Abstract: A composite comprises a first metal or alloy component having a thin refractory oxide layer on a first surface thereof. A second metal or alloy component has a second thin refractory oxide on the first surface thereof. Means are provided having a closely matched coefficient of thermal expansion to the first and second metal or alloy components for bonding the first and second thin refractory oxide layers and for electrically insulating the first component from the second component whereby thermal stress between the metal or alloy components and the bonding means is substantially eliminated.

Abstract: A system for machining and sizing optical fibers is described herein. The system uses a laser beam to machine oversized regions of a buffer material surrounding an optical fiber to create a coated optical fiber having a substantially uniform maximum outer dimension that is within a desired tolerance specification. The machining of the buffer material to size the optical fiber is accomplished by generating at least one laser beam transverse to the buffer material, rotating the beam or beams about an axis coaxial with the optical axis of the optical fiber, and moving the fiber past the rotating laser beam or beams. The rotating laser beam or beams vaporize any excess or oversized regions of buffer material and substantially provide the optical fiber with the desired outer dimension or diameter.

Abstract: A process and apparatus for producing surface treated metal foil is described. The process comprises plating a relatively smooth metal foil onto a cathodic surface and thereafter forming a dendritic layer on the foil and firmly bonding it thereto while the foil is still on the cathodic surface. In one embodiment, the apparatus comprises an electrolytic cell containing an electrolyte, a rotating drum cathode at least partially immersed in the electrolyte, at least two primary anodes and a plurality of treatment anodes embedded in one of the primary anodes.

Abstract: An electrochemical cell for regenerating temperature sensitive solutions is described. In a preferred construction, the cell comprises a central electrode chamber and two counterelectrode chambers. To maintain the temperature of the electrolyte within a desired temperature range, the electrode in the electrode chamber is formed from at least one hollow tube through which a heat exchange medium flows. In a preferred construction, the electrode comprises a plurality of hollow tubes and a plurality of current collectors bonded to the tubes to form a grid-like structure.

Abstract: A casing for an electrical component comprises a metal lead frame having the electrical component connected thereto. A metal base member is bonded to one surface of the lead frame. A plastic housing member is bonded to a second surface of the lead frame. An adhesive seals and bonds the metal base member and plastic housing member to the lead frame so as to enclose the electrical component.

Abstract: A method and apparatus for assembling an optical fiber communication cable is disclosed herein. The cable has a tubular core formed from a strip of composite material. The composite material has a first layer of high strength metal or metal alloy, a plurality of electrical conductors formed by a material having a conductivity in excess of 50% IACS, and an electrical insulating material separating the first layer and the electrical conductors. At least one optical fiber is located within the tubular core.

Abstract: A process for rolling a metal strip for reducing its thickness and for increasing the maximum reduction attainable per pass using a cooperative type rolling mill comprises applying differential separating forces to the metal strip without changing the magnitude of the compressive force applied to the rolls. By doing this, the maximum strip tension and the forward tension required to pull the strip through the mill may be reduced. The maximum strip tension and the required forward tension force may further be reduced by driving at least one work roll at a desired value of torque as well as applying differential separating forces. The cooperative type rolling mill uses a roll spacing arrangement to space at least some of the rolls for reducing the separating force applied to the metal strip at selected roll bites. In addition, individual drive motors to drive the work rolls at desired torque values may be utilized.

Abstract: A heat treatment for providing copper-tin alloys with a substantially continuous tin-phosphorous-oxide protective layer that improves the appearance and the tarnish resistance of the alloys is disclosed. The heat treatment comprises heating the alloys in a reducing atmosphere having a dew point of at least about 65.degree. F. and a temperature in the range of about 700.degree. C. to about 900.degree. C. for a time in the range of about 2 hours to about 24 hours.

Abstract: A method and apparatus are disclosed for fabricating an optical fiber communication cable having a metal containment tube and at least one optical fiber in static compression therein. The containment tube is preferably formed by applying a tensile load to a strip of metal and drawing the strip of metal through at least one forming die. Each fiber is inserted into the forming tube without the application of any significant tension. As a result, each fiber is in a substantially no-load condition at the same time that the strip is undergoing maximum plastic extension and said tube is undergoing elastic tension from the applied tensile load. Upon release of the tensile load, the tube will shrink and each fiber is placed into static compression.

Abstract: A process for casting a material comprising a coolant application device comprising a fluidized bed cooling system. A control system for the fluidized bed cooling system determines the most upstream position at which the fluidized bed contacts the material being cast. The control system is adapted to adjust the pressure differential between the gas used to fluidized the bed of particles and an opposing gas flow. The casting system may be a continuous or semi-continuous one and preferably employs an electromagnetic mold.

Abstract: An apparatus or process for casting metals by electromagnetically forming molten metal into a desired shape by applying a magnetic field to the molten metal. The magnetic field defines a containment zone for the molten metal. The hydrostatic pressure exerted by the molten metal in the containment zone is sensed and in response thereto the flow of molten metal into the containment zone is controlled. This minimizes changes in the hydrostatic pressure.

Abstract: An apparatus and process for electromagnetically forming a material into a desired thin strip shape. The apparatus comprises a first portion for electromagnetically containing and forming the material in molten form into a cross-sectional shape substantially the same as the desired thin strip shape. A second portion receives the molten material in the thin strip shape from the first portion. In addition, the second portion reduces the distortion in the cross-sectional shape due to surface tension. The second portion includes a device for providing an electromagnetic field having a reduced strength as compared to the strength of an electromagnetic field in the first portion. The electromagnetic field may be reduced in strength by providing an inductor having hollow inner surfaces facing the molten material so as to form substantially straight vertical surfaces in the molten material.

Abstract: The present invention relates to either a batch or continuous process for decarburization of metals and metal alloys. A shallow melt of metal or metal alloy having a depth of between about 2 in. to about 24 in. is provided. The carbon content of the melt is reduced from its initial value to a range of about 0.3 to 0.1 wt. % carbon. To accomplish this reduction, an oxygen enriched gas is blown onto the surface of the melt at a velocity of about 10 to about 50% of supersonic velocity so as to decarburize the melt without creating any substantial splashing of the melt. At the same time, the melt is stirred by injecting an inert gas below the melt surface. Subsequently, the carbon content of the melt is further reduced from the carbon percentage achieved in the first reduction to a value of not less than about 0.001 wt. % carbon.

Abstract: An apparatus and process for casting metals wherein the molten metal is contained and formed into a desired shape by the application of an electromagnetic field. The apparatus includes an inductor and a non-magnetic shield. Changes in the location or the location of the top surface of the molten metal head are continuously displayed during the casting run by monitoring electrical parameters of the electromagnetic casting system including at least one electrical parameter of the non-magnetic shield.

Abstract: An apparatus and process are provided for forming molten thin strip material into a desired thin strip shape. The apparatus comprises a device for electromagnetic forming of the molten material. This device includes a first and second inductor disposed on either side of the molten thin strip material for generating first and second magnetic fields about the first and second edges of the thin strip material. Third and fourth inductors are disposed adjacent opposite edges of the thin strip material for generating third and fourth magnetic fields which interact with the first and second magnetic fields, respectively. Structure regulates the strength of the fields induced by the inductor device to form the molten material into the desired thin strip shape.

Abstract: A process and apparatus for treating a metal foil to enhance its ability to be bonded to a substrate comprise immersing the metal foil in an electrolytic cell having an electrolyte bath solution containing copper and applying a current having regularly recurring pulses and preferably flowing in only one direction to the cell. The current causes a dendritic layer of copper to be deposited on at least one surface of the metal foil at a first current density and bonded thereto at a second current density. The process and apparatus are particularly suited for treating copper foil.

Abstract: A process for forming a composite material from a core material having a first yield strength and a clad material having a second yield strength comprises passing the materials through at least one roll bite formed by at least two rolls rotating at different speeds relative to each other. A bond is formed between the core and clad materials by causing a reduction in the thickness of the materials as they pass through the at least one roll bite. The amount of reduction and the compressive force magnitude required to effect the bond is minimized. The process also includes applying back tension forces to the materials. In a preferred embodiment, different back tension forces are applied to the core and clad materials.

Abstract: An apparatus for collecting ferromagnetic particles distributed in metal or metal alloy material is disclosed. A tank containing an electrolyte is provided to electrochemically dissolve the metal or metal alloy material without substantial dissolving of the particles. A support surface is provided within the electrolyte for supporting the dissolving metal material and collecting undissolved particles. The support surface further comprises the working electrode in conjunction with the metal material. A magnetic field forming device is associated with the support surface for magnetically adhering undissolved particles to the support surface so as to maximize recovery of the particles.

Abstract: An electromagnetic casting process and apparatus utilizing an active transformer-driven copper shield. The shield is actively driven with a voltage out of phase with the voltage in the containment inductor with the result that a bucking current is produced in the shield which is out of phase with the current induced in the shield by the inductor. An active transformer-driven duplex variable impedance shield is also disclosed.

Abstract: A method is disclosed for producing iron or iron alloy particles. A metal or metal alloy strip having fine particles or iron or alloy distributed throughout is provided. The metal strip is selectively dissolved without substantial dissolving of the iron or iron alloy particles in order to recover the particles.