Abstract: The melting of solder in a reflow soldering operation is detected by examining the rate of change of the solder temperature or by detecting a change in a surface reflectance characteristic of the solder which occurs upon melting.

Abstract: A high speed low inertia fine wire clamp is provided for automatic wire bonders of the type which move the bond head and bond head frame relative to the workstation which supports the semiconductor device to be wire bonded. The wire clamp comprises a fixed clamp lever mounted on a bond head link and a movable lever which is pivotally mounted on the fixed wire clamp lever. The wire clamp jaws of the wire clamp levers are spring biased to a normally closed position and are moved relative to each other by a voice coil motor mounted on the wire clamp levers and controlled by a microprocessor to apply predetermined forces on the wire between the wire clamp jaws and to monitor the distance between the jaws.

Abstract: A laser welder fault detector system, including a microphone and an associated electronic circuit operatively connected to a solenoid actuated ink jet, is provided to detect the formation of defective welds by an intermittently energized laser and to spray ink on sheets of metal being welded to mark the location of the defective welds. Defective welds are detected by acoustic signals generated during the welding process and picked up by the microphone, the amplitude of the signals, when defective welds are being formed, being relatively low compared to those generated when normal welds are being produced. The electronic components of the system compare the acoustic signals generated during the welding process with a reference signal characteristic of the formation of a normal weld.

Abstract: A method for axially aligning adjacent opposing faces of a first and second shaft segment having a respective joint face, of a steam turbine rotor to be welded together includes mating the joint faces of each shaft segment, placing a crushable lip, which axially extends from one of the joint faces, under an axially compressive force, and supporting the joined shaft segments at their axially outboard ends. An apparatus for axially aligning opposing end faces of a first and second shaft segment to be welded together, the first and second shaft segments including a respective joint face. An adjustable support for raising and lowering the joined shaft segments thereby changing the axial distance across the annular groove defined by adjacent opposing end faces to be welded. Means for measuring the force at the adjustable support, provides an indication of the weight counteracted by the support when optimum axial alignment of the shaft segments is achieved.

Abstract: Apparatus and method for determining if a lead bond created by an ultrasonic transducer has the characteristics of a good bond. The current supplied to the transducer is monitored and the envelope of the supplied current is sampled periodically and supplied to a computing means. The computing compares selected characteristics of the sampled signal with characteristics previously determined to create good lead bonding. The results of this comparison are stored in a bond quality control data processing system and supplied to a host data processing system. The host data processing system can take appropriate action. The bond quality control data processing system can control the power supplied to the ultrasonic transducer to provide better characteristics.

Abstract: An apparatus for controllably delivering power from a device to a workpiece is useful, for example, in performing qualitative material tests on various materials. In the instant apparatus, a sonic generator means controllably supplies sonic power to a workpiece, causing the surface of the workpiece to erode. A sensing means produces an actual power signal having a magnitude responsive to the power consumed by the sonic generator means. A settable means produces a desired power signal, and a control means compares the desired and actual power signals and supplies motor control signals in response to the respective magnitudes of the power signals and to a tracking time interval signal. In response to termination of the tracking time signal, the control means blocks the motor control signals. A motor means controllably moves the sonic generator means relative to the workpiece in response to receiving the motor control signals.

Abstract: The present invention relates to a method and apparatus used to determine the heat flux through a portion of a surface of a heat exchanger tube, using heat flux sensor means that is installed on the inner wall of the heat exchanger tube and send a signal to a connected heat flux meter.

Abstract: An apparatus and a method for remotely refurbishing valve seats are disclosed herein. The apparatus generally comprises a welding assembly having a welding head for depositing a bead of metal around the valve seat, and a positioning assembly detachably mountable onto the valve body for angularly and radially moving the welding head around the valve seat at a selected point along the axis of rotation of the seat. Additionally, the apparatus includes a control means operatively connected to the positioning assembly for controlling the movement of the welding head around the valve seat. In operation, the control means, which may include a microprocessor, first angularly moves the welding head 360.degree. around the circumference of the valve seat, then moves the welding head to a different point along the axis of rotation of the valve seat, and then rotates the welding head 360.degree. around the valve seat again for as many cycles as is necessary to rebuild the valve seat.

Abstract: A method for axially aligning adjacent opposing faces of a first and second shaft segment having a respective joint face, of a steam turbine rotor to be welded together includes mating the joint faces of each shaft segment, placing a crushable lip, which axially extends from one of the joint faces, under an axially compressive force, and supporting the joined shaft segments at their axially outboard ends. An apparatus for axially aligning opposing end faces of a first and second shaft segment to be welded together, the first and second shaft segments including a respective joint face, comprises an adjustable support for raising and lowering the joined shaft segments thereby changing the axial distance across the annular groove defined by adjacent opposing end faces to be welded. Means for measuring the force at the adjustable support, provides an indication of the weight counteracted by the support when optimum axial alignment of the shaft segments is achieved.

Abstract: An apparatus and method is disclosed for testing leaks in welds securing a wellhead to a caisson on which the wellhead is mounted without waiting for the welds to cool. The wellhead is placed in co-axial, overlapping relationship around a portion of the caisson on which it is to be mounted to form an annular chamber between the caisson and wellhead. The chamber has an open annular upper junction and an open annular lower junction formed by the overlap between the wellhead and caisson, and a continuous weld is placed along each of these junctions to secure the wellhead to the conduit. Oil is heated to a temperature similar to the temperature of the welds, wellhead and caisson after welding, and this oil is introduced into the chamber before the welds, wellhead and caisson have cooled to test for leaks in the welds.

Abstract: An apparatus for supplying wire to a wire bonding mechanism is presented. Lengths of wire are fed to a low mass wire-loop reservoir while the bonding process is taking place. Wire is then supplied, at a high speed, from the wire-loop reservoir for the next bonding operation. The amount of wire supplied is precisely measured by measuring the change in the amount of wire stored in the reservoir. The apparatus can supply both single lead wire and twin lead wire. When twin lead wire is supplied, the two wires of the twin lead are separated at predetermined points before being fed to the wire-loop reservoir.

Abstract: First and second transparent metallized gauge plates (52 and 52') of solder-nonwettable, heat-resistant material, such as glass or quartz, each have a solder wave test pattern in the form of spaced parallel metal strips (56 and 56') formed thereon. The metal strips (56) on the first gauge plate (52) are of progressively increasing widths, with a narrowest strip located adjacent one edge of the plate and a widest strip located adjacent an opposite edge of the plate. The metal strips 56' on the second gauge plate (52') are of uniform widths. The first gauge plate (52) is engaged with a solder wave (34) to measure the activation level of a soldering flux (44) being introduced into the solder wave, and thereby to determine the capability of the solder wave to produce properly soldered printed circuit board assemblies (10).

Abstract: A heat-recoverable soldering device comprises a heat-recoverable member having a fusible solder insert and associated with the solder insert, a solder flux composition which undergoes a visible color change at a critical temperature. Solderable substrates are positioned within the device and heated until a critical temperature has been reached as indicated by a color change in the flux. The critical temperature depends on the material of the particular heat-recoverable member and the solder used. It is that temperature which is required to effect a solder joint between the substrates and recovery of the heat-recoverable member. Novel flux compositions and their use in soldering are also disclosed.

Abstract: It has been found that the soldering properties of a wave soldering system can be quantitatively determined by measuring the wickability of the molten solder of the solder bath beyond the areas of direct immersion into the molten solder bath of a solder wave. The test is conducted by providing a test board having a pair of parallel strips of a solderable material such as copper. One of the parallel strips is formed in a continuous length. The other of the parallel strips is formed with discontinuity in the solderable material at regularly predetermined intervals along the length thereof. When conducting the test method of this invention, the test board is partially immersed into the solder wave in the same manner as a printed circuit board assembly, with the parallel strip being in alignment with the machine direction of the wave soldering apparatus. The test board is then removed from the solder wave. The point of maximum direct contact with the solder of the wave is determined from the discontinuous strip.

Abstract: A method for positioning and fixing optical components relative to one another which comprises the steps of providing a carrier plate having an optical component, securing an optical component on a retainer plate having at least one solderable area, positioning the retainer plate above the carrier plate with a reference mark on said plates being aligned and the solderable area on each of the two plates being disposed in aligned pairs of solderable areas, applying at least one solder piece to each pair of solderable areas as the plates are held in the position, melting the solder pieces, allowing the molten metal to solidify to secure the aligned plates together and then releasing the secured aligned plates.

Abstract: An automatic wire bonder for bonding at least one wire between a first predetermined location on a workpiece and a second predetermined location on a substrate on which the workpiece is carried includes a wire feeding head, and means for moving the head, in x, y, and z directions, relative to the workpiece, x and y being at least parallel to the plane of the workpiece and z being an elevation direction above the workpiece. Means are included for determining a z direction measurement between the first and second predetermined locations. The bonder is computer controlled to automatically dispense the wire and to configure it to a predetermined configuration to include a partially circular portion and an adjacent straight portion to be bonded between the first and second predetermined locations. The shape of the partially circular portion and the length of the straight portion are automatically determined by at least the z direction measurement.

Abstract: Disclosed is a two-step process of joining a lead wire to a 2.times.10.sup.-6 m thick platinum alloy film which rests upon an equally thin alumina insulating layer which is adhered to a metal substrate. Typically the platinum alloy film forms part of a thermocouple for measuring the surface temperature of a gas turbine airfoil. In the first step the lead wire is deformed 30-60% at room temperature while the characteristic 10.sup.6 ohm resistance of the alumina insulating layer is monitored for degradation. In the second step the cold pressed assembly is heated at 865.degree.-1025.degree. C. for 4-75 hr in air. During the heating step any degradation of insulating layer resistance may be reversed, provided the resistance was not decreased below 100 ohm in the cold pressing.

Abstract: A process is described in which a weld is produced without residual stresses; or with residual stresses reduced to a low value. Stress cycles of low value at low frequency are applied in the longitudinal direction of the weld by means of an air operated vibrator during welding. Application of stress cycles may be continued after welding, during or after reheating which may be applied to the solidified weld. Stress cycles are applied at high temperature when the weld metal is in a molten state, semi-solid state and solidified state, and thus brings about reduction in dislocation density in solidified crystals. Stress exists at each dislocation and since the dislocation density is reduced, reduction in residual stress takes place thereby eliminating the need for additional stress relieving operations. Since stress cycles are applied during welding, gases in molten metal are driven out and porosity in the solidified weld is reduced.

Abstract: An automated welding system takes initially randomly oriented negative glow lamps and welds a resistor to each lamp. Lead wires are trimmed to desired lengths and the physical strength of the weld between the lamp and the resistor is tested.

Abstract: A wire bonding machine for wedge bonding fine wires to semiconductor devices is provided with a rotating bonding head which is mounted on a fixed machine frame and having a X-Y table mounted on the fixed machine frame opposite a vertically movable bonding tool mounted on the rotating bonding head. The bonding head is provided with means for articulating the bonding tool in a vertical direction and in a rotational direction. The rotational movement of the novel bonding head does not impart vertical movement to the bonding tool.

Abstract: A method is disclosed for producing one or more contact connections at solder locations between a lacquer-insulated wire and corresponding contact member of an electrical component by use of soft solder. The solder location is heated to a temperature sufficient to melt the lacquer insulation of the wire off and also to insure a secure electrical connection. Both temperature and electrical contact between the wire and contact member are sensed so as to switch off the heat source at the conclusion of soldering.

Abstract: This specification discloses a wire banding method and machine, which comprises a base member, a circular guideway and wire feeding and tensioning means. Wire is fed across the base and past an article to be bound and then around the guideway until the leading edge thereof strikes a stop. At this time, clamping means on a first member on the base clamps and holds the leading end of the wire. Then the feeding means is reversed to tension the wire about the article. At the end of the tensioning step a second member on the base clamps the wire and the wire is severed prior to welding, then during the welding operation means are provided to prevent the welding current from damaging the articles being banded, then after welding the ends of the wire band, the weld is tensioned to check the integrity thereof.

Abstract: A method for series production of an outer column for a safety steering column for motor vehicles in which a first tubular blank is stepwise moved to a plurality of working stations in which the blank is deformed respectively punched to form a substantially smooth-walled protecting tube of the outer column. A second tubular blank is simultaneously moved to a working station in which it is transformed into a corrugated tube and subsequently the two tubes are fed against each other so that end portions of the tube overlap and the overlapping tubes are then welded together in a main welding station. Thereafter at least one pressed metal part is welded to one of the tubes at an auxiliary welding station. At least one control station is coordinated with at least one working station for the first tubular blank and at least one additional control station is coordinated with at least one of the welding stations for checking the work performed by the at least one working and the at least one welding station.

Abstract: Method and apparatus for expeditious installation of bottom-supporting and side-anchoring blocks for a tube and tube sheet bottom repair apparatus in the interior of the channel head of a steam generator at one side of the divider plate in a nuclear power plant, involving use of special tools and fixtures for location and welding of such blocks in position by use of information derived from measurement of the extent and direction of tilt of the tube sheet bottom from a purely horizontal attitude.

Abstract: Apparatus including a planar support having a plurality of terminations such as plated through holes arranged therein in an array and a plurality of sensing devices respectively associated with the terminations for measuring a physical quantity thereat such as temperature. The resulting structure is useful for training a person in a manual skill such as soldering. Also disclosed is a common connector plug for receiving at one side of the support a plurality of electrical leads from the sensing devices and an analyzer and indicator connected to the common plug for measuring the time required for the temperature and/or pressure at one of the terminals to rise from an initial value to a final value, the terminal being that to which a device such as a soldering iron is applied to effect the soldering of an electrical connection thereat.

Abstract: A method and apparatus is disclosed for monitoring the parameters of a rock bit which utilizes electronic sensing principles. The use of these sensing devices will provide continuous measurement of the rock bit through remote monitoring equipment. The sensing devices monitor the rock bit parameters during the electron beam welding process to assure that both the height and the gage of the rock bit remains within set tolerances while the welding process is taking place.

Abstract: A method and apparatus is disclosed for monitoring the gage diameter of a rock bit which utilizes electronic sensing principles. The use of electronic sensing devices provides continuous measurement of the rock bit gage through remote monitoring equipment. The sensing devices monitor the gage of the rock bit during the electron beam welding process to assure that the gage of the rock bit remains within tolerance.

Abstract: A contacting device for making a wire connection on a microcircuit by applying ultrasonics or thermocompression. A contacting horn is provided with a capillary which, in turn, is associated with a wire clamping device for feeding or clamping the wire during movement of the contacting horn. The wire clamping device has two clamping members for grasping the wire. The clamping members are movable relative to each other for clamping the wire, and both are arranged to pivot jointly to move the clamped wire in its lengthwise direction. A controllable actuation unit is each associated with the second clamping member which moves relative to the first, and the two clamping members jointly. The clamping members may be formed as a strip for grasping the wire between outer end regions. The second clamping member is mounted on a support of the first clamping member, and its outer end is pressed by a leaf spring fastened to the first clamping member.

Abstract: A system for measuring time/temperature profiles of a mass soldering operation is described. In accordance with the invention a data probe and miniature transmitter is carried through the soldering operation on top of the circuit board being soldered. A plurality of probes are attached to various components, component leads and selected board areas and provide electrical signals in response to the temperature and dwell time the components and board are subjected to during preheating and soldering. The temperature of the solder at the point the solder contacts the board may also be detected. The electrical signals are wireless transmitted, e.g. by means of low frequency electromagnetic transmission, to a remote stationary receiver for integration and display.

Abstract: A TIG pipe welding method which employs two sets of machine guide surfaces on the pipe ends. First radially inner guide surfaces cooperate with a sensor coupled to the welding torch to continuously monitor the arc gap between the welding electrode and the weld puddle as the welding electrode moves around the circumference of the pipe. The second set of radially outer surfaces cooperate with a welding carriage to guide the carriage and welding modules around the pipe joint. The carriage is constructed to provide a sealed welding chamber surrounding the electrode. An additional flow of shielding gas is provided around the torch electrode of a TIG or hot wire TIG welding module to augment the normal gas shield.

Abstract: A method of forming a hard vacuum seal for use in a gas laser but not limited thereto. The method comprising the steps of polishing the surfaces to be joined together and then cleaning the surfaces with a plasma cleaner. Next, a force is applied to hold the surfaces in contact and then molten indium is applied onto the adjoining surface and allowed to cool in order to set the seal. In the method of forming the gas laser seal for fine alignment of the mirror surfaces, the seal is reheated, the mirrors realigned by sliding across the laser cavity while the laser is operative and the laser output is measured for maximum laser output. Then the seal is allowed to reset.

Abstract: A method of making a pipe string from separate pipes of arbitrary length welded end to end wherein the joints are positioned off forbidden zones. A reference model of the pipe string having the forbidden zones marked thereon and a working model of the arbitrary pipe lengths arranged in random sequence so as to exceed the length of the desired pipe string are prepared, and by shifting the working model with respect to the reference model, a mutual arrangement is found where all pipe joints lie off the forbidden zones marked on the reference model and the excess portions of the beginning and trailing pipe lengths which are to be cut off determined. An automatic line for measuring the pipe lengths, storing measured pipes, welding the pipe lengths together, and cutting off the excess parts in accordance with the working model is used to make the pipe string. A computing device for calculating a working model of the pipe string is also disclosed.

Abstract: Methods of pipeline construction in arctic and subarctic regions and apparatus for carrying out those methods are disclosed. Following the disclosed methods, summer-constructed fabrication yards are established at locations along the pipeline right-of-way spaced at intervals of 100 to 150 miles. Each summer-constructed fabrication yard is regarded as being at or close to the center of its associated pipeline division, which is approximately 100 to 150 miles in length. Each fabrication yard comprises a group of summer-constructed buildings adapted for carrying out the steps in fabricating a pipe section, including quality control, X-ray, hydrostatic testing, external coating, final inspection, and river coating and weighting, along with yard facilities for moving elongated (e.g., 2500 foot) pipe sections from place to place during their fabrication, inspection, coating, etc.

Abstract: Method and apparatus for processing continuous strand material in a continuous processing line wherein movement of the strand is continued at a subsequent processing station despite halting movement of the strand at a preceding station and for providing an indication of when the portion of the strand present at the preceding station when halted reaches the subsequent processing station or position.

Abstract: A method and apparatus for the manufacture of rotary drill bits such as are used for oil well drilling which are constructed from a multiplicity of segments. The segments are provided with registration means for positioning the segments relative to one another and are placed in a fixture where they are sized to a desired outer diameter without sliding the faces of the segment one against the other during the sizing operation. The faces are then brought into abutment, clamped and welded along the abutting surfaces between segments.

Abstract: Stripped wire ends are coated with a "solder friendly" resin such that when they are placed in physical contact with terminals during assembly of electrical circuitry preparatory to soldering the same to the terminals, there is no appreciable conduction. After a routine soldering operation, the resin melts and vaporizes so that a solid electrical connection results, the resin itself serving to inhibit oxidation of the soldered connection. When a routine quality control testing operation is carried out on the electrical circuitry, any overlooked soldered connections will be immediately indicated by non conduction or poor conduction of the unsoldered portions as a result of the presence of the resin. These overlooked unsoldered connections can thus be immediately corrected. In the absence of the resin, the routine quality control testing would indicate a proper connection merely because of the physical contact of the wire with the terminal even though not soldered.

Abstract: A method, in the art of brazing metallic parts to one another, including a step of subjecting a brazed assembly to relatively high temperatures over a relatively short period of time in a manner to induce blistering of unbrazed or weakly brazed areas. Blistered material can then be removed, leaving a soundly brazed structure which in use will not fragment and give up loose materials to ambient surroundings.

Abstract: A method and apparatus for joining metal workpieces using high frequency vibratory energy includes applying short bursts of high frequency energy to the workpieces to be joined and the constant monitoring of the power supplied during the applied bursts of energy. Responsive to the power exceeding a predetermined level, high frequency vibratory energy is applied to the workpieces for a predetermined time interval for creating welds exhibiting consistent quality.

Abstract: An automatic welding apparatus having a robot and a welding torch, the robot including a main body serving as a drive means, an arm supported and driven by the main body to move in three-dimensional directions, and a wrist connected to a forward end of the arm for universal pivotal movement and supporting the welding torch. The wrist has mounted thereon two tactile sensors for sensing the positions of components to be joined by welding into a unitary structure, one of such sensors extending radially of the pivotal axis of the wrist and the other tactile sensor extending in the direction of the pivotal axis of the wrist. The positions of points at which welding should be performed are calculated based on the amount of displacement of each tactile sensor whereby the operation of the welding torch can be controlled.

Abstract: A machine for winding electrical coils from thin strip or ribbon, having a spindle on which the conductor is wound. A welding device welds intermediate or final terminations to the strip with predetermined spacing. The welding unit is mounted movably in relation to the winding spindle. Means are provided for precisely rotating the winding spindle and consistently stopping it at a fixed position. Means are provided for measuring precisely the length of one turn or known portion thereof so as to locate and weld the connection at a point that will cause it to fall in the required place when the connection has been wound onto the coil.