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: A process and apparatus for forming a semi-solid thixotropic alloy slurry and preferably a rheocasting therefrom. Molten metal in a mold is cooled under controlled conditions while it is mixed under the influence of a moving magnetic field. A non-zero, magnetic field is provided across the full cross section of the mold and over the entire solidification zone. This results in a magnetomotive stirring force of sufficient magnitude to provide mixing of the molten metal to form the slurry. Preferably, a two pole induction motor stator is used to generate the magnetic field.

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.

Abstract: A process for restructuring thin strip semiconductor material is disclosed. It comprises the steps of providing relative movement between the thin strip material and the heating station. The thin strip material is heated at the heating station to a desired temperature between the recrystallization temperature and the melting temperature. The strip is maintained at the desired temperature whereby preferred recrystallization and stress relief occurs within the material. In addition, the thin strip material may be elongated through elevating the temperature of the thin strip and/or increasing the longitudinal tension on the strip.

Abstract: Novel and advantageous metal laminates particularly useful in making coins comprising a copper core and a cladding metallurgically bonded thereto of a copper base alloy containing from 2 to 3.5% aluminum, from 1 to 2.5% silicon and the balance essentially copper. Disclosure also teaches a method of preparing copper laminates by providing a copper core in strip form in the hard temper and a copper alloy cladding fully annealed in strip form, wherein the components are rolled together in a single pass with a reduction of from 50 to 75% to provide the metallurgically bonded laminate.

Abstract: A process for recrystallization of thin strip material includes a device for electromagnetically melting the thin strip material to provide a molten surface layer and a substantially solid core. Apparatus provides relative movement between the thin strip and the device for electromagnetically melting. Also, an apparatus resolidifies the molten surface layer to provide a preferred crystal structure in the thin strip material.

Abstract: A rolling mill apparatus and process comprise a plurality of rolls defining a plurality of roll bites defining a gap spacing between adjacent rolls. A fixed gap spacing is employed for at least one roll bite. A floating gap spacing is provided for at least one other roll bite. It is thereby possible to control in a desired manner the amount of thickness reduction at a desired roll bite in a pass through the mill.

Abstract: Novel and advantageous metal laminates particularly useful in making coins comprising a copper core and a cladding metallurgically bonded thereto of a copper base alloy containing from 2 to 3.5% aluminum, from 1 to 2.5% silicon and the balance essentially copper. Disclosure also teaches a method of preparing copper laminates by providing a copper core in strip form in the hard temper and a copper alloy cladding fully annealed in strip form, wherein the components are rolled together in a single pass with a reduction of from 50 to 75% to provide the metallurgically bonded laminate.

Abstract: A process and apparatus for reforming an improved strip (12) of material from a starting strip (16) of material. An electromagnetic device (18) maintains a floating molten zone (20) of the material in the starting strip (16) of the material and also forms the floating zone into the improved strip (12). The apparatus is provided with a susceptor device (80) arranged adjacent to the starting strip and operatively associated with the electromagnetic device (18) for initially heating the starting strip to be sufficiently conductive so that the starting strip can be directly heated by the electromagnetic device. Further, a control device (67) provides relative movement between the susceptor device (80) and the electromagnetic device by positioning the susceptor device in and out of the field of the electromagnetic device.

Abstract: A process is disclosed for joining narrow width thin gage metal or alloy strip end to end to form an elongated coil. The trailing end of a first strip segment and the leading end of a second strip segment are cut so as to match when placed in a butting relationship and to establish a joint between the strips. A preselected gap is established between the butting ends and a braze material is inserted in the gap. After heating to braze the strip segments together, the brazed joint is hammered to reduce the joint geometry to that of the parent metal strip segments.

Abstract: An apparatus and process for rolling metal strip to provide increased percentage reductions in the thickness of the strip per pass and increased total reduction between anneals. A 4-high rolling mill is modified so that it is back-up roll driven such that the back-up rolls have different peripheral speeds in the same ratio as the desired strip reduction. The strip travels through the mill in a serpentine arrangement to provide three reductions per pass. Forward and back tension are applied to the strip during rolling.

Abstract: The invention relates to an improved method for the preparation and delivery of semi-solid thixotropic metal slurries for use in metal forming processes such as the rheocast and thixocast processes. The method includes inducing turbulent motion within the metal during solidification by electromagnetic or electrodynamic techniques under controlled temperature conditions so as to produce a highly fluid semi-solid slurry with a degenerate dendritic structure comprising solid spheroids dispersed in liquid. In the method of the preferred embodiment of the present invention, flow of the thixotropic metal slurry from the vibrating chamber is controlled by electromagnetic techniques and may be continuous or semi-continuous.

Abstract: A process and apparatus for forming an as-rolled composite metal panel comprised of at least two sheets of metal having a bond therebetween which can be broken by inflation to form a desired pattern of tubular passageways. The deformation of the sheets of metal during inflation is limited by a maximum aspect ratio. Inflation is provided using an inflation needle having a cross section which is a part or full oval. A fixture is provided for limiting the peeling apart of the composite metal panel upon insertion of the inflation needle.

Abstract: A process and apparatus for making composite sheet and heat exchanger panels therefrom. At least two sheets of metal are bonded together by cold rolling to form a "green" bond. Immediately following the bonding operation the as bonded composite is quickly cooled to a temperature at which noticeable bond enhancement will not occur. A desired pattern of tubular passageways is then inflated into the composite while the composite is held in a die.

Abstract: A process for making aluminum alloy conductor wire having an electrical conductivity of at least 60.0% IACS which involves processing an alloy containing from 0.04 to 1.0% by weight iron, from 0.02 to 0.2% by weight silicon, from 0.1 to 1.0% by weight copper, from 0.001 to 0.2% by weight boron, balance essentially aluminum and processing said alloy without a final redraw step into wire. The process preferably includes hot working from at least approximately 900.degree. F. without reheating to form the redraw rod. This hot working is performed in order to allow the wire produced from this process to meet the desired properties at the final gages, such properties including high electrical conductivity under rapid annealing conditions.

Abstract: An improved method and apparatus for supporting the shaving tool in an adjustable tool holder for use in the production of multiple gauge strip is disclosed wherein the adjustable tool holder is vertically positioned on gauge blocks and thereby rigidly supported against the strip to be shaved by applying a vertical load on the adjustable tool holder.

Abstract: An improved method and apparatus for the production of multiple gauge metal strip is disclosed wherein the metal strip is drawn over an arced surface under a shaving tool apparatus whereby the arced surface provides effective hold-down of the metal strip thereby allowing a greater volume removal of material per pass. The present invention contemplates an improved apparatus for holding the shaving tool's position with respect to the arced surface and the strip.

Abstract: A method of cladding metal plate with a protective layer of copper or copper base alloy is disclosed. The metal plate is contacted with a standing waveform of molten copper or copper base alloy in order to provide the cladding layer. This clad composite material is used to provide corrosion resistance for the metal plate substrate and an inexpensive alternative to solid thick sheets of copper or copper base alloy to deter corrosion.

Abstract: Multiple gauge metal strip is prepared by a process which comprises first shaving said strip by a process comprising drawing said strip through a shaving apparatus adjusted to achieve maximum stock removal in relation to the yield strength of said strip whereby said yield strength is not exceeded whereby surface reduction is confined to an area comprising 5 to 50% of total surface area and volume reduction ranges from 10 to 60% of initial strip cross sectional area, and drawing the strip through a die which defines the desired final cross sectional configuration to produce a reduction of said strip to final dimension, wherein said drawing is performed without direct surface-to-surface contact between said strip and said die.

Abstract: A clip exhibiting improved corrosion resistance and reduced weight is processed by a drawing operation which is preferably conducted without interannealing treatments and which may employ a variation of drawing speeds. The clip of the present invention is prepared from an aluminum base alloy comprising from about 0.05-6.0% silicon, about 0.10-0.8% iron, about 0.02-0.3% copper, up to 1.0% manganese and up to 7.0% magnesium. The resulting clips possess comparable tensile properties to conventional tin and zinc-coated steel clips with an economy of processing.