Abstract: A syntactic metal foam composite that is substantially fully dense except for syntactic porosity is formed from a mixture of ceramic microballoons and matrix forming metal. The ceramic microballoons have a uniaxial crush strength and a much higher omniaxial crush strength. The mixture is continuously constrained while it is consolidated. The constraining force is less than the omniaxial crush strength. The substantially fully dense syntactic metal foam composite is then constrained and deformation worked at a substantially constant volume. The deformation working is typically performed at a yield strength that is adjusted by way of selecting a working temperature at which the yield strength is approximately less than the omniaxial crush strength of the included ceramic microballoons. This deformation causes at least work hardening and grain refinement in the matrix metal.

Abstract: A track shoe includes a base plate, a grouser extending from the base plate, and at least one white iron member. At least a portion of the grouser includes a substantially martensitic structure. The at least one white iron member is fixed to a portion of the grouser.

Abstract: An automobile vehicle engine includes multiple water jackets individually formed in a cast engine block proximate to successive ones of multiple cylinder bores. Multiple cast-in place transition regions are individually formed during a casting operation of the cast engine block at entrances to individual ones of the multiple water jackets. Individual ones of multiple sawcuts open into individual ones of the multiple cast-in place transition regions.

Abstract: A method of managing an energy storage system that includes a plurality of smart energy storage cells, and a related method of operation for said smart cells. The cells are arranged into a two-dimensional array, and at least one management unit for controlling and monitoring the smart cells is coupled to the array. The smart cells and management units engage in wireless communication that has relatively short range and is relatively directional, with the direction being electronically-steerable in the plane of the array. The management method assigns direction codes to each smart cell which the cells utilize to steer the directions of their communication links, thereby organizing the smart cells into a plurality of serially-linked communication networks. The methods include steps for automatically determining the size and arrangement of the array, including the orientation of each smart cell.

Abstract: The presently disclosed subject matter relates to an improved system for hydrocarbon cracking. In a specific non-limiting embodiment, a hydrocarbon cracker system can include one or more furnace tubes having a plurality of indentations disposed thereon, where the indentations do not project into the interior of the furnace tube.

Abstract: A method for manufacturing an inner door panel for a vehicle side door that employs a die casting process. The method includes providing a die cast mold having opposing mold halves that combine to define a die cavity configured to provide the inner door panel. An impact beam is positioned in the mold cavity prior to combining the first mold half and the second mold half, and a molten metal is provided to the mold cavity so that molten metal flows into all areas of the mold cavity and around the impact beam after the first mold half and the second mold half are combined. A solidified molded inner door panel is then removed from the die cast mold that includes an encapsulated impact beam.

Abstract: System and method of producing multi-layered aluminum alloy products are disclosed. A multi-layered aluminum alloy product may be formed by first heating a first aluminum alloy to a first temperature where the first temperature is at least about 5° C. lower than the eutectic temperature of the first aluminum alloy, second heating a second aluminum alloy to a second temperature where the second temperature is at least about 5° C. higher than the liquidus temperature of the second aluminum alloy, and coupling the second aluminum alloy to the first aluminum alloy to produce a multi-layered aluminum alloy product.

Abstract: A molten metal infiltrating method for infiltrating a linear material with a molten metal, wherein a linear material previously coated with a flux is used.

Abstract: The present invention relates to a liquid-solid rolling bonding method for heterogeneous metals and an apparatus therefor. The method comprises: pouring a liquid metal onto the surface of a heterogeneous solid base metal coated with a soldering flux; rolling the liquid metal and the solid metal under pressure; solidifying the liquid metal and making it bond to the surface of the solid base metal under rapid cooling to realize metallurgical bonding of the two or more metals. The apparatus comprises an unrolling machine, a soldering flux tank, a drying-heating apparatus, a pouring nozzle, an interior water-cooling rollers and a roll-collecting machine arranged in order, a pouring basket is disposed above the pouring nozzle and a base frame is disposed below the pouring nozzle. The present invention has the advantages of high bonding strength, lower production cost, high production efficiency, good product quality, fewer investment for the apparatus and lower consumption of energy.

Abstract: A method of joining an aluminum cast member to an aluminum component. The method includes the steps of coating a surface of an aluminum component with flux comprising cesium fluoride, placing the flux coated component in a mold, filling the mold with molten aluminum alloy, and allowing the molten aluminum alloy to solidify thereby joining a cast member to the aluminum component. The flux preferably includes aluminum fluoride and alumina. A particularly preferred flux includes about 60 wt. % CsF, about 30 wt. % AlF3, and about 10 wt. % Al2O3.

Abstract: A method of joining an aluminum cast member to an aluminum component. The method includes the steps of coating a surface of an aluminum component with flux comprising cesium fluoride, placing the flux coated component in a mold, filling the mold with molten aluminum alloy, and allowing the molten aluminum alloy to solidify thereby joining a cast member to the aluminum component. The flux preferably includes aluminum fluoride and alumina. A particularly preferred flux includes about 60 wt. % CsF, about 30 wt. % AlF3, and about 10 wt. % Al2O3.

Abstract: The present invention relates to a liquid-solid rolling bonding method for heterogeneous metals and an apparatus therefor. The method comprises: pouring a liquid metal onto the surface of a heterogeneous solid base metal coated with a soldering flux; rolling the liquid metal and the solid metal under pressure; solidifying the liquid metal and making it bond to the surface of the solid base metal under rapid cooling to realize metallurgical bonding of the two or more metals. The apparatus comprises an unrolling machine, a soldering flux tank, a drying-heating apparatus, a pouring nozzle, an interior water-cooling rollers and a roll-collecting machine arranged in order, a pouring basket is disposed above the pouring nozzle and a base frame is disposed below the pouring nozzle. The present invention has the advantages of high bonding strength, lower production cost, high production efficiency, good product quality, fewer investment for the apparatus and lower consumption of energy.

Abstract: Method of making wire comprising polycrystalline &agr;-Al2O3 fibers within a matrix of substantially pure elemental aluminum, or an alloy elemental aluminum and up to about 2% copper.

Abstract: A process for sealing a ceramic filter by infiltrating a metal into an end of the filter. The process includes the steps of contacting the end of a porous ceramic filter with a molten metal, whereby the metal enters into the ceramic matrix to substantially fill the void space. The ceramic filter is cooled to form a filter having a ceramic-metal composite portion. The present invention also provides a filter having an infiltrated metal seal. Methods for joining infiltrated ends are also provided.

Abstract: A process for sealing a ceramic filter by infiltrating a metal into an end of the filter. The process includes the steps of contacting the end of a porous ceramic filter with a molten metal, whereby the metal enters into the ceramic matrix to substantially fill the void space. The ceramic filter is cooled to form a filter having a ceramic-metal composite portion. The present invention also provides a filter having an infiltrated metal seal. Methods for joining infiltrated ends are also provided.

Abstract: A method for producing pore-free cast-on-strap joints for lead-acid batteries including the steps of cleaning a plurality of positive and negative plate lugs by a combined action of flux and ultrasonic vibration, water rinsing the plate lugs under ultrasonic vibration, and drying the plate lugs by gas blasting. The gas blasting occurs prior to the formation of the cast-on-strap joint. The cast-on-strap joint is formed by introducing the plate lugs into a molten lead-based strap alloy contained in a strap mold and solidifying the molten strap alloy in the strap mold.

Abstract: A method for wetting and bonding refractory alumina or aluminosilicate fibers or particles with molten aluminum or aluminum alloys by forming a boron oxidized interface between the fiber and the metal is exists. The method comprises the steps of (a) coating alumina fibers with an effective amount of a thermally decomposable precursor of boron oxide; (b) heating the coated fiber sufficiently to form a boron oxide; and (c) forming a composite with aluminum metal or an aluminum alloy. Thermally decomposable precursors of boron oxide include ammonium pentaborate, ammonium diborate and orthoboric acid.

Abstract: A method for casting a cast part onto the end of a hollow section places the end of the hollow section in a defined position in a die which is then closed. The end opening in the hollow section is closed in a sealed manner against the penetration of cast material, at least during casting, the molten cast material is introduced into the remaining free space in the die and the hollow section is thereby cast around in a positive-locking manner, at least at the end. To improve the fixing of the hollow sections within the cast part, the hollow section is cooled during the casting of the cast part.

Abstract: A technique for simultaneously forming large numbers of solder ball (or bump) contacts on a surface of a substrate is described. A mold is provided for receiving a substrate. Recesses in the mold are shaped to form contacts of a desired size, and are arranged to align with contact pads on the surface of the substrate. When the substrate is inserted into the mold and the mold is closed, the contact pads align with the recesses. Molten solder is introduced into the recesses and, upon cooling, forms conductive raised bump contacts on the contact pads. The substrate is then removed from the mold. Various features of the invention are directed to forming "tall" contacts with an aspect ratio (height to width ratio) of greater than 1:1, processing more than one substrate at a time, processing substrates of different sizes, and processing substrates with different contact patterns.

Abstract: The present invention relates to a novel process for forming metal matrix composite bodies. Specifically, in a particularly preferred embodiment for making metal matrix composite bodies by a spontaneous infiltration technique, an infiltration enhancer or an infiltration enhancer precursor or an infiltrating atmosphere are in communication with a rigidized filler material or a rigidized preform, at least at some point during the process, which permits molten matrix metal to spontaneously infiltrate the rigidized filler material or riigidized preform. A structural refractory material which holds the preform is made by forming a first precursor to the supportive structural refractory material and subsequently causing the precursor to become a rigid supportive structural member. Such spontaneous infiltration occurs without the requirement for the application of any pressure or vacuum.

Abstract: A tough, wear resistant body is provided. The body includes hard carbide particles embedded in and bonded with a first casted steel matrix material. The body may be embedded in and bonded with a second steel matrix to form a wear resistant composite. The second steel matrix has a melting point at least 200 degrees F. greater than the melting point of the first steel matrix, thereby facilitating a metallurgical bond between the surface of the wear resistant body and the second steel matrix. The composite structure is particularly suitable for earthmoving and other severe mechanical applications.

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 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: A composite aluminum member joining process. A chemical film including potassium and fluorine is formed on an aluminum member or a flux including potassium and fluorine is coated on an aluminum member. The coated aluminum member is buried together with a disposable pattern in a predetermined assembled state in a mold including molding sand. Then, molten aluminum alloy is poured into the mold, thereby molding an aluminum alloy cast member. The mold is decompressed through the molding sand, thereby expelling tar-like substances generated when the disposable pattern comes in contact with the molten aluminum alloy, burns and vaporizes, at least from the boundary surface between the disposable pattern and the molding sand to the molding sand disposed around the disposable pattern and preventing the tar-like substances from interposing between the aluminum member and the aluminum alloy cast member made from the molten aluminum alloy.

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: A process for producing composite materials with a metal matrix and with a content of powder reinforcer agent lower than is minimum theoretical compaction value, with said process being based on an infiltration technique, is disclosed, which essentially consists in charging the reinforcer material to a casting mould, and then infiltrating into the same mould the metal matrix in the molten state, with said metal matrix being let cool until it solidifies, and characterized in that the reinforcer agent, consisting of non-metal powders, is blended, before being charged to said casting mould, with a diluting agent having a different compaction degree, constituted by metal fibres and/or ceramic fibres and/or ceramic whiskers and/or metal powders of the same composition as of the matrix.

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 of casting metal matrix composites wherein there is a wide disparity in the respective densities of the metal matrix and the reinforcing particles. The particles are added to a melt of molten metal and the mixture is stirred using an impeller rotating at a high speed so as to ensure an even distribution of the less dense reinforcing particles throughout the denser metal matrix.

Abstract: A composite article having a first and a second metal component, and a resultant composite metal article, wherein a flux coating is applied over at least a substantially oxide-free bond surface of the first component, the first component with the flux coating is preheated and, with the first component positioned in a mold to fill a portion of a cavity of the mold, a melt for providing the second component is poured into the mold so as to flow over the bond surface; the first component being preheated to a first temperature and the melt being poured at a second temperature such that, on flowing over the bond surface, the melt displaces the flux coating and wets the bond surface, and that such initial temperature equilibration between the surface and the melt results in an interface temperature therebetween at least equal to the liquidus temperature of the melt, thereby resulting on solidification of the melt in attainment of a bond between the components.

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 double molded over method of manufacturing a lightning arrester in which a central core 1 is made of zinc oxide in a first step, then two metal end fittings 5, 6 are molded onto the end faces and over the side thereof, and finally a coating of elastomer material 7 is molded around the side wall of the central core and over side portions of the end fittings. The core may be formed of a plurality of smaller section bars of zinc oxide regularly disposed about a longitudinal axis with the end fittings molded onto the end faces and about the sides of the end bars whose end faces are partially metallized. In a further variant, a stack of zinc oxide based pellets having the same cross-sectional area as the core in the first example, with the stack having the same overall length as the core if stiffened by thermal compression with fusible metal inserted between pairs of pellets. The stack assembly is then compressed mechanically in conjunction with heat treatment to effect very good mechanical bonding.

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 method of forming a composite article having a first and a second metal components, and a resultant composite metal article, wherein a flux coating is applied over at least a substantially oxide-free bond surface of the first component, the first component with said flux coating is preheated and, with said first component positioned in a mould to fill a portion of a cavity of the mould, a melt for providing the second component is poured into the mould so as to flow over said bond surface; the first component being preheated to a first temperature and the melt being poured at a second temperature such that, on flowing over the bond surface, the melt displaces said flux coating and wets said bond surface, and that such initial temperature equilibration between said surface and the melt results in an interface temperature therebetween at least equal to the liquidus temperature of the melt, thereby resulting on solidification of the melt in attainment of a bond between the components.

Abstract: A cast steel stave cooler comprising a carbon steel cooling pipe having a roughened surface and having a coating thereon, and a cast steel embedding the cooling pipe therein. The cast steel contains 10 to 25% Cr and has a very reduced liquid-solid zone so as to prevent fusion of the cooling pipe during the casting. The cooling pipe is provided with fins which are integratedly welded to the cast steel.

Abstract: A method of casting metal straps on lugs of battery cell elements utilizes an electrically heatable mold having a strap cavity section and comprises introducing strap metal into the cavity section, conducting electrical current through the mold for heating the mold to a predetermined temperature in excess of the melting temperature of the strap metal, immersing the element lugs into the cavity, cooling the mold to a temperature below the solidification temperature of the strap metal and removing the element lugs from the cavity with straps cast thereon.

Abstract: A method and apparatus for casting straps onto the plate lugs of battery cell elements. The apparatus includes a rotatably indexable table having a plurality of mold and element carrying stations which each are successively indexed through a plurality of operating stations, including an element loading station, an element lug alignment station, a molten-metal pouring station, a lug fluxing station, a casting station, a plurality of mold cooling stations, and an element unloading station. The mold of each table station is adapted for efficient and precisely controlled electrical resistance heating and forced-air cooling during each cycle of operation. In the illustrated embodiment, each table-station mold is successively heated from electrical sources at a plurality of operating stations upon indexing of the respective table station to such operating stations and is cooled by directing air through air-direction tubes mounted on each table station in close proximity to the respective mold.

Abstract: A reactor tube for thermally cracking or reforming hydrocarbons comprising a tube member made of Fe-Cr-Ni heat resisting material and a covering layer of self-fluxing alloy fusing to the inner surface of the tube member, the covering layer made of heat resisting material free from Ni or with a low Ni content. The tube member is manufactured by centrifugal casting, and the covering layer is formed by applying the self-fluxing alloy powder by scattering with or without thermit agent or spraying the alloy to the inner surface of the tube member.

Abstract: A novel "cast-on" method and apparatus are disclosed wherein in the preferred embodiment only one major moving part is provided which is indexed through various positions to cast a group or element from a battery plate stack engaged thereby. In the preferred embodiment, a mold carriage block having a plurality of mold voids formed therethrough slidingly reciprocates along a base plate on which are defined fluxing (loading), casting and part-release positions. In the casting position, lead gravitationally siphons into the mold voids defined in the mold carriage through molten lead supply orifices defined in the base plate along which the carriage slides. Once the casting operation is completed, sliding the carriage out of the casting position effectively seals the molten lead supply orifices. The apparatus and method are particularly suited for use by a single operator who manually loads stacks into the apparatus and subsequently unloads completed groups or elements from the apparatus.

Abstract: A method of forming a composite rod having tungsten carbide particles embedded in a matrix comprising the steps of washing the tungsten carbide particles, placing a predetermined quantity of the carbide particles in a graphite mold, heating the mold and the carbide particles to a range of about 300.degree. to 500.degree. F. and pouring a water solution of flux in the mold while maintaining the temperature whereby the water boils off and the flux coats the surfaces of the carbide particles, placing a matrix in the mold and applying a multi-flame heat to the mold and carbide particles while stirring the particles in the mold with a graphite rod to assist in intimate contact and bonding of the melted matrix with the carbide particles to form a composite rod. The composite rod is then boiled in a weak solution of sodium hydroxide, rinsed and polished by buffing with wire bristles.

Abstract: In pipes and the like of relatively heavy section, a boss is formed on the side of the pipe or section by drilling a hole in the pipe, forming a mold around the hole with the hole in relatively vertical position and depositing in the mold and against the walls of the pipe, thereby joining to those walls, electroslag metal which forms a boss on the pipe.

Abstract: A method of fabricating a lighter composite master brake cylinder is disclosed along with the resulting product. A seamless steel tube of critical thickness, closed at one end, and treated by acid etching on its exterior, is oriented vertically within a mold cavity. The tube is pretreated to contain critically dimensioned punched and coined openings for brake fluid filling and fluid delivery. Openings in the cast body are defined by pin cores aligned with the tube openings and are dimensioned to separate the edge of the tube openings from the cast opening. The tube is supported by a plug extending snuggly into the interior of said tube, said plug being joined at one end to the die walls; the cores are also supported by suitable attachment to the die walls.

Abstract: A lined bearing is made by tinning at least the radially inner surface of a bearing ring, providing an atmosphere of water vapour adjacent the tinned surface to which a flux is also supplied, and centrifugally casting on the lining material. Tinning can be achieved by applying a slurry of tin powder in a flux solution, e.g. an aqueous zinc chloride solution, followed by heating at least to a tinning temperature. Further flux solution can be sprayed onto the hot tinned surface in the centrifugal casting machine to form the desired atmosphere and to disperse the flux as fine particles. Quenching by spraying on cold water preferably commences immediately after casting of the white metal or other lining material begins.