Abstract: A plumbing part is made from a permanent core and a body cast around the core. The core is formed of a material which meets the requirements as to the permitted leachability of lead and/or other undesirable materials from the core into water flowing through it. The core material has a melting point preferably at least 200.degree. F. above that of the cast body. The core also has a coefficient of expansion which is equal to or less than that of the material forming the cast body.

Abstract: A method of fabricating a metal matrix composite containing electrically isolated areas and the MMC formed from the method. The method comprises: (a) providing a liquid pool of unreinforced aluminum alloy; (b) infiltrating the unreinforced aluminum alloy into a stack comprising upper and lower porous preforms and an electrical insulator material placed between the preforms; (c) solidifying the liquid-phase metal to form a metal matrix composite product that completely surrounds the stack; and (d) forming at least one groove in the solidified metal, the groove extending downward to at least one insulating substrate so as to electrically isolate at least one region on the surface of the metal matrix composite.

Abstract: A method is provided for producing by centrifugal casting an alloy tubular article of manufacture in the form of a composite tubular product comprised of an outer alloy layer (first alloy) and at least one inner alloy layer (second alloy) while substantially inhibiting the formation of a metallurgical bond between layers in the final casting. The product is produced using a rotatable centrifugal casting mold having a cylindrical inner surface adapted to receive a molten metal alloy. A first layer of an alloy is poured into the rotatable mold, the alloy having a melting point of at least about 1300.degree. C. and generally at least about 1400.degree. C. Centrifugally casting said alloy as an outer layer during rotation of said mold. The outer layer is solidified and cooled to a temperature not exceeding about 92% of its absolute melting point in degrees Kelvin. At least one inner layer is poured into the outer layer, the alloy of the inner having a melting point of at least about 1300.degree. C.

Abstract: The present invention is an apparatus and method for an improved actuator arm assembly in a disc drive. The improvement arises by casting a steel sleeve into the actuator arm to define a pivot bore. A steel bearing and shaft assembly cooperates with the pivot bore to enable the actuator arm to rotate about the shaft. This all steel arrangement minimizes the bearing preload necessary to create a stable actuator arm assembly having a minimum amount of friction in the bearing system.

Abstract: The present invention relates to the use of a gating means in combination with a spontaneous infiltration process to produce a metal matrix composite body. Particularly, a permeable mass of filler material or a preform is spontaneously infiltrated by molten matrix metal to form a metal matrix composite body. A gating means is provided which controls or limits the areal contact between molten matrix metal and the filler material or preform. The use of a gating means provides for control of the amount of matrix metal which can contact the preform or filler material, which may result in less machining of a formed metal matrix composite body compared with a similar metal matrix composite body made without a gating mean. Moreover, the use of a gating means ameliorates the tendency of a formed metal matrix composite body to warp due to the contact between the formed composite body and matrix metal carcass.

Abstract: The design and construction of past port liners with heat insulation capabilities have had to become more simple in order to reduce costs. However, less costly exhaust port liners may have inferior heat insulation capabilities. Additionally, port liners cast into a cylinder head of an internal combustion diesel engine must endure the stresses associated with the high casting temperatures of cast iron. The present invention overcomes these and other problems by utilizing a ceramic port liner containing a low temperature softening phase. The ceramic port liner is surrounded by a blanket formed when a fiberglass cloth encapsulates an insulating layer of material. The ceramic port liner and surrounding blanket are cast within a cylinder head. During the casting process, the ceramic port liner remains in a softened state. As the casting cools, the ceramic port liner returns to a regular solid state at a progressively sufficient thermal rate to protect it from damage.

Abstract: The present invention relates to the formation of bodies having graded properties. Particularly, the invention provides a method for forming a metal matrix composite body having graded properties. The graded properties are achieved by, for example, locating differing amounts of filler material in different portions of a formed body and/or locating different compositions of filler material in different portions of a formed body and/or locating different sizes of filler materials in different portions of a formed body. In addition, the invention provides for the formation of macrocomposite bodies wherein, for example, an excess of matrix metal can be integrally bonded or attached to a graded metal matrix composite portion of a macrocomposite body. Moreover, if desired, it is possible to produce a metal matrix composite body with substantially the same properties throughout.

Abstract: A method of forming a cast orthopaedic implant having a porous surface layer is disclosed. The method includes placing a porous layer on a wax replica of the implant such that a portion of the pores of the layer are filled with the wax material. The wax replica and porous surface layer are coated by a ceramic material consistent with investment casting technology. The ceramic material fills the remainder of the pores of the porous layer. After the ceramic material is solidified, the wax material is melted away leaving a cavity within the ceramic material. The pores once filled by wax are now exposed and extend into the cavity. A molten metal is poured into the cavity and partially melts the exposed porous layer to form a melt bond with the molten metal. When the metal is cooled, the ceramic material is stripped away exposing the portion of the porous layer previously filled with the ceramic medium.

Abstract: A heat dissipation apparatus having a base structure (11) and fins (29, 43) and a method for making the heat dissipation apparatus. The base structure (11) is formed as a molded porous preform structure having a top surface (12), a bottom surface (13), and grooves (14) in the bottom surface (13). A layer of dielectric material (17) is placed on the top surface (12) and the porous base structure is infiltrated with a conductive material, thereby bonding the layer of dielectric material (17) to the base structure (11). The grooves (14) are coated with a conductive epoxy and the fins (29) are inserted into the grooves (14) to form a heat dissipation apparatus (30). Alternatively, the fins (43) are formed when the porous base structure is infiltrated with the conductive material, thereby forming a unitary heat dissipation apparatus (44).

Abstract: The present invention relates to a novel method for forming metal matrix composite bodies. Particularly, a permeable mass of filler material is formed into a preform. An infiltration enhancer and/or an infiltration enhancer precursor and/or an infiltrating atmosphere are also in communication with the preform, at least at some point during the process, which permits molten matrix metal to spontaneously infiltrate the preform when the preform is placed into the molten matrix metal. A means for maintaining the preform at least partially below the surface of the molten matrix metal can also be utilized.

Abstract: The present invention relates to a novel method for forming metal matrix composite bodies. Particularly, a permeable mass of filler material is formed into a preform. The preform material can then be placed onto the surface of or into a matrix metal alloy, whereupon the matrix metal alloy spontaneously infiltrates the preform. After substantial complete infiltration of the preform, the preform begins to at least partially sink into the matrix metal alloy supply. The depth to which the preform may sink into the molten matrix metal alloy is controlled by utilizing a support means. The support means prevents the preform being infiltrated from submerging completely beneath the surface of the matrix metal alloy supply. The matrix metal which has infiltrated the preform is then allowed to cool, thus forming a metal matrix composite body.

Abstract: The present invention relates to a novel process for forming thin metal matrix composite bodies. Particularly, an infiltration enhancer and/or an infiltrating atmosphere are in communication with a filler material or preform, at least, at some point during the process, which permits molten matrix metal to spontaneously infiltrate the filler material or preform. Such spontaneous infiltration occurs without the application of any pressure or vacuum. In an embodiment of the present invention, the filler material may be sprayed upon a thin sheet of matrix metal. Alternatively, the filler material may be shaped via tape casting, slip casting, etc. to provide a thin preform. In another embodiment of the present invention, a body of matrix metal may be coated with a filler material such that upon spontaneous infiltration a metal matrix composite body is produced which inversely replicates the configuration of the original body of matrix metal.

Abstract: The present invention relates to the formation of a macrocomposite body for use as an electronic package or container. The macrocomposite body is formed by spontaneously infiltrating a permeable mass of filler material or a preform with molten matrix metal and bonding the spontaneously infiltrated material to at least one second material such as a ceramic or ceramic containing body or a metal or metal containing body. Moreover, prior to infiltration, the filler material or preform is placed into contact with at least a portion of a second material such that after infiltration of the filler material or preform by molten matrix metal, the infiltrated material is bonded to said second material, thereby forming a macrocomposite body. The macrocomposite body may then be coated by techniques according to the present invention to enhance its performance or bonding capabilities.

Abstract: A method for producing composite materials by forming one material in a die cavity such that another material can be forced into the same die cavity and infiltrate the spaces in the first material. A method for producing a composite comprising the steps of injecting reinforcement material in a binder or suspension into a die cavity; burning off or removing the binder or suspension such that the reinforcement material remains in the die cavity; injecting liquid metal into the same die cavity such that it infiltrates the reinforcement material; solidifying the liquid metal; and removing the metal infiltrated composite material from the die cavity. An apparatus comprised of a die and a die cavity disposed inside the die. The apparatus is also comprised of a first port extending from the die cavity to the surface of the die through which reinforcement material in a binder is injected into a die cavity.

Abstract: A "lost foam" method of making a casting having a preform embedded at a selective location therein including the steps of: engulfing a porous preform in a fugitive pattern; embedding the pattern in a loose sand mold in a vessel; pouring molten metal into the mold cavity via a sprue and runner system formed in the sand bed so as to destroy the pattern and fill the mold cavity with metal; pressurizing the vessel to force molten metal from the cavity into the porous preform; replacing metal lost from the cavity with make-up metal from the sprue and runner system; allowing the casting to solidify; and removing the casting from the sand bed.

Abstract: The present invention relates to modifying the properties of a metal matrix composite body by a post formation process treatment and/or a substantially contiguous modification treatment. The post formation process treatment may be applicable to a variety of metal matrix composite bodies produced by various techniques, and is particularly applicable to modifying the properties of a metal matrix composite body produced by a spontaneous infiltration technique. The substantially contiguous modification process may also be used primarily in conjunction with metal matrix composite bodies produced according to a spontaneous infiltration technique. Particularly, at least a portion of the matrix metal of the metal matrix composite body and/or the filler material of the metal matrix composite body is modified or altered during and/or after the formation process.

Abstract: Metal-matrix composites and methods for producing these composites are provided. The manufacturing methods include providing a ceramic preform having a uniform distribution of ceramic particles sintered to one another. The particles include an average particle size of no greater than about 3 microns, and at least one half of the volume of the preform is occupied by porosity. The preform is then disposed into a mold and contacted by molten metal. The molten metal is then forced into the pores of the preform and permitted to solidify to form a solid metal-matrix composite. This composite is machinable with a high-speed steel (HSS) bit for greater than about 1 minute without excessive wear occurring to the bit. This invention preferably employs metal-matrixes including Al, Li, Be, Pb, He, Au, Sn, Mg, Ti, Cu, and Zn. Preferred ceramics include oxides, borides, nitrides, carbides, carbon, or a mixture thereof. Inert gas pressures of less than about 3,000 psi can be used to easily infiltrate the preforms.

Abstract: A process for forming pressure cast alumina tile reinforced aluminum alloy rmor in which a silver coated aluminum disc is first inserted into a mold assembly, the mold assembly includes a base plate, a hollow steel die with a removable steel liner located on the base plate, a plug disposed on the base plate within the die cavity, and a punch movably disposed within the die cavity, the aluminum disc being inserted within the die cavity over the plug. Next, an alumina tile preform is prepared by cutting a plurality of alumina tiles and weaving the tiles together with a stiff steel wire. The alumina tile preform is inserted over the silver coated aluminum disc in the cavity of mold assembly. The steel die, the plug and the disc are heated. The punch is also heated separately. A melt of molten aluminum is prepared and poured into the die cavity, completely covering the alumina tile preform. The heated punch is immediately driven into the cavity to apply pressure to the molten aluminum.

Abstract: The present invention relates to a novel process for forming metal matrix composite bodies by using a barrier material. Particularly, an infiltration enhancer or an infiltration enhancer precursor or an infiltrating atmosphere are in communication with a filler material or a preform, at least at some point during the process, which permits molten matrix metal to spontaneously infiltrate the filler material or preform up to the barrier material. Such spontaneous infiltration occurs without the requirement for the application of any pressure or vacuum. Accordingly, shaped metal matrix composite bodies can be produced having superior surface finish.

Abstract: A method to at least partially impregnate a porous ceramic body with a metal comprising positioning a sacrificial porous ceramic transport means in physical contact with the metal and between the porous ceramic body to be impregnated and the metal; interposing a sufficient amount of a ceramic powder in contacting relationship between the ceramic body and the transport means to enable the metal to flow from the ceramic transport means to the ceramic body and insufficient to permit metal bonding between the transport means and the ceramic body, at least one constituent of the powder being wettable by, and chemically reactive with the metal; and maintaining at least the ceramic body and metal transport means at a temperature, and for a time, sufficient for at least a portion of the metal to flow through the transport means and into the ceramic body to impregnate the ceramic body a predetermined amount to form a metal impregnated ceramic body of near net shape.

Abstract: The present invention relates to a novel process for making a macrocomposite body. Specifically, a metal matrix composite body is first formed and thereafter, a ceramic body or a ceramic matrix composite body is caused to form from at least one surface of the already formed metal matrix composite body. The ceramic or ceramic composite body can be formed by, for example, changing from spontaneous infiltration conditions which permit a molten matrix metal to infiltrate a filler material or preform to conditions which favor the growth of a ceramic oxidation reaction product from the matrix metal (e.g., the matrix metal serves the dual role of a matrix metal and a parent metal for growth of oxidation reaction product). The growth of oxidation reaction product can occur from one or more surfaces of a metal matrix composite body and can be controlled to result in any desired shape.

Abstract: A potassium hexatitanate whisker having a tunnel structure containing aluminum and niobium impurities in such amounts that Al.sub.2 O.sub.3 /Nb.sub.2 O.sub.3 molar ratio is 0.6 or higher and composite materials using the same. Also disclosed are processes for producing composite materials using the potassium hexatitanate whiskers having a tunnel structure with a light alloy or a thermoplastic resin.

Abstract: A hermetic compressor assembly is disclosed including a motor compressor disposed within a hermetically sealed housing, wherein the housing has an oil sump in the bottom thereof from which oil is drawn to lubricate the compressor mechanism. An electric drive motor includes a vertical rotor having a lower axial end ring with rotor counterweight die cast therein, whereby turbulence and resulting agitation of the oil in the oil sump is prevented during rotation of the rotor. By die casting the counterweight within the end ring additional attachment parts and manufacturing steps are eliminated.

Abstract: The present invention relates to a novel process for forming metal matrix composite bodies. Specifically, a metal which typically would not exhibit spontaneous infiltration properties under a given set of processing conditions can be induced to infiltrate a filler material or preform when combined or contacted with a matrix metal which does exhibit spontaneous infiltration properties. Stated more particularly, when an infiltration enhancer and/or an infiltration enhancer precursor and/or an infiltrating atmosphere are in communication with a filler material or a preform, at least at some point during the process, and a metal which, under the process conditions, ordinarily would not exhibit spontaneous infiltration, is combined with (e.g., alloyed, mixed with and/or exposed to) a matrix metal which does exhibit spontaneous infiltration behavior under the same processing conditions, the combination of metals will spontaneously infiltrate the filler material or preform.

Abstract: A cylinder block has a cylinder block body and a cylinder liner block mounted by casting in the cylinder block body. The cylinder liner block is formed from a material having a rigidity larger than that of the cylinder block body, and the cylinder liner block comprises a liner section mounted by casting in position in a cylinder barrel portion of the cylinder block body, and a reinforcing wall section mounted by casting in position in a bearing wall of a crank case portion of the cylinder block body. Thus, it is possible to increase the wear resistance of cylinders in the cylinder block, as well as to provide an increase in performance by reductions in vibration and noise of the engine including the cylinder block, and to provide reductions in size, weight and cost of the cylinder block by a reduction in thickness of the bearing walls.

Abstract: The present invention relates to the formation of a metal matrix composite body by a spontaneous infiltration technique. Particularly, an infiltration enhancer and/or infiltration enhancer precursor can be positioned at least partially between or at an interface between a matrix metal and a filler material (or preform) which is to be infiltrated by molten matrix metal. Moreover, at least at some point during the process, an infiltrating atmosphere may be in communication with the filler material or preform and/or matrix metal.

Abstract: Method for hardfacing of parts of the edges of a chainsaw guide bar, where the chain is guided by a groove, where a wear-resistant alloy is applied in a molten state to parts of the edges (12,13) of a guide bar blank and solidified in nearly final configuration, comprising the steps of:making a guide bar blank (10) having edges located at greater distance from the groove bottom (18) along the sides (17) which are not to be hardfaced than in those parts (12,13) which are to be hardfaced, andapplying a mold (15) with an extending plate (14) against the blank with the edge (23) of the plate in contact with the groove bottom (18), andfilling the space between the wall (19) of the mold and the edges (12,13) of the blank with a paste (16) made from finely powderized hardfacing alloy and a liquid, andheating the paste (16) locally to melt the alloy.

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 light weight cast metal wheel having a disk-shaped wheel disk formed across an annular wheel rim and including a reinforcing layer of a metal matrix composite extending radially across the wheel disk. The reinforcing layer also can extend axially across a portion of the wheel rim. The metal matrix composite layer is formed by securing a preform formed from a reinforcing material within the wheel mold prior to casting the wheel. The use of a preform assures that the resulting reinforcing layer is uniform.

Abstract: Apparatus and methods for hermetically sealing materials that cannot be satisfactorily sealed directly to one another using conventional techniques are disclosed. A laminar sheet material having adjacent bonded dissimilar metallic layers is interposed between elements being sealed. One of the metallic layers bonds metallurgically to one of the elements, while the other metallic layer is hermetically sealed to the other element using conventional techniques such as welding. The methods and apparatus of the present inventions are especially suitable for hermetically sealing metal matrix composite electronics packages.

Abstract: Metal heated to a molten state is injected under a high hydrostatic penetion pressure into extremely small and closely spaced channels of an insulating matrix to form an array of electrically conductive pins or wires. The materials for the pins and matrix are selected for compatibility with respect to melting, matrix sintering and surface tension penetration conditions associated with the fabrication of a high density charge transfer device.

Abstract: A method for producing a composite having graphite fibers in a matrix of copper/copper alloy. The graphite fibers are coated with a refractory metal which both protects the graphite fibers from the molten copper/copper alloy while also acting as a wetting agent on the graphite fibers for intimate infiltration by the molten copper/copper alloy. The coated graphite fibers are prepared in a structure and placed against a copper/copper alloy element which is melted to produce the molten copper/copper alloy. The infiltration of the graphite fiber structure with the molten copper/copper alloy is characterized by the absence of pressure on the molten copper/copper alloy.

Abstract: The thin film electrode is prepared by first forming a bath of a molten lithium material in a vessel. The molten lithium containing material is selected among lithium, a lithium alloy and lithium containing compounds. A substrate is coated with a thin layer of the molten material by transporting the substrate below the vessel where it contacts the molten lithium material.

Abstract: A piston assembly (10) for use in an engine. The piston assembly (10) includes a piston body (12) with a liner (24) covering the interior surface (22) thereof. The liner (24) imbues added strength and dimensional stability during casting, machining, engine assembly, and in service. At the same time, piston weight for a given volume is reduced without sacrificing strength. The invention also includes a method for manufacturing the piston assembly (10).

Abstract: A metal matrix composite consisting of aluminum silicon alloy reinforced with graphite fibers exhibits improved mechanical and physical properties when the graphite fibers are subjected to external cooling.

Abstract: A metal wood golf club head with a hollow body shell of a first lightweight material and a sole plate of a second material having a higher specific weight density than the first material. The sole plate is attached to the shell without welding, fasteners or force-fitting. The center of gravity of the head is lowered, and other weight distributions can be achieved by alternate sole plate configurations, such as heel, toe or rear weighting. The head is fabricated by a process which includes the steps of providing the sole plate of the second material, disposing a core adjacent the interior surface of the sole plate, disposing an exterior mold about the core so that the exterior mold, the core and sole plate collectively define a mold cavity in the form of the body shell, filling the cavity with the second material in a fluid state, and permitting the second material to solidify. Upon solidification, the second material locks onto the sole plate, fixing the sole plate in position.

Abstract: A method for manufacturing a structural component includes forming a groove in an outer surface of a fiber reinforced body. Molten metal is introduced to an exposed surface of the groove and to a predetermined portion of the outer surface of the body. The metal is cooled in a controlled manner to thermally alter sufficient resin to create a secure interconnection of the metal on the body. The metal adjacent the groove is sized so that it will fail prior to separation of the metal from the body under excessive tensile loads. A portion of the metal remains on the body so that elongation of the component significantly exceeds ultimate elongation of the fiber reinforced body and the cast metal.

Abstract: A two-step two-piece high-pressure casting process for the fabrication of a scroll member containing a generally circular end plate, a scroll hub on one side of the end plate and an involute wrap on the other side thereof. The involute wrap is pre-fabricated from a wear-resistant alloy or aluminum alloy based composite having low liquidus temperature which is placed inside the involute groove of a scroll mold. The scroll mold contains a mobile scroll mold and a stationary scroll mold. The mobile scroll mold contains a first cavity having the shape of the scroll hub; whereas the stationary scroll mold contains a second cavity having the shape of the circular end plate and an involute groove disposed below the second cavity.

Abstract: A method for manufacturing a structural component includes forming a groove in an outer surface of a fiber reinforced body. Molten metal is introduced to an exposed surface of the groove and to a predetermined portion of the outer surface of the body. The metal is cooled in a controlled manner to thermally alter sufficient resin to create a secure interconnection of the metal on the body. The metal adjacent the groove is sized so that it will fail prior to separation of the metal from the body under excessive tensile loads. A portion of the metal remains on the body so that elongation of the component significantly exceeds ultimate elongation of the fiber reinforced body and the cast metal.

Abstract: A method for casting a housing and insert assembly including a housing and a cast-in-place insert. The casting method comprises the steps of providing a prefabricated insert, surrounding the insert with an evaporable foam pattern to form a pattern and insert assembly, and utilizing the pattern and insert assembly in a lost foam casting process wherein the pattern is replaced by a material to form the housing and insert assembly.

Abstract: This invention relates generally to a novel method of preparing self-supporting bodies, and novel products made thereby. In its more specific aspects, this invention relates to a method for producing self-supporting bodies comprising one or more boron-containing compounds (e.g., a boride or a boride and a carbide, etc.) by reactive infiltration of molten parent metal into a preform comprising boron carbide or a boron donor material combined with a carbon donor material and, optionally, one or more inert fillers, to form the body. Specifically, a boron carbide material or combination of a boron donor material and a carbon donor material, and in either case, optionally, one or more inert fillers, are sedimentation cast, spray coated, tapped, slip cast, pressed, etc., onto or into a body and into a particular desired shape.

Abstract: A method for preparing an engine block casting having integral cylinder bore liners (10). A barrel slab core (14) includes barrel cores (18). Bore liners (10) surround the barrel cores (18) and are fixed in relation to the barrel slab core (14). A cylinder block mold core package (22) is assembled from the barrel slab core (14), and other cores (24, 26, 28). The liners (10) are heated while they are within the cylinder block mold core package (22) by induction heating. Access holes (30) are defined within the barrel slab core (14), each access hole (30) communicating with the interior of one barrel core (18). A heater (32) is inserted through each access hole (30). Thermal energy is thus transferred across the barrel core (18) to the cylinder bore liner (10) to assure optimum integrity of bonding between a solidified cylinder block casting and the cylinder bore liners (10). The heaters (32) are then retracted before adding the molten metal.

Abstract: An improved two membered substantially crack-free water jet mixing tube of an abrasive water jet cutting device and a method of its preparation. The method comprises chemically vapor depositing diamond layer on a funnel shaped support member to form an inner member of the mixing tube, separating the inner member from the support member, depositing and then cooling an outer member on the outer side of the inner member to produce a compressive stress on the inner member that substantially prevents formation cracks on the inner member. The inner side of the inner member has a smooth bore having a microcrystalline structure and the outer member has a higher coefficient of thermal expansion than diamond. The invention is also directed to a water jet cutting device that incorporates the aforementioned improved substantially crack-free water jet mixing tube.

Abstract: The present invention relates to a novel process for forming internal shapes in metal matrix composite bodies. Particularly, an infiltration enhancer and/or an infiltration enhancer precursor and/or an infiltrating atmosphere are in communication with a filler material or a preform, at least at some point during the process, which permits molten matrix metal to spontaneously infiltrate the filler material or preform. Additionally, the filler material or preform may contain a mandrel which is capable of surviving the infiltration process, said mandrel being removed after infiltration has occurred. Such spontaneous infiltration occurs without the requirement for the application of any pressure or vacuum.

Abstract: A film-like molded body having a hollow portion of a predetermined contour and made from a disappearing material is formed first using a mold. Also, a disappearing model is prepared by dividing it into a plurality of disappearing model elements. Then, the disappearing model elements are placed so as to enclose the film-like molded body with the film-like molded body as a core and are bonded together and fixed using an adhesive. Accordingly, the disappearing model can be prepared easily while preventing the adhesive from being forced out into the disappearing model and dispensing with extraction of the film-like molded body.

Abstract: A method of manufacturing one-piece composite drill bits or coreheads suitable for drilling or coring petroleum wells or in mining. A shell (32) of hard wear-resistant and erosion-resistant material is formed by investment casting in a finished form requiring nominal or no finish shaping. A shank (44) of machinable material is then cast inside the shell, in conditions which cause fusion bonding of the two materials to form a one-piece composite drill bit (42) or corehead by the two-stage casting procedure. The shank (44) is finish machined to form a connection for attachment to a drill string. Pockets (20) for cutter inserts and gauge protectors can be pre-formed to final dimensions in the hard shell (32). The investment mold for the shell (24) allows the hard material to be cast in the required shape with little or no final shaping. The method enables drill bits and coreheads to be manufactured at relatively low cast by eliminating most or all skilled manual finishing operations.

Abstract: The present invention relates to a novel process for removal of at least a portion of at least one metallic component of a metallic constituent from a multi-phase composite body. Particularly, by providing at least one of an infiltration enhancer or an infiltration enhancer precursor or an infiltrating atmosphere to be in communication with a permeable mass, which contacts at least a portion of a composite body, said metallic component of the composite body, when made molten, is caused to spontaneously infiltrate the permeable mass. Such spontaneous infiltration occurs without the requirement for the application of any pressure or vacuum. The metallic constituent is essentially leached or removed from the multi-phase body by spontaneous infiltration.

Abstract: A porous body is formed and joined to the component by sintering a metal powder to the component. The porous body and component are placed into a piston casting die. Molten metal is poured into the die such that the porous body becomes infiltrated with the molten metal and the molten metal is allowed to solidify. The porous body may be formed by sintering loose metal powder to the component, or by forming a separate body by die pressing of metal powder and which body may be subsequently sintered and joined to the component.

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 tough, wear resistant body is provided. The body includes hard carbide particles embedded in and bonded with a first casted steel matrix material. The body may be embedded in and bonded with a second steel matrix to form a wear resistant composite. The second steel matrix has a melting point at least 200 degrees F. greater than the melting point of the first steel matrix, thereby facilitating a metallurgical bond between the surface of the wear resistant body and the second steel matrix. The composite structure is particularly suitable for earthmoving and other severe mechanical applications.