Abstract: A connecting adapter configured to mate on opposite ends with a standard adapter shank and a standard welding electrode of the resistance type. The connecting adapter is a hollow body with male and female connecting portions. The male portion, integral with the female portion, is sized to accommodate the standard welding electrode thereon. The female portion is sized to accommodate a taper portion of the shank within the hollow body and has exterior cross-sectional dimensions similar to those of the shank. The connecting adapter being formed of a wear-resistant conductive martial is replaced only periodically, thus reducing greatly the wear on the more expensive standard adapter shank.

Abstract: A process is provided for forming a resistance welding electrode. The process includes the step of providing a billet formed from a high conductivity metal. The billet includes a first portion having a first inner cavity formed therein. The process further includes the steps of inserting an insert into the first inner cavity of the billet, and deforming the insert so as to mechanically lock the insert in place in the billet. The deformed billet comprises the resistance welding electrode.

Abstract: A process is provided for forming a resistance welding electrode. The process includes the step of providing a billet formed from a high conductivity metal. The billet includes a first portion having a first inner cavity formed therein. The process further includes the steps of inserting an insert into the first inner cavity of the billet, and deforming the insert so as to mechanically lock the insert in place in the billet. The deformed billet comprises the resistance welding electrode.

Abstract: A method of manufacturing a hollow point bullet is disclosed. A cavity is formed in an end portion of a slug of generally solid material. A plurality of grooves are formed on an outer surface of the end portion of the slug. A slit is cut through a portion of each of the grooves substantially adjacent a peripheral edge of the end portion. The end portion of the slug is contoured so that the bullet has a desired shape and geometry.

Abstract: A process is provided for forming a resistance welding electrode. The process includes the step of providing a billet formed from a high conductivity metal. The billet includes a first portion having a first inner cavity formed therein. The process further includes the steps of inserting a dispersion strengthened copper insert into the first inner cavity of the billet thereby forming an insert-containing billet, and deforming the insert-containing billet so as to mechanically lock the insert in place in the billet. The deformed insert-containing billet comprises the resistance welding electrode.

Abstract: An enhanced machining oxygen-free copper alloy is provided which contains at least 0.02% by weight silver and from 25 to 100 parts per million sulfur. The copper alloy is anneal resistant and has sufficient ductility to permit cold working.

Abstract: A heat sink mounting for a semi-conductor device includes a base member having a base body defining a generally cylindrical recess and a downwardly extending stem portion. The base body further defines an annular groove extending around the side surface of the cylindrical recess. A cap member detachably engages the base member and encloses the cylindrical recess. The cap member includes a tab arrangement which extends radially outward from the bottom of the cylindrical side wall of the cap member to engage the annular groove.

Abstract: A pill-shaped billet which is tapered in thickness toward an outer, relatively thin rim, extending circumferentially therearound, is cold formed into a metal part having an annular flange. Upper and lower die elements define cavities, and shoulders extending circumferentially therearound, and are positioned in a sleeve with the shoulders being directly opposed, thereby defining an annular space. The billet is placed between the upper and lower die elements in the sleeve with the rim of the billet in the annular space. The upper and lower die elements contact the billet only along the edges between their respective shoulders and cavities. When the upper and lower die elements are moved toward each other, the annular flange is formed by extruding radially outward the part of the billet between the shoulders, while simultaneously cold forming the billet into the first and second cavities.

Abstract: A method of making a male resistance welding electrode includes a forward extrusion step in which the shank portion of the electrode is partially formed by extruding a cut-off billet of dispersion strengthened copper over a pin in a first die. Subsequently, the preform billet produced in the first die is inserted into a second die which defines a tapered shank cavity region around a central pin and a larger cavity region from which the head portion of the electrode is ultimately formed. The shank portion of the electrode is formed and the head portion worked substantially by the application of pressure to the preform billet by a first forming member. Final forming occurs when a second forming member applies pressure to the head of the electrode while the electrode remains in the second die.

Abstract: A method and apparatus for forming an electrical connector having a first hollow cylindrical portion of a first outside diameter and a second hollow cylindrical portion of a second outside diameter which is less than the first outside diameter, are provided in which two successive extrusion operations are performed. In the first extrusion operation, a billet of ductile metal is placed in a first die and an intermediate billet is formed by back extruding the first portion of the connector over a punch while forward extruding a part of the billet in the die to form a portion of reduced diameter approximately equal to the second outside diameter of the electrical connector. In the second extrusion operation, the intermediate billet is placed in a movable die section and the intermediate billet and the movable die section are moved downward from an initial position by means of a finish punch. The finish punch contacts the intermediate billet and is received within a first cylindrical recess defined by the billet.

Abstract: A bi-metal resistance welding electrode has a dispersion strengthened copper tip and a high conductivity copper shank. The electrode is made by forming a tip member in two successive upsetting operations to produce a tip member having a coating of high conductivity copper covering substantially all of one end thereof. A solid, high conductivity copper, cylindrical billet is formed and brazed to the tip member at its coated end to form an extrusion blank. The extrusion blank is back extruded with the high conductivity copper material being worked substantially, while only partially back extruding the tip portion of the extrusion blank.

Abstract: A bi-metal resistance welding electrode has a dispersion strengthened copper tip and a high conductivity copper shank. The electrode is made by forming a tip member in two successive upsetting operations to produce a tip member having a coating of high conductivity copper covering substantially all of one end thereof. A solid, high conductivity copper, cylindrical billet is formed and brazed to the tip member at its coated end to form an extrusion blank. The extrusion blank is back extruded with the high conductivity copper material being worked substantially, while only partially back extruding the tip portion of the extrusion blank.

Abstract: A method of making a semi-conductor heat sink mounting includes two extrusion steps. Initially, a substantially cylindrical copper billet having an upper cylindrical locating portion of reduced diameter is formed. A steel ring is then brazed to the copper billet such that it surrounds the locating portion. The copper billet and the steel ring are then extruded to form a sink body portion, a pedestal portion extending upwardly from said body portion defining a disc receiving recess therein, and a resistance welding ridge surround the pedestal portion. A molybdenum disc is brazed into the disc receiving recess. A stem is then extruded downwardly from the body portion of the heat sink mounting as a substantially evenly distributed downward force is applied to the heat sink body portion, the pedestal portion and the molybdenum disc.

Abstract: A bimetal resistive welding electrode having a dispersion strengthened copper tip portion and a shank portion formed of a high conductivity copper is produced by brazing together a conductive copper billet and a dispersion strengthened copper billet to form an extrusion blank. The brazing temperature is such that the dispersion strengthened copper is not annealed. The extrusion blank is then extruded into the shape of a welding electrode with the extruding process hardening the conductive copper shank portion to produce a full hard electrode.

Abstract: The invention provides a double insulated commutator in which the steel V-rings which interlock with the dovetail bases of the commutator bars to lock the bars in place have a first insulator material applied in the form of a powdered epoxy resin which is heated to form a thin continuous insulating layer, and over which there is a thicker layer of laminated sheet material such as mica, a Nylon paper material, or the like.

Abstract: A process for the formation of a mount for a semi-conductor, such as a rectifier or the like, in which a steel ring and a steel tube are brazed in position on the upper surface of a previously formed hexagonal copper billet, following which the parts are cold-formed in a plurality of extrusion steps for producing an accurately formed mount in which the copper material is work-hardened.