Abstract: This invention relates to a solventless polyurethane no-bake foundry binder system comprising, as individual components (a) a polyol component comprising a polyether polyol, glycol, and an aromatic polyester polyol, (b) an organic polyisocyanate component, and (c) a liquid tertiary amine catalyst component. Foundry mixes are prepared by mixing the binder system with a foundry aggregate by a no-bake process. The resulting foundry shapes are used to cast metal parts from ferrous and non-ferrous metals.

Abstract: A PCB package for shielding electromagnetic radiation from exiting or entering the package. In one embodiment the package includes first and second electrically conductive covers and first and second electrically conductive frames. The first frame electrically connected to the first cover and the second frame electrically connected to the second cover. The first frame is then electrically connected to the second frame. The first and second frames can be made of electrically conductive plastics or metals or any other electrically conductive materials. Methods of assembling the packages of the various embodiments are also set forth.

Abstract: A method for producing depressed center railcars involves a combination of casting and fabrication. Transition members of the railcar can be casted, preferably with interlocking ledges on the ends of the transition members. The center section can be fabricated from, preferably precambered, longitudinal stringers which can then be connected between the casted transition members via the interlocking ledges. Standard steel warehouse plates can be attached to the fabricated framework of longitudinal stringers to form the surface of the center section. The transition members can be cast with integral provision to accept a center plate member. The fabricated framework of stringers can include reinforcement members for added strength. The framework can also be constructed to allow for the placement of the parts of the brake system and other components on the underside of the railcar.

Abstract: Improved targets for use in DC_magnetron sputtering of aluminum or like metals are disclosed for forming metallization films having low defect densities. Methods for manufacturing and using such targets are also disclosed. Conductivity anomalies such as those composed of metal oxide inclusions can induce arcing between the target surface and the plasma. The arcing can lead to production of excessive deposition material in the form of splats or blobs. Reducing the content of conductivity anomalies and strengthening the to-be-deposited material is seen to reduce production of such splats or blobs. Other splat limiting steps include smooth finishing of the target surface and low-stress ramp up of the plasma.

Abstract: A method of applying molten solder to connection surfaces on a substrate. The substrate, which has a surface which can be wetted with solder or at least one area which can be wetted while the rest cannot, is immersed in an organic liquid medium whose boiling point is the same as or above the melting point of the solder. Solder is applied to the surface or the area on the substrate where a terminal is to be formed to produce a solder bump, the quantity of solder to be placed on the connection surface is in the liquid medium, at least at the moment when it makes contact with the surface, and the temperature of the liquid medium is at or above the melting point of the solder.

Abstract: A process for increasing the productivity of aluminum castings from a hot chamber die casting machine, as well as a process for increasing the working life of an injection chamber for use in a hot chamber aluminum die casting machine, both of which involve the use of a passivated aluminum alloy in the machine. In the preferred embodiment, the process involves the use of an aluminum alloy which is passivated through the introduction of an amount of TiBr.sub.2, provided in amounts sufficient to retard corrosion of the steel of the hot chamber casting machine.

Abstract: The subject invention relates to a foundry binder system which cures in the presence of a volatile amine curing catalyst comprising (a) an epoxy resin,(b) an organic polyisocyanate, (c) a reactive unsaturated acrylic monomer or polymer, and (d) an oxidizing agent. The foundry binders are used for making foundry mixes. The foundry mixes are used to make foundry shapes which are used to make metal castings.

Abstract: A wear resistant, high-impact iron alloy member (20,22) suitable for use in an impact rock crusher and a method of making the same. The invention provides a white iron alloy member (20,22) having at least one wear surface (24) with carbide granules encapsulated in a matrix (28) of white iron and contained in a selected region adjacent the wear surface (24) of the member (20,22). The iron alloy member is made by a method of casting comprising the steps of: placing a molding insert (35,40) in a mold (60) at a selected location adjacent the wear surface (24); positioning a quantity of carbide granules (29), most preferably tungsten carbide granules 29, in the molding insert (35,40) before pouring; and pouring molten white iron alloy into the mold (60) to form the casting.

Abstract: The surface features of an article are replicated by preparing a master model having a preselected surface feature thereon which is to be replicated, and replicating the preselected surface feature of the master model. The replication is accomplished by providing a piece of a bulk-solidifying amorphous metallic alloy, contacting the piece of the bulk-solidifying amorphous metallic alloy to the surface of the master model at an elevated replication temperature to transfer a negative copy of the preselected surface feature of the master model to the piece, and separating the piece having the negative copy of the preselected surface feature from the master model.

Abstract: A method of improving structural stability of a ceramic core used in the casting of turbine components includes the steps of a) providing a die having a predetermined geometry which gives the ceramic core a shape corresponding to interior spaces in the turbine component; b) inserting elongated strengthening members into interior or more areas of the die corresponding to one or more of the interior spaces; c) injecting a ceramic slurry into the die so as to substantially enclose the strengthening members; and d) firing the ceramic slurry to form a hardened ceramic core. A ceramic core used in a high temperature gas turbine component casting process includes a ceramic body having a geometry corresponding to internal passages of a gas turbine component; and at least one elongated rod or tube incorporated in the ceramic body, the rod or tube comprised of a material which retains structural stability at temperatures in excess of about 2600.degree. F.

Abstract: The invention relates to modified polymeric aromatic isocyanates having allophanate linkages prepared by (a) reacting a polymeric aromatic isocyanate with a monofunctional aliphatic alcohol to form an intermediate modified polymeric isocyanate; and (b) reacting the intermediate modified polymeric isocyanate at an elevated temperature in the presence of a divalent metal catalyst. The invention also relates to foundry binder systems which use these modified polyisocyanates. These modified polyisocyanates, along with a phenolic resole resin, are added to a foundry aggregate to form a foundry mix which is shaped and cured with a gaseous amine curing catalyst by the cold-box process.

Abstract: A consumable billet for melting and casting a metal matrix composite component is made of a consolidated powder metal matrix composite having a titanium or titanium alloy matrix reinforced with particles. The preferred billet is a blended and sintered powder metal composite billet incorporating titanium carbide or titanium boride into a Ti--6Al--4V alloy.

Abstract: A combustible carbonaceous composition and method of making a charcoal briquette wherein a finely divided carbonaceous material is combined with an activated carbon and/or an activated graphite (which may be formed in-situ during pyrolysis of the composition by reacting a humic-containing ore with a low VOC-containing carbon and/or graphite). The combustible carbonaceous composition is present in the briquette composition in an amount of about 65% to about 99.9% by weight; a binder is included in the composition in an amount of about 1% to about 15% by weight when forming a charcoal briquette or an igniter log; and the activated carbon and/or activated graphite is present in an amount of about 0.1% to about 20% by weight. The activated carbon and/or activated graphite absorbs most of the VOCs entitled from the combustible carbonaceous material, thereby preventing the VOCs from escaping to the atmosphere.

Abstract: A titanium aluminide is composed of 31.5 to 33.5 weight % of Al, 1.5 to 2.3 weight % of Fe, 1.5 to 2.1 and 3.7 to 4.8 weight % of Nb, 0.07 to 0.12 weight % of B with remainder being Ti and inevitable impurities. The 1.5-2.0 weight % of Nb may be replaced with 0.5 to 2.0 weight % of V if severe oxidation resistance is not necessary. The titanium aluminide is melted and poured into a mold, and the melt is cooled in the mold naturally.

Abstract: A method of maintaining foundry molding sand and/or a foundry core sand compositions relatively free of benzene and/or total quantity of volatile organic compounds (total VOCs) at 1800.degree. F. and 1 atmosphere pressure by periodically analyzing the sand mold and/or sand core compositions for one or more aromatic hydrocarbons, such as benzene and/or other single ring aromatic hydrocarbons, such as toluene, and/or extractable organic matter (EOMs). If the sand composition is determined by analysis, e.g., by volatilizing the hydrocarbons and passing the volatilized material through a gas chromatograph, or by thermogravimetric analysis, to contain more than a desired amount of aromatic hydrocarbons, e.g., more than about 0.1 mg/g; and/or more than a desired amount of total VOCs, or extractable organic matter (EOM), e.g., more than about 0.5 mg/g total VOCs at 1800.degree. F.

Abstract: An activated carbon and/or activated graphite foundry sand additive, and method of casting molten metal against a foundry sand containing the additive composition. In another embodiment, the activated carbon and/or activated graphite additive (or portion thereof) is formed in-situ by adding to the foundry sand a humic acid-containing and/or a humic acid salt-containing ore (hereinafter referred to separately or in combination as "humic-containing ore") and low VOC-containing (<1 mg/g at 1800.degree. F.) carbon or graphite or admixtures of low VOC-containing carbon and graphite. The combination of low VOC-containing carbon and/or graphite and the humic-containing ore react in-situ when the foundry sand is heated by contact with molten metal, at temperatures of about 450.degree. F. to about 2300.degree. F., particularly in the range of about 600.degree. F. to about 2000.degree. F., to activate the carbon and/or graphite.

Abstract: The height of a layer of material formed by molten metal disposition is measured by ejecting the material as elongate extrusions and measuring the time required for each extrusion to contact the workpiece, then using this time interval along with the speed at which the extrusion is ejected to measure the gap between the ejection head and the workpiece. This gap is then used for calculating the height of the previous layer. By making the workpiece and the ejected material electrically conductive, this time interval can be measured by noting when electric current flows through the extrusion.

Abstract: A casting mold member is produced from a master which has a section with a spirally symmetrical outer contour such that the casting mold member surrounds the section in an azimuthally closed manner with respect to the axis of symmetry. The casting mold member is used to provide a casting mold. The casting mold member is filled by feeding a cast iron melt, and solidifying the melt by using a graphitization pressure to prevent cavities and pores in the casting and by chilling the melt to obtain shell hardening.

Abstract: A method of extruding a boron carbide-aluminum alloy metal matrix composite includes heating the ingots of the composite to temperatures of about 570.degree. C., holding the ingots at about 570.degree. C. to soften the ingots, placing the ingots in a heated extrusion chamber, and extruding the softened ingots at pressures about 15% to 20% higher than typical pressures used to extrude aluminum alloys. A method of casting a boron carbide-aluminum alloy metal matrix composite includes heating ingots of the composite to about 700.degree. C. to melt the ingots, gently stirring the melt, removing dross from the melt, vigorously stirring the melt with an impeller without creating a vortex, degassing the melt with an argon diffuser wand, and continuously removing froth formed during degassing until the rate of froth formation is reduced and the melt gently bubbles.

Abstract: The present invention relates generally to a new apparatus and method for molding metallic materials, such as, for example, solder. More particularly, the invention encompasses an apparatus that is used to form metallic interconnections, such as, for example, solder connections, such as, BGA (Ball Grid Array) or CGA (Column Grid Array) in a mold for later use to electrically or mechanically connect two devices, such as, for example, semiconductor devices. A method for forming the metallic connections that are used to electrically or mechanically connect two devices, such as, for example, semiconductor devices is also disclosed. However, these metallic interconnections in a mold could also be used to form other structures, such as, for example, heat sinks with fins, etc.

Abstract: The present invention is directed to a foundry sand additive composition, and method of casting molten metal against a foundry sand containing the additive composition. The additive composition comprises a humic acid-containing and/or a humic acid salt-containing ore (hereinafter referred to separately or in combination as "humic-containing ore") and carbon or graphite or admixtures of carbon and graphite. The combination of carbon and/or graphite and the humic-containing ore react in-situ when the foundry sand is heated by contact with molten metal, at temperatures of about 450.degree. F. to about 2300.degree. F., particularly in the range of about 600.degree. F. to about 2000.degree. F., to activate the carbon and/or graphite. The carbon and/or graphite, activated in-situ during the molding process, absorb and/or adsorb (sorb) gaseous volatile organic compounds (VOCs) within the mold, so that the VOC gases are held by the in-situ-activated carbon and/or graphite to satisfy VOC emissions requirements.

Abstract: The present invention is directed to an activated carbon and/or activated graphite foundry sand additive, and method of casting molten metal against a foundry sand containing the additive composition. In another embodiment, the activated carbon and/or activated graphite additive (or portion thereof) is formed in-situ by adding to the foundry sand a humic acid-containing and/or a humic acid salt-containing ore (hereinafter referred to separately or in combination as "humic-containing ore") and carbon or graphite or admixtures of carbon and graphite. The combination of carbon and/or graphite and the humic-containing ore react in-situ when the foundry sand is heated by contact with molten metal, at temperatures of about 450.degree. F. to about 2300.degree. F., particularly in the range of about 600.degree. F. to about 2000.degree. F., to activate the carbon and/or graphite.

Abstract: Disclosed is a practical aluminum-based alloy containing 1 to 99 weight percent beryllium and improved methods for the investment casting of net shape aluminum-beryllium alloy parts.

Abstract: Methods of manufacturing fully annealed metal anodes are disclosed. The methods contemplate supplying metal and heating the metal until it has obtained a molten state. The molten metal is permitted to flow into a die and transported therethrough where it is cooled until it solidifies. The flow rate of the metal through the die and the extent of cooling are selected such that a fully annealed metal anode is obtained.

Abstract: A shock tower includes first and second portions for attaching a suspension damper and a control arm to a vehicular body. The first portion includes a cap with a central opening. A plurality of ribs are formed on the cap and radially spaced about the central opening. The second portion projects downwardly from the first portion. A plurality of longitudinal ribs are formed on the second portion. Preferably, the first and second portions are formed as a single casting.

Abstract: The liner cap assembly includes an outer tubular sleeve, an inner cowl and a cone portion extending between the outer sleeve and the inner cowl. The cone portion includes a plurality of annular, concentrically arranged directional vanes on a downstream surface of the cone portion. At least the inner cowl and the cone portion are formed by casting. Plural apertures are formed in the cone portion during casting or after casting.

Abstract: Disclosed are a foamable resin composition which comprises a copolymer with a weight-average molecular weight of 150,000-350,000 produced by copolymerization of a monomer mixture of 55-85% by weight of styrene and 45-15% by weight of a methacrylic acid ester represented by general formula (I)CH.sub.2 .dbd.C(CH.sub.3)COOR (I)(wherein R represents a C.sub.

Abstract: A process for casting an amorphous alloy member comprising the steps of preparing a molten metal from an amorphous alloy composition having a relationship of Tg<Tx between the crystallization temperature Tx and the glass transition temperature Tg, pouring the molten metal into a casting mold, and maintaining the molten metal under a pressed condition until the temperature of the molten metal is brought from a temperature in a molten state to a temperature between the crystallization temperature Tx and approximately the glass transition temperature Tg.

Abstract: Metal ingots are mold cast at a smelter with a solid, unmelted alloy or metallurgical additive body placed in the mold so that the molten metal in the ingot solidifies around the body. The metal and body in the ingot are melted at a foundry to freshly distribute the melted alloy or metallurgical additive material in the body throughout the remelted ingot metal immediately before casting useful articles from the melted ingot.

Abstract: A method of allowing for the identification of artistic shapes by the workpiece purchaser. Casting variable workpieces where the subject matter to be cast is not identified prior to casting.

Abstract: A method of manufacture of a net form product, including directing a stream of liquid from a nozzle onto a collector of the shape of the desired product, applying an amplitude and time dependent modulated disturbance to the stream to produce a droplet stream, and with the nozzle and collector in a chamber, controlling the chamber environment. An apparatus for manufacturing a net form product having a source of molten material under pressure, a support for positioning a product collector in a chamber with the collector defining a desired product, a droplet stream generator positioned within the chamber and including a nozzle, a conduit for conducting molten material from the material source to the generator nozzle, a mechanism, typically a modulator, for amplitude and time dependent modulation disturbance of the droplet stream, and a drive mechanism for relative movement of the nozzle and support.

Abstract: The plate-like valve elements (10 and 20) of the microvalve are provided with a plurality of valve seats and, respectively, corresponding valve members. The sealing surfaces of a secondary valve element (10) are respectively formed by molding to copy the sealing faces of a primary valve element (20) so that the sealing surfaces of both valve elements are completely complementary to each other. The sealing surfaces need no further processing such as machining. Despite liberal tolerances of manufacture a high precision register of the valve elements in relation to each other is ensured.

Abstract: Apparatus for transporting and guiding a portable furnace to transfer molten material from the furnace to a die cast machine includes a platform which supports the furnace. The platform has wheels at one end and fixed legs at the other end. The wheels roll on rails secured to the floor which guide the platform to a predetermined position, and a stop locates the platform in the proper position. The furnace is placed on the platform when the platform is in an aisle adjacent the machine, and the platform is pushed into place by lifting the fixed legs and pushing the platform. After the operation of the machine, the furnace can be removed by pulling the platform into the aisle and lifting the furnace off of the platform. The furnace can then be moved to another platform to transfer molten material to another machine.

Abstract: The present invention concerns essentially a method for moulding a rocker arm for an internal combustion engine and the mould structure for carrying out this method, which mould structure comprises a device for maintainiing a ceramic reinforcing element of the arm of the rocker arm co-operating with the cam of a camshaft and comprising a spindle-forming part disposed on the end of the reinforcing element and a pusher-forming assembly located above the spindle-forminig part to forcibly urge the latter against the reinforcing element.

Abstract: A method and apparatus for manufacturing a composite article by use of a mold core and a cavity block and wherein a skin and insert are placed in the mold cavity and foam precursors are poured into the mold cavity to complete the article includes a process in which a series of part replicas are formed and used to cast thermally stable liners that are carried by the mold core and mold cavity. The thermally stable liners have low melt temperatures and can be reused and recast following wear during the molding process. The liners are made from material which has low shrinkage and expansion rates to define a mold assembly that will produce repeatable parts.

Abstract: The handle is made by casting in a two part mold. The lower mold part includes a vertical split post having two vertical spaced posts with their upper ends in the form of lateral tabs. The upper mold part has a flat wall member cooperating with the lateral tabs.

Abstract: Apparatus for the production of a metal article comprises means for maintaining a reservoir of molten metal with a free surface, means for rotating the free surface of the reservoir about an axis such that the molten metal is atomized and thrown outwardly away from the said surface by centrifugal action, and a substrate in the path of the atomized particles of said molten metal, whereby a solid article may be built up on the substrate by solidifying the atomized particles thereon. The molten metal may be produced by melting an electrode or otherwise.An annular solid metal article is disclosed having excellent mechanical properties. The solid metal article is produced in a single step by a spray deposition process. Molten metal is centrifugally atomized to splat and build up on a cooled mold surface disposed around the centrifuge means. Controlled relative reciprocatory movement in the direction of the rotational axis of the centrifuge is provided.

Abstract: A hypereutectic aluminum-silicon casting alloy having particular use in casting cylinder blocks for marine engines. The alloy is composed by weight of 16% to 19% of silicon, 0.4 to 0.7% magnesium, up to 0.37% copper and the balance aluminum. With the stated silicon content the alloy has good fluidity and the precipitated silicon crystals provide excellent wear resistance. In addition, the alloy has a narrow solidification range of less than 150.degree. F., thereby providing the alloy with excellent castability. The copper content is maintained at a minimum so that the alloy has improved resistance to salt water corrosion.

Abstract: A crucible for melting metals therein to form an active brazing alloy is made of slip cast silica with an yttria lining on the inside surface thereof.

Abstract: A pressure plate for a self-energizing disc brake of the spreading type is provided with angularly spaced integrally cast ears which project inwardly from the inner peripheral edge of the plate, and a recess or dimple is also cast integrally in each ear in the face of the ear adjacent to the braking face. A region of each ear outwardly of the recess or dimple defines an abutment face forming an anchorage for one end of an anchorage portion of a tension return spring with the recess or dimple accommodating the free end of the anchorage portion. In a modification each abutment face may be machined in the respective ear by turning down the ear over an arcuate area passing through the center of the recess or dimple and using the braking face as a datum.

Abstract: A hypereutectic aluminum-silicon casting alloy having particular use in casting cylinder blocks for marine engines. The alloy is composed by weight of 16% to 19% of silicon, 0.4 to 0.7% magnesium, up to 0.37% copper and the balance aluminum. With the stated silicon content the alloy has good fluidity and the precipitated silicon crystals provide excellent wear resistance. In addition, the alloy has a narrow solidification range of less than 150.degree. F., thereby providing the alloy with excellent castability. The copper content is maintained at a minimum so that the alloy has improved resistance to salt water corrosion.

Abstract: A method is set forth for simultaneously preparing a plurality of castings of a solution of an element, or compound, in a solvent, which solvent may also be an element and/or a compound. The solution is saturated at a temperature T.sub.s. A problem in liquid epitaxy growth processes is the simple preparation of growth charges of sufficient reproducible composition and size to produce epitaxial layers of reproducible composition and thickness. The present invention provides a melt consisting of the solvent, of the solvent together with at least one constituent of the solution, or of a solution which is unsaturated at the temperature T.sub.s, which melt is prepared in a boat body of a liquid-tight boat assembly. An equilibrium is established at T.sub.s between the melt and a solid body having an excess of any constituent in which the melt is deficient with respect to the saturated solution so as to form the saturated solution.

Abstract: According to the invention, a silver product which is black-colored in its whole mass is obtained by pouring molten silver into molten sulfur or by heating silver pieces in the presence of sulfur pieces or still by subjecting silver sheets or silver threads to sulfur vapors until complete oxidation of the silver, by converting in powder the oxidized silver and by heating the powder thus obtained preferably in the presence of a flux. The product thus obtained may be used for the manufacture of jewels which comprise at least a portion made of black silver colored in its mass.

Abstract: A process for the preparation of granules of low-melting-point metals which comprises spouting a melt of a low-melting-point metal in the form of fine streams in a gas phase under melt fracture-causing conditions and introducing the fine streams of the molten metal into a collecting liquid phase so that the speed of the molten metal fine streams just above the liquid face is 50 to 300 cm/sec is disclosed. According to this process, granules having a substantially spherical shape and being uniform in the size can be prepared very easily at high efficiency.

Abstract: A mold for casting metals is provided with a roughened surface so that, on first contact of the mold with the melt, heat transfer is controlled in such a way that the melt comes into contact only with the peaks of the projections on the mold surface and an air gap is formed between the melt and the valleys on the surface. The pattern of roughness on the mold surface comprises a uniform arrangement of pyramidal or blunted-cone shaped projections. Neighboring projections are spaced a distance d of 0.05 to 1 mm apart and have a height h of 0.1d<h<d. The pyramid or blunted con surfaces satisfy the condition of 0.05<.function./d.sup.2 <0.5. A process which does not involve deformation is preferred for producing the rough pattern, for example, a photochemical etching process. The molds are suitable for many casting processes, in particular for continuous D.C. ingot or strip casting with moving molds and caterpillar track type mold belts.

Abstract: A method comprising the application of colloidally suspended graphite emulsified in water as a parting agent to hot surfaces and in particular to ladles to facilitate pouring therefrom and the formation of sound castings.

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. The invention comprehends an adapter back-shell for this junction which is a simple solder casting.

Abstract: There is disclosed a method for molding a plate-like cross-structure on a heat pipe or a bundle of heat pipes to serve as a support plate or a baffle. The plate-like cross-structure is formed integrally on the heat pipe within a molding box, in an extremely simplified manner irrespective of the shape of the pipe.

Abstract: An improved reinforcing material for concrete is manufactured by causing molten steel to impinge upon a relatively cold metal surface of great cooling capacity, moving rapidly substantially across the direction of delivery of the molten steel, to form at least one discrete relatively thin flake-shaped layer of molten steel on the metal surface, causing the layer to solidify on said metal surface to form a steel flake, and mutually adjusting the parameters which determine the shape and the dimensions of the steel flakes so as to give the flakes a shape tapering towards the ends of the flake and a thickness of about 0.1 mm to about 0.5 mm, a maximum width of at least about ten times the thickness but at least about 2 mm, and a length of at least about 100 times the thickness.

Abstract: Prevention of fins during a metal casting process is achieved by employing a mold having at least one protuberance along a parting line of the mold and a film of soft plastic covering the mold including the protuberance. When the mold is pressed against another mold the protuberance is held in place by the film of soft plastic. The pattern for forming the mold includes a shielding mold member of a soft plastic film formed over an inversely drafted part along a parting line of the pattern. The mold can also be formed from a pattern having a shielding mold member of a soft plastic film formed over at least one recess in a parting line of the pattern.