Abstract: A method of making a rotary drill bit comprises forming a hollow mould for moulding at least a portion of the bit body, packing at least a part of the mould with powdered matrix material, and infiltrating the material with a metal alloy in a furnace to form a matrix, the alloy being a copper based alloy containing phosphorus and being selected to provide an infiltration temperature which is not greater than 850.degree. C. and preferably not greater than 750.degree. C.

Abstract: A method of manufacturing a rock bit cone having a substantially conical body on a surface of which a number of teeth are formed is manufactured by pressure-casting with using a casting mold having a molding surface including a cone body defining surface portion and tooth defining surface portions, pouring a molten metal of very hard and low melting point alloy having a melting point of 1040.degree.-1120.degree. C. and Rockwell hardness of 55-65 to the casting mold to centrifugal-cast at least a predetermined area including a tip of each tooth with the hard metal, and pouring a molten tough metal to the casting mold to centrifugal-cast the cone body.

Abstract: A squeeze formed aluminium alloy article, such as a piston, is formed with a re-entrant cavity (14) with reinforced edges by locating an isostatically compacted salt core (10) and annular alumina-silicate fibre pad (11) in the mould cavity of the squeeze forming press prior to introduction of the molten metal therein. The core (10) is subsequently dissolved from the squeeze formed article to provide a reinforced corresponding shape to the article which does not require subsequent machining.

Abstract: Reinforced composite aluminum-matrix articles containing a non-oxide reinforcing material, such as silicon carbide fibers or particles, are produced by a casting process wherein a small amount of lithium less than about 1%, by weight, is included in a melt of aluminum matrix alloy to facilitate wetting of the reinforcing material and ready dispersal thereof in the aluminum matrix alloy.

Abstract: The present invention concerns processes for making composite materials.The process is characterized essentially by the fact that it consists in making a fibrous preform 1, in pre-treating this fibrous preform by a fluorine containing flux 3 and in wetting the said pre-treated preform by a light alloy.Utilization for the making of composite pieces with a fibrous armature such as carbon wet by a light aluminum-based alloy.

Abstract: Reinforced composite magnesium-matrix articles, containing silicon carbide fibers or particles, are produced by a casting process wherein a small amount of lithium, less than about 0.7% by weight, is included in a melt of magnesium matrix alloy to facilitate wetting of the reinforcing material and ready dispersal thereof in the magnesium matrix alloy.

Abstract: A process is described for producing fiber-reinforced light-metal castings in which a loose fiber tangle is placed in a casting mold and is saturated with molten light-metal under low pressure. Subsequently, the excess of molten light-metal is squeezed off while the fiber tangle is compressed. The outflow of the molten light-metal is then stopped with the molten light-metal being solidified under high pressure. The process is especially suitable for utilizing the solution-spun inorganic fiber tangles that up to now had not been especially suitable for the reinforcing of light-metals.

Abstract: A piston is formed in two parts. The main part is formed by gravity die casting from aluminum or aluminum alloy and a second part of the piston is formed by a squeeze casting process to produce a material which is stronger and more resistant than the gravity die cast aluminum or aluminum alloy. At least one piston ring groove is formed in the second part. The two parts are then electron beam welded together to form the complete piston. The squeeze cast portion may be reinforced with whiskers or fibres to further improve its properties. This method of construction has the benefit that only the minimum amount of the piston is formed by the more expensive and time-consuming squeeze casting process so that parts of the piston which do not require the improved properties given by squeeze casting are simply gravity die cast. This is of particular benefit in large diesel pistons.

Abstract: A process of forming a high alloy layer on a surface of an aluminum alloy casting. The process comprises steps of providing a mixture of fine powders having an average powder size finer than 10 microns, preferably finer than 1.0 micron, of an alloying metal or an alloying alloy and an acrylic binder, shaping the mixture into a sheet, heat treating the sheet at 150.degree. to 380.degree. C. for more than 5 minutes, placing the heat treated sheet on a surface of a casting mould or a chilling block, and casting molten aluminum alloy.

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: An elemental lithium-lithium alloy composite anode capable of high current ensity discharge for battery applications.

Abstract: A fiber reinforced metal alloy comprising a metal matrix and a fibrous reinforcement which is constituted by refractory fibers having a high tensile strength. The fiber reinforced metal alloy is manufactured by the use of a centrifugal casting method.

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 method of manufacturing by a powder metallurgy process a rotary drill bit including a bit body having a plurality of cutting elements mounted on the outer surface thereof comprises the steps of forming a hollow mould for moulding at least a portion of the bit body, packing the mould with powdered matrix material, and infiltrating the material with a metal alloy in a furnace to form a matrix. Before packing the mould with powdered matrix material, there are positioned in spaced locations on the interior surface of the mould a plurality of cutting elements, each of which is formed of a material, such as a polycrystalline diamond material, which is thermally stable at the temperature necessary to form the matrix. Also positioned in the mould, adjacent the rearward side of each cutting element, is a support material such that, at least after formation of the matrix, the support material has a higher modulus of elasticity than the matrix.

Abstract: Cast articles of fiber-reinforced aluminum composite excellent in plastic moldability and capable of forming drawn products featuring good mechanical properties, particularly wear resistance, are manufactured by mixing under pressure an inorganic fibrous material prepared in advance in the form of a multiplicity of doughy pills, with an aluminum melt thereby producing a mixed melt and casting this mixed melt in a desired shape.

Abstract: An implanting article which includes a base body composed of a mother material and a surface portion containing dispersed apatite particles. The base body and surface portion are formed in a mold by solidifying the mother material containing apatite particles under centrifugal force. The resulting implanting article has good mechanical properties because the base body scarcely includes apatite particles in addition the article has a good affinity with a live body because the surface portion contains apatite particles densely distributed thereat.

Abstract: A method of producing a fiber-reinforced composite material in which a fiber body is mounted on mounting surfaces in a mold cavity, which mounting surfaces are in fluid communication with the outside of the mold through air relief passages. A molten matrix metal is poured into the mold cavity and then subjected to a high hydrostatic pressure so as to be filled into the fiber body while expelling the air from the fiber body to the outside of the mold through the air relief passages. The molten metal is thereafter filled into the air relief passages and solidifies immediately to seal the mold cavity from the ambient atmosphere whereby the molten matrix in the mold cavity is rapidly solidified under high pressure to form a fiber-reinforced composite material of high quality with inclusion of substantially reduced voids or cavities.

Abstract: A composite material containing dispersed particles is manufactured by disposing within a mold a porous shaped article of ceramic particles, then pouring a molten metal into the mold, compressing the contents of the mold, subsequently allowing the molten metal to solidify, and subjecting the resultant solidified composite to a plasticizing treatment.

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: A process is provided for the production of fibre-reinforced light-metal castings by die casting. A fibre moulding is introduced into an auxiliary mould and the auxiliary mould is heated to an optimum temperature above the melting point of the light metal. The auxiliary mould is then inserted with positive fit into a die casting mould corresponding to the outer contour of the auxiliary mould and filled with light metal under pressure. The fibre moulding can optionally be stabilized by means of a temporary organic binder which decomposes when the auxiliary mould is heated.

Abstract: A method for forming metal base composite use a retainer made of water soluble salt with a high melting point. Molten metal and a reinforcement are compounded in the retainer and then solidified. After solidification the retainer is dissolved away by water.

Abstract: A composite material is manufactured from a formed mass of reinforcing material and matrix metal by introducing the reinforcing material mass into a pressure chamber and holding it there, introducing molten matrix metal into the pressure chamber so as to surround the reinforcing material mass, moving the reinforcing material mass from the pressure chamber into a casting chamber of substantially smaller volume than the pressure chamber while it is still being surrounded by molten matrix metal, and then allowing the molten matrix metal to solidify while applying pressure.

Abstract: A method of producing a machine part of a fiber-reinforced composite material comprising forming a fibrous-shaped body by effecting a partial diffusion-bonding of a plurality of inorganic fibers by copper solder. The fibrous-shaped body is self-supporting and is of relatively high density of the order between 2.0 and 5.0 g/cc. The mechanical part is produced by integrating the fibrous-shaped body with a matrix metal by high pressure solidification.

Abstract: A rotor for a rotary compressor having a metal central portion integral with two opposite end portions that are fiber-reinforced metal matrix composites having a matrix metal common to the central portion. Such rotors may be made by pressing inorganic fibers to form the end portions of the rotor, arranging the end portions in an opposing relationship in a mold to form the central portion between the end portions. Molten metal is placed into the mold such that it infiltrates the porous end portions while forming the central portion. Solidification of the metal forms fiber-reinforced metal-matrix composite end portions integral with the central portion.

Abstract: A method of making a connecting rod for an internal combustion engine which includes shaping a bundle of unidirectional inorganic fibers, placing the bundle into a shaping container and heating it partially in order to fuse the fibers to each other. The partially fused bundle is positioned in a mold in such a manner to produce an extra gap for a predetermined machining allowance between the bundles and cavities. A molten light metal alloy is squeeze cast into the mold under high pressure, i.e., 500-2000 kg/cm.sup.3, forming a matrix annular layer around the bundle. The rod portion of the obtained connecting rod is machined to remove defects in casting, such as a fatigue crack, a blow-hole or mixing of oxidated substances and takes the shape of a circular or elliptical cross-section.

Abstract: The invention provides a method for preparing a SiC whisker-reinforced composite material. A matrix material such as a metal, an alloy or a plastic is introduced into a fibrous base consisting of a SiC whisker sponge-like cake. The resultant structure is compressed into a desired shape as needed. The fibrous base is prepared by heating a mixture of silica gel or ashed rice hulls with a furnace carbon black and an additional amount of NaCl as a space forming agent for forming spaces conducive to whisker growth.

Abstract: First a reinforcing material mass is formed from a quantity of reinforcing material by binding it together with inorganic binder, and then this reinforcing material mass is compounded with matrix metal to form a composite material mass. Then the composite material mass is heated up so that the proportion of the matrix metal thereof which is in the liquid phase is at least 40%, and while still hot it is subjected to a plastic processing process to form the composite material object.

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

Abstract: A method and apparatus for producing a shaped composite article from a matrix material and a reinforcing material is disclosed wherein the composite article has predetermined physical and mechanical properties. As illustrated, the apparatus includes a matrix crucible (18) in which a matrix material is contained. A piston (30) is provided for maintaining and controlling the level of the matrix material (19) in the crucible (18) and for controlling the temperature of the matrix material by means of utilizing either a cooling coil (36) or a heating coil (40). A plurality of capillary tubes (26) are carried in a capillary plug (24) through which the reinforcing material is pulled during the process. Shape forming means includes a shape forming plate (42) having an opening (48) formed therein corresponding to the shape of the object being formed.

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

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

Abstract: A process for providing abrasion and corrosion resistance in the borehole of a steel body comprising placing an alloying material of solid form within the borehole of the steel body, the alloying material having abrasion and corrosion resistance, and thereafter melting the alloying material in a gas heated protective gas oven to effect diffusion bonding of the alloying material with the steel body and the formation of an abrasion and corrosion resistant lining on the steel body. The borehole is of non-circular shape in cross-section and, particularly, of figure 8 shape as shown in FIG. 2.

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

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

Abstract: A process and apparatus for the continuous production of shaped aluminum alloy-particulate composites. The process comprises metering at a substantially constant ratio a particulate solid molten aluminum alloy containing at least 0.10% by weight of magnesium into a mixing station while continuously vigorously agitating to produce a homogeneous mixture, simultaneously discharging from the mixing station a homogeneous mixture of molten aluminum alloy and particulate solid, transferring the mixture to a forming station and shaping and solidifying the composite.

Abstract: A rotary drill bit for drilling wells in earth formations is produced by a casting technique using a plastic foam, combustible casting form. The bit includes a tapered drill body having a plurality of passageways therein which form jets for introducing liquid between the earth and a plurality of selectively arranged, cutting members extending outwardly from the drill body. The combustible form is molded in a shape substantially identical to that of the drill body. The cutting members are mounted on the form in the selective arrangement thereof, and the assembly of the form and cutting members are then coated with a mold material to form a mold body. A cavity is created in the form for receiving a molding mandrel which defines the longitudinal passageway of the completed bit. Molding pins are introduced through the mold body into the mandrel to precisely hold the mandrel relative to the mold body. The cutting members are precisely held by the mold body after the form is removed by combustion.

Abstract: A compound substance of great hardness and toughness, comprising a metal matrix, having embedded therein, hard material granules of a size of 0.1 to 5 mm. The metal matrix comprises 1 to 4% carbon, 0.3 to 0.6% silicon, 0.5 to 1.5% manganese, 0.8 to 2.8% vanadium, 0.5 to 1.5% chromium, 2 to 10% tungsten, about 0.01% aluminum and the remainder, iron.

Abstract: The present invention comprises a process of forming a copper base alloy composite which is reinforced by graphite fibers, wherein the fibers are first coated with a continuous coating of an alloy constituent and then continuously coated with a coating of copper or a copper base alloy. The coated fibers are then heated in a vacuum under applied load, in combination with copper or a copper base alloy at a temperature above the melting point of the copper or copper base alloy but below the melting point of the alloy to be formed from the copper or copper base alloy and the alloy constituent with which said graphite fiber has first been coated.

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

Abstract: Apparatus for and method of die casting a part with a particulate inert filler material (e.g., sand) substantially uniformly dispersed through the casting thereby to decrease the amount of metal required to die cast the part.

Abstract: Disclosed in this specification is a method for casting, in which a shaped body of an inorganic fiber material is fixedly secured on a chill member, then the chill member together with the shaped body of inorganic fiber is incorporated in a predetermined part of a cast article through a fiber-reinforced composite layer to be brought about at the time of casting under high pressure solidification casting techniques.

Abstract: Lightweight filament reinforced composite metal matrix structures is provided. The preferred process for producing tubing comprises wrapping alternate layers of metal and filament material to be molded around a mandrel. The mandrel is removed and in its place a test tube-shaped hollow glass cylinder is inserted. The wrapped cylinder is next placed in a cylindrical shaped mold and the entire assembly placed in an oven which is capable of heating the unit to the liquidus temperature of the metal matrix. The glass, which is of a type which softens at about the melting point of the matrix material, is pressurized to a medium high pressure. Under the influence of this pressure, the glass expands, forcing the composite metal matrix against the interior surface of the mold. The consolidated tubing is then cooled to a completely solidified state and removed from the mold.

Abstract: Lead-coated alumina fibers which are obtained by reduction of lead oxide in a glass coating on alumina fibers are particularly useful for making strong lead matrix composites.

Abstract: A process for producing fiber-reinforced magnesium alloy materials with improved mechanical properties which includes the steps of placing a shaped article of silicon carbide whiskers or silica type, alumina type or silica-alumina type fibers in a casting mold, and pouring into the mold a molten matrix of a magnesium alloy at a temperature lower than 800.degree. C. The shaped article is impregnated with the molten matrix by means of a high pressure coagulation casting method while maintaining the original configuration of the shaped article to form a composite. A magnesium-silicon compound and/or a magnesium-aluminum compound are precipitated in the matrix at the filling and composite-forming step by reaction between the surface fibers of the shaped article and the molten matrix. The whiskers or fibers may be covered by a film of copper, nickel or silver to vary the amount of the precipitated compounds.

Abstract: Strips of amorphous metal containing embedded particulate matter and method for making it. Strips of amorphous metal containing embedded particles of abrasive material are useful for working the surfaces of solid articles by abrasion for forming or surface improvement. The method of making such strips involves forcing molten metal of a glass-forming alloy containing admixed particulate matter onto the surface of a moving chill body under pressure through a slotted nozzle located in close proximity to the surface of the chill body.

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

Abstract: A heat-insulating layer secured to a cast metal member of an internal combustion engine so as to be exposed to combustion gas in the engine. A porous or intersticed metal body, preferably having a soft structure, is used as a fundamental material of this layer. A surface portion of the porous metal body is impregnated with a ceramic material, and then the metal body is cast-inserted into the metal member such that the molten metal infiltrates into another surface portion of the porous metal body and that the ceramic-impregnated portion is exposed to combustion gas in the engine. This heat-insulating layer is excellent in toughness, durability and bonding strength and can be embodied in a combustion chamber wall, exhaust port wall or a top portion of a piston.

Abstract: A composite material of aluminum or an aluminum alloy, reinforced with a fiber or whisker form of unmodified alumina. The material is produced by preheating a mould and a mat of unmodified alumina to a temperature in the range of 700.degree. C. to 1050.degree. C. Molten aluminum or its alloy free of elements which react with the alumina are introduced into the mould to cover the mat. A pressure of at least 75 Kg/cm.sup.2 is applied to the contents of the mould to overcome the surface tension between the alumina and the molten mass of metal and to cause the molten mass to fully penetrate the alumina mat. Upon solidification of the molten aluminum, the composite material is obtained.

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