Abstract: A method for developing a pattern of electrically conductive material on a ceramic substrate is disclosed. The method includes the steps of depositing on the ceramic substrate in a desired pattern a thin layer of a heat fusible material which contains a granular current conducting base metal. An encasing layer is deposited over the pattern formed of the heat fusible material. The encasing layer is formed from an oxygen barrier material containing an oxygen getting material. This encasing layer is non-heat fusible and nonreactive with the heat fusible material. All of this structure is heated in an oxygen containing ambient to a temperature sufficient to permit the heat fusible material to fuse to the ceramic substrate.

Abstract: A method and apparatus for producing highly effective head exchanger elements of the type which comprise corrugated surface enlarging members of strip material fixed to thin walled substrates. The strip material which can be either pre-corrugated or corrugated synchronously with the heat exchanger element manufacturing process is advanced concurrently with a substrate material to a station at which the strip is lightly held in firm abutment with the substrate material by means of an impinging stream of gaseous medium and simultaneously metallurgically bonded to the substrate. The composite product is then cut into lengths to form finished heat exchanger elements.

Abstract: A method of making a portion of a sodium sulfur battery is disclosed. The battery portion made is a portion of the container which defines the volume for the cathodic reactant materials which are sulfur and sodium polysulfide materials. The container portion is defined by an outer metal casing with a graphite liner contained therein, the graphite liner having a coating on its internal diameter for sealing off the porosity thereof. The steel outer container and graphite pipe are united by a method which insures that at the operating temperature of the battery, relatively low electrical resistance exists between the two materials because they are in intimate contact with one another.

Abstract: A method of solid state anodization comprising contacting a solid anode with a solid insulator that separates and contacts the anode and a solid permeable cathode whereby an oxidant infuses through the permeable cathode while the anode is biased sufficiently positive to cause anodization.

Abstract: This application discloses a new powder composition which may be plasma sprayed onto the surface of an article to provide a protective coating therefor. The protective coating may be resistant to heat, wear, and corrosion. The coating may also provide a thermal or radiation barrier.In particular, the coating composition for arc plasma spraying consists of finely divided silicon carbide mixed with finely divided silicon. This coating composition is applied to a substrate by developing a plasma spray, feeding the coating composition to the plasma spray and directing the plasma spray at an exposed surface of the substrate so that the exposed substrate is coated with a coating which consists essentially of beta silicon carbide and silicon.The new article of manufacture disclosed in this application, is a substrate with a tightly adherent coating thereon consisting essentially of beta silicon carbide and silicon. The substrate may be any material, either metallic or non-metallic, to which the coating adheres.

Abstract: A method is disclosed for removing stock from a metal part comprised of steel, malleable cast iron or nodular cast iron. A moving relationship is established between the part and a cutting tool formed of a substantially full dense hot pressed ceramic material consisting essentially of a generally uniform mixture of 50-70% by weight Al.sub.2 O.sub.3 and the remainder substantially Si.sub.3 N.sub.4. The tool is advanced into the surface of the part at a predetermined depth of cut and feed rate which results in the removal of stock from the part during periods of relative movement. A portion of the Al.sub.2 O.sub.3 may be replaced by up to 15% stabilized ZrO.sub.2 or HfO.sub.2 to further improve strength at higher temperatures.

Abstract: A method of densifying a reaction bonded silicon nitride article is disclosed. In accordance with the broadest principles disclosed, a densification aid is incorporated into a reaction bonded silicon nitride article. The so-made reaction bonded silicon nitride article is enclosed in a chamber which also contains a mixture of silicon nitride powder and powder the same as the densification aid incorporated into the reaction bonded silicon nitride article. The reaction bonded silicon nitride article, and the powder mixture associated therewith, is subjected to a nitrogen gas pressure sufficient to prohibit a significant volatilization of silicon nitride at a sintering temperature. The reaction bonded silicon nitride article, the powder mixture and nitrogen gas associated therewith are heated to a temperature above 1700.degree. C. for a time sufficient to permit sintering of that article whereby the strength of the reaction bonded silicon nitride article is increased.

Abstract: A thermosetting composition particularly suitable as a high solids coating composition for automotive applications. Exclusive of pigments, solvents and ether non-reactive components, the composition consists essentially of: (A) an oligomeric hydroxy functional phosphate ester having a number average molecular weight of between about 500 and about 5000 and being prepared by reaction of a polyepoxide and an acid phosphate ester; (B) up to 50 weight percent of a hydroxy functional compound; and (C) between about 15 and about 50 weight percent of an amine aldehyde crosslinking agent.

Abstract: Thermosetting compositions comprising a film forming component bearing or capable of generating hydroxyl functionality, amine-aldehyde crosslinking agent, and a latent reactive catalyst having the formula: ##STR1## wherein R is selected from alkyl or aryl groups and X is selected from 2-hydroxycycloalkyl and aryl substituted 2-hydroxycycloalkyl groups.Preferred compositions within the scope of the invention include high solids, thermosetting coating compositions suitable for automotive applications.

Abstract: A method of making Si.sub.3 N.sub.4 based cutting tools (and the resulting product) is disclosed. A mixture is formed of three powders: a first powder of at least 75% crystalline Si.sub.3 N.sub.4, a second powder selected from the group Y.sub.2 O.sub.3, MgO, CeO.sub.2 and ZrO.sub.2, and a third powder selected from the group consisting of Al.sub.2 O.sub.3, WC, Wsi.sub.2, W and TiC. The mixture is cold pressed to a density of 50-70% of theoretical and then sintered to full density without the application of pressure.

Abstract: Porous polyurethane solids such as open cell polyurethane foams are rapidly heated and hydrolytically decomposed into separate polyol component and diamine component by contacting the porous solids with saturated steam in a heated vacuum chamber. Separation of high quality liquid polyol and diamine is achieved.

Abstract: This specification is directed to a dam structure which may be used in a float glass chamber for separating a hot entry end of the chamber from a cold exit end of the chamber. The dam has been specially designed so that it will mix tin currents sheared from a glass ribbon moving thereover of higher temperature with colder tin moving around the edges of the dam and returning from downstream of the float chamber. The mixing of the tin currents occurs at a position spaced outwardly fromm the position of movement of the glass ribbon over the dam so that glass ribbon is not subjected to zones of tin having varying temperatures which could cause optical distortions therein.

Abstract: A method of providing a substrate with a layer of a tertiary compound comprising silicon, silicon carbide and a transition series metal. In accordance with the method, a substrate having at least a surface layer thereon of a transition series metal is coated with silicon carbide particles having an average particle diameter in the range of up to about two microns. The coated substrate is then heated in an inert atmosphere to a temperature between 1000.degree. and 1300.degree. C. for sufficient time to allow diffusion to occur between the silicon carbide and the transition series metal layer, thereby forming the tertiary compound. Substrates coated with the tertiary compound are particularly suitable for preparation of alkali metal/polysulfide batteries wherein the substrate may be exposed to corrosive attack by molten polysulfide salts.

Abstract: A fast curing coating composition that is adapted for use as an automotive topcoat and which upon curing forms a hard, glossy, durable coating exhibiting excellent resistance to solvents and water. The coating composition which may contain greater than about 55 percent by weight of nonvolatile solids and, exclusive of pigments, solvents and other nonreactive components, consists essentially of:(A) a polyepoxide resin having a number average molecular weight (M.sub.n) of between about 140 and about 3,000;(B) a reactive catalyst comprising at least one phosphonic acid derivative;(C) an amino resin crosslinking agent; and(D) optionally, a hydroxy functional additive.The phosphonic acid derivative is included in the composition in an amount sufficient to produce between about 0.8 and about 1.

Abstract: A method of making metal castings is disclosed, and particularly a method for making ferrous castings employing multiple component sand core assemblies. The core assembly is devised to receive a disintegratable strap about one annular outer surface path of the assembly. The strap is drawn tight about the assembly by an automated strapping machine and fused to provide a positive mechanical securement. The strap is preferably arranged coplanar with the outer surface of core prints when used in the assembly. The strapped assembly is placed in any desired orientation within a bonded sand mold and molten metal introduced therein. The molten metal heats the mold and core surfaces and surrounding sand body to such an extent that the strap is volatilized immediately after the introduction of the molten metal.

Abstract: A method of making sintered powder metal parts which particularly includes a hot forging step, is disclosed. Selected powders of a predetermined particle size distribution, are blended and agglomerated by cold compaction into a preform. The preform or briquette is then coated with a thin shell of a chemically inactive radiation absorbing material, preferably graphite, under ambient conditions. The coated briquette is then sintered in a continuous through-put furnace with the temperature maintained at a level of at least 2000.degree. F. and the part being subjected to the furnace heating for a period of 5-30 minutes. The sintered part may then be subjected to direct hot forging with the retained temperature of sintering utilizing the graphite coating as a die lubricant, or the sintered part may be cooled and then subsequently reheated for hot forging, again utilizing the retained graphite coating as a die lubricant.

Abstract: An aluminum article is cleaned to prepare it for plating by soaking it in an aqueous solution containing sodium metasilicate, sodium pyrophosphate and sodium tetraborate at 140.degree.-180.degree. F. The article is then washed by a power spray of a second solution, constituted the same as the first cleaning solution, at 110.degree.-130.degree. F. The article is subsequently rinsed with water and immersed in an aqueous nitric acid solution.

Abstract: Polychloroprene compounded with large particle, high structure carbon black and finely divided silica especially when combined with certain curants and plasticizer yields, upon curing, articles which exhibit high tear resistance and low compression set and are admirably suited for high temperature, fatigue producing applications as suspension bushings.

Abstract: A method of forming a slip cast article having at least one zone of cellular construction is disclosed. The method may be utilized to make articles having zones of different cellular size as well as articles having zones of cellular construction adjacent zones of noncellular construction. In its simplest form, the method is carried out by providing a slip casting mold which has a casting volume formed therein. A stabilized casting slip is poured into the casting volume. The pH of the stabilized casting slip is increased until a hydrolysis reaction takes place between the water forming the vehicle and an oxidizable metal forming the casting material. This hydrolysis reaction results in the evolution of gases, some of which are trapped within the slip to develop a zone of cellular construction. The greater the increase in pH, the more vigorous is the hydrolysis reaction and the resulting cellular construction has larger sized cells.

Abstract: Improvements in molded articles from sinterable particulate solids, improvements in method for making such articles, and novel sacrificial binders for use in making such articles are disclosed. The sacrificial binders used in this invention comprise block polymers having the structural formulaX--B(AB).sub..eta. A].sub..eta. 'wherein "X" is a linking group, A or B, ".eta." is 0 or a positive integer, ".eta.'" is a positive integer greater than 2, "A" is a linear or branched polymer that is glassy or crystalline at room temperature and has its softening point in the range of about 80.degree. C. to about 250.degree. C. and "B" is a polymer different from A that behaves as an elastomer at processing temperatures, a plasticizer which may be oil, wax or oil and wax, and optionally other components.