Abstract: To prevent, in a cooled ring carrier (1) for pistons, durinh Alfin bonding, the formation of oxides induced by air that escapes due to porous ring carrier material and, as a consequence, an impairment of the ring carrier bond. To this end, the cooled ring carrier, once the ring carrier part and the sheet metal part (3) have been linked, is subjected to negative pressure in a vacuum tank.

Abstract: A casting apparatus comprises a die 2 which contains a molten metal which is poured via an opening section which is disposed above the die, a heater which is disposed above the die, a gas supplying structure for supplying an inert gas to a surface of the molten metal, a lid 6 which is disposed between the surface of the molten metal and the heater, and a lid moving structure for moving the lid to the die relatively so as to control the opening amount of the opening section above the die.

Abstract: This invention relates to foundry binder systems, which will cure in the presence of sulfur dioxide and a free radical initiator, comprising (a) an epoxy resin; (b) an acrylate; (c) an alkyl silicate; and (d) an effective amount of a free radical initiator. The foundry binder systems are used for making foundry mixes. The foundry mixes are used to make foundry shapes (such as cores and molds) which are used to make metal castings, particularly ferrous castings.

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

Abstract: A high-pressure vessel is allowed to be in an initial state, and a first chamber is disposed downward. Copper or copper alloy is placed in the first chamber, and SiC is set in a second chamber. The high-pressure vessel is tightly sealed, and then the inside of the high-pressure vessel is subjected to vacuum suction through a suction pipe. An electric power is applied to a heater to heat and melt the copper or copper alloy in the first chamber. At a stage at which the molten copper in the first chamber arrives at a predetermined temperature, the high-pressure vessel is inverted by 180 degrees to give a state in which SiC is immersed in the molten copper. An impregnating gas is introduced into the high-pressure vessel through a gas inlet pipe to apply a pressure to the inside of the high-pressure vessel. Thus, SiC is impregnated with the molten copper.

Abstract: The invention includes a method of forming a material which comprises at least two elements. More specifically, the method comprises providing an electrolytic cell comprising a cathode, an anode, and an electrolytic solution extending between the cathode and anode. A metallic product is electrolytically formed within the electrolytic cell. The forming of the metallic product comprises primarily electrorefining of a first element of the at least two elements and primarily electrowinning of a second element of the at least two elements. The invention also includes a mixed metal product comprising at least two elements, such as a product comprising tantalum and titanium.

Abstract: Alumina tiles within aluminum framing jigs are fixedly positioned by lock ns within an internally coated mold for centrifugal casting within a block of an aluminum alloy material. Such jigs and the tiles framed therein are coated with silver before casting to prevent aluminum oxidation by heating of the aluminum material to a molten state for deposit into the mold. Bonding of the tiles and framing of the jigs with the aluminum material being cast is also enhanced by such silver coating.

Abstract: The aim is to improve the strength of an intermetallic bond between engine component made from an aluminium alloy and a reinforcing element made from austenitic cast iron. For that purpose, the reinforcing element is annealed in a decarbonising atmosphere before the known prior art alfin process is carried out, in order to obtain an alfin layer largely free of graphite scales.

Abstract: The article is produced by prepositioning nonwoven reinforcement, coated h a bond enhancing compound inside of a centrifugal casting mold that is surface coated for protective shielding of the reinforcement. Molten matrix metal is then introduced into the mold while being rotated about its longitudinal axis until the molten metal completely encapsulates the reinforcement.

Abstract: An interposition layer (12) is formed on the outside surface of a part (10) made of thermostructural composite material containing carbon, and a metal case is formed by casting molten metal (22) around the part provided with its interposition layer. The interposition layer has closed porosity and it is proof against the metal of the case, such that shrinkage of the metal during cooling is absorbed by compacting or collapsing the porosity of the interposition layer, thereby preserving the integrity of the metal case, and the interposition layer constitutes a diffusion barrier preventing eutetics forming by contact between the metal of the case and the composite material.

Abstract: A preformed fiber reinforced metal matrix composite reinforcement insert is clad or covered with a material that is effective to avoid the adverse reactions between the insert/melt and any exposed insert fibers/matrix. The clad insert is suspended in the mold cavity and a melt is introduced into the mold cavity about the clad insert. The melt is solidified about the clad insert to provide a casting of the solidified melt having the clad insert disposed therein to reinforce the casting.

Abstract: Organometallic ceramic precursor binders are used to fabricate shaped bodies by different techniques. Exemplary shape making techniques which utilize hardenable, liquid, organometallic, ceramic precursor binders include the fabrication of negatives of parts to be made (e.g., sand molds and sand cores for metalcasting, etc.), as well as utilizing ceramic precursor binders to make shapes directly (e.g., brake shoes, brake pads, clutch parts, grinding wheels, polymer concrete, refractory patches and liners, etc.). A preferred embodiment of the invention involves the fabrication of preforms used in the formation of composite articles.

Abstract: A solid material is bonded to a metal cast thereagainst by means of a metallurgical diffusion bond. The solid material is coated with a latent exoergic coating which coating reacts exothermically to produce intermetallic phases at the surface of the solid when the metal is cast thereagainst. The heat generated by the intermetallic-phase-formation reaction promotes the diffusion bond.

Abstract: The article is produced by prepositioning nonwoven reinforcement made of a etallic mesh to which ceramic tiles are wired inside of a centrifugal casting mold. Molten matrix metal is then introduced into the mold while being rotated about an axis parallel to the inflow path of the molten metal until it completely encapsulates the reinforcement.

Abstract: A reinforcement made of a composite material is positioned inside of a ceifugal casting mold. Molten matrix metal is then introduced into the mold while being rotated about its longitudinal axis until the molten metal completely encapsulates the reinforcement.

Abstract: A method for metallurgically bonding cylinder liners (12, 12') within a cylinder block 14 of an internal combustion engine. The liners (12, 12') are cleaned (16) and their outer surfaces coated (18) with a low melting point cooling material (20) such as molten zinc forming a metallurgical bond therebetween. The coating (20) is allowed to solidify forming an outer oxidized layer (24) on the coating (20). The oxidized layer (24) is subsequently removed to expose an unoxidized outer surface (26) of the coating (20). The coated liners (12, 12') are then disposed within a casting mold and molten aluminum-based cylinder block material (36) is poured into the mold and about the coated liners (12, 12'). The molten cylinder block material (36) remelts the coating (20) on the liners (12, 12') and causes the coating to further alloy with the cylinder block material (36), whereupon cooling the cylinder liners (12, 12') are metallurgically bonded to the cylinder block (14).

Abstract: A preshaped body of ceramic fibers is placed into a mold and molten aluminum-silicon alloy material is charged into the mold. The pressure is increased in a controlled manner so that the shaped fibrous body is penetrated by the molten material and the final pressure is maintained until the molten material has entirely solidified. To permit the use of a distinctly lower final pressure, the shaped fibrous body before it is placed into the mold is impregnated with an aqueous solution of CuSO.sub.4, dried at a temperature from 60.degree. to 90.degree. C. and heated to a temperature from 500.degree. to 1200.degree. C., preferably 850.degree. to 1000.degree. C., and the molten material is caused to solidify under a final pressure from 10 to 100 bars.

Abstract: An improved process for forming objects such as turbine nozzles (10) with internal geometries without requiring machining of the internal geometry to produce a smooth complex internal surface (16, 18 and 19) is disclosed. The process includes forming a mandrel (30) containing a negative image of the internal geometry; coating the mandrel with a material (32) which is not chemically reactive with the material from which the mandrel is formed, capturing the mandrel in a mold or form (34) which is to receive the material from which the object is to be formed, the material (36) from which the object is to be made not being chemically reactive with the coating; filling the mold or form with the material to capture the mandrel and coating in solidified material contained in the form; and removing the form and the mandrel. If the material is a cast metal, the melting point of the material for forming the object should be below the melting point of the coating on the mandrel.

Abstract: A method of bonding a component in a piston, involves the steps of coating the component surfaces to be bonded with an oxidation-resistant particulate material, preheating the coated component, placing the preheated component in a casting die and then casting an aluminum alloy around the component. The casting technique may comprise squeeze-casting.

Abstract: A method of forming a break ring by providing a frame having a cross-section complementary to the exterior portion of the break ring, and the frame having an interior base of the cross-section of the break ring which will be in contact with the molten metal in the continuous caster is disclosed. The frame is thereafter filled with plasma sprayed boron nitride, silicon nitride, or whatever material is to immediately contact the metal in the horizontal continuous caster. This is subsequently followed by the spraying of a substrate onto the skin of the break ring, whereafter the body portion is finally filled. Detonation gun-type spraying is also contemplated, but a plasma gun forms a superior coating and gives more flexibility. Finally, the body is formed interiorly of the break ring further by plasma application or by casting. In one option, a cooling tube is laid into the body portion.

Abstract: A one-piece open-ended water-cooled continuous casting mold and a method of making it to improve the service life of such mold made up from galvanically precipitated layers of which an inner layer consists of a wear-resistant metal such as nickel and an exterior layer is made particularly from copper. After the mold has been manufactured and while still on the core it may be further improved by application of external pressure.

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: An improved method of manufacturing a swash plate assembly for use in a compressor, fluid motor or similar device in which a plurality of pistons are connected, by means of connecting rods, to a swash plate which drives (or is driven by) the pistons. A plurality of piston and rod assemblies are made by casting the piston around one end of a connecting rod which is formed with a ball at both ends, thus providing a ball-socket connection therebetween. The pistons are finish machined. A die-insert is utilized to locate the ball and rod prior to casting, and is thereafter moved along the rod to contact the other ball end. This insert thus serves to locate the rod section with the affixed piston in a mating socket of a swash plate die. The swash plate is cast about a plurality of such piston bearing rods to a carefully toleranced dimension. The swash plate end of the assembly is then finish machined.

Abstract: The disclosure relates to a process for the fabrication of low cost dual property turbine rotors having blades that are mechanically retained and a blade ring that is permanently bonded to a central hub.

Abstract: An improved method of manufacturing a swash plate assembly for use in a compressor, fluid motor or similar device in which a plurality of pistons are connected, by means of connecting rods, to a swash plate which drives (or is driven by) the pistons. A plurality of piston assemblies are made by casting the piston around one end of a connecting rod section which is formed with a ball thus providing a ball-socket connection therebetween. Mating spherical ends with through-bores to receive the piston connecting rod section are cast-in-place and captured in sockets within the swash plate. The connecting rod section of the pistons is mated to the through-bores of the mating spherical ends and are positioned in an appropriate fixture to a fixed final relationship. The connecting rod sections are secured to the sidewall of each through-bore by a means such as electron-beam welding to secure the overall length of the final assembly.

Abstract: A method of producing suction manifolds for automobile engines. In forming an exhaust gas re-circulating pipe passage integrally with a suction manifold for re-circulating exhaust gases from the engine to the suction manifold, a curved pipe of aluminum having a high-temperature resistant film formed on its surface is molded into a manifold of aluminum alloy at a suitable place on the latter.

Abstract: A finished ceramic airfoil is provided having within it a lining of thermal insulation and a fusible core having the desired contour of the metal core of the turbine blade. A casting mold is provided around the airfoil. The fusible core is melted and removed, leaving a cavity in the airfoil surrounded by the insulation lining. The cavity is filled with molten metal which is allowed to solidify to form the metal core of the turbine blade.

Abstract: The invention relates to fixing a metal strength member on a non-metal part. A heat-resistant fibre glass layer is inserted between the strength member and the non-metal part, the layer extending throughout at least the zone of the non-metal part which corresponds to the point where the molten metal which forms the strength member is injected and being coated with a non-adhering inert inorganic substance so that the layer is thus compressed between the non-metal and the metal part when the metal part is applied against the non-metal part. Application in particular to manufacturing tempered glass electric insulators with moulded aluminium caps.

Abstract: A method of surfacing mill guide rolls 1 in which a metallic powder (6) is deposited on to the surface of the rotatable roll by flame, arc or plasma spraying, fusion welded and then shaped and compacted while in a plastic condition by a roll former 7 rotatable and engageable with the guide roll whereby to impart thereto a surface in conformity with the profile of the former.

Abstract: A piston incorporating a thermal barrier is produced by first making an annular piston ring carrier insert from steel. The insert comprises an annular body to the upper and lower radially-inner edges of which are secured the upper and lower edges of an annular element which is channel shaped in radial cross-section and the channel in which faces radially outward. The element is soldered or welded to the insert body so that an enclosed annular space is defined between the element and body. The insert thus formed is then heated in molten aluminium to "alfinize" its external surface. The treated insert is subsequently placed in a piston mold and the piston is molded about it from aluminium.

Abstract: A method of producing foil in a coil relates to the art of applying coatings under vacuum and can prove to be most advantageous in producing foil from pure metals. The proposed method is characterized in that the foil is obtained by continuous condensation of metallic vapors under vacuum on a layer of antiadhesive, said layer being applied to the surface of a rotating substrata, this resulting in producing a metal layer - the foil, and in forming simultaneously a coil thereof, both said operations: the producing of the foil and forming the coil thereof being effected on one rotating substrata so that each next metal layer is being formed on an antiadhesive layer applied to the preceding metal layer. With the herein-proposed method the produced foil exhibits the same degree of reflectivity from both sides, and it is also possible for a coil to be formed while producing the foil which ensures an adequate quality of said foil.

Abstract: A method of producing layer-like clad metal materials is disclosed. The layer-like clad metal material is produced by applying an organic substance consisting mainly of carbon and hydrogen to the surface of a metallic core material having at its surface substantially no oxide film to form a coating film having a thickness of 50-3,000 .mu.m, placing said core material in a casting mold, pouring a molten metal having the same or different composition around said core material into said mold by a bottom pouring process to form a clad metal ingot, subjecting said ingot to slab rolling or forging to form an intermediate product, and then subjecting said intermediate product to a hot working and, if necessary, a cold working.

Abstract: Method for making a bicast article in which a solid metal preform is positioned in a mold and a molten metal is cast around portions of the preform which are exposed in the mold. In accordance with the present invention, the exposed portions are coated prior to the casting step with a boron containing alloy which is compatible with the preform and with the metal to be cast about it, the boron containing alloy having a melting range below the melting range of either the preform or the cast metal. The alloy also has a major ingredient which is the same as the major ingredient of at least one of the metals to be joined. After solidification of the molten metal in the casting cavity, the resulting bicast article is heat treated at a temperature below the melting range of either the preform or the solidified metal to cause diffusion of boron into the preform and into the solidified metal thereby providing an improved metallurgical bond.

Abstract: The invention relates to a process for forming a part including a bore with a bearing integrally cast thereto, the thus formed part and apparatus for thus forming the part. The process includes hot machining a bore into a billet in a non-oxidizing atmosphere and introducing molten bearing material, e.g., molten bronze about a mandrel positioned in the bore while maintaining the billet, the mandrel and the bearing material in the non-oxidizing atmosphere. The mandrel is drawn from the bore while the bearing material is cooled by cooling and solidifying means therein adjacent an end of the mandrel which is last to exit the bore. The cooling is sufficient to progressively solidify the material as the mandrel is drawn through it and out of the bore.

Abstract: The present invention relates to a method of manufacturing a metal-impregnated body in which a porous body is immersed under sub-atmospheric pressure in a molten alloy for impregnation with said alloy or a porous body is immersed under elevated pressures produced by various gases, the pressure then being reduced to normal level, after which the porous body is introduced together with a molten alloy into a metal mold, in which said molten alloy is impregnated into said porous body. The porous body is then separated from said molten alloy.

Abstract: A composite casting is produced by electrodepositing a wear resistance material onto a core, immersing the core in an aluminium melt and then casting an aluminium alloy around the core, before detaching the latter. The wear resistant layer may be given a roughened surface before immersing in the aluminium melt, by increasing the current density in the later stages of the depositing. The method may be used for casting light metal cylinders for internal combustion engines.