Abstract: A method of forming an electrode includes casting a molten metal in a mould to form an electrode with a header portion and a blade portion. The blade portion of the electrode is then rolled after it has been cast. The blade portion may be rolled into at least two different thicknesses. In one embodiment the metal is lead or lead alloy and the method relates to the forming of a lead or lead alloy anode.

Abstract: A lightweight spray device with spray body that is suitable for precision cast molding, solving general casting problems, such as shrinkage and bubbling; and a process for manufacturing the same. The spray device is one with magnesium spray body provided with a spray part and a handle part, characterized in that the magnesium spray body is one formed with the use of a mold for magnesium spray body wherein a first slide pin is provided at a region where the spray part and the handle part cross each other and wherein around the first slide pin, there is provided a product melt orifice.

Abstract: The present invention provides a steel plate having a low welding crack susceptibility and a yield strength of 800 MPa and a manufacturing method for the same. The steel plate having a low welding crack susceptibility comprises the following chemical components (wt. %: percent by weight): C: 0.03-0.08 wt. %, Si: 0.05-0.70 wt. %, Mn: 1.30-2.20 w.t %, Mo: 0.10-0.30 wt. %, Nb: 0.03-0.10 wt. %, V: 0.03-0.45 wt. %, Ti: 0.002-0.040 wt. %, Al: 0.02-0.04 wt. %, B: 0.0010-0.0020 wt. %, the balance being Fe and unavoidable impurities, and the welding crack susceptibility index meets the following formula: Pcm?0.20%. The thermo-mechanical controlled rolling and cooling processes is used to obtain an ultrafine bainite batten matrix structure, which increases the intensity, plasticity and toughness of the steel plate. The steel plate with a low welding crack susceptibility of the present invention has a yield strength of greater than 800 MPa, a tensile strength of greater than 900 MPa, a Charpy impact energy Akv (?20° C.

Abstract: A method of manufacturing a chassis is provided. The method comprises casting a first segment having a plurality of connected walls such that a window is cast in each of two of the plurality of connected walls in the first segment; casting a second segment having a plurality of connected walls such that a window is cast in each of two of the plurality of connected walls in the second segment; and coupling the first and second segments together to form the chassis having a window in four walls.

Abstract: The present invention generally provides a sputtering target comprising copper and a total of 0.001 wt %˜10 wt % alloying element or elements chosen from the group consisting of Al, Ag, Co, Cr, Ir, Fe, Mo, Ti, Pd, Ru, Ta, Sc, Hf, Zr, V, Nb, Y, and rare earth metals. An exemplary copper sputtering containing 0.5 wt % aluminum has superfine grain size, high thermal stability, and high electromigration resistance, and is able to form films with desired film uniformity, excellent resistance to electromigration and oxidation, and high adhesion to dielectric interlayer. An exemplary copper sputtering containing 12 ppm silver has superfine grain size. This invention also provides methods of manufacturing copper sputtering targets.

Abstract: The article comprises a substrate having a first surface, a plurality of elements extending from the first surface, and a protective coating disposed between at least a portion of the plurality of elements, on at least a portion of the plurality of elements, or both. The plurality of elements are integral with the substrate. A method for applying a protective coating onto an article is also provided.

Abstract: A protective helmet includes an outer shell having a generally dome-shaped section and a brim extending outwardly from the dome-shaped section. The dome-shaped section and the brim are formed from a thermoplastic material. The helmet further includes a brim support in operative connection with at least a portion of the brim. The brim support is formed from a material that is more heat resistant than the thermoplastic material. The brim support is sufficiently rigid to limit deformation of the brim upon exposure to high temperature. The brim support material can, for example, have a melting point above 500° F. A method of limiting high-temperature deformation in a helmet includes molding an outer shell of the helmet to consist essentially of thermoplastic material, the outer shell comprising a generally dome-shaped portion and a brim extending outwardly from the dome-shaped section by at least 2.

Abstract: The present invention relates to a metal matrix composite (MMC) and the method of manufacturing the MMC. The MMC includes a preform formed from a composition having ceramic particles and ceramic fibers. The metal matrix composite also includes a support element formed from a metal where the metal impregnates through the preform. The method of forming the MMC includes the step of extruding the composition through a multi-screw extruder to form an extrudate. The method also includes the step of heating the preform and positioning the preform within a mold. The method further includes the step of heating the metal for forming a molten metal and injecting the molten metal into a cavity of the mold under pressure for infiltrating the preform with the molten metal. The method also includes cooling the molten metal to solidify the molten metal and form the metal matrix composite and removing the metal matrix composite from the mold.

Abstract: A lead-free free-cutting magnesium brass alloy comprises 56.0 to 64.0 wt % Cu, 0.6 to 2.5 wt % Mg, 0.15 to 0.4 wt % P and other elements 0.002 to 0.9 wt % which comprise at least two elements selected from the group consisting of Al, Si, Sb, Sn, Re, Ti and B and the balance being Zn and unavoidable impurities. The process for producing such alloy is also proposed. The invented alloy is excellent in cuttability, castability, hot and cold workability, corrosion resistance, mechanical properties and weldability and particularly applicable in spare parts, forging and castings which need cutting, grinding and electroplating process. The cost of necessary metal materials of the invented alloy is lower than lead-free free-cutting bismuth and antimony brass alloy and is equivalent to lead-contained brass alloy.

Abstract: The invention provides foams of desired cell sizes formed from metal or ceramic materials that coat the surfaces of carbon foams which are subsequently removed. For example, metal is located over a sol-gel foam monolith. The metal is melted to produce a metal/sol-gel composition. The sol-gel foam monolith is removed, leaving a metal foam.

Abstract: In a die-casting mold used in a casting method, a fixed insert includes a recessed cavity portion, and a fixed mold body is arranged to hold the fixed insert. The fixed insert includes a first insert and a second insert. The first insert is held with the fixed mold body. The second insert is fitted and held within a recess formed on the first insert. The size of the second insert is minimized so as to just surround the recessed cavity portion.

Abstract: Endoprostheses including composites, and methods of making the endoprosthesis, are disclosed. The composites include at least a first material and a second material having different chemical compositions from each other.

Abstract: The invention relates to foundry engineering, more specifically to producing an antifriction layer of a plain bearing by casting babbitt into a bearing shell or backing and is applicable to the manufacture and renewal of plain bearings. The invention is aimed at improving the quality of a plain bearing antifriction layer. A method for producing an antifriction layer of a plain bearing including: casting babbitt into a bearing shell or backing and forcedly cooling the babbitt at a speed providing structural uniformity of the antifriction layer, mainly by cooling babbitt on the cast-in layer side, characterized in that said casting of babbitt into a bearing shell or backing produces a semifinished antifriction layer which is subjected to plastic deformation by means of a punch under superplasticity conditions to produce an antifriction layer, the bearing shell or backing being used as a die.

Abstract: The invention relates to the confinement of an alloy formed of actinide transuranic radioactive wastes and beryllium metal within a neutron moderating and reflecting apparatus to cause accelerated destruction (burning) of the actinide wastes. Waste actinides, including plutonium, neptunium, americium, and curium, emit alpha particles by radioactive decay. The alpha particles are converted into neutrons by the beryllium through an alpha-neutron (alpha, n) reaction. The neutrons developed by the alpha, n reaction are moderated by a surrounding layer of graphite, which allows the slowed neutrons to cause additional fission or decay events within the waste actinide alloy. This process is passive because the alpha particles that initiate the actinide burning are an intrinsic physical property of the actinides.

Abstract: A method for operating an automated reciprocator for applying lubricant in a die casting system. As a reciprocator is moved between two die halves and a fluid is applied to the dies with the reciprocator, a safety bar is moved ahead of the reciprocator. Any objects in the path of the reciprocator are detected by contact with the safety bar. If the safety bar contacts an object as the reciprocator is moving down, a sensor signals a control system and the reciprocator is stopped.

Abstract: A method for repairing a metallic hollow body including at least one damaged portion to be repaired in a wall enclosing at least one cavity of the hollow body, the wall being a metallic material, is provided. The method includes the steps of filling a settable filling compound into at least one partial area of the at least one cavity; setting the filling compound; removing a predefined partial surface of the wall in an area of the at least one damaged portion; sealing the wall in an area of the removed partial surface by producing a covering element by welding, soldering, or casting-on; and removing the filling compound.

Abstract: A method for making a turbine airfoil includes: (a) providing a mold having: (i) a core; (ii) an outer shell surrounding the core such that the core and the outer shell cooperatively define a cavity in the shape of an airfoil having at least one outer wall; and (iii) a core support extending from the core to the outer shell through a portion of the cavity that defines the at least one sidewall; (b) introducing molten metal alloy into the cavity and surrounding the core support; (c) solidifying the alloy to form an airfoil casting having at least one outer wall which has at least one core support opening passing therethrough; (d) removing the mold so as to expose the airfoil; and (e) sealing the at least one core support opening in the airfoil with a metal alloy metallurgically bonded to the at least one outer wall.

Abstract: The present disclosure is related to creating blocks of aluminum and/or copper material having embedded TPG elements for forming heatsinks. The metal blocks have an improved thermal conductivity in the X-Y plane. Furthermore, the TPG-embedded heatsinks can be created using methods capable of being performed using various machines and equipment in many various facilities.

Abstract: Substantially austenitic steel having high strength and good formability for cold rolling including (in weight percent): 0.05 to 1.0% C; 11.0 to 14.9% Mn; 1.0 to 5.0% Al; O to 2.5% Ni the remainder being iron and unavoidable impurities, wherein the microstructure includes at least 75% in volume of austenite, and wherein (Ni+Mn) is from 11.0 to 15.9%.

Abstract: A method for predicting and preventing occurrence of shrinkage cavity in an iron casting of any of various shapes or in each part of an iron casting precisely prior to casting. The shape of an iron casting is approximated entirely or partially to a rectangular parallelepiped or a cube, to the sum of the two long sides is divided by the short side to determine a shape coefficient, and occurrence of shrinkage cavity is predicted by determining whether the value exceeds a predetermined value (determination coefficient) or not.

Abstract: The present invention provides a method for manufacturing a clad material and the equipment for manufacturing the clad material, in which the productivity is excellent, the surface state and the flatness of the clad material can be readily controlled and the deterioration in adhesion rarely occurs in the clad material.

Abstract: A housing including a housing portion having a reinforcing rib including a cylindrical cross-section. The rib provides reinforcing for the housing and may simultaneously provide a cooling passage for the housing. A cooling path is defined through the housing by the cylindrical cross-section of the rib.

Abstract: A method of correcting the shape of a brittle cast component such as a low pressure turbine blade. The method includes steps of placing the component against a creep mould having a surface defining the desired profile of the component and HIP treating it to creep deform the component to the desired shape whilst consolidating it and removing gas and shrinkage porosity.

Abstract: A method of producing coil plate on a hot strip mill is disclosed. The method includes coiling hot rolled coil plate strip at a temperature that is selected (a) to minimise precipitation of Cr/Mo carbides or (b) so that any Cr/Mo carbides that form are sufficiently fine that they go into solution in any subsequent heat treatment of coil plate made from the strip.

Abstract: Removing of a casting core from a metal casting leaves at least one opening in a surface of the metal. The opening is filled with a sacrificial material. The metal and sacrificial material are machined at the opening. After the machining, a remainder of the sacrificial material is removed.

Abstract: The present invention provides a sputtering target for a phase change memory and a phase change memory film formed with such a target, and the manufacturing method thereof, characterized in that the sputtering target is composed from elements of not less than a three component system and has as its principal component one or more components selected from stibium, tellurium and selenium, and the compositional deviation in relation to the intended composition is ±1.0 at % or less.

Abstract: A method of fabricating soft copper alloy wire having flexure resistance and heat resistance, includes casting a molten alloy of a copper alloy including 10 mass ppm or less of oxygen, and 0.005 mass % to 0.6 mass % of indium, at a predetermined temperature, to provide a cast bar of the copper alloy having equiaxed crystal, rolling the cast bar of the copper alloy having equiaxed crystal to provide a rolled copper alloy, and conducting a cold drawing and annealing on the rolled copper alloy.

Abstract: A method and apparatus for preparing and delivering various types of carbon and microalloy steel, free of oxygen with abundance of nuclei, when cast producing ultra fine grain steel free of internal defeats with excellent quality. A horizontal sealed table caster has a chamber, containing a suitable atmosphere for casting, with a tube connecting to a tundish so as to allow a liquid to flow into the chamber. The liquid metal is captured on a cooling belt along the bottom of the chamber and is maintained as a specific width and depth. The cooling belt serves as a heat sink causing the liquid metal to solidify from the bottom up, allowing inclusions to migrate to the surface of the steel. A layer of liquid metal is maintained on top of the solidifying steel until the solidification reaches the surface. The belt moves the solid metal toward the exit of the chamber.

Abstract: A cast component having localized areas of improved physical properties is disclosed. The component may initially be produced having a void portion in a predetermined area requiring improved physical properties. A second molten material may be added to the void portion such that it chemically bonds to the void portion. The component may then be finished such to a final shape with a localized area of improved physical properties.

Abstract: A system and method for forming and heat treating metal castings is provided with a vertical heat treatment unit positioned adjacent and downstream from a pouring station at which a series of molds are filled with a molten metal to form the castings. The vertical heat treatment unit includes a vertically oriented furnace chamber in which the castings are received, and which has a reduced footprint to reduce the manufacturing floor space required for the vertical heat treatment unit, and to enable the vertical heat treatment unit to be positioned in close proximity to the pouring station.

Abstract: A method and apparatus for the casting of metal components is disclosed. The apparatus includes a plunger for drawing molten metal from a crucible of hot metal and for forcing the drawn molten metal through the system, a hot runner assembly having a nozzle tip positioned adjacent the mold cavity, and a machine nozzle disposed between the plunger and the hot runner assembly. An adaptive and universal hot runner manifold having removable hot runner injectors fitted thereto is provided for use with a variety of castings.

Abstract: A die casting process using pattern recognition techniques to identify those die castings manufactured under conditions likely to produce a die casting which would subsequently prove unacceptable for use. By promptly identifying such die castings, they may be discarded before being shipped to a remote facility for further processing. As a result, the rejection rate of die castings at the remote facility may be reduced and the raw materials used to form the discarded die castings may be more readily recycled.

Abstract: A composite is formed by inserting a ceramic powder into a channel of a preform to form a ceramic powder filled preform. The ceramic powder has at least one reactive ceramic powder. The preform is a ceramic, ceramic-metal composite, metal or combination thereof that has walls that define a plurality of channels each channel having an opening at a surface of the preform. The ceramic powder filled preform is infiltrated with a molten metal to form the ceramic-metal body, which has at least one ceramic phase that is a reaction product of the reactive ceramic and molten infiltrated metal.

Abstract: A composite material composed of nanocarbon materials and metallic materials for a matrix is extrusion molded to have the nanocarbon materials oriented in one direction.

Abstract: A method for manufacturing cast components, in which method the cast mold and/or macroscopic inserts to be placed either totally or partly inside thereof are left totally or partly as a part of the final component to be used, after the casting the piece is further treated with temperature and/or pressure in order to improve the compactness of both the cast materials and the materials acting as inserts and to improve the bond between the cast material and the solid material attached thereto, and the portion of the solid or partly solid material (inserts) to be placed into the cast mold and remaining in the final component, inclusive the portion of the mold eventually remaining in the final component, of the weight of the total component is more than 3 percent by weight.

Abstract: The present invention provides a manufacturing method of high precision titanium compressor wheel in which by removing pads attached on an entire surface entirely as a machining allowance in manufacturing process, dimensional accuracy at the time of manufacturing is intensified, and correction work of dynamic balance (rotation balance) is simplified or omitted so as to improve yield of products and suppress boosting of manufacturing cost. The outer peripheral face of a front cast boss portion of a cast titanium product is fixed with a chuck of lathe. A plurality of receiving plates projecting from the lathe are positioned between respective cast blades and front ends thereof are pressed against a disc-like large-diameter front end face formed on a rear half portion of a cast core portion. With a large-diameter front end face of the cast core portion and the outer peripheral face of the front cast boss portion as reference plane, the cast titanium product is held by the chuck and receiving plates and rotated.

Abstract: Various systems and apparatuses for processing a metal casting are provided.

Abstract: A method of producing thin foils of uranium or an alloy. The uranium or alloy is cast as a plate or sheet having a thickness less than about 5 mm and thereafter cold rolled in one or more passes at substantially ambient temperatures until the uranium or alloy thereof is in the shape of a foil having a thickness less than about 1.0 mm. The uranium alloy includes one or more of Zr, Nb, Mo, Cr, Fe, Si, Ni, Cu or Al.

Abstract: A method of producing metal fibers including melting a mixture of at least a fiber metal and a matrix metal, cooling the mixture to form a bulk matrix comprising at least a fiber phase and a matrix phase and removing at least a substantial portion of the matrix phase from the fiber phase. Additionally, the method may include deforming the bulk matrix. In certain embodiments, the fiber metal may be at least one of niobium, a niobium alloy, tantalum and a tantalum alloy and the matrix metal may be at least one of copper and a copper alloy. The substantial portion of the matrix phase may be removed, in certain embodiments, by dissolving of the matrix phase in a suitable mineral acid, such as, but not limited to, nitric acid, sulfuric acid, hydrochloric acid and phosphoric acid.

Abstract: A process for the production of thin walled parts of steel, wherein there are layers that are at least partly differently treatable relating to their strength and hardness qualities. This process can include creating a composite material from a plurality of different layers by connecting at least one core layer and at least one surface layer together. At least one layer of the core or surface layer is cast adjacent to another layer to form a composite material having an alloy gradient that is flat at each interface between any of the core layer or the surface layer. Next, the process can include deforming the composite material along a length of these layers. Finally the process can include heat treating the layers to transform the strength and hardness qualities of at least one of these layers.

Abstract: A method and an apparatus for machining a mold material to produce a mold. By casting based on a cast mold model (15), a mold material (20) is produced in a form having a work margin. Thereafter, a shape of the mold material (20) is measured by a measuring device (16), and measurement data and an envelope model (M2) generated based on the measurement data are stored in a storage unit (12A) of a computer (12). Thereafter, a mold model (M1) based on mold design data and an envelope model (M2) are displayed on a display unit (12C), and the envelope model (M2) is linearly moved in direction of three axes X, Y and Z orthogonal to one another respectively and rotated around the three axes to bring a product forming plane (M2B) of the envelope model (M2) into close proximity of a product forming plane (M1B) of the mold model (M1).

Abstract: A method for manufacturing a golf club head includes preparing a golf club head casting by casting, the golf club head casting having a striking face, forging the golf club head casting at least one time and removing cinders in the golf club head casting, thereby forming a golf club head blank, and removing burrs on the golf club head blank. The golf club head casting may be heated before the step of forging.

Abstract: A method and system of processing castings is provided in which one or more castings are deposited into a mobile furnace and moved from one station to another of a multi-station casting processing system. The interior of the mobile furnace is heated so as to maintain the temperature of the casting within a desired range of temperatures. The multi-station casting processing system may include a casting machine, a fluidized bed and a quench tank. The method may include transferring a casting into the mobile furnace and moving the furnace from one station to another.

Abstract: The newly proposed cast aluminum alloy product has the composition consisting of 6.5-8.0% Si, 0.25-0.45% Mg, 0.08-0.40% Fe, 0.001-0.01% Ca, P less than 0.001%, 0.02-0.1% Ti, 0.001-0.01% B, optionally one or two of 0.05-0.3% Cr and 0.05-0.2% Mn, and the balance being Al except inevitable impurities. It has the metallurgical structure that an ?-Al phase in a surface layer is of average grain size different by 50 ?m or less from an ?-Al phase in an inner part, and that a maximum size of eutectic Si particles is 400 ?m or smaller. It is manufactured by injecting a molten aluminum alloy into metal dies at an injection speed of 0.05-0.25 m/second, and then cooling the injected alloy at a cooling speed of 20° C./or higher in a temperature range between liquidus and solidus curves in a state charged with a pressure of 30 MPa or higher. Since the cast product is good of ductility, it is used as a member for coupling another member therewith by calking or the like.

Abstract: An implantable endoluminal device which is fabricated from materials which present a blood or body fluid and tissue contact surface which has controlled heterogeneities in material constitution. An endoluminal stent which is made of a material having controlled heterogeneities in the stent material along the blood flow surface of the stent and the method of fabricating the stent using vacuum deposition methods.

Abstract: A process of manufacturing an automobile component comprises molding a high strength first element of steel at a temperature about 1550° C.; removing dirt from a surface of the first element of steel and increasing a roughness of surface thereof by sand polishing; placing the first element of steel in a mold; casting a low tensile strength second element of iron on the first element of steel in the mold at a temperature about 1200° C.; cooling the mold; initially polishing a surface of the half-finished component; and diffusing a melted copper into gaps between the first element of steel and the second element of iron at a temperature ranged from about 1080° C. to about 1200° C. to produce the finished component.

Abstract: An oven shell and a method of fabricating same includes forming molds which have a plurality of indented troughs spaced from one another for a selected interval on diagonal locations according to preset frame rims and panels. Frame rims and an upper panel, a lower panel, side panels and a rear panel of different dimensions are formed through the forming molds by die casting a metal material. The frame rims and the upper panel, the lower panel and side panels are coupled and assembled according to preset oven shell locations to form the oven shell. By coupling the elements in the diagonal fashion, oven shells of different dimensions and shapes may be made at a reduced cost and assembly is much convenient.

Abstract: A method and system of processing castings is provided in which one or more castings are deposited into a mobile furnace and moved from one station to another of a multi-station casting processing system. The interior of the mobile furnace is heated so as to maintain the temperature of the casting within a desired range of temperatures. The multi-station casting processing system may include a casting machine, a fluidized bed and a quench tank. The method may include transferring a casting into the mobile furnace and moving the furnace from one station to another.

Abstract: A process for the rapid production of hollow components of flow machines, in particular turbine blades, for manufacturing development. In the process, the turbine blade to be produced is divided into two or more portions such that none of the portions has a cavity. The two or more portions are individually cast by means of a Rapid Prototype process, and are then joined together to form the hollow component. The process makes possible the simple and cost-effective production of turbine blades for manufacturing development, in particular for the development of the cooling systems.

Abstract: A process for manufacturing parts made of aluminum cast or aluminum alloy cast in a mold, which includes after casting, removing from the mold the part which constitutes the cast preform while still hot, and placing it between two halves of a die that defines a cavity having dimensions that are slightly less than those of the mold, forcing said two halves together in order to exert a combined in-depth impact forging and surface hardening effect on the casting placed between the two halves. The invention further includes the step of transferring the cast preform prior to the impact forging step at a temperature of about 400 to 500° C. to a furnace that ensures solution heat treatment for the aluminum alloy at its homogenization temperature.