Abstract: A process for obtaining bimaterial parts by casting an aluminum alloy onto an insert coated with a metal film. In this process, the oxide layer is removed from the insert by treatment under vacuum, and then the insert is coated with a titanium based film by physical vapor deposition, and the insert is placed in a mold which is filled with a casting alloy.

Abstract: Lightweight composite armor comprising a plurality of ceramic bodies embedded in a metal matrix. The ceramic bodies are preferably generally spherical alumina balls coated with a binder and ceramic particles. A particularly preferred coating comprises titanium dioxide and barium sulfate particles suspended in an aqueous sodium silicate solution at a thickness of about 0.76-1.5 mm.

Abstract: Sintered ceramic preforms for metal matrix composites fabricated by a method comprising: (a) preparing a homogeneous mixture containing appropriate amounts of silicon-containing fibers/particulates, such as silicon carbide, at least one solvent, at least one polymer, and an oxide-containing material, such as boric acid or phosphoric acid, capable of forming a low melting silicate with a silicon oxide, such as a borosilicate; (b) shaping a green ceramic preform from the mixture, such as by injection molding; (c) removing the solvent(s) and the polymer(s); (d) oxidizing the surfaces of the silicon-containing fibers to form a layer of the silicon oxide thereon; (e) heating the preform to a temperature sufficient to react the oxide-containing material with the silicon oxide to form the low melting silicate material; (f) liquid phase sintering the fibers in the presence of liquid silicate material to strengthen the preform; and (g) cooling the sintered preform to ambient.

Abstract: The article is produced by prepositioning nonwoven reinforcement made of a etallic mesh to which ceramic tiles are wired inside of a centrifugal casting mold. Molten matrix metal is then introduced into the mold while being rotated about an axis parallel to the inflow path of the molten metal until it completely encapsulates the reinforcement.

Abstract: Processes for coating a ferrous or aluminum article, such as an engine cylinder liner insert, to provide a metallurgical bond with aluminum alloy material cast around the article. The article surface to be bonded is treated to remove impurities, oxides, and foreign materials, and the article is preheated. A molten metallic bonding material, such as zinc or a zinc alloy, is provided and the treated and preheated article is immersed in the bonding material to provide a metallurgically bonded coating on the surface of the article being treated. The coated article, either shortly after coating or, alternatively, after having been cooled to ambient temperature and stored, can then be placed in a mold and molten aluminum alloy poured around it to metallurgically bond the aluminum to the coating on the article. The resulting structure provides a metallurgical bond that has improved heat transfer characteristics and improved structural integrity.

Abstract: A method of making a composite casting wherein a casting mold is provided having a melt-receiving mold cavity and a preformed metallic or intermetallic insert located in a predetermined position in the mold cavity. A melt is introduced into the mold cavity about the insert and is solidified to provide a composite casting having one or more interfaces between the insert, or an insert positioning member, and cast/solidified metal about the insert. The interface is exposed on or communicates with an exterior surface of the composite casting. After separation from the mold, the composite casting is subjected to a sealing operation to gas-tight seal the interface(s) at the exterior casting surface. For example, the interface can be sealed by providing fused material at the interface.

Abstract: In a dental prosthetic casting-on process, in which a secondary part made of metal is cast-on to a primary part made of metal, a primary part made from an oxide-forming metal alloy may be used if the latter's casting-on surface is alloyed, prior to casting-on, with a reducing metalloid. In this regard, boron, silicon or phosphorus, for example, can be made to diffuse into the surface lattice of the primary part. A primary part made from an oxide-forming dental alloy and suitable for such a casting-on process exhibits in its casting-on surface an enhanced boron or silicon or phosphorus content.

Abstract: The present invention relates to a novel process for forming metal matrix composite bodies by using a reactive barrier material. Particularly, an infiltration enhancer or an infiltration enhancer precursor or an infiltrating atmosphere are in communication with a filler material or a preform, at least at some point during the process, which permits molten matrix metal to spontaneously infiltrate the filler material or preform up to the reactive barrier material. Such spontaneous infiltration occurs without the requirement for the application of any pressure or vacuum. Accordingly, shaped metal matrix composite bodies can be produced having superior surface finish.

Abstract: Composites of ceramic and metal exhibiting high fracture strength and toughness are formed from layers of the ceramic that have unequal concentrations and unequal porosity. The composites are made by a process that involves arranging layers of the ceramic in a predetermined pattern to provide a body that can be fully infiltrated by the metal.

Abstract: Disclosed is a method and a mold for forming a zinc collar on an insulator metal cap. The zinc collar forming mold comprises a setting section for setting the metal cap in position on the mold and an upwardly opening cavity defined around the periphery of the setting section. For molding a zinc collar, the metal cap is immersed in a molten zinc, and the metal cap is set upright on the setting section of the mold with the lower half thereof being still in the molten state. Subsequently, a molten zinc is poured from the upper opening of the mold, and upon solidification of the molten zinc, a zinc collar can be formed around the external circumference of the metal cap.

Abstract: A reinforcement made of a composite material is positioned inside of a ceifugal casting mold. Molten matrix metal is then introduced into the mold while being rotated about its longitudinal axis until the molten metal completely encapsulates the reinforcement.

Abstract: A method is provided for forming a metallurgical bond between an aluminum-base insert and an aluminum-base casting material during a casting process, wherein the method entails wetting the oxide surface of the insert, coating the surface with a metallurgically compatible material, and raising the temperature of the insert to reduce the temperature gradient between the insert and the casting material. The insert is dipped into a molten zinc-base alloy which includes about 2 to about 10 weight percent aluminum. The zinc-base alloy coats the insert and remains on the surface of the insert until a molten casting material is introduced. As a result, the surface of the coated insert is nearly oxide-free. The aluminum content in the zinc-base alloy is preferably about 4 to about 6 weight percent of the zinc-base alloy. The zinc-base alloy also preferably contains between about 0.25 and 0.35 weight percent magnesium for the purpose of weakening the oxide film layer on the insert.

Abstract: The present invention relates to a method for bonding metal and ceramic parts to form a bonded component. The method of the present invention allows the metal part and the bond to be fabricated concurrently. The strength of the bond can be controlled through choice of the material for the metal part, and by varying the thickness of the bond region. The bond region is formed by mixing ceramic particles with fibers and subsequently removing the fibers forming voids within the ceramic part. The bond region is formed with a second ceramic particle region adjacent to it.

Abstract: A method for metallurgically bonding cylinder liners (12, 12') within a cylinder block 14 of an internal combustion engine. The liners (12, 12') are cleaned (16) and their outer surfaces coated (18) with a low melting point cooling material (20) such as molten zinc forming a metallurgical bond therebetween. The coating (20) is allowed to solidify forming an outer oxidized layer (24) on the coating (20). The oxidized layer (24) is subsequently removed to expose an unoxidized outer surface (26) of the coating (20). The coated liners (12, 12') are then disposed within a casting mold and molten aluminum-based cylinder block material (36) is poured into the mold and about the coated liners (12, 12'). The molten cylinder block material (36) remelts the coating (20) on the liners (12, 12') and causes the coating to further alloy with the cylinder block material (36), whereupon cooling the cylinder liners (12, 12') are metallurgically bonded to the cylinder block (14).

Abstract: A method of making a composite casting wherein a casting mold is provided for receiving a melt and a preformed metallic or intermetallic insert is positioned in the mold cavity. The preformed insert includes a working portion for incorporation in the casting and gas seal-forming means located at a region of the insert at least outboard of the insert portion. A melt is introduced into the mold about the insert and is then solidified to provide a composite casting having the insert working portion disposed in the solidified melt and as-cast gas seal regions located outboard of the insert working portion in the casting. The casting is then subjected to elevated temperature and isostatic gas pressure conditions wherein the as-cast gas seal regions are effective to inhibit gas penetration between the insert working portion and the solidified melt therearound so as to permit formation of a sound, void-free metallurgical bond therebetween.

Abstract: The disclosure relates to a method of obtaining, by moulding, bimaterial parts formed by two aluminium alloys one of which constitutes the core and the other the matrix. The method consists in using a core, optionally containing a refractory skeleton, removing a natural coating of alumina present on the surface of the core and immediately afterwards coating the assembly thus obtained with a film impermeable to gas and consisting of a metal such as nickel, placing the coated assembly in a mould which is filled with the alloy of the matrix in the molten state at a temperature such that at least 30% of the core is superficially remelted. The method can be applied to the manufacture of motor vehicle parts such as engine cylinder heads and the insertion of ducts into aeronautical parts.

Abstract: In the production of cast fittings by the precision casting process of the casting-on technique, primary and secondary pieces can be easily separated from one another if the primary piece surface is isolated with a ceramic interlayer being chemically not attackable by the constituents of the alloys used. An interlayer containing zirconium dioxide is especially preferred.

Abstract: The present invention relates to a novel process for forming macrocomposite bodies. Particularly, a suitable matrix metal, typically in a molten state, is in contact with a suitable mass of filler material or preform located adjacent to, or in contact with, at least one second material in the presence of a suitable reactive atmosphere in an impermeable container, at least at some point during the process, which permits a reaction to occur between the reactive atmosphere and the molten matrix metal and/or mass of filler material or preform and/or impermeable container, thereby causing molten matrix metal to infiltrate the mass of filler material or preform due to, at least in part, the creation of a self-generated vacuum. The impermeable container being sealed by a molten glassy material. Such self-generated vacuum infiltration occurs without the application of any external pressure or vacuum.

Abstract: The present invention relates to the use of a gating means in combination with a spontaneous infiltration process to produce a metal matrix composite body. Particularly, a permeable mass of filler material or a preform is spontaneously infiltrated by molten matrix metal to form a metal matrix composite body. A gating means is provided which controls or limits the areal contact between molten matrix metal and the filler material or preform. The use of a gating means provides for control of the amount of matrix metal which can contact the preform or filler material, which may result in less machining of a formed metal matrix composite body compared with a similar metal matrix composite body made without a gating mean. Moreover, the use of a gating means ameliorates the tendency of a formed metal matrix composite body to warp due to the contact between the formed composite body and matrix metal carcass.

Abstract: A metal matrix composite material having uniformly dispersed intermetallic compounds and no micropores is manufactured by forming a porous preform including 60% to 80% by volume fine fragments essentially made of aluminum, 1% to 10% by volume fine fragments essentially made of nickel, copper or both, and 1% to 10% by volume fine fragments essentially made of titanium so that these fine fragments occupy in total 62% to 95% by volume of said preform, and at least a part of the preform is contacted with a melt of a matrix metal selected from aluminum, aluminum alloy, magnesium and magnesium alloy, so that the porous preform is infiltrated with the melt under no substantial application of pressure to the melt.

Abstract: A method for metallurgically bonding cast-in-place cylinder liners 12 to a cylinder block 38 includes first coating the outer surface of the liners 12 with a low melting point molten metal material 14 and allowing it to solidify. The coated liners 12 are then positioned within a cylinder block casting mold 22 and molten cylinder block metal introduced into the mold 22. At a time prior to the cylinder block metal contacting and surrounding the coated liners 12, induction heating coils 28 are activated to premelt the coating material 14. The molten cylinder block metal then contacts and mixes with the molten coating metal 14 to form a metallurgical bond between the liners 12 and cylinder block 38 upon solidification.

Abstract: A method for forming a reinforced metal structure having a filamentary reinforcement evenly distributed therein is taught. The structure is formed by the plasma spray deposit of matrix metal onto and about a filamentary reinforcement. A plurality of layers of filamentary reinforcement are embedded in the structure. Between each layer an abrasive grinding and smoothing operation is performed to render the surface of the spray deposited metal smooth and even and to permit the even spacing of filament reinforcement on the spray deposited surface. The abrasive grinding of the spray formed surface does not have deleterious effects on the property of the composite reinforced structure which is formed.

Abstract: A method of forming a ceramic-metal composite including steps of providing a body of ceramic material; infiltrating molten metal into open spaces of the body at an elevated pressure; cooling the metal to form a solid composite; and reacting a portion of the metal in the composite at an elevated temperature with an oxidizing gas. A particularly preferred composite is made by infiltrating an alumina body with an aluminum alloy and then oxidizing in air at an elevated temperature. The composite is useful for making armor plate and other products where a combination of high hardness, good strength, and light weight are needed.

Abstract: Process for the production of ingots of castable discontinuous metal matrix omposites by encapsulating particulate refractory material of the B.sub.4 C or SiC in a matrix metal of Li or al to form a solid master alloy, and introducing the master alloy into molten Mg or an alloy thereof, mixing and then cooling to solidify the resultant mixture and form an ingot with the refractory material substantially dispersed in the ingot.

Abstract: Metal and ceramic particles of various morphologies are clad with a coating from the transistion metal group consisting of silver, gold, copper, nickel, iron, cobalt, aluminum etc., or combinations thereof, to provide improved coated particles for microelectronics or metal matrix composites or other uses. Refractory metal precursor core particles, such as tungsten, molybdenum, niobium and zirconium, as examples, are provided from a composite of tungsten and copper, for example, made by pressurizing and infiltrating or liquid phase sintering of molten copper into a porous tungsten skeleton. Precursor chip particles derived from a tungsten impregnated billet are used as starter particles which may be further enhanced by cogrinding in an attritor ball mill with smaller copper particles to thereby produce an enhanced copper clad-coating of tungsten particles with predetermined percent by weight of copper and tungsten content.

Abstract: A turbine engine component is made by forming a heat resistant layer on each airfoil of a plurality of airfoils. This heat resistant layer has a higher melting temperature than the melting temperature of material forming the airfoil. After heat resistant layers have been formed on the airfoils, a mold is formed around the airfoils. Molten metal is poured into the mold. The molten metal engages the heat resistant layers on the airfoils and solidifies to form a shroud ring. As the molten metal solidifies, slip joints between the solidified metal and end portions of the airfoils are free of bonds. The heat resistant layer is at least partially formed of chromium sesquioxide (Cr.sub.2 O.sub.3). A layer of chromium sesquioxide is formed by heating a nickel-chrome superalloy airfoil. As the airfoil is heated, the layer of metal immediately adjacent to the outer surface of the airfoil is depleted of chromium.

Abstract: A method for eliminating porosity defects in aluminum cylinder blocks (22) having cast-in-place metallurgically bonded cylinder liners (12) includes coating the liners (12) with a low melting point molten metal such as zinc and thereafter removing a virtually entire outer layer of pure Zn, which would otherwise melt during casting and invade the block metal, leaving behind shrinkage defects in the resultant cylinder block (22).

Abstract: The present invention relates to a novel process for forming net or near net-shape metal matrix composite bodies. Particularly, a molten matrix metal is in contact with a filler material or a preform in the presence of a reactive atmosphere, at least at some point during the process, which permits molten matrix metal to react, at least partially or substantially completely, with the reactive atmosphere, thereby causing molten matrix metal to infiltrate the filler material or preform due to the creation of a self-generated vacuum. Forming a glassy seal on the reaction system, the self-generated vacuum infiltration occurs without the application of any external pressure or vacuum. The molten matrix metal infiltrates the filler material up to at least a portion of a provided barrier means.

Abstract: The present invention relates to the use of a gating means in combination with a spontaneous infiltration process to produce a metal matrix composite body. Particularly, a permeable mass of filler material or a preform is spontaneously infiltrated by molten matrix metal to form a metal matrix composite body. A gating means is provided which controls or limits the areal contact between molten matrix metal and the filler material or preform. The use of a gating means provides for control of the amount of matrix metal which can contact the preform or filler material, which may result in less machining of a formed metal composite body compared with a similar metal matrix composite body made without a gating mean. Moreover, the use of a gating means ameliorates the tendency of a formed metal matrix composite body to warp due to the contact between the formed composite body and matrix metal carcass.

Abstract: A preshaped body of ceramic fibers is placed into a mold and molten aluminum-silicon alloy material is charged into the mold. The pressure is increased in a controlled manner so that the shaped fibrous body is penetrated by the molten material and the final pressure is maintained until the molten material has entirely solidified. To permit the use of a distinctly lower final pressure, the shaped fibrous body before it is placed into the mold is impregnated with an aqueous solution of CuSO.sub.4, dried at a temperature from 60.degree. to 90.degree. C. and heated to a temperature from 500.degree. to 1200.degree. C., preferably 850.degree. to 1000.degree. C., and the molten material is caused to solidify under a final pressure from 10 to 100 bars.

Abstract: A method for manufacturing an assembly of an outer ring of a one-way clutch and a stator housing of a torque converter is provided. An outer ring is provided and its outer peripheral surface is subjected to a plastic deformation process, such as forging, to thereby form an up and down structure which extends from one side only halfway through to the outer side of the outer ring. Preferably, the main body of the outer ring is deformed such that side projections are formed at spaced intervals in a circumferential direction to thereby define a spline-like structure. Then, the outer ring is machined only at its inner peripheral surface and its side surface which is opposite to the side where the up and down structure is formed. Thus, the outer peripheral surface and the side surface where the up and down structure is formed are left unmachined. Then, a stator housing is formed either by molding or casting using the outer ring thus formed as an insert.

Abstract: A framework template of non-reinforcing material is provided containing, distributed therein and bonded to the building constituents thereof, a reinforcing material such as particles, fibers or whiskers of high tenacity nitrides, carbides, borides, oxides and the like, this distribution being arranged according to some given pattern of orientation and packing density. The template is placed in a mould which is then filled with molten metal which solidifies by cooling. During casting, the constituents of the template may be destroyed by the heat, or they may dissolve in the metal, or they can remain embedded therein.

Abstract: The disclosed method forms a zinc sleeve on an insulator pin by dipping the insulator pin in molten zinc at about 450.degree.-650.degree. C. to heat and wet the insulator pin with the molten zinc, setting the hot and wetted insulator pin in a die having an open-top cavity in such a manner that an annular open-top molding cavity is defined around the insulator, the die being at about 50.degree.-300.degree. C. when receiving the insulator pin, pouring molten zinc in the annular molding cavity through its open top, and solidifying the zinc thus poured.

Abstract: A process is described for forming a composite cast article comprising an aluminum-silicon alloy matrix containing a modifying amount of strontium and a preform of bonded-together reinforcing fibres incorporated in the matrix, in which the preform of reinforcing fibres is infiltrated under pressure by a melt of the alloy and the composite article thus formed is allowed to solidify by cooling. According to the novel feature, the fibres of the preform are coated with strontium, preferably in the form of SrO, before being infiltrated by the alloy melt. The strontium on the fibres is free to react with the Al-Si melt and thus modify the structure in the region of the preform such that an excess of silicon particles adjacent the fibres is avoided.

Abstract: An aluminum metal matrix composite comprises an aluminum metal matrix embedding a second filter, such as a ceramic second filler, and is formed by contacting, for example, a molten aluminum metal with a permeable mass of second filler within a ceramic impervious mold formed by growing a polycrystalline oxidation reaction product into a first filler. By hermetically sealing the second filler within the mold with a body of molten aluminum metal, the latter spontaneously infiltrates the mass of second filler at moderate temperatures, e.g. about 900.degree. C., without need of any other infiltration expedients. The molten mass containing the infiltrated ceramic filler is solidified to provide the metal matrix composite which may be recovered from the mold.

Abstract: The invention provides a method and a set-up for production of castings containing cast-in steel tubes, preferably to provide cooling elements for metallurgical furnaces. The castings are from cast steel and the steel tubes are cast-in with a superheated cast steel melt. Before the casting the tubes are filled with a granular, highly thermal conductive, refractory material. In order to assure that the cast-in steel or respectively cooling tubes remain free from leaks, the invention provides to employ as a filling material one or more of the materials: burned magnesite (sintered magnesite), corundum, sintered aluminum oxide, chromite, silicon carbide, silicon nitride.

Abstract: A method of making a crankshaft involves positioning a serpentine-shaped tube in a casting mold with a plurality of removable (breakaway) portions of the tube spaced apart along the length thereof supported in the mold body and a plurality of oil line-forming portions of the tube between the removable portions bridging across a crankshaft-shaped mold cavity formed in the mold. Molten metal is cast into the mold cavity about the oil line-forming portions of the tube to form a cast crankshaft with the oil line-forming portions of the tube cast in-situ therein and the removable portions of the tube disposed externally of the cast crankshaft. After separating the cast crankshaft and the mold, the removable portions of the tube are severed from the cast crankshaft, preferably broken off from the cast crankshaft at scored locations on the serpentine-shaped tube, to leave a plurality of open-ended, tubular oil lines cast in-situ in the crankshaft.

Abstract: A method for making a composite material. Porous reinforcing material such as fiber material is charged into a container which has an opening; then substantially all of the atmospheric air in the container and in the interstices of the reinforcing material is replaced by substantially pure oxygen; and then molten matrix metal is admitted into the container through the opening so as to infiltrate into the interstices of the reinforcing material. During this infiltration the oxygen within the container and in these interstices is absorbed by an oxidization reaction, and thus substantially all the gas present within the interstices of the reinforcing material is disposed of, thus not hampering the good infiltration of the molten matrix metal into the reinforcing material. Thus a high quality composite material is formed. The oxidization reaction may either be with the molten matrix metal itself, or with a getter element provided within the container.

Abstract: A machine part such as a cylinder or a feeding screw of an injection molding machine and the like is produced such that a separating metallic plate is inserted in a mold adapted to mold the cylinder or the feeding screw, thereby providing two molding cavities on both sides of the separating plate, and melted metals adapted to form a main portion and a corrosion and wear resistant portion of the cylinder or feeding screw are poured into the two cavities. In this manner the two kinds of metals poured into the two cavities are metallurgically fused together with the separating plate interposed therebetween.

Abstract: A centrifugal injection machine comprises a rotor arm bearing at each of a pair of free ends a pivotably mounted container. A holder which retains a multiplicity of workpieces is insertable into a capsule or cavity within each container. The rotary arm contains a reservoir associated with each container or liquifying a charge of material. Upon rotation of the machine at a high velocity, the liquified material is transferred from the reservoir to the container in a vacuum and is pressurized therein as a result of centripetal acceleration. Upon the termination of a predetermined interval, a trip mechanism is activated to rotate the containers so that the molten liquid which has not been injected under pressure into recesses in the workpieces is ejected or discharged from the containers. The containers rotate within a vacuum chamber which is depressurized prior to the centrifuge operation.

Abstract: In a composite casting process for making aluminum alloy components for internal combustion engines, which components are provided at highly loaded surfaces with shaped elements which consist of fibers or whiskers and are bonded to the castings, the shaped elements consisting of fibers of whiskers are infiltrated with an aluminum alloy which has a higher melting point than the aluminum alloy of the casting. The infiltration is effected in such a manner that the infiltrated aluminum alloy forms a cover layer on the shaped element. In order to ensure the formation of a bond between the casting and the shaped element as the aluminum alloy for making the casting is cast in contact with the shaped element, the infiltrated shaped elements are dipped into a molten solder alloy before the aluminum alloy for making the casting is cast in contact with the shaped element, and the latter is subsequently placed into the heated mold for making the casting, whereafter the casting is made.

Abstract: A ceramic body for use as a gas conduction channel or duct and preferably used to define an exhaust channel in a cylinder head of an internal combustion engine, where the cylinder head is cast around the ceramic body. The ceramic body is provided with a thickening or external layer over at least a part of its outer surface. This external layer adds stability and strength to the ceramic body and allows it to withstand the pressures occurring during the casting of the cylinder head. The thickening or external layer is formed from a pressure resistant material and may be applied to a depression in the ceramic body or into the space between two parallel ceramic bodies to provide the required strength and stability.

Abstract: The disclosure relates to a process for the fabrication of low cost dual property turbine rotors having blades that are diffusion bonded to a blade ring that is simultaneously diffusion bonded to a central hub.

Abstract: An improved method of manufacturing a swash plate assembly for use in a compressor, fluid motor or similar device in which a plurality of pistons are connected, by means of connecting rods, to a swash plate which drives (or is driven by) the pistons. A plurality of piston and rod assemblies are made by casting the piston around one end of a connecting rod which is formed with a ball at both ends, thus providing a ball-socket connection therebetween. The pistons are finish machined. A die-insert is utilized to locate the ball and rod prior to casting, and is thereafter moved along the rod to contact the other ball end. This insert thus serves to locate the rod section with the affixed piston in a mating socket of a swash plate die. The swash plate is cast about a plurality of such piston bearing rods to a carefully toleranced dimension. The swash plate end of the assembly is then finish machined.

Abstract: A process and apparatus for producing a metallic laminar composite material utilizes a pressure tank, a ladle, and a dip tube for transferring molten metal into a mold which has a metallic plate suspended within it. The molten metal is supplied by the ladle and the dip tube in such a way that slag and scum existing on the surface of the molten metal are not introduced into the mold. Prior to introducing the molten metal into the mold, the mold is purged with an inert gas to prevent oxidation of the surface of the metallic plate. The mold is made of freely movable carbon segments which permit easy assembly and disassembly of the mold for varying the size of the molding chamber.

Abstract: A method of and apparatus for fabricating clad ingots or clad slabs includes a hollow body which corresponds to the dimensions of a finished slab and which has at least one side plate of cladding material and other thinner side sheets forming an upright tubular hollow body which is inserted into a larger ingot mold. Refractory insulating material is disposed between the bottom end of the hollow body and the bottom wall of the mold and between the sides of the hollow body and the sides of the mold, the hollow body being subsequently charged with a molten base metal. Prior to inserting the hollow body into the mold, the bottom end thereof is sealed closed by a bottom wall and a cover plate is placed on the top end of the hollow body.

Abstract: An improved method of manufacturing a swash plate assembly for use in a compressor, fluid motor or similar device in which a plurality of pistons are connected, by means of connecting rods, to a swash plate which drives (or is driven by) the pistons. A plurality of piston assemblies are made by casting the piston around one end of a connecting rod section which is formed with a ball thus providing a ball-socket connection therebetween. Mating spherical ends with through-bores to receive the piston connecting rod section are cast-in-place and captured in sockets within the swash plate. The connecting rod section of the pistons is mated to the through-bores of the mating spherical ends and are positioned in an appropriate fixture to a fixed final relationship. The connecting rod sections are secured to the sidewall of each through-bore by a means such as electron-beam welding to secure the overall length of the final assembly.

Abstract: A method of producing suction manifolds for automobile engines. In forming an exhaust gas re-circulating pipe passage integrally with a suction manifold for re-circulating exhaust gases from the engine to the suction manifold, a curved pipe of aluminum having a high-temperature resistant film formed on its surface is molded into a manifold of aluminum alloy at a suitable place on the latter.

Abstract: Disclosed in this specification is a method for casting, in which a shaped body of an inorganic fiber material is fixedly secured on a chill member, then the chill member together with the shaped body of inorganic fiber is incorporated in a predetermined part of a cast article through a fiber-reinforced composite layer to be brought about at the time of casting under high pressure solidification casting techniques.

Abstract: Strong, light weight master cylinders for hydraulic braking systems are produced by incasing a section of steel tubing within a diecasting of metal such as an alloy of magnesium or aluminum. Master cylinders can thus be produced by diecasting the metal in situ around the tube so that it incases the exterior surface and extends over one end thereof. Tooling requirements are minimal, with little if any machine being needed following the diecasting operation. Unit production cost is thus lower than that of castings made with permanent molds. Light weight diecastable metals can thus be used in combination with strong but relatively thin steel tubing to provide durable master cylinders that are lighter, simpler and less expensive to make than cast iron cylinders.