Abstract: A method of coating and bonding a substrate with particles of a ceramic selected from the group consisting of diamond, carbon, graphite, and graphite or carbon-carbon composite, comprising: providing the substrate and at least one of the ceramic particles; selecting at least a carbide-forming substance consisting principally of an element which is other than Ni, Cr, and Co and is capable of forming a carbide to provide a coating material; applying said coating material onto at least one component of the substrate and the at least one ceramic particle; placing the at least one ceramic particle on the substrate; and heating the product of step (D) at a temperature sufficient to form a liquid-diffusion formed, carbide coating on the at least one ceramic particle. The ceramic particles are then coated with strong, adherent, substantially defect-free, and thermomechanically shock resistant metallized layers which are capable of practical uses over 630.degree. C.

Abstract: Carbon/carbon materials are joined together by the placement of a brazing alloy between the materials to be joined applying a clamping pressure and passing an electric current through the parts and brazing alloy until the brazing.multidot.k15H alloy melts and when allowed to solidify forms a unitary structure from the parts.

Abstract: Ceramics are joined to themselves or to metals using a transient liquid phase method employing three layers, one of which is a refractory metal, ceramic or alloy. The refractory layer is placed between two metal layers, each of which has a lower melting point than the refractory layer. The three layers are pressed between the two articles to be bonded to form an assembly. The assembly is heated to a bonding temperature at which the refractory layer remains solid, but the two metal layers melt to form a liquid. The refractory layer reacts with the surrounding liquid and a single solid bonding layer is eventually formed. The layers may be designed to react completely with each other and form refractory intermetallic bonding layers. Impurities incorporated into the refractory metal may react with the metal layers to form refractory compounds. Another method for joining ceramic articles employs a ceramic interlayer sandwiched between two metal layers.

Abstract: This active brazing preferably serves to braze (join) ((aluminum-)oxide-)ceramic parts or single crystals or metal parts or to braze (join) ((aluminum-)oxide-)ceramic parts to single crystals or ((aluminum-)oxide-)ceramic parts or single crystals to metal parts. In addition to the zirconium-nickel alloy, which is composed of 70 atom % to 85 atom % zirconium and 15 atom % to 30 atom % nickel, it contains titanium.

Abstract: A method for brazing together two parts at least one of which comprises a titanium aluminide material is described wherein a metallic layer of foil or powder is inserted between the parts in laminar contact with respective confronting surfaces thereof to be joined, the metallic layer comprising a metal which forms with titanium a eutectic composition having a characteristic fusion temperature lower than the fusion temperature of the metal, and the metallic layer and confronting surfaces of the parts are heated to a temperature of about the characteristic fusion temperature of the eutectic composition.

Abstract: A shielding apparatus for use with a non-conductive package has an insulated lid (102) which is retained in contact with a substrate (104) for holding an electrical circuit. The shielding apparatus includes a first conductive flash (201) deposited on the interior surface of the insulated lid (102), to produce a substantially contiguous conduction layer, and a second conductive flash (203) deposited over a film (110) disposed on the edge of the insulated lid (102), to produce a partially contiguous conduction layer. The shielding apparatus also includes a layer (108) for affixing the insulated lid (102) to the substrate (104), to produce an enclosure for isolating the electrical circuit from extraneous radio frequency (RF) energy.

Abstract: A ductile brazing material containing gold, nickel, vanadium and, optionally chromium or molybdenum is disclosed for directly bonding ceramic to ceramic or ceramic to metal over an optimum temperature range.

Abstract: A method for bonding a first ceramic element and a second ceramic element utilizes a silver powder paste composed of silver particles dispersed in a volatile vehicle. A film of the paste is applied and dried onto a faying surface of each element. The elements are assembled with the films in contact and heated to sinter the silver particles into an integral silver layer that is bonded to the faying surfaces, thereby bonding the elements together. The method is particularly well suited to manufacturing a stripline filter, wherein the sintered layer not only bonds the ceramic elements, but also forms a metallic feature, such as a resonator, of the filter.

Abstract: A superconducting electronic circuit device, useful when impedance matching is desired, especially suited to microwave frequencies, consisting of a thin dielectric layer with superconducting layers on both sides. A superconductor such as Yttrium Barium Copper Oxide (YBCO) is formed on a first substrate such as lanthanum aluminate. A protective layer like gold is deposited on the YBCO and a second carrier substrate is bonded to the protected YBCO. The first substrate is then thinned into a thin dielectric film and a second layer of superconductor is epitaxially grown thereon to create the desired circuits.

Abstract: A method for forming a ring structure having a high volume fraction of a filament reinforcement within a metal matrix is disclosed. The ring structure is formed by consolidating a set of nested rings each of which has a high volume fraction of the filamentary reinforcement therein. The nesting is done to provide a clearance between the rings of the nest of about 2 or 3 mils. The nested rings are enclosed within a HIPing can and the structure is HIPed at about 15 ksi and 1000.degree. C. for over an hour. A single superring structure results from the HIPing.

Abstract: An abrasive article comprising a coated abrasive bonded to a substrate by means of a metallic adhesive and a method for producing the abrasive article by heating.

Abstract: A method for coating a ceramic with a strong, adherent, substantially defect-free, and thermomechanically shock resistant metallized layer for practical use at over 630.degree. C. comprising selecting a ceramic metallizing composition; preparing the composition by proportioning the differing sizes of the mixed ingredients to have gravitationally substantially nonsegregating qualities when applied onto said ceramic; coating the ceramic with the metallizing composition; heating the coated ceramic surface to achieve ceramic metallization; and keeping the composition molten sufficiently long time to form the required metallized layer.

Abstract: Two or more ceramic bodies are bonded together by oxidizing with a vapor-phase oxidant molten metal obtained from a body of precursor metal to form an oxidation reaction product bond. The oxidation reaction product is formed between adjacent facing, substantially congruent surfaces of the ceramic bodies and bridges the surfaces, thus bonding the ceramic bodies to each other. Promoters may optionally be used to facilitate formation of the oxidation reaction product.

Abstract: The use of a conductive reactive braze material, loaded in via holes of a diamond substrate and heated in a suitable temperature range, results in conductive vias with excellent adherence to the via hole in the diamond material. Cracking of the diamond substrate, and loose or lost via elements, are minimized. A form of the disclosure is directed to a method for producing a circuit board having a multiplicity of conductive vias. A generally planar diamond substrate is provided. A multiplicity of via holes are formed through the substrate. The holes are loaded with a conductive reactive braze material. The braze material and the substrate are heated to a temperature which causes the braze material to melt and to react with the inner surface of the via holes and bond thereto.

Abstract: Ceramic and metal articles are joined using three metal layers one of which is a refractory metal or alloy. The refractory metal layer is placed between the other two layers, which each include a metal or alloy having a lower melting point than the refractory metal layer. The three metal layers are pressed between two articles to be bonded to form an assembly. The assembly is heated to a bonding temperature, at which the refractory metal layer remains solid, but the other two layers melt to form a liquid. The assembly is held at the bonding temperature. The refractory metal layer dissolves in surrounding liquid and a single solid bonding layer is eventually formed, at the bonding temperature, between the two articles. The bonding method may be referred to as a transient-liquid-phase or isothermal bonding method.

Abstract: A ceramic substrate is used for an electric or electronic circuit, and comprises a ceramic foundation and at least one conductive island formed of aluminum or an aluminum alloy and bonded to one surface of the ceramic foundation for providing conductive paths to circuit components connected thereto, wherein the aluminum or aluminum-alloy island is brazed to the ceramic foundation with a brazing alloy selected from the group consisting of aluminum-silicon alloy, aluminum-germanium alloy, aluminum-silicon-magnesium alloy and aluminum-silicon-germanium alloy so that thermal stress between the ceramic foundation and the conductive island is taken up.

Abstract: A diffusion bonding process for bonding one rhenium-coated carbonaceous body to another. The rhenium-coat surfaces 18,20 of the bodies are coated with ruthenium, and the bodies are diffusion bonded at the interface formed by adjoining ruthenium coats 22,24.

Abstract: A one step ceramic brazing material preferably for use in joining ceramics to each other or in joining a ceramic to a metal. The brazing material includes a strip of a eutectic alloy and greater than 3% titanium or titanium hydride in powder form, in a polymer coating thereon. The brazing material incorporates these amounts of titanium or hydride without exhibiting blushing, decreased plasticity, and brittleness in the braze joint. The brazing material is made in the form of a coated strip so that it can be stamped to washers, rings or discs for particular applications.

Abstract: The tooling includes a central die member and an outer die member spaced thereabout to form an annular, draftless chamber for receiving a composite preform. An annular punch is received in the chamber for pressing the preform at an elevated temperature sufficient to consolidate and bond the preform into the desired composite. The tooling with the preform therein can be enclosed in a gas impermeable envelope (e.g., a steel can) and hot isostatically pressed at the elevated temperature to press the punch against the preform for purposes of consolidation. The coefficient of thermal expansion of the central die member is selected greater than that of the outer die member and the consolidated composite to facilitate removal of the composite from the draftless chamber.

Abstract: A method is provided which bonds a composite abrasive compact to a cemented carbide pin. The method includes the steps locating a braze alloy having a perforated metal material embedded therein between a surface of the composite abrasive compact and a surface of the cemented carbide pin. The braze alloy has a melting point below that of the metal material. The surfaces are urged together, the temperature of the braze alloy is raised to above its melting point and maintained at this temperature for a short period. The alloy is then allowed to cool and solidify and bond the surfaces together.

Abstract: The invention relates to a method of making high-strength brazed joints in metal/ceramic and ceramic/ceramic composite materials. The brazing surface of the ceramic part is structured prior to brazing by introducing bores having an average diameter in the range of 50 .mu.m-500 .mu.m and a depth in the range of 100 .mu.m-2 mm. Preferably, the structuring is effected by laser working. Brazing is subsequently carried out in a conventional manner. The resulting joint displays increased strength characteristics and resistance to thermal stresses over joints produced by conventional methods.

Abstract: A metal matrix composite is produced by forming a rapidly solidified aluminum base alloy into wire. The wire is arc sprayed onto at least one substrate having thereon a fiber reinforcing material to form a plurality of preforms. Each of the preforms has a layer of the alloy deposited thereon, and the fiber reinforcing material is present in an amount ranging from about 0.1 to 75 percent by volume thereof. The preforms are bonded together to form an engineering shape.

Abstract: A unique class of adhesive alloys and bonding methods for their use are provided which enable the user to join non-conductive materials to themselves or to electrically conductive materials. The bonding alloys have enhanced wetting properties and a melting point less than 100.degree. C. in all instances. The bonding alloys are unusual and advantageous in that they create an intimate, direct, and enduring contact between the materials while minimizing mechanical and chemical stresses.

Abstract: Disclosed is a ceramics bonded product, which comprises a ceramics sintered body bonded to another ceramics sintered body or a metal member through a ductile metal and a group IVa transition metal nitride interposed therebetween. Also disclosed is a method of producing a ceramics bonded product, which comprises bonding a ceramics sintered body and another ceramics sintered body or a metal member by allowing a ductile metal and a group IVa transition metal nitride to exist therebetween.

Abstract: An assembly of parts forming an angle between facing surfaces of the parts and a process for producing an assembly is described. The parts (2, 4) are provided with contact elements or pads (6, 8, 10, 12) for connection to one another by means of a relatively low melting point metallic soldering material. The surface of each of the pads is wettable by the low melting point metallic material in the molten state, while areas surrounding the pads are not wettable. The contact pads of one of the parts are covered with flat coils or wafers (10, 12) of the low melting point metallic material. The wafers have the same thickness, but different volumes. The contact pads of the other part are placed on the corresponding wafers. The wafers' thickness, volumes, and spacing are chosen so that when the wafers are heated to the molten state and form truncated spherical drops due to surface tension, the parts form between them a predetermined angle. The invention has particular application to the manufacture of mirrors.

Abstract: A method for fabricating a titanium aluminide composite structure consisting of a filamentary material selected from the group consisting of silicon carbide, silicon carbide-coated boron, boron carbide-coated boron, titanium boride-coated silicon carbide and silicon-coated silicon carbide, embedded in an alpha-2 titanium aluminide metal matrix, which comprises the steps of providing a beta-stabilized Ti.sub.3 Al foil containing a sacrificial quantity of beta stabilizer element in excess of the desired quantity of beta stabilizer, fabricating a preform consisting of alternating layers of foil and a plurality of at least one of the aforementioned filamentary materials, and applying heat and pressure to consolidate the preform. In another embodiment of the invention, the beta-stabilized Ti.sub.3 Al foil is coated on at least one side with a thin layer of sacrificial beta stabilizer.

Abstract: Ceramic bodies are bonded together via a layer of an oxidation reaction product of a molten metal, which metal is present in one or both of the ceramic bodies prior to bonding. At least one of the ceramic bodies comprises a ceramic product formed by the oxidation reaction of molten parent metal (e.g., alumina from molten aluminum) and grown as molten metal is transported through, and oxidized on the surface of, its own oxidation product. One or both of the ceramic bodies used in the bonding process contains surface-accessible channels of residual metal, i.e., metal channels which have resulted from molten-metal transport during the ceramic growth process. When the suitably assembled ceramic bodies are heated in the presence of an oxidant at a temperature above the melting point of the residual metal, molten metal at the surface of at least one of the body ceramic bodies reacts with the oxidant to form a layer of oxidation reaction product, which may or may not incorporate at least one filler material.

Abstract: A composite structure comprising a symmetric bimetallic laminate bonded to a separate substrate is provided by eutectic bonding the bimetallic laminate to the substrate. A variety of beneficial structures can be provided.

Abstract: An electrode assembly for a plasma reactor, such as a plasma etch or plasma-enhanced chemical vapor deposition reactor, comprises an electrode plate having a support frame attached to one surface thereof. The electrode plate is composed of a substantially pure material which is compatible with a particular reaction being performed in the reactor, while the support frame is composed of a material having desirable thermal, electrical, and structural characteristics. The support frame is bonded to the electrode plate using a bonding layer, usually a ductile metallic bonding layer, which provides effective thermal and electrical coupling while permitting a degree of thermal expansion mismatch between the support frame and the electrode plate.

Abstract: Two metallic surfaces are bonded together by coating each of the metallic surfaces with a layer of a first material and a layer of a second and different material contacting the layer of the first material. The first material and second material are chosen so that a eutectic liquid layer will form at the interface between them. The layers of the second material on each of the metallic surfaces are abutted together and then the layers are heated above the eutectic temperatures to form a localized liquid, which upon solidification results in an interconnection between the surfaces.

Abstract: Inert non-magnetic metals are adhesively bonded to surfaces of metal oxides, for example ferrites, by means of a water vapor-hydrogen atmosphere. Reduction of the metal oxide only takes place at the interface of the inert metal and the metal oxide, after which the metal formed is partly dissolved in the inert metal.

Abstract: The following steps are performed for joining workpieces of metal or ceramic to each other by boundary surface diffusion at the junction location. After laying together the surfaces at which the workpieces are to be joined together, a layer is applied to the outer edge of the joint location consisting of a material compatible with the material of the parts to be joined and mechanically stable under high static pressure. The layer is fixed and sealed. Thereafter the workpieces are diffusion welded by hot isostatic pressing (HIP). A layer meeting the requirements of this process can be applied by plasma spraying onto the region of the seam at the outer edge of the junction location.

Abstract: Two different members, such as a silicon nitride member and a carbide alloy member or a metal member, is attached with a joining member interposed therebetween and is heated at a preselected temperature higher than approximately 1,000.degree. C. under a vacuum or in a reducing atmosphere to be joined together as an integral member. The joining member in the form of a thin layer is made up of a material consisting of a gold-copper (Au-Cu) alloy and titanium (Ti) having a content of 1 to 30, desirably 10 to 30, weight percent of the joining layer.

Abstract: An method and apparatus for integrally joining at least two composite structures using a bonding material which will melt under heating, with a method comprising the steps of heat-melting the bonding material interposed between the composite structures disposed opposite to each other, changing at least once the pressure of the atmospheric gas surrounding the bonding material in a fused state in a reciprocative manner between an initial pressure and pressure different therefrom, and solidifying the fused bonding material.

Abstract: A method and apparatus for uniting workpieces of silicon-infiltrated silicon carbide with large dimensions includes surrounding each of two silicon-infiltrated silicon carbide workpieces with at least one tightly closing shell in the vicinity of a junction between the workpieces, defining at least one intermediate space between the shell and the workpieces. A vacuum or an inert gas atmosphere is maintained in the intermediate space or spaces. Solder is placed at the junction and the junction is locally heated to soldering temperature for materially bonding the workpieces by soldering at the junction.

Abstract: A seal between two ceramic articles, or between a ceramic article and a metal article, is formed by providing a sealing member comprising an aluminum body, and a film of zinc or tin being deposited threon, with the inevitable aluminum oxide surface film removed, and subsequently a coating of silver and/or gold, or a suitable alloy containing silver or gold, being provided. The sealing member is positioned between the articles, and the bonding operation comprises heating the assembly in an inert atmosphere, or in a high vacuum, to melt the composite sealing member, there being obviated the need to apply pressure during the bonding operation. Any oxide film on silver readily decomposes at a temperature of, at most, 250.degree. C. No oxide film is formed on gold. The zinc or tin film, and the coating, are readily absorbed into the molten aluminum produced during the bonding operation. Subsequently, the bonded assembly is out-gassed at a temperature up to 600.degree. C.

Abstract: A method of providing a joint between articles of materials of different coefficients of thermal expansion comprises providing a preform of Indium between the articles, and, at ambient temperature, applying pressure to the articles to compress the Indium therebetween, the pressure being applied in a cyclical manner. A satisfactory joint is provided without employing complex cleaning of the co-operating surfaces of the constituent parts of the joint.

Abstract: Disclosed is a brazed implement comprising a thermally-stable polycrystalline diamond compact, e.g. a compact of self-bonded diamond particles having a network of inter-connected empty pores dispersed throughout the compact, bonded to another of said compact or bonded to a cemented carbide support by a brazing filler metal disposed therebetween. The brazing metal comprises an alloy having a liquidus above about 700.degree. C. and containing an effective amount of chromium. Translational shear strengths exceed about 50 kpsi even upon furnace cycling of the brazed implements and often exceed 90 kpsi. The method for fabricating the brazed implement also is disclosed.

Abstract: A thin metal foil or an array of fine wires or a graphite web, mat or the ke, having electrical conductivity was interposed between clean polished surfaces of ceramic parts which are to be joined, with application of pressure. A high current electrical discharge with very short duration puts so much energy into the conducting material that it explosively vaporizes and penetrates interacts with the ceramic before the ceramic can absorb an appreciable amount of heat and before the hot material can undesirably react with the surrounding atmosphere, so that an inert atmosphere is not necessary for the process. Metals that form silicides and/or carbides are for e.g. desirable for connecting SiC parts and conducting forms of carbon such as graphite are also suitable. Precoating the surfaces to be joined, with reactive or reaction-promoting material as well as a thermal treatment of the joint may be favorable.

Abstract: Active brazing metals that can joint ceramic members mutually or a ceramic member and a metallic member to each other with high joint strength and improved availability can be provided in various shapes such as plate or wire, even when a metal of poor ductility is used as a raw material of the brazing metals.

Abstract: Disclosed is a brazed implement comprising a thermally-stable polycrystalline diamond compact, e.g. a compact of self-bonded diamond particles having a network of inter-connected empty pores dispersed throughout the compact, bonded to another of said compact or bonded to a cemented carbide support by a brazing filler metal disposed therebetween. The brazing metal comprises an alloy having a liquidus above about 700.degree. C. and containing an effective amount of chromium. Translational shear strengths exceed about 50 kpsi even upon furnace cycling of the brazed implements and often exceed 90 kpsi. The method for fabricating the brazed implement also is disclosed.

Abstract: A method of making a hermetic seal for a solid-state device is disclosed. The device includes a ceramic housing having a cavity for an element such as an image sensor. A cover formed of a transparent material is sealed to the housing to close the cavity. A metallization support is formed on the cover and on the housing. In order to form a hermetic seal at a relative low temperature, a layer of indium is coated on the metallization support of either the cover or the housing, and a layer of tin is coated on the support of the other of the two parts. The cover is then placed on the housing, and the parts are placed in a furnace where a temperature under the melting temperature of the composite alloy of tin and indium is maintained for a period long enough to diffuse the tin and indium together. The temperature is then raised to a temperature sufficient to melt the alloy, and the device is then slowly cooled to ambient temperature.

Abstract: A method of fabricating irregular shapes wrapped with metal matrix composite monotape utilizing a cylindrical deposition drum wrapped with a spiraling array of evenly spaced strands of high strength fibers and overlaid with a metal matrix, which is cut into a narrow ribbon which is transferred to a spool and then wound on the irregular shape in a helical manner so that the opposite side margins are adjacent each other in adjacent turns.

Abstract: Two or more ceramic bodies are bonded together by oxidizing with a vapor-phase oxidant molten metal obtained from a body of precursor metal to form an oxidation reaction product bond. The oxidation reaction product is formed between adjacent facing, substantially congruent surfaces of the ceramic bodies and bridges the surfaces, thus bonding the ceramic bodies to each other. Promoters may optionally be used to facilitate formation of the oxidation reaction product.

Abstract: A brazing alloy-filler metal for brazing parts made of TiAlNb alloys has a brazing temperature of about 1020.degree. to 1250.degree. C. and a composition of, in weight percent, 37-75 titanium, 5-43 niobium, 20-58 nickel.

Abstract: In the brazing of a component which comprises a carbide substrate carrying a layer of PCD (polycrystalline diamond) to a steel body, appropriately shaped brazing shims are placed between mating surfaces which are to be brazed. The component is forced towards the steel body and the steel body is heated uniformly across its surface where brazing is to take place. This is achieved by means of an induction heater placed adjacent the steel body at a position remote from that surface of the steel body where brazing is to take place. The local temperature at the PCD layer is monitored continuously and the heating process controlled so that this local temperature does not exceed 750.degree.. After brazing, the component and steel body are permitted to cool down slowly to ambient temperature.

Abstract: In a sealed structure consisting of ceramic members opposing each other and a frame coupled to the ceramic members and defining an He-tight chamber with the ceramic members, the melting point of a joint member for bonding one of the ceramic members to the frame is lower than the melting point of another joint member for bonding the other of the ceramic members to the frame so that rebonding can be made.

Abstract: A three-layer clad plate or a laminated sheet comprising a core piece made of aluminum or its alloy and surfaces made of an aluminum-silicon alloy is inserted between the bonding surfaces of ceramics or between the bonding surface of a ceramic and that of a metal. The resulting structure is maintained at a bonding temperature lower than the melting point of aluminum or its alloy and higher than the solidus of the aluminum-silicon alloy while pressurizing the inserting material, thus bonding the ceramics to each other or the ceramic to the metal.

Abstract: A method of bonding molybdenum and zinc sulfide devices (10, 12) together comprising the steps of lapping the surface of the nickel layers to about a 20,000 Angstrom smoothness, placing nickel layers (16, 16') of about 700 Angstroms respectively on the devices, plating layers of gold (18, 18') of about 4 microns thickness respectively on the nickel layers, respectively immersing the gold-plated layers in a bath (20) of mercury, inverting one (10) of the devices above the other (12), bringing the devices together to effect contact between the mercury films (22, 22'), pressing the devices together within a pressure range of 2 kilograms per square inch to 20 kilograms per square inch for a minimum of 16 hours at room temperature, and sealing the periphery of the gold-mercury seal contact with a nickel seal (26).

Abstract: The present invention is directed to a process of brazing a ceramic mater to graphite. In particular, the brazing procedure is directed to the production of a novel brazed ceramic graphite product useful as a Faraday shield.