Abstract: A copper foil for lamination to a dielectric substrate is coated with a laser ablation inhibiting layer having an average surface roughness (Rz) of less than 1.0 micron and an average nodule height of less than 1.2 micron that is effective to provide a lamination peel strength to FR-4 of at least 4.5 pounds per inch. The coated foil further has a reflectivity value of at least 40. The coated foil is typically laminated to a dielectric substrate, such as glass reinforced epoxy or polyimide and imaged into a plurality of circuit traces. Blind vias may be drilled through the dielectric terminating at an interface between the foil and the dielectric. The coated foil of the invention resists laser ablation, thereby resisting piercing of the foil by the laser during drilling.

Abstract: A flexible circuit to interconnect two components of an electrical device is formed with a flexible polymeric substrate. A copper alloy is laminated to the flexible substrate. This copper alloy is processed to have relatively high strength, an ultimate tensile strength in excess of about 80 ksi, by either alloying additions, by processing or by a combination of the two. When such an alloy is laminated to the polymeric substrate, the resultant flexible circuit has improved (more cycles to failure) dynamic fatigue performance when compared to both pure copper and dilute copper alloys.

Abstract: Spray cast copper-manganese-zirconium alloys are disclosed. In one embodiment, the alloy is spray cast in nitrogen and contains from about 1 ppm to about 20 ppm of dissolved nitrogen. In a second embodiment, the alloy contains an addition selected from the group consisting of chromium, titanium, erbium and mixtures thereof. The alloys are useful for sound damping as the combination of zirconium and the addition inhibits degradation of the specific damping capacity of the alloy.

Abstract: There is disclosed methods for the manufacture of a metal matrix composite having a metal or metal alloy matrix and a uniform dispersion of a second phase. The second phase is either a refractory metal or a nonmetal. An element which reacts with both the matrix and the second phase is added to increase the loathing density of the second phase and to improve adhesion between the components of the composite. When the metal alloy matrix is copper or a copper based alloy, suitable reactive elements include zirconium, titanium, chromium and mixtures thereof.

Abstract: There is provided an apparatus and method for the manufacture of metallic articles. A molten metal stream is disrupted, such as by gas atomization, to form a plurality of molten metal droplets. The molten metal droplets pass through a cooling zone having a length sufficient to allow up to about 30 volume percent of each of the droplets to solidify. A mold then receives and completes solidification of the metal droplets. When under about 30 volume percent of the droplets is solid, the droplets retain liquid characteristics and readily flow within the mold.

Abstract: Metal is spray cast onto a moving substrate using at least two sprays, the first of which has a solid fraction greater than 20% at the time the spray contacts the substrate, but less than the solid fraction of the second spray.

Abstract: A method of casting metal material wherein metallic metal is deposited on a foil moving underneath the feeding means for the molten metal and is supported on a supporting substrate. The foil is formed with side edges before receiving a deposit of molten metal to contain the flow of molten metal thereon in a direction transverse to the direction of movement of the foil.

Abstract: A method of casting metal wherein molten metal is deposited on a moving planar substrate to form a strip thereon. The strip is removed from the moving substrate onto an open mesh support prior to the strip becoming completely solidified throughout its thickness. Ideally, the strip is removed as soon as it forms a solidified shell on its bottom which is thick enough not to fracture under the weight of the remaining molten metal. This arrangement overcomes the problem of cooling the bottom surface of the cast metal due to an air gap forming between a solid supporting substrate and the cast metal.

Abstract: A molten metal gas-atomizing spray-depositing apparatus has an atomizer which employs a pressurized gas flow for atomizing a stream of molten metal into a spray pattern of metal particles being initially hotter than the solidus temperature of the metal. The apparatus also has a substrate system which includes an outer substrate of metallic foil and an inner substrate for supporting the outer substrate. The outer foil substrate is movable relative to the metal particles in the spray pattern thereof and disposed below the atomizer for receiving on a surface of the foil a deposit of the particles in the spray pattern to form a product on the outer foil substrate. The outer foil substrate is of a thickness which is less than a predefined maximum thickness at which the capacity of the foil to absorb heat from the deposit is equal to the latent heat and super heat, if present, of the deposit.

Abstract: A method and apparatus for the casting of metals in which a molten stream of metal is atomized into a spray of highly liquid droplets. The droplets are deposited on a moving substrate such as an endless belt provided with side dams. The droplets flow in a direction transverse to the direction of movement of the substrate and are contained by the side dams. The droplets may have an average size of 300 microns and the spray may have a liquid to solid ratio of at least 50%. This arrangement overcomes the problems of splashing and turbulence caused by the relative flow between the melt and the belt in regular belt casting and overcomes porosity problems associated with spray casting.

Abstract: Spray cast alloys having reduced porosity and increased ductility are provided as well as a process for the manufacture of the alloys. An effective amount of a reactive metal which reacts with the spray casting atmosphere but not with the desired alloy is dissolved into the alloy prior to spray casting. Preferred reactive metals readily form a nitride which is finely dispersed throughout the spray cast alloy.

Abstract: A method of producing a grain refined copper base alloy containing iron in the amount of less than 2.3% by weight and which is cast into an ingot by conventional direct chill casting. Calcium is added to the melt before casting, preferably in the form of a copper-clad or iron-clad calcium feedwire.

Abstract: A metal extrusion process and apparatus in wich a semisolid material is fed into a passageway formed between first and second members, with one of the members being moved toward a die such that the moveable member draws the semisolid material through the passageway and through the die means.

Abstract: A metal extrusion process and apparatus in which a semisolid material is fed into a passageway formed between first and second members, with one of the members being moved toward a die such that the semisolid material is drawn through the passageway and solidifies before passing through the die means.

Abstract: The present invention relates to a technique for forming silicon carbide coated porous filters for use in filtering molten metal, especially copper and copper alloy melts. The technique comprises preparing a silicon carbide containing slurry having a viscosity in the range of about 1 to about 50, preferably from about 5 to about 30, centipoise and impregnating a rigid porous substrate material with the slurry. In a preferred embodiment, the slurry contains mono-aluminum phosphate as a binding agent, ethylene glycol as a wetting agent, powdered silicon carbide having a maximum settling rate of about 0.1 mm./min. and the balance essentially water. After draining of the excess slurry, the coated substrate material is heated to substantially prevent foaming of the coating during firing and fired to bond the silicon carbide coating to the substrate material.

Abstract: The average diameter of atomized droplets is reduced thereby reducing both the frequency of collisions between droplets as well as the turbulence at the liquid/solid interface. Reducing the porosity of a spray cast deposit leads to improvements in both the ductility and the electrical conductivity of the deposit.

Abstract: A molten metal gas-atomizing spray-depositing apparatus has an atomizer for atomizing a stream of molten metal into metal particles in a divergent spray pattern thereof being of higher temperature at a center region of the pattern than at an outer peripheral region thereof. A substrate is continuously movable along an endless path and has an area thereon disposed below the atomizer for receiving a deposit of the particles in the spray pattern to form a product on the substrate being substantially uniform in thickness. The deposit-receiving substrate area has consecutively arranged upstream, intermediate and downstream portions upon which respective inner, intermediate and outer cross-sectional portions of the metal deposit are layered one upon the next to form the product.

Abstract: A metal extrusion process and apparatus therefor in which a strip material of a rectangular shape may be produced by maintaining frictional engagement of the metal by passageway-defining surfaces of a member which is moved toward a die such that the frictional drag of the passageway-defining surfaces urges the metal through the die. The process utilizes strip material as the starting material which enables the extrusion of metal strip by the frictional drag process to be accomplished.

Abstract: A molten metal gas-atomizing spray-depositing apparatus has an atomizer which employs a pressurized gas flow for atomizing a stream of molten metal into a spray pattern of semi-solid metal particles and producing a flow of the particles along with the gas flow in a generally downward direction. The apparatus also has a substrate disposed below the atomizer for impingement on the substrate of the gas flow at a steady state temperature resulting from heat transfer by the metal particles to the gas flow and for receiving a deposit of the particles in the spray pattern to form a product thereon.

Abstract: A method and apparatus for the casting of metals in which a molten stream of metal is atomized into a spray of highly liquid droplets. The droplets are deposited on a moving substrate such as an endless belt provided with side dams. The droplets flow in a direction transverse to the direction of movement of the substrate and are contained by the side dams. The droplets may have an average size of 300 microns and the spray may have a liquid to solid ratio of at least 50%. This arrangement overcomes the problems of splashing and turbulence caused by the relative flow between the melt and the belt in regular belt casting and overcomes porosity problems associated with spray casting.