Abstract: A piston of a light alloy matrix material having a cavity for containing heat insulating air immediately below its head or a cavity for passing cooling oil inside the grooved side wall is manufactured by preforming a precursory member having the shape of the cavity from an extractable material which remains in solid state at room temperature and is convertible into a fluid, gas or liquid when heated at a temperature below the melting point of the matrix metal. The precursory member is disposed in place in a pressure casting mold having a cavity corresponding to the shape of the piston, and covered with a porous member stable to the molten matrix metal. A head member of heat resisting metal material to constitute at least a portion of the piston head may be disposed on the mold cavity bottom. Molten matrix metal is then cast into the mold cavity and a pressure is applied thereto to form a piston-shaped casting having precursory member and porous member embedded therein.

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: A trimetallic cylinder according to the preferred embodiment of the present invention includes a mild or alloy steel cylindrical body with stainless steel end rings welded or otherwise suitably joined to each end of the body. A wear and corrosion resistant alloy lining is provided for the composite cylinder, the combination resulting in improved corrosion resistance for the overall assembly.

Abstract: A method and an apparatus are described for anchoring cables, bundles of parallel or standard wire, or the like, of preferably high-tensile steel wire. At least one end of the cable or the like is introduced into a fixed anchoring socket and sealed with a pourable material. In order for the anchoring apparatus to have improved properties under static stress, and in particular under great dynamic stress, without requiring additional structural safety features, while enabling lower-cost manufacture, it is provided that the bundle be twisted and the bundle or cable opened for some distance from the associated end in such a manner that the wires or strands extend uniformly all the way through the conical inner region of the anchoring socket. Further, a metallic casting material is poured into the anchoring socket between the opened wires or strands, and a direct metal-to-metal joint is established between the metallic casting material and the wires or strands of the cable or bundle.

Abstract: A continuous casting chill mold, for the continuous casting of metals, particularly of steel, comprises a water-cooled interior section and an outer jacket section which avoids the problems associated with the machining of the cooling channels and at the same time reduces wastage, in that the interior section is produced by chipless (i.e. non-machining) production methods as a thin-walled sleeve having a dense microstructure, the interior section is surrounded by a coiled cooling pipe which, together with the interior section, is positively materially bonded to the outer jacket section consisting of copper applied by casting techniques. Neither in the cooling zone nor in the wall region of the mold cavity is there any risk of cutting into pores or pipes because all chip-removing machining is dispensed with.

Abstract: A vane air pump has a vane holder which includes a main body. A vane extends outward from one side of the main body and a balance weight extends outward from the other side of the main body in a direction opposite to the vane. The balance weight is cast integrally with the main body. The method discloses integrally forming a balance weight with the main body of the vane holder.

Abstract: A method of making die castings of one metal with a row of spaced fingers of another metal mounts the fingers in slots of an elongated holder with portions of the fingers projecting beyond the holder. The holder is mounted in a die casting machine having a molding cavity surrounding the projecting portions of the fingers. Metal is die cast around the projecting portions of the fingers to form a frame. The casting and the holder are ejected from the die casting machine, and the holder is stripped from the fingers. The method is especially useful for making relays for teleprinters and the like where electrical input produces mechanical movement and where the fingers become cores of electromagnets with the die casting metal being non-magnetic.

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: While the leading end of a first heated workpiece is processed in a rolling mill, the trailing end is joined to the leading end of a second heated workpiece. End portions of the workpieces at the gap therebetween are held by clamp members at a spaced-apart location so that both workpieces advance at the same speed toward the rolling mill. The end portions of the workpieces are cleaned to remove scale and then a mold is positioned to span the gap and contact the end parts of the workpieces. Liquid-weld metal is introduced into the mold and allowed to at least partially solidify before the mold is removed while the rolling operation continues. The weld metal substantially solidifies and is passed through the rolling mill.

Abstract: A wear part with high wear and abrasion resistance combined with unlimited weldability and good mechanical strength or toughness, comprising a composite part of hard metal portion, a cast metal alloy body portion and attached thereto to joining portion, characterized in that the joining portion consists essentially of a weldable steel which by casting is bonded to the cast metal alloy body portion to a combined mechanical-metallurgical bond is provided, as well as a method for forming such a wear part.

Abstract: A hollow metallic envelope 10 of a finned cast recuperator tube is cast with preformed interior fins 12 and exterior fins 16 integral therewith. A sand core 30 is formed about the preformed interior fins 12 with portions of the fins 12 protruding outwardly from the sand core, and a sand mold 40 is formed to a cavity for receiving the sand core 30 with the preformed exterior fins 16 embedded in the sand mold with portions of the fins 16 protruding therefrom into the cavity. The sand core 30 is placed into the sand mold 40 in spaced relationship therewith so as to provide a clearance space 50 between the sand core 30 and sand mold 40 into which the portions of the interior fins 12 and exterior fins 16 extend. Molten metal is poured into the space 50 which upon cooling solidifies to form the envelope 10 with the interior fins 12 and exterior fins 16 fused integrally therewith.

Abstract: The disclosure relates to a turbine rotor and method of manufacture thereof. A plurality of blades having dovetails at the radially inner ends thereof are arranged in a circumferentially spaced circular array. A metallic hub is cast about the dovetails of said blades which are metallurgically bonded by the operation. Alternatively, the blades may be joined to the hub thereafter by an electron beam weld that extends axially to the rotor.

Abstract: Method of making a cast reinforced article, such as a connecting rod which includes preparing a bundle of uni-directional inorganic fibers, at least some of which are metallic or metal coated by placing the bundle into a shaping container and heating it to partially fuse the metallic or metal coated fibers to each other. The partially fused bundle is positioned in a mold with a fixed minimum gap surrounding it. A molten light metal alloy is squeeze cast into the mold forming a matrix of the alloy and the bundle. In the case of a connecting rod, the bundle should be shaped elliptically and positioned in the mold such that (I(c) y<I(c) x).

Abstract: The invention relates to composite metal armour comprising ceramic inserts arranged in a regular manner within a metal casting. To ensure that the ceramic inserts are arranged at regular intervals within the metal, each of the inserts is provided with an encasing shell including male and female portions which are receivable into the male and female portions of adjacent inserts in order to maintain the inserts in a regular pattern during casting.

Abstract: A method for producing a fiber reinforced composite body, wherein a shaped body of inorganic fiber or a sintered body of metal or ceramic material is placed in a metal mold, and a melt of a metal alloy as a matrix is caused to be penetrated or impregnated into the shaped body by a high pressure solidification casting method so that the matrix may perfectly fill in the voids or pores of the shaped body and solidify to be a desired composite body.

Abstract: A positive, gastight, and undetachable connection of two metal parts, especially a cylinder head and a cylinder tube of an internal combustion engine. A groove is located in one of the two parts; this groove, together with a counterpiece of the second part, which counterpiece engages in the groove, forms an annular chamber which is filled with molten metal according to the diecast method, and in such a way as to be free of occlusions.

Abstract: A method is disclosed for the manufacture of a drill bit having a hollow tubular body, or drill bit components, with an exterior tungsten carbide coated surface, and with cutting elements positioned in the cutting surfaces thereof. The drill bit body, or a bit component, such as a cutting blade, is formed by casting in a mold providing the precise dimensions required in the finished bit. The mold is packed or coated over selected portions of the inner surface with particles of sintered tungsten carbide or similar sintered refractory hard metal. The mold has a plurality of soft iron or steel plugs extending from the walls thereof which are of the same diameter as the cutting inserts or passages into the bit body or bit component. A steel alloy, or cast iron, or nodular cast iron, is melted and poured into the mold. The temperature of the molten steel is sufficient to desinter the sintered tungsten carbide particles.

Abstract: A method of producing a composite material from porous reinforcing material and molten matrix metal. First the porous reinforcing material is heated up to a temperature substantially above melting point of the matrix metal. Then the molten matrix metal is infiltrated into the porous structure of the reinforcing material under a substantial pressure. Then the combination of the reinforcing material and the matrix metal infiltrated thereinto is cooled down to a temperature below the melting point of the matrix metal, while maintaining the abovementioned substantial pressure. Optionally, the reinforcing material may be charged into a case; and, again optionally, the case may have one opening only, and a vacant space may be left between another part of the case and the reinforcing material charged in the case, with the reinforcing material interrupting communication between the opening and the vacant space. The case can be made of stainless steel, or of a refractory material such as porous brick.

Abstract: The present invention relates to method and apparatus for fabricating materials and objects, and processing and refining metals in space by means of available sunlight energy.

Abstract: Method for investment casting of metal matrix composites by vacuum infiltration using a ceramic mold formed directly on the pattern.

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: A positive, gastight, and undetachable connection of two metal parts, especially a cylinder head and a cylinder tube of an internal combustion engine. A groove is located in one of the two parts; this groove, together with a counterpiece of the second part, which counterpiece engages in the groove, forms an annular chamber which is filled with molten metal according to the diecast method, and in such a way as to be free of occlusions.

Abstract: A connecting rod for a radial piston motor including a spherical surface portion, a rod portion and a pad portion having a sliding surface. The spherical surface portion, rod portion and pad portion are formed integrally, and the sliding surface has a bearing alloy attached to its surface by centrifugal casting. An overlay may be provided on the bearing alloy. The connecting rod is produced in a mass production basis by a method including the steps of integrally forming the spherical surface portion, rod portion and pad portion into a blank, assembling a plurality of such blanks in ring form and welding them together at joints into a single blank, machining the sliding surface of the pad portion of the blank, attaching a bearing alloy by centrifugal casting to the sliding surface of the pad portion, machining the surface of the bearing alloy, and dividing the blank at the joints into a plurality of pieces constituting a plurality of connecting rods.

Abstract: A metal-capped electrical insulator and method of making same by forming a metal cap on an insulator dielectric by directly casting molten metal round a portion of the dielectric to embed it therein. Before casting the metal (16 or 17), a metal washer (1 ) is placed in contact with the boundary on the insulator at the edge of the portion to be embedded. The washer has a circular groove (2) open on the side through which the molten metal is poured. Before casting, said washer is deformed, by pressing it hard in a metal-casting mould (30) to the dielectric and deflecting the walls (3, 4) of the groove (2) to create an undercut in the metal washer.

Abstract: Ultrasonically joining a plurality of discrete lead parts into a shaped, substantially metallurgically homogeneous joint. Preshaped lead pieces are placed in an ultrasonically vibrated mold for fusing the pieces and shaping the joint. The method is exemplified in the making of terminal posts for Pb-acid storage batteries.

Abstract: A method of manufacture of novel light-weight pistons of aluminum forgings with an integral iron insert ring by fusion welding is described. The aluminum piston forging is provided with a configuration adapted to receive the iron insert ring which may be coated to provide an inter-metallic joining alloy. The configured piston forging is placed in a mold, the ring is positioned in the configuration. The mold is rotated and molten alloy is introduced at an angle to deoxidize the forging and the ring, sweep the oxides to non-critical areas of the mold and to join the forging to the ring upon cooling to form a fusion weld.

Abstract: The invention deals with the manufacture of fully segmented sabots used in he launching of subcaliber projectiles. The prior method required the machining of individual sabot segments and fitting them on to the sub-projectile. The improvement involves the casting of the sabot segments with the shimmed sub-projectile pre-positioned in a mold.

Abstract: A method of producing a fiber reinforced composite article comprising forming a shaped fiber body of predetermined configuration from inorganic fibers, placing a tubular member in the shaped fiber body, the tubular member having an opened end and a plurality of communication ports therein and charging a molten matrix alloy by squeeze casting from the outside of the shaped fiber body and, additionally, from the inside of the shaped fiber body through the tubular member. The article can be a connecting rod of an internal combustion engine and the shaped fiber body can be located at a position corresponding to a rib for reinforcing the connecting rod.

Abstract: A composite metal sheet or plate is manufactured by completely immersing an assembly of parallel or substantially parallel metal core sheets in molten metal at a lower melting point than the metal of the core sheets, and after the molten metal has solidified reducing the thickness of the ingot by hot rolling in a direction generally normal to the planes of the core sheets. The method has a particularly useful but by no means exclusive application in the production of reinforced aluminium alloy sheets and plates.

Abstract: A method of forming ceramic fiber and metal composite structures is disclosed. The method is particularly useful in forming such structures having a complex shape. Fibers are coated with an investment grade sticky wax as a fugitive organic binder. Aluminium oxide coated with a sticky wax binder have been found to have greater flexibility than the fibers alone or fibers coated with other binders. The coated fibers are then laid up into a preform of the desired shape. The preform is elevated to a moderate temperature prior to pressure compaction. The preform may be combined with other preforms to form a more complex shape. The preform is then installed in a casting mold and elevated to a temperature sufficient to remove the sticky wax binder. Molten metal is then introduced into the mold where it fills the voids created by the removal of the sticky wax. Subsequent to cooling, the fiber and metal composite material is removed from the casting mold.

Abstract: A method of producing a unidirectional fiber-reinforced composite material by covering bundles of an inorganic fiber having unidirectionally high elasticity and high strength with a wire-like, foil-like or knit-like material which is the same as, or different from, a matrix metal and is capable of being molten and diffused into said matrix metal, to thereby form a fiber body having an optional shape, volume and fiber density; placing the resulting fiber body in an appropriate location within a mold; pouring a molten matrix metal into said mold; and squeeze casting said molten matrix metal along with the fiber body to form the unidirectionally fiber-reinforced composite material while causing said covering material to melt and diffuse under heat of said molten matrix metal into the latter.

Abstract: Composition brake drums are made by die casting aluminum or other light weight metal around (A) the periphery of a substantially biplanar stamped steel drum back having a plurality of alternating holes and voids in its outermost edge in a plane and (B) a cast iron braking ring with smooth inner braking surface and rough outer surface whereby the lightweight die cast fills the holes and voids and interlocks with the rough outer surface to provide a brake drum of unitary construction that has improved braking performance with reduced weight and cost, especially compared to similar brake drums having a drum back of cast lightweight metal.

Abstract: This invention relates to an improvement in the process for performing aluminothermic rail connection weldings, in which the rail ends to be welded together and being laid with a gap are enclosed with a fireproof, prefabricated casting mold producing a weld reinforcement covering the gap, and aluminothermically-produced steel is poured into the casting mold cavity, the improvement comprising pouring the steel melt into the casting mold in the form of at least two separate casting streams positioned opposite each other in the longitudinal rail direction, whereby the casting streams are so guided that they will intermix approximately in the area of the rail head center of the two rails to be welded together. The invention also relates to a casting mold for performing the process.

Abstract: Battery plates are assembled into stacks forming positive and negative rows of lugs and the stacks are placed within the cells in a battery case. Molding channels are automatically formed around the positive and negative rows of lugs and molten lead alloy is automatically introduced into the molding channels to cast the straps and intercell connections simultaneously within the battery case.

Abstract: A fiber-reinforced light alloy cast article for use in various mechanical parts such as, for example, a connecting rod, a rocker arm, and so forth in an internal combustion engine. The composite light alloy cast article includes therein a portion filled with a shaped body made of an inorganic fiber material of high elasticity and high mechanical strength, and another portion filled with a shaped body of inorganic fibers having low elasticity and high hardness and having an appropriate bulk density suited for required purposes, the fiber-shaped bodies being filled in the required portions of the composite light alloy cast article by high pressure solidification casting.

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: Bushing and sleeve assembly are attached in an alignment fixture and placed in the stay ring-discharge ring. An internal pilot bearing is placed in the headcover to accommodate an aligning bar which is lowered through the headcover and pilot. The lower end of the aligning bar is engaged with the aligning fixture and the pilot can then be engaged with the headcover to automatically align the bushing and sleeve assembly with the two headcover bushings at the upper bearing pilot and the internal intermediate pilot.

Abstract: The present invention provides an improved method of forming a metal article having a plurality of airfoils which extend outwardly from a hub. The metal airfoils are formed separately from the hub. In forming a mold to cast the article, blade portions of the metal airfoils are coated with wax. The metal airfoils are then placed in a circular array and are covered with a coating of liquid ceramic mold material. This wet coating of ceramic mold material is dried to form an annular mold wall section having a plurality of recesses in which the blades of the metal airfoils are disposed. The wax coating over the metal airfoil blades is subsequently removed from the recesses to provide space between the blades and the side walls of the recesses. The annular mold wall section in which the blade containing recesses are formed is then connected with top and bottom mold sections to further define a mold cavity having a configuration corresponding to the hub portion of the article.

Abstract: A method of providing a secure, long-lasting electrical connection between the concentric neutral wires of a Underground Residential Distribution (URD) cable and a sacrificial anode. The invention provides for the prevention of corrosion of the neutral wires of the URD cable. The method comprises: securing a mold around the URD cable and the concentric neutral wires over the area of contact with the anode connecting wire; pouring a low-melt alloy into the mold to surround the URD cable so as to contact at least 50% of the surface area of each of the neutral wires and the anode connecting wire in the area of contact; and cooling the low-melt alloy to form a solid casting around the concentric neutral wires and the area of contact with the anode connecting wire, whereby a secure, long-lasting electrical connection is provided between the neutral wires and the anode.

Abstract: A rotor for in-out electric motor having a shaft coaxial with its stator, ferromagnetic portions external to the stator and a cup-like shield which rigidly connects one end head of the ferromagnetic portions to one transversally extended head of the shaft, the head being at least peripherically incorporated in and made rigid with a cast metal component forming a part of the shield and which is rigid with the ferromagnetic portion. A process for producing the resulting rigid assembly is provided wherein the coaxiality of the shaft and portions is ensured. Also there is shown a mould for casting the cast metal component.

Abstract: An exhaust manifold for an internal combustion engine is provided with internal insulation so as to maintain the outside skin temperature preferably below 450.degree. F. The manifold is provided with an exhaust conduit or lining that is comprised of interfitting relatively axially movable sections in contact with the exhaust gases. A low specific gravity or porous sleeve of insulating material is fitted in slightly spaced relationship around the exhaust conduit. The sleeve of insulating material may be wrapped to prevent the metal of the outer cast manifold housing from penetrating the insulation. Each section of the exhaust conduit has a branch for connection to a flanged nipple which is permitted some limited movement relative to the manifold housing when connected to the exhaust ports of the engine.

Abstract: A method of forming a joint between a metal structural tubular member and a metal sleeve. The method comprises placing the sleeve around a part of the tubular member so that there is a space between the sleeve and the adjacent part of the tubular member, closing the ends of at least a part of the space between the tubular member and the sleeve, injecting a hardenable composition into the space between the closed ends and maintaining the pressure until set.The method can be used for joining together structural tubular members or for repairing a damaged structural member.

Abstract: A method and apparatus for manufacturing a heat exchanger. A plurality of parallel pipes are advanced from a magazine to an axially slotted open ended shell blank which is radially compressed against the pipes. The contacting surfaces of the pipe openings are then welded together, after which the ends of the package of pipes are immersed in a casting mass, which, after solidifying, is severed along a line therethrough so as to open the pipes at both ends. A wall enclosing each open end is then connected to each end of the pipe package.

Abstract: A manifold for internal combustion engines is provided which has a unique insulation system for maintaining a skin temperature of the manifold below 400.degree. F. The manifold includes an exhaust conduit made up of axially spaced and aligned segments with provision for preventing excessive leakage of exhaust gases between the spaced segments. Each segment has an exhaust port extending at an angle thereto. Two or more members of corrugated or crumpled thin foil are concentrically arranged about the ports and about the conduit with air gaps between the conduit and the innermost member, between the port and the innermost member, and between each member. An outer casing is cast about the members and embeds the ends of the members therein. The foil from which the members are made is polished on the surfaces to be highly reflective thereby reducing the transfer of heat through the successive concentric members. A method of manufacturing the improved insulated manifold is provided.

Abstract: A plate strap is die-cast integrally with an upstanding conducting member, which may be either a terminal post or a riser to form part of an intercell connector, by means of a mold having a cavity affording an elongated plate strap position which is closed at the top and has slots in the floor through which the plate lugs project, and a chimney position upstanding from the plate strap position to form the upstanding conducting member. The part of the floor between the plate lugs is formed by cylindrical dowels each having a diameter substantially equal to the spacing between adjacent lugs. The dowels are retracted to permit removal of the mold from the plate strap or straps. A single mold may form a row of plate straps associated with a number of intercell connectors and a pair of terminal posts.

Abstract: Method for fixing a connecting cap (4) on a non-metallic part (1) by molding of the metal or alloy of the connecting cap in the melted state on the outer surface of the non-metallic part. One or several metallic parts closely applied more particularly a sleeve (2) or a ring, is arranged at least on a part of that outer surface.

Abstract: For inclusion as spacer between first and second axially spaced apart members mounted for limited angulation about a common axis, the first member having a seal recess formed in one face, the second member having an end face opposite the seal recess, the improvement of: a laminated torsielastic bushing arranged in one piece, and in the recess.

Abstract: The invention relates to shielded cables and in particular to an electrically conductive junction between the conduit which shields the cable and the electrical connector at the end of the cable which serves as the cable termination. In accordance with the invention this junction is molded directly onto the conduit and the electrical connector.

Abstract: The method comprises forming four like, and interfitting molds, with cavities therein, and closing all the molds together in envelopment of a cruciform element. The element, preferably, carries bearings on opposite ends of the pins or shafts thereof. Casting material, such as high tensile bronze is introduced into the molds cavities to cast the end product therein, onto the cruciform element and bearings. The method has particular application and utility in the casting of assemblies of articulatable components, such as universal joints, and the like, in that it affords the fabrication of such assemblies, complete, in a single casting operation. The casting means comprises a mold which is interfittable with others thereof for use in the practice of the above-noted method.

Abstract: A coupling device is disclosed for rapidly and ecnomically mechanically joining a pair of elongated structural elements such as reinforcing bars in the field. The cylindrical couplingdevice includes an outer annular chamber containing porous substance which can be made to react exothermically, such as a mixture of aluminum and iron oxide powder which releases molten material, e.g. iron, upon being activated. The mass of exothermic material includes air in a quantity determined by the material's porosity when packed into the outer annular chamber. When the exothermic material is made to react, it heats the contained air and causes it to expand and act as a propellant, which causes molten iron from the exotheric reaction to be propelled from the outer chamber into an interior cylindrical chamber or chambers which contain the ends of the reinforcing bars.