Abstract: A new apparatus and process for soldering surface-mount and through-hole type electronic components into a printed circuit board (PCB) in an automated fashion utilizing localized electromagnetic induction heating. Current manufacture technology for packaging electronic components depends exclusively on the reflow and wave soldering processes. Both processes heat up to relatively high temperature the entire assembly, namely its PCB and all the electronic components been soldered into it. Such high temperature environment frequently causes components damage resulting in rejects and/or demanding rework. With this invention however, during a soldering operation only the leads and pads, or joints, being soldered are heated but neither the body, or casing, of said electronic components nor the dielectric material forming said PCB are heated. Because of this selectively localized heating, the invention permits to reduce cost and improve the quality and reliability of manufactured products.

Abstract: An apparatus for joining metal pieces using induction heating. Preceding and succeeding metal pieces are followed by a carriage which carries an inductor. The inductor has the ability to move in the longitudinal direction of the metal pieces relative to the carriage to allow the inductor to move more or less upon the preceding or succeeding metal pieces to increase or decrease the induction heating effect, thereby taking into account any thickness variation of the metal pieces and yet still heating them evenly with regard to each other, prior to their being pressed against each other for joining before hot finishing rolling.

Abstract: An external inductor for magnetic pulse welding and forming includes an outer steel frame and an inner beryllium-bronze alloy insert which is removably mounted within the frame. The steel frame and the beryllium bronze insert respectively split the responsibility for higher mechanical strength and more concentrated pulse current on the inner surface of inductor's central opening. The improved external inductor design is capable of creating greater impulse forces onto the outer workpiece and has been demonstrated to perform at least 25-30% more deformation than a simple one piece simple steel external inductor for a full metallurgical joint.

Abstract: A method and apparatus for permanently joining two or more metallic vehicle frame components using magnetic impulse welding techniques is disclosed. In a first embodiment, an overlap joint is formed by the joinder of two individual open channel side rail sections to form a portion of a vehicle frame side rail. The first side rail section is initially formed slightly smaller in size than the second side rail section so that it may be disposed telescopically therein with clearance. An electromagnetic coil is provided for generating a magnetic field which causes the side rail sections to move toward one another at a high velocity. The high velocity impact and the large pressures cause the two side rail sections to weld or molecularly bond. Alternatively, a bracket can be joined to a side rail section in a similar manner. In a second embodiment, a pair of closed channel structural members are formed using hydroforming techniques.

Abstract: A sheet bar joining apparatus comprises a heater provided between a delivery-side clamp for clamping a rear end of a preceding sheet bar and an entry-side clamp for clamping a front end of a succeeding sheet bar; upper and lower anti-buckling plates provided on the entry-side clamp and located above and below the sheet bars; upper comb tooth portions and lower comb tooth portions formed in the upper and lower anti-buckling plates, respectively; a heat resistant insulator provided at a surface of each comb tooth portion opposed to the sheet bars; and a plurality of groove portions provided near the surface of each comb tooth portion opposed to the sheet bars.

Abstract: A first electromagnetic induction pump system includes a first plurality of electromagnetic induction pumps, arranged in the direction parallel to the width of workpiece. The first plurality of electromagnetic induction pumps extend vertically along a first vertical plate portion at a workpiece inlet side of a single reservoir. A second electromagnetic induction pump system includes a second plurality of electromagnetic induction pumps, arranged in the direction parallel to the width of workpiece. The second plurality of electromagnetic induction pumps extend vertically extends along a second vertical plate portion at the workpiece outlet side of the reservoir. Brazing filler metal is ejected upward in waves by the electromagnetic induction pump systems to braze workpieces carried by the ejected waves into and out of the device.

Abstract: A post continuous hot rolling method where a rear end portion of a preced metal block and a fore end portion of a succeeding metal block are cut and the metal blocks joined to each other by heating and pressing followed by a finish rolling, wherein a poorly joined portion is removed by shaving the defective portion through application of rotating cutters prior to a final finish rolling of the joined blocks.

Abstract: An electric heating element having a central conductor and an outer metallic sheath is welded to a base of vessel to provide a heating container, for hot water in a domestic appliance for example. In order to carry out the welding, the vessel is heated up by an induction heater to a certain temperature and the temperature of the actual contacting welding surfaces raised above the certain temperature to a fusing temperature by applying and controlling electric power supplied to the conductor while the heating element is held firmly in position against the base.

Abstract: A method for securing components of a vehicular driveshaft includes disposing a neck of an end fitting into the open end of a driveshaft tube. The end fitting is held with respect to the driveshaft tube so that an annular gap is formed between the neck and the driveshaft tube. An inductor is provided about the driveshaft tube adjacent the end receiving the neck. The inductor is energized to generate a magnetic field for collapsing the driveshaft tube about the neck at a high velocity so that the driveshaft tube and the end fitting are welded to each other.

Abstract: According to the invention, the rear end of a preceding metal piece and a front end of a succeeding metal piece are heated, pressed and joined prior to the finishing hot rolling. An alternating magnetic field running through the metal pieces in the thickness direction thereof is generated in an end region on opposed faces of the respective metal pieces to perform heating. Another alternating magnetic field whose direction is reverse with respect to that of the former alternating magnetic field is partially generated in the end region on the opposed faces of the metal pieces and in either a region where the metal pieces exist or a region outside width ends of the metal pieces. This assures a uniform heating of the end region on the opposed faces of the metal pieces over their full width to reliably join the both metal pieces to each other.

Abstract: The present invention is a method for improving the strength and quality of thermoplastic welds by annealing the weld following its formation at a temperature of at least about 500.degree. F. (i.e., about 125.degree. F. below the melt) for about 20 minutes to control cooling of the weld.

Abstract: Problems associated with accurately positioning a susceptor at the bond line between two or more prefabricated, fiber reinforced, resin composite detail parts to facilitate thermoplastic welding (i.e., fusion bonding) between the detail parts. The integrated susceptor detail part is compatible with Z-pinning along the bond line for the pulloff strength enhancement associated with Z-pin reinforcement. We make the parts by (1) preparing the faying overface of the prefabricated part or prepreg preform for the overlayment of the bond line materials, (2) placing a thermoplastic film on the part or preform, (3) placing the susceptor on the film, and (4) securing the film and susceptor to the part by applying suitable heat and pressure to produce a prefabricated, consolidated detail part having an integrated susceptor in a resin rich region intended as the bond line to other parts in the final assembly.

Abstract: An apparatus and method for fusing intercell connectors to battery cell terminal posts. The apparatus includes inexpensive, non-metallic molds, each having a mold opening and being positionable onto a connector with the mold opening in aligned relation to a terminal post positioned in a connector opening for defining a mold cavity adjacent an end of the terminal post and the connector opening. A selectively positionable induction heating head is provided for locating an induction heating coil in predetermined spaced relation to a terminal post and connector to be fused such that generation of a high frequency, oscillating current in the coil causes melting and fusion of the terminal post and connector with the mold retaining and forming the molten lead. The induction heating head may be manually positionable for use with batteries with different post locations and orientations and includes safety and position locating features.

Abstract: Target members of titanium or a titanium alloy with melting point M are bonded together by first forming a bonding layer with melting point J lower than M on at least one of the bonding surfaces over which the target members are to be joined together. While the target members are pressed against each other over the bonding surfaces, end parts of the target members adjacent the bonding surfaces are heated to an intermediate temperature T such that J<T<M and is kept at this intermediate temperature for a specified length of time to effect liquid-phase diffusion bonding. Alternatively, an insert member of titanium or a titanium alloy may be inserted between the bounding surfaces of the target members to form liquid-phase diffusion bonding by first forming bonding layers of the type described above on mutually opposite end surfaces of the insert member and then inserting the insert member between the target members.

Abstract: A method of joining or welding of at least a portion of a first metal workpiece to at least a portion of one or more second metal workpieces, comprising inducing movement in said portion of the first workpiece by means of a pulsed magnetic force so as to impact said portion of the second workpiece, the movement imparting a kinetic energy on the at least portion of the first workpiece to cause the two at least portions to join or weld to one another.

Abstract: An apparatus for welding together two metal sheets (4, 5) includes clamping rails (17, 18; 23, 24) for positionally fixing the sheets (4, 5) each on a table (2, 3), and an induction device movable towards and away from a joint (15) between the metal sheets (4, 5) and along the direction (16) for heating the metal sheets (4, 5) in the joint region (1 5). The induction device displays a first conductor which extends along and adjacent the joint (15). The clamping rails (17, 18; 23, 24) are disposed two (17, 23) at the one sheet (5), and two (18, 24) at the other sheet (4), one on either side of each respective sheet, and along and a slight distance away from the joint (15). The clamping rails (17, 18; 23, 24) are disposed without electric conducting connection with the first conductor, are manufactured from electrically conductive material, and are electrically connected to the sheets (4, 5).

Abstract: A method of bonding two or more sintered compacts of tungsten heavy alloys. The method includes the steps of providing two or more sintered compacts of tungsten heavy alloy powder and then positioning the sintered compacts in adjacent alignment in a furnace chamber. A localized induction field is applied only at the juncture of the sintered compacts to bond the sintered compacts and produce a monolithic assembly of sintered compacts having a bond strength substantially equal to the strength of the sintered compacts.

Abstract: The invention comprises a continuous hot rolling method in which a rear end portion of a preceding metal block and a fore end portion of a succeeding metal block are cut and the metal blocks are joined to each other by heating and pressing followed by a finish rolling. A region of each metal block is restrained from a clamping position to the end portion thereof in order to prevent a change in level of the metal blocks in heating and pressing the piece. The end portions of the metal blocks can be thus prevented from deformation.

Abstract: A method of fusing and programming a fuse frame for use in a semiconductor package is disclosed. A fuse frame includes an external lead arranged for electrically connecting to a first internal element of the semiconductor package and to extend externally from the semiconductor package and an internal lead arranged to be positioned entirely within the semiconductor package is also provided for electrically connecting a second internal element of the semiconductor package to a third internal element of the semiconductor package. A fuse bar supportably connects the internal lead to the external lead. The fuse bar includes a conductive material which fuses when excess current runs through it. A semiconductor package is made of a fuse frame and a die is mounted on the fuse frame such that the die supports the internal lead of the fuse frame. A programmable fuse frame is disclosed. A programmable fuse frame includes a matrix of fuse bars and lead bars.

Abstract: Thermoplastic welds suffer from significant residual tensile strain caused by differences in the coefficient of thermal expansion between the carbon fiber reinforced composite laminates and the unreinforced weld. A structural susceptor alleviates this strain by adding fiber reinforcement to the weld. A structural susceptor is a laminate of alternating layers of thermoplastic resin and fiber reinforcement sandwiching a conventional metal susceptor. A further advantage of the structural susceptor is the ability to peel it in selected locations to fill the gap between the laminates, eliminating costly profilometry of the faying surfaces and the associated problem of resin depletion where machining occurred to match the faying surfaces.

Abstract: An apparatus for forming and consolidating organic matrix composites. An organic matrix composite panel comprising laid-up prepegs is placed between sheets of a susceptor material that is susceptible to inductive heating to form a workpiece. The resulting workpiece is placed within upper and lower dies formed of a material that is not susceptible to inductive heating. An induction coil embedded within the dies is energized and inductively heats the susceptor sheets surrounding the panel. The sheets in turn conductively heat the organic matrix composite panel. A pressure zone between the workpiece and one of the dies is pressurized to form the workpiece to the contour of a forming surface on one of the dies. The pressure in the pressure zone is maintained on the workpiece until the organic matrix composite panel is fully consolidated and formed.

Abstract: A method and apparatus for forming and consolidating organic matrix composites. An organic matrix composite panel comprising laid-up prepregs is placed between sheets of a susceptor material that is susceptible to inductive heating to form a workpiece. The resulting workpiece is placed within upper and lower dies formed of a material that is not susceptible to inductive heating. An induction coil embedded within the dies is energized and inductively heats the susceptor sheets surrounding the panel. The sheets in turn conductively heat the organic matrix composite panel. A pressure zone between the workpiece and one of the dies is pressurized to form the workpiece to the contour of a forming surface on one of the dies. The pressure in the pressure zone is maintained on the workpiece until the organic matrix composite panel is fully consolidated and formed.

Abstract: A method and apparatus for forming and consolidating organic matrix composites. An organic matrix composite panel comprising laid-up prepregs is placed between sheets of a susceptor material that is susceptible to inductive heating to form a workpiece. The resulting workpiece is placed within upper and lower dies formed of a material that is not susceptible to inductive heating. An induction coil embedded within the dies is energized and inductively heats the susceptor sheets surrounding the panel. The sheets in turn conductively heat the organic matrix composite panel. A pressure zone between the workpiece and one of the dies is pressurized to form the workpiece to the contour of a forming surface on one of the dies. The pressure in the pressure zone is maintained on the workpiece until the organic matrix composite panel is fully consolidated and formed.

Abstract: A constant section gasket based on elastomer, plastic, or like material, the gasket comprising a constant section element that is extruded or molded in at least one material selected from elastomers, plastic, thermoplastic elastomers, and like materials. The gasket also includes a sole-piece for fixing on a support(s), in particular a metal part of car bodywork, with the sole-piece being fixed thereto by means of an induction heating machine.

Abstract: A method of bonding two structural members, such as two metal sheets, by heating a bonding material disposed between juxtaposed perimeter edges of the two sheets. An induction heater is disposed adjacent one sheet surface and adjacent the juxtaposed perimeter edges of the two sheets to induce heat to the bonding material from one surface of one sheet and from the perimeter edges of both sheets to cure the bonding material. The induction heater is formed of first and second elements disposed in a non-parallel arrangement adjacent one surface and along one perimeter edge of two juxtaposed structural members. The first and second elements are joined together at adjacent ends. A base and a riser are connected to intermediate spaced ends of the first element for attaching the first element to a high frequency electrical current source.

Abstract: Multisheet SPF parts with braze joints at selected locations are produced with improved energy efficiency and at lower cost by heating the multisheet pack to its superplastic forming range below the melting point of the braze alloy, superplastically forming the pack to define braze joints having unmelted braze alloy; increasing the temperature to the braze temperature of the braze alloy, and cooling the pack below the superplastic range to freeze the braze alloy in the braze joint.

Abstract: A method is presented for uniformly heating plastically deformable material, which comprises particles of electrically conducting matter. This method comprises inducing an electric current, or causing hysteresis loss within such material, by using electromagnetic radiation with frequency between about 50 Hertz and about 10 MegaHertz, to cause heating of the material.

Abstract: This invention rapidly and surely joins sheet bars to each other for continuously hot rolling in a high productivity by a combination of a treatment that the front end portion and the back end portion of these sheet bars are contacted and heated at such a contact region by applying alternating magnetic fields so as to pass in a thickness direction of the sheet bar with a treatment of pushing at least one of these sheet bars.