Abstract: Methods are provided for manufacturing a component. In one method, first metal material is cast into a first body. At least a portion of the first body is machined. Second metal material is cast onto at least the machined portion of the first body to form a monolithic second body. A first portion of the second body is formed by the first metal material, A second portion of the second body is formed by the second metal material. The second metal material is different from the first metal material.

Abstract: A superconducting joint that electrically joins superconducting wires has a block of thermally and electrically conductive material that is coated with an electrically isolated coating that covers at least a part of a surface of the block. Molded semiconducting joint material is provided in contact with the electrically isolating coating. Superconducting filaments of the superconducting wires are embedded within the molded superconducting joint material.

Abstract: To provide a sputtering target structure which has good machinability and thermal conductivity and has good wettability with soldering materials, which is inexpensive and can be used repeatedly for a long period of time, and which is free from problems of cracking and peeling of the sputtering target therein, a sputtering target structure is formed by bonding a sputtering target and a backing plate. The backing plate is formed of a material that has the difference in the linear expansion coefficient between it and the sputtering target material of at most 2×10?6/K, and a copper plate having a thickness of from 0.3 to 1.5 mm is disposed on at lest one face of the backing plate.

Abstract: An assembly of like two rib cores enclosing a splitter core are used to carry two or four sound damping inserts for sand mold casting of a pair of vented and damped brake rotors. Sand mold bodies are configured to define outboard surfaces of hub and rotor surfaces of the cast brake rotors. The three-piece core assembly is shaped to define the complex inner surfaces in casting of vented rotor bodies carrying one or two annular sound damping inserts.

Abstract: The invention relates to a method for producing a piston for a combustion engine comprising a combustion recess, during which an annular fiber preform for reinforcing the edge of the combustion recess is firstly fastened inside the casting mold. Afterwards, a low-silicon aluminum/copper melt is introduced into the casting mold by which the fiber preform is infiltrated and molded into the recess edge within the scope of the casting process. The piston blank produced in this manner is then subsequently compacted by a high-temperature isostatic pressing before the piston is completed by means of a machining completion process. The flanks and the base areas of the second and third annular groove are coated by means of anodic oxidation, and the hub boreholes are smoothed and hardened by roller-burnishing. This results in a very high-quality and heavy-duty piston.

Abstract: Earth-boring tools for drilling subterranean formations include a particle-matrix composite material comprising a plurality of silicon carbide particles dispersed throughout a matrix material, such as, for example, an aluminum or aluminum-based alloy. In some embodiments, the silicon carbide particles comprise an ABC—SiC material. Methods of manufacturing such tools include providing a plurality of silicon carbide particles within a matrix material. Optionally, the silicon carbide particles may comprise ABC—SiC material, and the ABC—SiC material may be toughened to increase a fracture toughness exhibited by the ABC—SiC material. In some methods, at least one of an infiltration process and a powder compaction and consolidation process may be employed.

Abstract: A die for use in a sheet metal forming process includes a die material having a surface. A plurality of depressions is formed in a predetermined portion of the surface, where each of the plurality of depressions has a predetermined diameter and depth. Interaction of a surface of a sheet metal blank with i) the plurality of depressions, and ii) a solid forming lubricant, including particles of an average predetermined size and distribution, disposed on one of the die material surface or the sheet metal blank surface substantially reduces adhesion between the sheet metal blank surface and the die material surface during the sheet metal forming process.

Abstract: A slip for support of a downhole tool is cast with inserts positioned in the mold. The inserts can have a unique shape to allow them to be retained in the cast slip while having the proper position relative to each other and proper extension and orientation. A placement tool is envisioned to allow sets of inserts to be initially placed in the mold at one time and released from the tool.

Abstract: A substrate support and method of fabricating the same are provided. Generally, one method of fabrication includes assembling a subassembly comprising a first reinforcing member and a heating element, supporting the subassembly at least 40 mm from a bottom of a mold, encapsulating the supported subassembly with molten aluminum, and applying pressure to the molten aluminum. Alternatively, a method of fabrication includes assembling a subassembly comprising a stud disposed through a heating element sandwiched between a first reinforcing member and a second reinforcing member, supporting the subassembly above a bottom of a mold, encapsulating the subassembly disposed in the mold with molten aluminum to form a casting, forming a hole in the casting by removing at least a portion of the stud, and disposing a plug in at least a portion of the hole.

Abstract: A substrate support and method of fabricating the same are provided. Generally, one method of fabrication includes assembling a subassembly comprising a first reinforcing member and a heating element, supporting the subassembly at least 40 mm from a bottom of a mold, encapsulating the supported subassembly with molten aluminum, and applying pressure to the molten aluminum. Alternatively, a method of fabrication includes assembling a subassembly comprising a stud disposed through a heating element sandwiched between a first reinforcing member and a second reinforcing member, supporting the subassembly above a bottom of a mold, encapsulating the subassembly disposed in the mold with molten aluminum to form a casting, forming a hole in the casting by removing at least a portion of the stud, and disposing a plug in at least a portion of the hole.

Abstract: A stamped, steel insert for use in metal die cast articles. The insert includes first and second interconnected stamped steel insert halves spaced from one another at certain locations to define a void. Openings communicating with the void extend through each insert half to facilitate material flow and to improve interlock of the insert and die cast material. The edges of the insert lie below the surface of the casting to avoid bimetallic machining. The insert halves cooperate to define a pair of elongated passages, which are bored following die casting to form fastener holes. At least one of the passages has an elongated cross section to allow for expansion and contraction of the insert during casting.

Abstract: Bimetal casting of wearing parts including a cast retaining part enclosing a plurality of inserts. The method consists in casting an insert in a first mould, disposing the insert thus cast in a second mould and in casting the part in this second mould around the insert in such a way as to form a mechanical bonding between the two castings. The wearing part thus cast advantageously comprises an insert having a high resistance to wear while the rest of the part is made of a more ductile material which is resistent to mechanical stresses. The primary application is in the realization of crushing wheels, termed ferrules, and crusher hammers.

Abstract: A method and apparatus for making a rotor assembly for an electric motor wherein the rotor core of the assembly includes a stack of annular laminations having fixed molded annular end rings on opposed faces thereof with a rotor shaft extending through the core and fixed thereto by a molded rotor hub shaped in cup-like fashion at one end thereof to cooperate in forming an oil return member therewith.

Abstract: The invention relates to the manufacture of composite metal armour plating comprising ceramic inserts (42) regularly disposed through the thickness and giving reliable, reproducible ballistic efficiency.The ceramic inserts are positioned at regular intervals by disposing them in enveloping shells comprising male and female portions fitting into one another in order to bring about relative predetermined positioning and leave gaps into which the actual casting metal can flow during casting.

Abstract: A method for producing a metallic component provided with a ceramic lining in a mold includes applying a first ceramic layer to a mold. A sliding layer is applied to the first ceramic layer. A second ceramic layer divided by joints into individual zones is applied to the sliding layer. The second ceramic layer is coated with a metal forming a finished component.

Abstract: A method and apparatus for making a rotor assembly for an electric motor wherein the motor core of the assembly includes a stack of annular laminations having fixed molded annular end rings on opposed faces thereof with a rotor shaft extending through the core and fixed thereto by a molded rotor hub shaped in cup-like fashion at one end thereof to cooperate in forming an oil return member therewith.

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 method of casting a fiber-reinforced caliper wherein inorganic fiber is wound up in a direction parallel to the axis of cylinder around a core conforming approximately to the inside shape of the bridge portion of a caliper, the wound-up fiber is cut off in the shape of the bridge, and matrix metal is cast onto the cut-off molding of fiber under high pressure to form the shape of caliper, or the whole shape of caliper is formed by a casting method after the bridge portion is formed by casting under high pressure.

Abstract: A method for production of fiber-reinforced metal composite material having high fiber content, wherein a bundle of fiber material is impregnated with water, then this water-impregnated fiber bundle is subjected to compression and freezing to form a high density fiber shaped body, subsequently, the high density fiber shaped body is subjected to thawing and drying, while maintaining its shape as compressed, and finally molten metal is infiltrated into the fiber shaped body.

Abstract: A method and an apparatus for manufacturing a fiber reinforcement body which is to be incorporated into a metal matrix in a fabrication technique based on a molten metal infiltration process for producing a metal matrix composite material are disclosed herein. The method according to the invention comprises preparing at least two metal insert chills each having the shape of a spool or reel, forming windings of a yarn of reinforcing fibers on each of the two chills, and forming windings of the yarn around, and extending between the two chill members so as to connect them together. The apparatus of the invention comprises means for supporting the chill members in longitudinally spaced relation to each other, means for forming uniformly distributed windings of the yarn on each of the chills, and means for forming similar windings of the yarn around, and extending between the chills in a way so as to connect them together.

Abstract: The present invention relates to castings constituted by a metal matrix reinforced by fibres and having outgrowths.Firstly, a reinforcing framework is produced, which is incorporated into the fibrous strengthening member, the complete entity being placed in a mould and the metal matrix is cast. The latter penetrates the fibrous strengthening member and the reinforcing framework. The latter is positioned at the location of an outgrowth which, after solidification of the metal matrix, is consequently reinforced.Application to the production of castings having fixing tabs or lobes.

Abstract: A method of producing a fiber-reinforced composite material comprising the steps of arranging a fiber shaped article in a cavity of a casting mold; pouring a molten metal acting as a matrix into the cavity and subjecting the molten metal to primary pressure; holding the molten metal under pressure for a predetermined period of time; and subjecting the molten metal, at least in proximity of one end of the fiber shaped article, to secondary pressure with a high hydrostatic pressure after the predetermined period of time has passed, to fill the molted metal into the fiber shaped article and integrate them.

Abstract: A method for bonding aluminum and aluminum alloys to refractory materials. A body of metal is heated to an elevated temperature at a total pressure above the vapor pressure of aluminum but less than atmospheric pressure. Oxygen partial pressure is maintained sufficiently low to prevent substantial oxidation of the metal. The heated body is contacted with a mass of refractory material and cooled, thereby forming a composite.

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 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: Methods are disclosed for manufacturing graphite fiber metal matrix bearing materials using liquid metal pressure infiltration to achieve a high degree of intimate wetting, contact and infiltration of a compliant metal between and around graphite (carbon) fibers to provide graphite fiber metal matrix bearing material having a predetermined volume percentage of graphite fibers. In one embodiment, graphite fibers are wrapped around a removable cylindrical mandrel and the graphite fiber-wrapped mandrel is inserted into a mold and the mold which contains a liquid compliant metal, such as lead, to cause intimate wetting, contact and infiltration of the compliant metal between and around all of the graphite fibers.

Abstract: A die cast rotor for an electric motor in which an integral tubular oil return/rotor shaft mounting member is sealingly cast-in-place within the body of the rotor. The integral oil return/rotor shaft mounting member is preferably a one-piece impact extruded member. A method of fabricating such a die cast rotor is also disclosed.

Abstract: A method of aluminothermic welding of members of austenitic steel containing by weight 10 to 20% manganese, 0.5 to 1.5% carbon and 0 to 5% nickel, and particularly low carbon austenitic steels containing by weight 14 to 17% manganese, 0.5 to 1.5% carbon and 0 to 5% nickel, comprises using a particulate mix for forming the aluminothermic steel, which mix is substantially free from phosphorus and silicon and a mould whose body material is predominantly a non-silicon material.

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: A method of attaching a pair of opposite end frames of a dynamoelectric machine to a structural component thereof predeterminately positioned with the end frames for assembly within receiving means respectively provided in the end frames. Molten metal is introduced into the receiving means of one of the end frames for solidifying and forming a rigid tie between the one end frame and the structural component in their respective predetermined positions, and the end frame and structural component are simultaneously inverted upon the solidification of the molten metal for disposing the receiving means of the other of the end frames in position for introducing molten metal thereinto.Other methods of attaching components of a dynamoelectric machine are also disclosed.

Abstract: A method of connecting a pipe to a pressure conveying element, especially a pipe plate, a pressure container, and a collector, according to which the pressure conveying element is within the region of its intended connection with the pipe provided with lips. After the pipe provided on its inside and outside with a lip has been introduced into the pressure conveying element, the pipe is at its outer lip connected to the lip of the element by a complete through weld. Subsequently a centering bushing is introduced into the pipe and is clamped therein so that the outer surface of the centering bushing together with the inner surface of a bore in the conveying element--which bore is substantially coaxially arranged with regard to the pipe--forms a flat annular trough, whereupon the space between the outside surface of the centering bushing and the inner surface of the trough is filled with welding material.

Abstract: Improved methods and apparatus for positive displacement casting and/or for positive displacement bonding and, more particularly, for automatically forming, on a continuous, reproducible basis, fusion bonds devoid of structural, electrical and cosmetic defects between two or more workpieces by moving a heated electrode into the area to be bonded so as to uniformly heat and melt the portions of the workpieces to be bonded while, at the same time, displacing substantially all of the molten material from the area to be bonded into a storage area or reservoir surrounding the heated electrode where such molten material is maintained in its uniformly heated molten state, and then retracting the electrode so as to permit the molten material to return to the cavity formed by the electrode in the workpieces where such molten material is allowed to cool and solidify, thus forming a flawless bond between the workpieces--thermal or fusion bonds are made in accordance with the methods of the invention and with the apparat

Abstract: A method of assembling a dynamoelectric machine having a stationary member, a rotatable member, and a pair of means for rotatably supporting the rotatable member within the stationary member. In this method, beams are attached to the stationary member, and opposite end portions of the beams extend from the stationary member. The rotatable means is then mounted with the stationary member and the supporting means with one of the opposite end portions of the beams within means in one of the supporting means for receiving them. The receiving means is at least partially filled with molten metal which solidifies for interconnecting the one opposite end portion of the beams with the one supporting means, and the other of the supporting means is then secured to the other of the opposite end portions of the beams.