Abstract: A termination for high-current electrical apparatus comprises a lead in the form of an elongated strip of relatively soft aluminum, a terminal in the form of a plate of relatively hard aluminum-base alloy, and a butt weld between the edges of the strip and the plate comprising a fillet of aluminum alloy extending across the width of the terminal. A plurality of holes in the lead adjacent the butt weld serve to weaken the lead sufficiently so that the lead in the region of the holes is more susceptible to deformation than the weld as a result of bending forces applied to the termination through the terminal.

Abstract: A method for forming cores for an electrical transformer is disclosed. Also disclosed are the cores made from such a method. In one embodiment an amorphous metal core has relatively thick superimposed laminations comprised of relatively thin amorphous metal sheets. The amorphous metal sheets are heated and bonded together by a metallic bonding agent to form relatively thick amorphous metal packets for the superimposed laminations of the core. The heating and bonding of the amorphous metal sheets reduce the mechanical stresses normally induced into the amorphous metal during the fabrication process. In another embodiment a hybrid core has superimposed laminations certain of which comprise sheets of non-crystalline amorphous metal and one or more sheets of crystalline silicon steel metal.

Abstract: A bimetallic electrical terminator, formed from aluminum and copper members and having a hot pressure bond lock between its members is disclosed. A method for forming such a terminator is also disclosed. The bimetallic electrical terminator may be used within a separable connector to interconnect two branches of a high voltage electrical network. The bimetallic terminator has a low electrical resistance and a high mechanical strength between its aluminum and copper members.

Abstract: A sound, low resistance joint is provided between two electrically conductive members, at least one having a bonded insulation coating thereon. In one form of the method of the present invention, a continuous metallic penetrator having sharp edges or burrs, such as a brass screen, is interwoven about at least two bonded insulation coated conductive members. The coated conductive members and interwoven penetrator are placed in a conductive connector member having chamfered holes therein. Welding electrodes subject the connector member to heat and pressure with welding current flowing between the welding electrodes. At least some of the welding current flows through the continuous metallic penetrator before the penetrator makes electrical contact to the insulation coated conductive members. The penetrator becomes heated by thermal heat from the welding electroides and resistance heat as the welding current passes therethrough.

Abstract: One form of the method includes disposing a silver contact pad on only a portion of a metal body. The joint between the silver contact pad and the metal body includes a metal which is metallurgically compatible with the silver contact pad and with the metal body. Heat and pressure are applied to the joint through welding electrodes. This joins the contact pad to the metal body and forms a metallurgical bond therebetween. In one embodiment, the metal body comprises copper and the compatible metal comprises tin. The welding electrodes may include shaping surfaces thereon so that the contact pad can be joined to the metal body while substantially simultaneously shaping the combination of the contact pad and the metal body. The resultant contact pad is arc-resistant,i.e., resistant to erosion, and has a typical thickness in the range of from about 0.0005" to about 0.010".

Abstract: In this panel-type radiator a pair of panels are disposed in adjacent, side-by-side relationship, and each is made of two thin dished sheets of steel. Adjacent sheets of the adjacent panels are each provided with a thin-walled embossment of generally truncated conical form having a central opening extending through its outer end. Each embossment also comprises a radially-extending flange surrounding the opening and an annular portion of rounded cross-section joining the flange and the generally conical portion of the embossment. The flanges are disposed in juxtaposition with the openings generally aligned, thus providing externally of the flanges a groove of generally V-shaped cross-section between the annular portions of the embossments. A deposit of silicon bronze forms a brazed joint between the embossments, and this deposit comprises an annular filet of silicon bronze disposed in the V-shaped groove and a film of silicon bronze between the juxtaposed flanges.

Abstract: This panel-type radiator for extracting heat from liquid flowing therethrough comprises a panel through which the liquid flows in a downward direction. The panel is made from two dished metal sheets having aligned vertically-extending embossments welded together along a vertically-extending zone and providing spaced vertically-extending flow channels on opposite sides of the vertically extending zone. The portions of the sheets defining the walls of said channels are provided with vertically-spaced embossments arranged on each sheet in a generally herringbone pattern, with the individual embossments extending transversely of the vertically-extending zone via a path that slopes upwardly as the vertically-extending zone is approached.

Abstract: A bracket of generally U-shaped cross-section comprising spaced-apart legs terminating in edges having projections thereon is joined to a cylindrical steel wall by a method that comprises the steps of: (a) locating the bracket so that said edges extend along the length of the cylindrical steel wall and said projections contact the external surface of the wall, (b) projection-welding the bracket to the wall by an operation that collapses the projections, locates the edges closely adjacent the external surface of the steel wall, and provides a gap of V-shaped cross-section between each edge and the external surface of the wall, and (c) then fillet-welding the bracket to the wall by applying a welding fillet to the external surface of the wall and the outer surface of each leg of the bracket in the region of the V-shaped gap.

Abstract: A method of welding aluminum to aluminum by thermal resistance welding, providing good electrical and mechanical characteristics. The method uses special electrodes for thermal heat that are hard and have a high electrical resistance, such as molybdenum or tungsten alloy and also relies on the aluminum oxide coating on the aluminum to provide the desired resistance heating of the aluminum to cause welding of the aluminum material. The machine disclosed provides a means for securing aluminum leads to the start and finish end of an aluminum winding automatically and simultaneously.

Abstract: A method of welding aluminum to aluminum by thermal resistance welding, providing good electrical and mechanical characteristics. The method uses special electrodes for thermal heat that are hard and have a high electrical resistance, such as molybdenum or tungsten alloy and also relies on the aluminum oxide coating on the aluminum to provide the desired resistance heating of the aluminum to cause welding of the aluminum material. The machine disclosed provides a means for securing aluminum leads to the start and finish end of an aluminum winding automatically and simultaneously.

Abstract: A metal welding gasket secured between a cover and a container to prevent expulsion of weld material into the interior of the device being welded.

Abstract: A metal welding gasket secured between a cover and a container to prevent expulsion of weld material into the interior of the device being welded.