired ceramic insulation that has preferably a consistent microstructure and a fully gelled sol-gel binder through its entire thickness. If we use a metal, it corrodes (i.e., oxidizes) or otherwise reacts to form a refractory binder that augments the sol and reduces the need to infuse sol incrementally to achieve strength. Using metal powder significantly reduces the cost of manufacture.

Abstract: We make particulates, especially magnetic Fe—Co alloys having high magnetic permeability, of controlled dimensions, especially those having a narrow thickness size distribution centered around a median or target thickness in the range of about 0.1-1.0 &mgr;m, using electrodeposition typically on a smooth (polished) titanium cathode. Our preferred continuous process uses a rotating drum cathode inside a fixed anode to grow flakes and to produce them automatically by inherent instability in the deposited film. The drum preferably rotates about a substantially vertical axis. The particulates shed (slough off) into the electrolyte (because of mismatch between the cathode surface and the plated metal or alloy at the molecular level) where they are separated in a magnetic separator or other suitable device. If the flakes are soft iron or iron-cobalt alloys, the drum generally is titanium or titanium alloy.

Abstract: A magnetic field sensor which can be used as an active antenna is disclosed that is capable of small size, ultrawideband operation, and high efficiency. The sensor includes a multiplicity of magnetic field transducers, e.g., superconducting quantum interference devices (SQUIDs) or Mach-Zehnder modulators, that are electrically coupled in a serial array. Dummy SQUIDs may be used about the perimeter of the SQUID array, and electrically coupled to the active SQUIDs for eliminating edge effects that otherwise would occur because of the currents that flow within the SQUIDs. Either a magnetic flux transformer which collects the magnetic flux and distributes the flux to the transducers or a feedback assembly (bias circuit) or both may be used for increasing the sensitivity and linear dynamic range of the antenna.

Abstract: Aliphatic tetraketimine of the present invention are a novel class of compounds represented by the formula: wherein Et is ethyl, Me is methyl, and R is a residue of an aliphatic diisocyanate. The tetraketimine is made by condensing a novel ketimine with a diisocyanate. The ketimine has a free secondary amine after a polyamine selected from the group consisting of: H2N—C2H4—NH—C2H4—NH2, H2N—C2H4—NH—C2H4—NH—C2H4—NH2, H2N—(CH2)6—NH—(CH2)6—NH2, or tris(2-aminoethyl)amine is reacted with a ketone.

Abstract: We combine superplastic forming (SPF) with adhesive bonding (AB) to produce quality multisheet sandwich panel structures, especially those using a superplastic aluminum alloy, such as Al 2004, Al 8090, or Al 1570. We produce the parts with improved energy efficiency and at lower cost. We heat the multisheet pack having an adhesive, preferably a polyimide, between the core sheets and the face sheets to its superplastic forming range. Then, we superplastically form the pack to define adhesive bonds between the sheets in the core and between the core and the face sheets with the flowing adhesive. Finally, we cool the formed pack below the superplastic range to set the adhesive.

Abstract: The present invention relates to a seal pin indexed precisely in a resin transfer molding die to assure the desired resin-to-fiber ratio in the mold part, and, thereby, to produce reliably and consistently a part of minimum weight with adequate strength. The index/resin seal pin of the present invention for RTM mold dies is novel in that it provides the seal (via replaceable O-rings) on the threaded stem of the pin to prevent low viscosity resin from invading the threads, bolts pins, or other elements of the internal mandrel. The pin allows the entire inner mandrel to be enclosed and sealed within the mold cavity, simplifying the sealing system. The invention also relates to a method for using the seal pin in a resin transfer molding process.

Abstract: The present invention is a method for joining thermoplastic composite sandwich panels with thermoplastic welds (fusion bonds) made without autoclave processing of the joint. The preferred joint is a double interleaf staggered joint with supporting titanium doublers providing a tensile strength of at least 12,000 lb/in. The joint is particularly suited for joining sections of a cryogenic tank for spacecraft.

Abstract: We control the cure temperature within ±15° F. (8° C.) for organic resin matrix composites with a thermal diffusion apparatus which contains a liquid fluid transfer medium to convey heat from an immersed resistance heater to the repair site. Uniform heating of the repair site occurs despite differences in the underlying structure of the repair site, such as the location of underlying spars or other structural features or variations in the skin thickness, because of natural convection within the heat transfer fluid. The fluid transfer medium preferably is a solid, at ambient temperature, but melts at a relatively low, elevated temperature below the cure temperature. We achieve uniform heating that is necessary for suitable repairs to temperatures of at least about 350° F. (177° C.) and simplify monitoring of the repair site temperatures because of the uniform heating we naturally achieve.

Abstract: An apparatus for forming and consolidating organic matrix composites. An organic matrix composite panel comprising laid-up prepregs is placed between sheets of a susceptor material that is susceptible to inductive heating to form a workpiece. The resulting workpiece is placed within upper and lower dies formed of a material that is not susceptible to inductive heating. An induction coil embedded within the dies is energized and inductively heats the susceptor sheets surrounding the panel. The sheets in turn conductively heat the organic matrix composite panel. A pressure zone between the workpiece and one of the dies is pressurized to form the workpiece to the contour of a forming surface on one of the dies. The pressure in the pressure zone is maintained on the workpiece until the organic matrix composite panel is fully consolidated and formed.

Abstract: Thrust reverser inner wall structure comprising a thermally conductive nonmetallic carbon pitch fiber honeycomb core sandwiched between a top and bottom layer. The core is adhered by a reticulated layer of adhesive to a perforated carbon fiber top layer, and adhered to a base layer of nonmetallic, nonperforated carbon fiber reinforced fabric.

Abstract: The method of the present invention detoxifies spent aluminum potliners to remove hazardous cyanides, fluorides, and polynuclear aromatics by reacting crushed potliners with a CaCl2/HCl leach mill solution in the presence of iron. The method produces a solid waste suitable for landfill disposal and a recyclable reaction liquor. The reaction to destroy the polynuclear aromatics preferably occurs at a pH of no more than about 0.2, at about 120° C. and 80 psig following destruction of the cyanides and converting of the fluorides to florspar in an initial oxidation at a lower temperature, lower pressure, and higher pH.

Abstract: Thin film metal particulates are removed from FEP sheetstock cheaply and quickly by immersing the coated FEP first in a base and then in an acid. Occasionally, ultrasonic vibration of the FEP may also be required. The particulates are useful as paint pigments when isolated and conversion coated. The FEP is reusable. A preferred binder for carrying the pigments is a two-component system having a tetraketimine and an isocyanate.

Abstract: A method and system for calculating the range between a source which emits electromagnetic energy having an unknown frequency and a first receiver of electromagnetic energy at at least three points along a portion of a source trajectory. The source trajectory portion is a substantially straight line which has two end points. The first receiver moves along a first, substantially straight-line receiver trajectory so that the frequency of the electromagnetic energy is Doppler-shifted. The first receiver measures the Doppler-shifted frequency at at least three predetermined times. Next, at least two ratios of frequencies are calculated, the ratios being functions of the Doppler-shifted frequencies and bearing angles. Finally, the range between the first receiver and the source is calculated from the frequency ratios at the at-least-three points. In a first preferred embodiment the source is stationary.

Abstract: A fibrous ceramic mat is molded from a slurry of ceramic fibers and/or ceramic microparticles and/or a metal. The mat is impregnated with a sol prior to drying. A catalyst for the sol is introduced into the mat to cause the sol to gel. The sol-gel binder forms bonds so that the mat is dimensionally stabilized. The mat is dried to produce the desired ceramic insulation that has preferably a consistent microstructure and a fully gelled sol-gel binder through its entire thickness. If we use a metal, it corrodes (i.e., oxidizes) or otherwise reacts to form a refractory binder that augments the sol and reduces the need to infuse sol incrementally to achieve strength. Using metal powder significantly reduces the cost of manufacture.