Abstract: Systems and methods for continuously casting Al—Mg alloy sheet or plate product having a high amount of magnesium are disclosed. The Al—Mg products have 4 or 6 to 8 or 10 wt. % Mg and are resistant to both stress corrosion cracking and intergranular corrosion.

Abstract: A latch having a housing and a latch mechanism located within an interior portion of the housing. The latch mechanism includes an arm, a pair of socket screws, a pair of torsion springs, each of which is connected rotatably to the arm and engages a corresponding one of the pair of socket screws, a bolt mechanism attached rotatably to the housing, and a link attached pivotally to the arm and attached to the bolt mechanism. The socket screws are utilized to adjust loads on the springs. The bolt mechanism is movable between a first position, in which the arm and the link are toggled with one another under the loads of the springs and the bolt mechanism is adapted to engage an external structure, and a second position, in which the link and the arm are untoggled with one another and the bolt mechanism is disengaged with the external structure.

Abstract: A composite structure has a pair of parallel aluminum extrusions bridged by a polymer cap and defining a U-shape hollow. The hollow is filled with an expandable foam that adheres to and mechanically interdigitates with the extrusions, which have channels for receiving insertion legs of the extrusions and have extensions, which the foam encapsulates. End caps may be used to further delimit the hollow. The caps and the foam have a thermal conductivity less than that of the extrusions, providing a thermal break. An upper cap may be used and may incorporate features to compensate for the foam expansion. Excess foam may be trimmed. A forked tool may be used to hold the extrusions during joining.

Abstract: An apparatus and method for fastening dissimilar metals like steel and aluminum utilizes a steel rivet and a spot welding machine. The rivet and metals are stacked and the heat from the welder's electric current softens the lower melting point aluminum allowing the rivet to penetrate the aluminum and weld to the steel layer. The fastener may be used to join stacks with several layers of different materials and may be used to apply a threaded socket or stud made from steel or titanium to an aluminum or magnesium alloy structure. Layers of non-conductive materials like plastic and ceramics may also be affixed to a conductive layer using the fastener made from a compatible material that extends through a pilot hole.

Abstract: Methods for creating three-dimensional volume quality models of additively manufactured metal bodies are disclosed. In one embodiment, a method comprises additively manufacturing each metal layer of a metal body. One or more images of the first metal layer are obtained. The image(s) are processed to detect and map potential manufacturing defects in the first metal layer. A two-dimensional contour of the first metal layer is generated from the three-dimensional CAD model. The mapped defects are integrated into the two-dimensional contour. A first layer of a three-dimensional volume quality model of the metal body is created based on the integrated two-dimensional contour.

Abstract: A fastener including a bolt having an elongated shank having a first end, a second end opposite the first end, and a threaded portion having an external bolt thread, the bolt thread including a bolt pitch. The fastener includes a nut having a first end, a second end opposite the first end of the nut, and an internal nut thread extending between the first and second ends of the nut and adapted to engage threadedly the bolt thread of the bolt. The nut thread includes a nut pitch and a hardness that changes gradationally between the first and second ends of the nut. The bolt pitch of the bolt thread of the bolt is mismatched with the nut pitch of the nut thread of the nut.

Abstract: A handle mechanism includes a gear drive having an interior end and an exterior end; an inside handle fixed to the interior end; a button; a finger; a handle drive; an outside handle; and a spring. The button has an interior end and an exterior end, which is positioned within the exterior end of the gear drive. The handle drive is positioned within the exterior end of the gear drive and is rotatable relative thereto. The outside handle and the handle drive rotate together. The outside handle moves between a first position, wherein it is constrained from rotation, and a second position. The finger is fixed to the exterior end of the button, which moves between a first position, wherein the finger causes the gear drive and the handle drive to rotate together, and a second position. The spring biases the button and the outside handle toward their first positions.

Abstract: A locking member for a fastener, such as a nut or a collar, includes a shank portion and a flanged portion, a bore extending the shank portion and the flanged portion and including a first interior portion located within the shank portion and a containment cavity located within the flanged portion, and an inner wall defining the containment cavity. The containment cavity includes an inner diameter that is greater than an inner diameter of the first interior portion of the bore. The inner wall of the containment cavity includes one or a combination of flat/linear surfaces, concave surfaces, and convex surfaces.

Abstract: A weather seal that inserts into a gap between glazing panels has an H-shape with a snap-on female receiver at either end for receiving a tongue extending from a structure at one end and a cap tongue in the other. A web extending between a pair of walls provides a weather barrier and allows the walls to flex enabling the snap-on action. A pair of sealing fins and a pair of bulbs extend laterally from the H-shape, bridging the gap to exclude weather infiltration. The second receiver is covered by extensions joined at a slit permitting the weather seal to be used without a cap. Alternatively, the cap may be affixed to the weather seal by pushing a cap tongue through the slit and into engagement with the second receiver.

Abstract: A pawl latch having a pin assembly with a pin and a receiver assembly adapted to receive the pin assembly. The receiver assembly includes a receiver housing having a slider positioned slidably on the receiver housing, a cam rotatably mounted in the receiver housing, and a link connecting the cam and the slider. Rotating the cam moves the slider along the receiver housing. The receiver assembly includes a pawl and a stop, each having arms, respectively, that rotate. When the receiver assembly receives the pin assembly, contacts the arms of the stop and facilitates their rotation, in which the cam is enabled to be rotated and, in turn, facilitates movement of the slider. The arms of the pawl are rotated in order to lock the pin head of the pin assembly within the receiver assembly.

Abstract: Methods for producing forged products and other worked products are disclosed. In one embodiment, a method comprises using additive manufacturing to produce a metal shaped-preform and, after the using step, forging the metal shaped-preform into a final forged product. The final forged product may optionally be annealed.

Abstract: An apparatus and method for fastening dissimilar metals like steel and aluminum utilizes a steel rivet and a spot welding machine. The rivet and metals are stacked and the heat from the welder's electric current softens the lower melting point aluminum allowing the rivet to penetrate the aluminum and weld to the steel layer. The fastener may be used to join stacks with several layers of different materials and may be used to apply a threaded socket or stud made from steel or titanium to an aluminum or magnesium alloy structure. Layers of non-conductive materials like plastic and ceramics may also be affixed to a conductive layer using the fastener made from a compatible material that extends through a pilot hole.

Abstract: Systems and methods for continuously casting Al—Mg alloy sheet or plate product having a high amount of magnesium are disclosed. The Al—Mg products have 4 or 6 to 8 or 10 wt. % Mg and are resistant to both stress corrosion cracking and intergranular corrosion.

Abstract: A swage collar includes a shank, a flange, and a through bore. The shank includes a first end, a second end opposite the first end, an outside diameter, and an overall length between the first end and the second end. The flange extends from the first end of the shank. The through bore extends longitudinally through the shank from the first end of the shank to the second end of the shank. The through bore defines an inside diameter. The inside diameter and the outside diameter together define a wall thickness of the shank. The wall thickness of the shank is in a range of about 0.1 times the overall length of the shank to about 0.16 times the overall length of the shank.

Abstract: A pressure relief door having a panel with an exterior side and an interior side, a pair of pressure relief latches mounted to the interior side of the panel, and a pair of hinges mounted to the panel and each including a lock mechanism mounted thereto. Each of the lock mechanisms includes a mounting bracket. The door is adapted to be installed within a structure and moveable between a closed position, such that the exterior side of the panel is substantially flush with an exterior surface of the structure, the lock mechanisms are engaged with an interior surface of the structure, and the pressure relief latches are engaged with the interior surface of the structure, and an open position, such that the pressure relief latches are disengaged with the interior surface of the structure, while the lock mechanisms remain engaged with the interior surface of the structure.

Abstract: A composite structure has a pair of parallel aluminum extrusions bridged by a polymer cap and defining a U-shape hollow. The hollow is filled with an expandable foam that adheres to and mechanically interdigitates with the extrusions, which have channels for receiving insertion legs of the extrusions and have extensions, which the foam encapsulates. End caps may be used to further delimit the hollow. The caps and the foam have a thermal conductivity less than that of the extrusions, providing a thermal break. An upper cap may be used and may incorporate features to compensate for the foam expansion. Excess foam may be trimmed. A forked tool may be used to hold the extrusions during joining.

Abstract: A weather seal that inserts into a gap between glazing panels has an H-shape with a snap-on female receiver at either end for receiving a tongue extending from a structure at one end and a cap tongue in the other. A web extending between a pair of walls provides a weather barrier and allows the walls to flex enabling the snap-on action. A pair of sealing fins and a pair of bulbs extend laterally from the H-shape, bridging the gap to exclude weather infiltration. The second receiver is covered by extensions joined at a slit permitting the weather seal to be used without a cap. Alternatively, the cap may be affixed to the weather seal by pushing a cap tongue through the slit and into engagement with the second receiver.

Abstract: A glazing system for holding glazing units to a frame member has an aluminum pressure plate and a composite plate co-extruded from a plurality of polymers and having a pair of gaskets and a central isolator. A pair of polymer extrusions extend from the isolator and have ledges at the end that embrace and seal against the metal plate. The metal and composite plates are coupled together by a pair of ribs extending from the composite plate into a pair of slots in the metal plate.

Abstract: Methods for producing forged products and other worked products are disclosed. In one embodiment, a method comprises using additive manufacturing to produce a metal shaped-preform and, after the using step, forging the metal shaped-preform into a final forged product. The final forged product may optionally be annealed.