Abstract: A brake component is disclosed. In various embodiments, the brake component includes a ceramic matrix composite (CMC) structure including a plurality of nominally dense plies, interleaved with a plurality of interlayers, wherein the plurality of nominally dense plies and the plurality of interlayers are bonded by at least one of a Field Assisted Sintering Technique (FAST), a Spark Plasma Sintering (SPS) process, or a localized heating process. In various embodiments, the brake component is a rotor disk or a stator disk.

Abstract: A radiating fin and a connection structure composed of multiple radiating fins. Each radiating fin has a main body formed with a first plane face. A first bending edge and a second bending edge extend from two sides of the first plane face. The first plane face is formed with a first perforation and a second perforation and a third perforation and a fourth perforation. A first extension section and a second extension section respectively from the first and second bending edges. Two front ends of the first extension section are bent and formed with a first latch plate and a second latch plate. Two front ends of the second extension section are bent and formed with a third latch plate and a fourth latch plate. The latch plates of a forward radiating fin are correspondingly passed through and latched in the perforations of an adjacent rearward radiating fin.

Abstract: A wellbore isolation device comprises: a first material and a second material, wherein the first material and the second material form a galvanic couple and wherein the first material is the anode and the second material is the cathode of the galvanic couple, and wherein the second material is a fiber or a plurality of fibers. A method of removing the wellbore isolation device comprises: contacting or allowing the wellbore isolation device to come in contact with an electrolyte; and causing or allowing at least a portion of the first material to dissolve.

Abstract: A process for making a turbine rotor includes steps of providing a shaft made of a first metal composition and having an integral pin projecting axially therefrom, providing a mold that defines a cavity for investment casting a turbine wheel, disposing the pin within the cavity of the mold, pre-heating the mold and the pin to a mold temperature, pouring a molten second metal composition into the cavity of the pre-heated mold such that the molten second metal composition envelopes the pin within the cavity, and controlling the process so that the pin acts as a chill member causing the second metal composition around the chill member to solidify with a finer equiaxed grain structure than would be the case without the chill member. The turbine wheel is joined to the shaft via the casting of the turbine wheel about the pin.

Abstract: A metallic housing of an electronic device, includes a metallic outer frame and an inner structural member. The metallic outer frame comprises a plurality of latching portions protruding, and a plurality of latching grooves. The inner structural member is made from metal-alloy and embedded in the outer frame by die-casting. The inner structural member comprises a peripheral sidewall, a plurality of engaging portions, and a plurality of matching portions. The plurality of engaging portions and the plurality of matching portions protrude from the peripheral sidewall outwardly. Each latching portion comprises at least two parallel latching ribs, and forms a receiving groove between two adjacent latching ribs. The plurality of engaging portions is respectively embedded in the plurality of receiving grooves, and the plurality of matching portions is respectively embedded in the plurality of latching grooves. The present disclosure further provides a manufacturing method for the metallic housing.

Abstract: A metallic housing of an electronic device includes a metallic outer case and an inner structural member embedded in the inner side of the outer case by die-casting. The outer case includes a bottom plate and a peripheral sidewall. The bottom plate is equipped with a number of latching hooks. The latching hooks are spaced from each other. The peripheral sidewall defines a receiving groove at an inner side along the peripheral sidewall. The inner structural member is made of metal alloy, and includes a base plate and a frame sidewall surrounding a periphery of the base plate, a protruding flange protruding from the frame sidewall, and a plurality of combining grooves on the base plate. The protruding flange is received in the receiving grooves, and the number of latching hooks is respectively received in the number of combining grooves.

Abstract: Provided is a solder bump forming method that enables micro-solder bumps to be formed without the possibility of occurrence of a bridge due to excess molten solder. An injection head 11 for supplying molten solder has a nozzle 16 brought into contact with a mask with openings that is disposed over a substrate 8. After completing a supply operation, the injection head 11 is forcedly cooled by heat transfer from a cooling unit 13 through a heater unit 12 whose operation has been stopped. Molten solder 15 in the cooled injection head 11 does not drool from the nozzle 16 when the injection head 11 moves up.

Abstract: A composite ballistic armor or other composite component may be formed by encapsulating one or more ceramic elements in a casting shell and introducing molten base metal into the casting shell, such that the molten base metal encapsulates the one or more ceramic elements to form the composite component. Prior to the pouring process, the ceramic elements are pre-heated to, or near, the melting point temperature or pouring temperature of the encapsulating metal. Additionally, the cooling rate following the metal pour may be less than a predetermined rate for a predetermined period of time. The encapsulating metal may comprise, for example, a steel alloy, such as 4140 or 8630 AISI, a stainless steel alloy, or FeMnAl.

Abstract: Disclosed are a bonded product, and a manufacturing method and manufacturing device therefor. To obtain a bonded product formed of a solidified material of a molten metal which has been poured into a forming mold with a workpiece, all or part of which is already held therein, or formed of a semi-solidified slurry which is contained in the forming mold together with the workpiece, the semi-solidified slurry or the molten metal is relatively made to flow on the end faces of the workpiece while friction sufficient to break the passive state existing at the surface of the molten metal or the semi-solidified slurry is generated between the workpiece and the semi-solidified slurry or the molten metal.

Abstract: A method and apparatus involve positioning an insert within a cavity of a mold, heating an insert wall within the cavity of the mold, and casting a molten metal into the cavity adjacent the insert. A surface of the insert absorbs heat from the molten metal to melt and fuse to the molten metal.

Abstract: The invention relates to a molten material processing device having an elongated thermal element like a heating element, a thermocouple, a sensor, a heatpipe and a cooling pipe which is characterised in that said elongated thermal element (2) is located in a recess (3) provided in a surface (6) of the molten material processing device (1), the recess (3), comprising a first portion (4) and a second portion (5), has a cross-section which is larger than a cross-section of the thermal element (2), so as to provide a clear space (7) between the thermal element (2) and the surface (6) of the processing device (1), the clear space (7) which is limited by the first portion (4) and the thermal element (2) is filled by a thermally sprayed material (8) and the second portion (5), which is adapted to the cross-section of the thermal element (2), partially surrounds and directly contacts same.

Abstract: A method for preparing engine block cylinder bore liners is disclosed, the method including preconditioning of the cylinder bore liners for use in sand casting of engine cylinder blocks, wherein an efficiency of the preconditioning process is maximized, a metal pour temperature is minimized, and material properties of the casting are optimized.

Abstract: A process for the injection of an electric motor rotor, said rotor comprising: a lamination stack (10) having a central axial bore (11) and a plurality of axial channels (12); and a cage (30) of aluminum, which is formed by an upper end ring (31) and a lower end ring (32), which are interconnected by a plurality of bars (33) molten in the axial channels (12).

Abstract: The present invention provides a method and apparatus for die-casting copper and other metals that are cost-effective and practical for production use in die-casting, for example, copper motor rotors. In motor rotors, the incorporation of die-cast copper for conductor bars and end rings in place of aluminum is known to result in improvements in motor energy efficiency. Previous attempts to die-cast copper motor rotors in a commercially feasible manner have failed because copper's high melting point places too great a stress on the die material, resulting in cracking and fracturing of the molds. High temperature die materials such as nickel, tungsten and molybdenum based alloys with a high melting point are employed, and a die casting apparatus is provided to pre-heat the molds prior to injection of the molten copper. Pre-heating and high operating temperatures provide extended die life.

Abstract: In order to impregnate a porous workpiece with a liquid impregnating agent, the pre-manufactured workpiece is arranged in an injection mould or diecasting mould and the liquid impregnating agent is introduced into the mould with the aid of a commercially available injection moulding or diecast moulding apparatus. To limit the need for post impregnation cleaning and/or shaping, the mould cavity is configured to closely fit the shape of the pre-manufactured workpiece. The impregnating agent may be a natural or synthetic lubricant, a plastic or, more commonly, a molten metal or metal alloy.

Abstract: A method and apparatus for molding wind chimes reduces the likelihood that a glass insert will fracture when they are placed in a mold and the mold is charged with molten metal. The casting temperature of the molten metal is adjusted to compensate for the surface area of the glass insert that is contacted by the molten metal. The glass insert are annealed prior to molding. A flexible mold is utilized. The tolerances of the glass insert are carefully controlled. The molded wind chime is carefully cooled.

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

Abstract: Metal matrix composite wires that include at least one tow comprising a plurality of substantially continuous, longitudinally positioned fibers in a metal matrix. The fibers are selected from the group of ceramic fibers carbon fibers, and mixtures thereof. The wires have certain specified characteristics such as roundness values, roundness uniformity values, and/or diameter uniformity values.

Abstract: Metal matrix composite wires that include a plurality of substantially continuous, longitudinally positioned fibers in a metal matrix. The wire exhibits zero breaks over a length of at least 300 meters when tested according to a specified test.

Abstract: The cylinder head for internal combustion engines is produced by pouring liquid cylinder head material, especially aluminum, into a cylinder head mold containing a mold core having stepped sections in the region of the valve seat ring and the valve guide. The valve seat rings and valve guides are produced from a conventional material based on steel or copper by pressing and sintering in such a way that they have an open pore volume of 5 to 15%, a valve seat and/or a valve guide are laid on the stepped sections of the mold core, whereafter liquid aluminum is poured into the preheated mold and the mold core is removed in the conventional way after the molten aluminum has solidified.

Abstract: A mold with a cylindrical sidewall, is provided. A shell is positioned around the sidewall. The shell is heated to between 500 and 1,000 F. Molten iron alloy between 2550 and 2650.degree. F. is poured into the mold. The resulting composite brake drum is cooled and cleaned. The method of casting includes positioning a brake drum shell around a mold defining a cavity interior of the shell, heating the shell, pouring molten iron alloy into the mold to fill the cavity and cooling and cleaning the composite brake drum.

Abstract: A process of making a vane for a rotary expansible chamber device, comprising the steps of: providing an open vane die having a die cavity, wherein said die cavity comprises a body cavity section corresponding to a body of the vane, a first tip cavity section corresponding to a first tip of the vane, and a second tip cavity section corresponding to a second tip of the vane; providing a preheated, porous carbon preform in the first tip cavity section of the vane die, the preform having a shape corresponding to at least a portion of the first tip cavity section; closing the vane die; injecting a castable admixture comprising a metal alloy and a plurality of inorganic particles into the die cavity and filling the vane die cavity with the injected admixture; impregnating the preform with the metal alloy of the injected admixture, substantially all of the inorganic particles from the injected admixture being filtered out by the preform as the admixture flows into the preform; allowing the castable admixture to sol

Abstract: Metal matrix composite is made by assembling pre-forms of porous reinforcing material with an array of separator plates in a die in a pressure vessel, and infiltrating molten metal matrix material. Pre-evacuation followed by pressurisation when the molten metal matrix material is introduced into the die aids the infiltration. Re-introduction of gas during initial heating prior to melting speeds the heat-up process.

Abstract: The method comprises the step of arranging at the periphery of a shell (10) capable of withstanding a temperature of at least 400.degree. C. inserts (16) of highly wear-resistant material, preheating the shell (10) and the inserts (16) in an oven, removing rapidly the shell (10) together with the inserts (16) from the oven, placing them on a centrifugal casting machine which is set in rotation, pouring ductile cast iron (18) and demoulding after cooling.

Abstract: The present invention provides a method for infrared pressureless infiltration of composites, including infiltration of carbon fibers and silicon carbide fibers with aluminum and titanium matrices. Composites produced by the methods of the present invention are also included within the scope of this invention.

Abstract: In carrying out a cast-in process, a cast-in insert member is placed into a cast forming cavity in a casting mold, and a casting is conducted. The cast-in insert member has a barrier layer on its non-deposited surface for inhibiting the deposition of a molten metal. During casting, a portion of a molten metal is introduced to a heating chamber on the side of the barrier layer to come into contact with the barrier layer. Thus, the cast-in insert member can be heated not only from the side of its deposited surface, but also from the side of its non-deposited surface, thereby providing an enhanced strength of deposition of the cast-in insert member.

Abstract: A process for pressure infiltration casting of a metal matrix composite in a metallic article is disclosed. A metallic base component is formed. A portion of the exterior surface of the metallic base component is adapted for mating with a corresponding exterior surface of a preform at an interface. A preform having interconnecting porosity is formed. An infiltration metal for forming a molten infiltrant charge and having a melting temperature "y" at least equal to or greater than the melting temperature "x" of the base metal is selected. A first mold including the base component is provided and preheated to a temperature in the range of (x-200).degree.F. to (x-50).degree.F. A second mold including the preform and the infiltration metal is provided and positioned adjacent the first mold. The second mold, preform and infiltration metal are heated to a temperature in the range of about (y-200).degree.F. to about (y+200).degree.F. The preform is evacuated and a vacuum is isolated in the preform.

Abstract: The present invention relates to a novel method for forming metal matrix composite bodies. Particularly, a permeable mass of filler material is formed into a preform. An infiltration enhancer or an infiltration enhancer precursor or an infiltrating atmosphere are also in communication with the preform, at least at some point during the process, which permits molten matrix metal to spontaneously infiltrate the preform when the preform is placed into the molten matrix metal. A means for maintaining the preform at least partially below the surface of the molten matrix metal can also be utilized. In a preferred embodiment a reservoir may be employed to supply a second metal which has a different composition from the first source of matrix metal.

Abstract: Infiltrate a porous, self-reinforced .beta.-Si.sub.3 N.sub.4 preform with a metal or a crystallizable glass to yield a composite material. The preform possesses a low glass phase and has a density of from about 50 to about 70 percent of theoretical density. Prepare the .beta.-Si.sub.3 N.sub.4 preform by subjecting a porous body formed from an .alpha.-Si.sub.3 N.sub.4 powder composition to two sequential heat treatments. The first heat treatment occurs below the .alpha.- to .beta.- conversion temperature and results in a strengthened body that can be machined. The second heat treatment occurs above that temperature and yields the self-reinforced .beta.-Si.sub.3 N.sub.4 preform. Conventional infiltration procedures with an infiltrant that is a metal or a glass results in a Si.sub.3 N.sub.4 /metal or Si.sub.3 N.sub.4 /glass composite material that has 50 to 70 percent of its volume occupied by .beta.-Si.sub.3 N.sub.4 whiskers.

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 producing a reinforced composite material. A molten matrix metal is heated to a temperature substantially greater than the melting point of the matrix metal. The matrix metal is poured into a mold containing a mass of reinforcing material, and an oxide layer formed from said molten matrix metal is ruptured so that the molten matrix metal infiltrates the mass of reinforcing material.

Abstract: The present invention relates to processes to produce ceramic reinforced and ceramic-metal matrix composite articles. More specifically, the invention concerns the use of pressure filtration to infiltrate a reinforcing organic or inorganic network with ceramic particles. Centrifugation is also used to separate the liquid form the slurry. After heating the reinforced ceramic article is produced. Pressure filtration is also used to infiltrate an organic polymer or organic fiber network with ceramic particles. The solvent is removed carefully followed by intermediate heating to remove the organic network without deforming the preform shape. After densification, the preform is heated and contacted with molten metal (optionally) with pressure to infiltrate the open channel network. Upon cooling the ceramic metal matrix composite is obtained. The reinforced matrix articles are useful in high temperature and high stress applications, e.g.

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 method is disclosed for producing a reinforced composite material. A molten matrix metal is heated to a temperature substantially greater than the melting point of the matrix metal. The matrix metal is poured into a mold containing a mass of reinforcing material. The matrix metal is solidified.

Abstract: Bearing alloy is applied to a bush (10) by mounting the bush (10) on a support structure (14) having an upstanding mandrel (17) so as to form an annular interspace (20) for reception of the bearing alloy in liquid form. The mandrel (17) projects above the bush (10) and has certain predetermined minimum dimensions. Infrared heating is applied to the bush (10) and the mandrel (17) sufficient to prevent the liquid bearing alloy freezing on contact with any of the surfaces defining the interspace (20). After degassing the liquid alloy is controllably cooled by coolant applied to the exterior of the bush (10) and finally the metalled bush is freed from the support structure (14).

Abstract: Method of dimensionally stabilizing the interface between metal parts of differing thermal expansion characteristics (TEC), regardless of temperature variations under normal designed use of such parts, comprising: (a) hot extruding a mixture of ceramic fibers (i.e., Si.sub.3 N.sub.4, SiC, Al.sub.2 O.sub.3) and a powder of the metal having the higher TEC (i.e., Al, Ti, Mg) while aligning the fibers generally along the direction of extrusion, to form an insert; (b) shaping the insert to align its fibers generally in at least one direction of anticipated thermal growth that may interfere with the interface; (c) casting the insert in place within a first part compound of the higher TEC metal and with the insert's fibers (i) oriented as above, and (ii) preheated to a temperature no greater than 35-45% of the temperature of the molten light metal; and (d) bringing together the first metal part with a second part of lower TEC metal (i.e., Fe or steel) to form the interface.

Abstract: A cast-in member and a heating member are set in a mold with the cast-in member being in the vicinity of the heating member. Molten metal is poured through an ignition runner into contact with the heating member to ignite the latter and produce heat. The cast-in member is heated with the heat from the heating member. Thereafter, molten metal is poured through a runner into a cavity in the mold to cast the metal around the cast-in member.

Abstract: This invention relates to an improvement in the process of mold welding two metal parts together having respective base sections, which includes enclosing the end sections of said metal parts in aligned end-to-end relation in a mold having an entrance gate, flowing molten metal through said entrance gate into said mold, and out of said mold at rates so related as to cause some of the metal admitted into the mold to be discharged from said mold while the rest of the molten metal accumulates as a metal bath to cause the molten metal during the early stage of its admission into the mold to preheat the metal parts, and conducting some of the said molten metal during said early stage from the entrance gate through a recess and directly onto said base sections in direct impingement with said base sections to promote better heat transfer between said molten metal and said metal parts, the improvement comprising discharging molten metal through at least two separate exit gates into separate discharge chambers located

Abstract: A brake crown rotor is produced by casting in a mold the substantially cylindrical cast metal crown, and fusing to the upper portion thereof the outer perimeter of a round prefabricated sheet metal cover, the fusion taking place in the mold.

Abstract: A fiber reinforced metal is made by introducing an array of fibers into a die, charging the die with molten metal by vacuum infiltration and then applying pressure by means of an inert gas to improve the penetration of the molten metal into the fiber array. Apparatus for producing a reinforced metal cylinder comprises a cylindrical former (2) onto which a composite fiber (3) of boron, silicon and carbon is wound. The former (2) forms an inner closure member for the die defining a cylindrical die cavity (8) with an outer die body (4). A central cavity (15) within the former (2) is for insertion of a heating element to facilitate the flow of metal through the cavity (8). The die cavity is evacuated via conduit (16) and molten metal is then drawn into the cavity via the passage (7). After charging the die with molten metal the conduit (16) is connected to a source of high pressure nitrogen.

Abstract: First a reinforcing material mass is formed from a quantity of reinforcing material by binding it together with inorganic binder, and then this reinforcing material mass is compounded with matrix metal to form a composite material mass. Then the composite material mass is heated up so that the proportion of the matrix metal thereof which is in the liquid phase is at least 40%, and while still hot it is subjected to a plastic processing process to form the composite material object.

Abstract: A method for joining a member to a diecast article using an apparatus comprising dies, an injection sleeve communicating with a cavity of the dies and a plunger tip slidably arranged in the injection sleeve for filling the cavity of the dies with the molten metal previously poured in the injection sleeve. According to the invention, the plunger tip is formed with an insert aperture for receiving the member to be joined such that a portion of the member extending beyond an upper surface of the plunger tip is exposed in the molten metal when it is poured in the injection sleeve, thereby sufficiently transmitting the heat of the molten metal to the portion of the member to obtain a metallurgical bond at a boundary between the member and the diecast article.

Abstract: A method is provided for teem-welding metals, preferably light metals, particularly aluminium and its alloys, in which the metal, during its introduction into a casting mould, is caused to form one or more metal jets which are directed as far as possible at right-angles to and concentrated against the surfaces to be melted of the workpiece or workpieces. There is used a mould of such volume and with such an arrangement of the workpiece or workpieces therein, that the desired melting is achieved with that quantity of metal which, as the process proceeds, accumulates in and fills the mould, which quantity constitutes all the metal introduced into the mould.

Abstract: A rotary rock bit bearing is produced by filling a groove in the bearing pin of the bit with a hardfacing material. A crucible is positioned around the bearing pin. Hardfacing material is positioned in the crucible. A heating means for heating said crucible is positioned around the crucible and energized. A temperature sensitive primary control means for controlling said heating means is operatively connected to said crucible. A temperature sensitive secondary control means for controlling said heating means is operatively connected to the bearing pin ball bearing raceway flange. The primary control means is operative during the first portion of the hardfacing operation and the secondary control means is operative during the second portion of the hardfacing operation.

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: The apparatus and method provide an arrangement in which molten babbitt is fed into a spinning cylindrical bearing shell from a stationary molten babbitt tank having a babbitt pump immersed in the tank at an intermediate level, with the pump discharge being connected to piping to discharge molten babbitt into a babbitt trough from which the babbitt feeds to the interior of the spinning shell. The babbitt pump is driven for a controlled time period to feed a specified volume of babbitt into the trough and bearing in a continuous uninterrupted flow so that a carefully metered amount of molten babbitt is fed to the bearing. The apparatus also includes a control system operable to energize and deenergize various operating elements in a sequence including the drive motors, means for admitting a coolant about the hot spinning bearing shell, and the molten babbitt pump.

Abstract: A process for the aluminothermic welding of rails in which the rail ends to be joined are surrounded by a prefabricated, dry refractory casting mold and sealed from the rails with plastic mold materials, such as, moistened sand; a reaction crucible is arranged above the casting mold and filled with an aluminothermic reaction mixture; the rail ends are preheated, for example, by burning a mixture of propane and oxygen and directing the flames downwardly into the riser-duct of the casting mold for a period of time up to about 2 minutes and at a temperature between about 300.degree. C and about 700.degree.C; the aluminothermic reaction mixture in the reaction crucible is ignited; and, upon completion of the reaction of the aluminothermic reaction mixture, the lower outlet of the reaction crucible is opened and the steel melt is poured into the mold.The amount of aluminothermically produced steel utilized is between about 0.15 and about 0.25 parts by weight based on the weight per meter of the rails to be welded.