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: 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: Multicurved copper films having fine-line elements suitable for radome applications can be improved by cutting the elements with reproducible precision to close tolerance (typically line widths of 3-10±0.25 mil) using an etchant comprising a concentrated saline solution of CuCl2.

Abstract: A method of forming a pin-reinforced foam core sandwich structure (10) including placing first and second face sheets (12), (14) on opposite sides of a foam core (16), the foam core (16) having at least one low density sublayer (28), an optional high density foam sublayer (26), and a plurality of Z-pins (20) positioned therein. The combination of the foam core (16) and face sheets (12), (14) forming a preliminary structure. Autoclave curing the preliminary structure according to a particular temperature and pressure regime, to crush the at least one low density sublayer (28) and to force the plurality of Z-pins (20) into the first and second face sheets (12), (14). Also provided is a pin-reinforced foam core sandwich structure (10) formed by the above process. In a second embodiment, all, or a portion, of the foam core (16) is removed using a solvent to dissolve the foam core (16), but not the Z-pins, to create a column structure (40).

Abstract: Improved pin-reinforced sandwich structure ties the face sheets (typically on opposite sides of a foam core) together with a plurality of Z-pins that extend into each face sheet (through the core). The pins are arranged in a tetrahedral or hat section configuration in 2-dimensional or 3-dimensional arrangements to provide enhanced reinforcement, particularly in shear. We are able to improve the pulloff strength additionally by dimpling the core surrounding the pins to produce adhesive fillets along the pins.

Abstract: Rib and spar webs are joined in a composite wingbox to eliminate fasteners by welding the webs along bond lines defined by overlapping sections of the webs. Heat to produce the weld is generally achieved resistively by connecting a multistrip susceptor positioned along the bond line to a current source, since the geometry makes it difficult to heat these web joints inductively. The wingbox is completed without fasteners by welding skins to the rib-spar wingbox.

Abstract: A ceramic composite is provided comprising ceramic fibers, glass microballoons and/or diatoms, bound together with a ceramic reinforcing cloth with a sol-gel ceramic binder. The composite is particularly useful as a high strength, high temperature insulation material.

Abstract: An improved apparatus to store an insulated electrical conductor cable in a overlapped configuration within a drill pipe includes a track attached to the drill pipe to guide a lower cable guide so that the overlapped portions of conductor cable will not snarl or twist during rotary drilling operations. To insure against entanglement, further restriction of rotation may be gained by additionally tracking the lower cable guide on a tensioned portion of the conductor cable which extends from a subsurface instrument package upwardly to an upper cable guide. A method for installing this improved apparatus is also disclosed.