Abstract: A casing for an electrical component comprises a metal base member. A metal housing member is mounted on the base member to provide a hollow enclosed casing for receiving the electrical component. A metal lead frame is provided within the enclosed casing and is electrically connected to the electrical component. The lead frame has terminal leads projecting between the base member and the housing member external to the casing. The improvement comprises an adhesive for sealing and bonding the terminal leads to both the base member and to the housing member to form the enclosed casing.

Abstract: A method and apparatus for electromagnetic casting of metal and alloy ingots of desired shape having portions of small radius of curvature. A modified shield is provided which provides for a reduction of the electromagnetic field intensity at the corners of the forming ingot by increasing local screening of the field at the corners. Increased local screening at the corners is achieved by locally increasing shield depth, by providing for deeper displacement of the shield, by changing the shield section, or by changing the shield orientation. Also disclosed is a modified inductor which is shaped so as to be located at a greater distance from the portions of small radius of curvature of the ingots than from portions of the ingots adjacent to the portions of small radius of curvature. The modified shield may be combined with the modified inductor and/or with a coolant manifold to simultaneously modify and control coolant application elevation such that the elevation is a minimum at the corners of the ingot.

Abstract: An improved method and apparatus for the production of multi-gauge strip is disclosed wherein the multi-gauge strip comprises a first strip of metal having a first thickness and extending longitudinally for a given length. A second strip of metal has a second thickness, is narrower in width than the first strip, and coextends longitudinally with the first strip of metal. The first and second strips of metal are intimately bonded in direct metal-to-metal contact without the use of a welding or brazing material. The multi-gauge strip has a first portion extending the given length with a third thickness substantially equal to the sum of the first and second thicknesses and a second portion of substantially constant width extending the given length having a fourth thickness substantially equal to the first thickness.

Abstract: A multi-strand process is provided for casting molten materials into ingots of desired shape. The process uses two inductors for receiving the molten material and applying the first and second electromagnetic force fields to form the molten material into the ingots. The inductors are located adjacent each other so that the first and second force fields interact with each other. A first device is associated with one of the inductors for applying a first alternating current at a first desired frequency to an associated inductor to generate the first magnetic force field. A second device is associated with the other of the inductors for applying a second alternating current at a second desired frequency to generate the second magnetic force field. The second frequency is set to a desired value in relation to the first frequency in order to control the first and second resulting containment currents circulating in the molten material.

Abstract: Copper or copper alloy sheet or foil displaying excellent solderability and high resistance to tarnish is prepared by the provision over its surface of a coating containing a copper salt of an organophosphonic acid. To form the coating, the sheet or foil is immersed for a short time in an aqueous solution containing a phosphonic acid, rinsed and dried, the treatment being combined with or preceded by oxidation of the sheet surface.

Abstract: A multi-strand apparatus and process for casting molten material into at least two ingots of desired shape. Structure is provided for receiving and electromagnetically forming the molten material into ingots of desired shape. Each of the receiving and forming structures includes an inductor for applying an electromagnetic force field to the molten material. When the inductor is in operation, it is spaced from the molten material by a gap extending from the surface of the molten material to the opposing surface of the inductor. The improvement comprises a device for distributing a common alternating current to the inductors to generate the magnetic fields. A device is provided for minimizing variations in the gaps during operation of the casting apparatus.

Abstract: A multi-strand apparatus and process for casting molten material into ingots of desired shape. A plurality of structures are provided for receiving and electromagnetically forming the molten material into the desired shape. Each receiving and forming structure includes an inductor for applying a magnetic force field to the molten material. When the inductor is in operation, it is spaced from the molten material by a gap extending from the surface of the molten material to the opposing surface of the inductor. Structure is provided for distributing a current in the inductor to generate the magnetic field. The improvement comprises a device arranged below the inductor for modifying the current distribution in the inductor to minimize the variations in the gap.

Abstract: A process and apparatus for determining the value of parameters which affect emissivity of radiation from a metal load in an electromagnetic casting system. Infrared radiation being emitted from the surface of the load is sensed by an array of fiber optic filaments secured within elements of the electromagnetic casting system. Radiation signals are transmitted by the filaments to a signal processor which enables readout display of electromagnetic casting parameters such as liquid temperature, maximum load temperature, position of the liquid/solid interface, and head position.

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 process for casting a material comprising a casting system for said material including a coolant application device. The coolant application device comprises a fluidized bed cooling system. The casting system may be a continuous or semi-continuous one and preferably employs an electromagnetic mold.

Abstract: A composite structure having improved solderability shelf life and contact resistance is formed by coating a copper alloy substrate material with a tin-containing material. The copper alloy substrate material consists essentially of about 15% to about 30% nickel and the balance essentially copper. The copper alloy may further include up to about 25% zinc. The nickel in the alloy retards the growth of copper-tin and/or copper-zinc-tin intermetallic compounds and the diffusion of the copper through the coating. The coating may be formed from tin or tin alloys including tin solders, e.g. 60% Tin-40% lead solder.

Abstract: A continuous lubrication casting mold for use in a process of continuously casting molten metals and alloys wherein a parting and/or lubricating agent reservoir is provided in the mold body. The agent is continuously applied over the inner surface of the mold after being introduced through passages within or through the mold section. The lubricant passages may be an intrinsic characteristic of the mold material or may be provided in the form of feed holes through the mold section. The ability to transmit lubricant through to the internal surface of the mold can be varied within the length of the casting mold to provide for variable lubricant transfer rates to different parts of the casting surface.

Abstract: A process and apparatus for bonding lead wires to a metal substrate. A lead wire is positioned on the substrate and a spot of metal is deposited over a portion of the lead wire and metal substrate to firmly bond the wire to the substrate.

Abstract: An apparatus and process for casting a material comprising a coolant application device comprising a fluidized bed coolant system. The casting is carried out utilizing a casting mold which defines a casting zone. A soundwave generating system is provided for enhancing the flow of the fluidized bed into the vicinity of the casting zone.

Abstract: An improved copper base alloy for use in electrical springs and a process of treating the alloy provide improved resistance to stress relaxation when the alloy is in a solution treated and aged condition having a discontinuous precipitate. The alloy consists essentially of from about 10% to about 15% nickel, from about 1% to about 3% aluminum, up to about 1% manganese, from about 0.05% to less than about 0.5% magnesium and the balance copper. The alloy is readily hot workable if held within a critical temperature range of from about 880.degree. C. to about 980.degree. C. prior to hot working.

Abstract: A composite material having improved bond strength and a substantially smooth external surface comprises a deoxidized copper alloy core material and a copper-aluminum-silicon clad material. The composite is formed by rolling together the core and clad, preferably in an unheated condition, in a single pass with a reduction of about 50% to 75% to form a metallurgical bond between the core and clad and thereafter enhancing the bond strength by heating the bonded core and cladding to a temperature in the range of about 200.degree. C. to about 750.degree. C. for a time period of about 5 minutes to about 24 hours.

Abstract: A continuous lubrication casting mold for use in a process of continuously casting molten metals and alloys wherein a parting and/or lubricating agent reservoir is provided in the mold body. The agent is continuously applied over the inner surface of the mold after being introduced through passages within or through the mold section. The lubricant passages may be an intrinsic characteristic of the mold material or may be provided in the form of feed holes through the mold section. The ability to transmit lubricant through to the internal surface of the mold can be varied within the length of the casting mold to provide for variable lubricant transfer rates to different parts of the casting surface.

Abstract: A process for electromagnetically containing and forming molten material into a desired thin strip shape. At least two inductors are employed which are powered at respectively different frequencies. The frequency of the current applied to the upstream inductor is substantially lower than the frequency applied to the downstream inductor thereby providing improved efficiency and reduced power consumption.

Abstract: An apparatus and process is disclosed for forming a cap-like member from a blank of material. The apparatus comprises a die for shaping the cap-like member. A device is provided to co-act with the die for simultaneously forming both the member and internal threads within the member.

Abstract: An apparatus and process for operating a rolling mill having at least two rolls rotating at different speeds to produce a continuous strip material having a substantially constant final thickness comprises a mechanism for controlling the magnitude of the compressive force between the rolls in response to the ratio of the incoming strip speed to the outgoing strip speed. A mechanism is provided for comparing the ratio of the strip speeds to a ratio of the roll speeds and for adjusting the compressive force magnitude until the two speed ratios are substantially equal. In this manner, the amount of off-stage strip material produced during mill start-up is reduced and process stability and gage control during steady state operation is enhanced.