Abstract: Casting aluminum by a lost foam process is improved by treating the metal during pattern replacement with a halide salt flux to inhibit formation of oxide fold defects. A preferred flux comprises a mixture of alkaline metal chloride compounds and includes an aluminum fluoride salt, such as sodium aluminum fluoride. In a preferred embodiment, the flux is incorporated into a polystyrene pattern prior to embedding the pattern in a sand mold and becomes dispersed on a front of the cast metal as the front progressively decomposes the pattern.

Abstract: In the preferred embodiment, a method is presented for filling depressions in fabricated steel surfaces by applying a metallic body solder consisting of 15 to 20 weight percent copper, 2 to 3 weight percent zinc and the balance tin. The body solder alloy is heated to a temperature above about 210.degree. C. to form a workable thixotropic paste that is applied with spreading onto the steel surface. Upon cooling, the body solder forms a dense, tightly adherent fill that is grindable and paintable in conjunction with the surrounding steel surface.

Abstract: In the preferred embodiment, a method is presented for filling depressions in fabricated steel surfaces by applying a metallic body solder consisting of 15 to 20 weight percent copper, 2 to 3 weight percent zinc and the balance tin. The body solder alloy is heated to a temperature above about 210.degree. C. to form a workable thixotropic paste that is applied with spreading onto the steel surface. Upon cooling, the body solder forms a dense, tightly adherent fill that is grindable and paintable in conjunction with the surrounding steel surface.

Abstract: In a preferred embodiment, a method is presented for filling depressions in fabricated steel surfaces by applying a metallic body solder consisting of 14 to 20 weight percent copper, 1 to 7.5 weight percent zinc, 0.5 to 1.5 weight percent iron and the balance tin. The body solder alloy is heated to form workable thixotropic paste that is applied with spreading onto the steel surface. Upon cooling, the body solder forms a dense, tightly adherent fill that is grindable and paintable in conjunction with the surrounding steel surface.

Abstract: A method of making a negative lead-acid storage battery plate wherein a gossamer mat of elongated, carbon/graphite fibers is bonded to a thin paper sheet which is thereafter applied to the face of the plate such that the carbon/graphite fibers lie contiguous the active material of the plate and serve to distribute the "formation" current more uniformly across the face of the unformed plate and into the regions of the unformed active material most remote from the conductive grid wires.

Abstract: Lightweight grids for lead-sulfuric acid type storage batteries are characterized by their laminated reticulated open meshed portions for retaining chemically active, lead-based paste materials. The laminated portions comprise a support layer of a rigid or semi-rigid plastic, an electrically conductive lead foil layer coextensive with the plastic layer, and a sulfuric acid resistant adhesive bonding layer between the plastic support and foil layers. In a preferred embodiment, the grid wires and nodes are twisted relative to the principal plane of the grid so that the lead foil layer is oriented to face the grid header portion and act as a ledge for retaining a desired battery paste. Such laminated grids may be rapidly and inexpensively formed by expanded metal processes of the type used to make battery grids made entirely of lead.

Abstract: In the preferred embodiment, a method is presented for filling depressions in fabricated steel surfaces by applying a metallic body solder consisting of 15 to 20 weight percent copper, 2 to 3 weight percent zinc and the balance tin. The body solder alloy is heated to a temperature above about 210.degree. C. to form a workable thixotropic paste that is applied with spreading onto the steel surface. Upon cooling, the body solder forms a dense, tightly adherent fill that is grindable and paintable in conjunction with the surrounding steel surface.

Abstract: This invention relates to an improved method of making a distributor rotor electrode wherein dielectric particles are dispersed in an electrically conductive metal matrix for suppressing radio frequency intereference. More particularly, the invention relates to a method of making such electrodes wherein a mixture comprised of silica and copper oxide is fused into a solid material which is then comminuted into powder particles 50 microns in size, or less, and having irregular shapes. The powder particles themselves are comprised of a microscopic interspersion of a silica based phase and a copper oxide based phase. These powder particles are thereafter combined with a powder of an electrically conductive metal to form a uniform second mixture comprising about 0.5 to 15 weight percent silica. The second mixture is then pressed in a compact for a rotor electrode body and sintered to form a wear resistant densified rotor electrode.

Abstract: Lightweight grids for lead-sulfuric acid type storage batteries are characterized by their laminated reticulated open meshed portions for retaining chemically active, lead-based paste materials. The laminated portions comprise a support layer of a rigid or semi-rigid plastic, an electrically conductive lead foil layer coextensive with the plastic layer, and a sulfuric acid resistant adhesive bonding layer between the plastic support and foil layers. In a preferred embodiment, the grid wires and nodes are twisted relative to the principal plane of the grid so that the lead foil layer is oriented to face the grid header portion and act as a ledge for retaining a desired battery paste. Such laminated grids may be rapidly and inexpensively formed by expanded metal processes of the type used to make battery grids made entirely of lead.

Abstract: An ignition distributor for an internal combustion engine is provided with a novel rotor electrode which substantially reduces radio frequency interference generated by spark discharges across the rotor gap. At least the tip segment of the rotor electrode is formed of a composite material consisting of a first phase of fibers of a dielectric material interspersed with a second phase of a conductive material. In operation, dielectric fibers protrude from the conductive phase into the gap promoting ionization therein so that electrical discharge occurs at voltages where radio frequency signal production is substantially suppressed.

Abstract: An ignition distributor for an internal combustion engine is provided with a novel rotor electrode which substantially reduces radio frequency interference generated by spark discharges across the rotor gap. At least the tip segment of the rotor electrode is formed of a composite material consisting of a dielectric phase interspersed with a conductive metal phase. In operation, the dielectric phase protrudes from the surface of the electrode promoting ionization in the rotor gap so that electrical discharge occurs at voltages where radio frequency signal production is substantially suppressed.