Abstract: A method of forming a plurality of individual heating cables sets includes creating at least a portion of a master cable set by coupling alternating sections of cold and hot cable section, each section of cold cable section having a length twice a model cold cable section length and each section of hot cable section having a length twice a model hot cable section length. A continuous metallic ground sheath is applied about substantially all of the master cable set and a continuous outer jacket is applied about the continuous metallic ground sheath. The master cable set is segmented at defined locations to create a plurality of individual heating cable sets having an overall length of the model hot cable section length plus the model cold cable section length.

Abstract: Provided is a clad welded pipe or tube that has improved pipe or tube mechanical properties by reducing the width of a weld without its function as a clad pipe or tube being impaired. A clad welded pipe or tube comprises: a first layer made of base metal; and a second layer placed on one surface of the first layer, and made of first cladding metal that is a material different from the base metal, wherein a pipe or tube circumferential length L1 of weld metal at a pipe or tube inner surface and a pipe or tube circumferential length L2 of the weld metal at a pipe or tube outer surface in a weld are each 0.0010 mm or more and 1.0 mm or less, and the base metal is not exposed at a first cladding metal-side surface of the clad welded pipe or tube in the weld.

Abstract: A method of manufacturing a base pipe for use in horizontal well completion, the method includes wrapping an inner shroud around a base pipe, the inner shroud is disconnected from the base pipe and forms seams along each edge of the inner shroud; fusing the seams together; allowing the inner shroud to cool, the inner shroud shrinks around the base pipe to form a friction lock between the base pipe and the inner shroud; laying a filter medium onto an outer shroud, wherein the filter medium is disconnected from the outer shroud, thereby creating a mesh filter medium/outer shroud sheet; wrapping filter medium/outer shroud sheet around the inner shroud, the filter medium is positioned between the inner shroud and outer shroud, thereby creating a second set of seams; and fusing the second set of seams together, thereby creating a second friction lock between the outer shroud and the inner shroud.

Abstract: A bonding member that includes a base material that has a spiral shape when viewing a cross section thereof orthogonal to a longitudinal direction thereof, and contains a low melting point metal; and a coating film in a gap between opposed surfaces of the base material when the base material is in the spiral shape. The coating film contains metal particles of a high melting point metal that forms an intermetallic compound having a melting point higher than that of the low melting point metal by reaction of the high melting point metal with a melt of the low melting point metal. The low melting point metal is, for example, Sn or a Sn alloy. The high melting point metal is, for example, a Cu—Ni alloy, a Cu—Mn alloy, a Cu—Cr alloy, or a Cu—Al alloy.

Abstract: The present invention provides an isothermal processing method for making an isothermal processed copper clad aluminum composite comprising: providing an aluminum component and a copper component; cleaning the aluminum component and shape finishing the aluminum component; extruding the aluminum component into a core aluminum billet; cleaning the copper component; transforming the copper component into a copper cladding layer; cladding longitudinal and circumferential surfaces of the core aluminum billet with the copper cladding layer and molding the core aluminum billet and the copper cladding layer together to form a copper cladded aluminum billet; and transforming the copper cladded aluminum billet into an isothermal processed copper cladded aluminum composite through isothermal rolling and annealing. The present invention also provides an isothermal processed copper cladded aluminum composite and a system for manufacturing an isothermal processed copper cladded aluminum composite.

Abstract: According to aspects of the present disclosure, a lightweight busbar includes an aluminum body, a copper connector, and a cladded interface. The aluminum body defines a first end and a second end opposite the first end. The copper connector is disposed proximate the first end of the aluminum body. The copper connector is configured to be fastened to an external component. The cladded interface bonds the copper connector to the first end of the aluminum body. The cladded interface inhibits yield between aluminum and copper during thermal cycling.

Abstract: A filter element (1) wound from a plurality of filter layers in which the circumferential contour (5, 5?) of a cross-sectional area (4) of the filter element (1) has at least one circumferential contour section (5?) undercutting the envelope contour (6, 6?) of the cross-sectional filter element area (4).

Abstract: An apparatus for filtering well fluids and method of manufacture is disclosed. The apparatus comprises an inner support, a filter spirally wrapped around the inner support, and an outer support wrapped around the filter enclosing the filter between the inner and outer supports. The filter has longitudinal edges which overlap and the filter is held in place by friction with the inner and outer supports. The method of manufacturing the apparatus comprises continuously and simultaneously wrapping a filter and outer support around an inner support and disposing the filter between the outer and inner supports.

Abstract: The invention relates to a method of continuously fabricating a coaxial cable in which ring-shaped corrugations are imparted to a conductor of the cable in a corrugator. The corrugator is made to operate at constant speed.

Abstract: An apparatus for filtering well fluids and method of manufacture is disclosed. The apparatus comprises an inner support, a filter spirally wrapped around the inner support, and an outer support wrapped around the filter enclosing the filter between the inner and outer supports. The filter has longitudinal edges which overlap and the filter is held in place by friction with the inner and outer supports. The method of manufacturing the apparatus comprises continuously and simultaneously wrapping a filter and outer support around an inner support and disposing the filter between the outer and inner supports.

Abstract: A method of producing an overhead contact wire for supplying power to electrically driven vehicles is proposed which comprises a copper-clad steel wire and a copper wire that is metallically joined to the copper-clad steel wire. The method includes the following steps: a) heating a steel wire to a temperature about 950.degree. C.; b) joining first and second metal band sections to a surface of the steel wire by means of rolling at a temperature of about 950.degree. C. under protective gas atmosphere to produce a combined element; c) reducing the cross-section of the combined element by at least 20%; d) heating a copper wire to a temperature about 950.degree. C.; e) joining the heated copper wire to the reduced diameter combined element in the area covered by the first band section by rolling at about 950.degree. C. under protective gas to produce a prepared wire; and f) reducing the cross-section of the prepared wire to produce an overhead contact wire.

Abstract: Large amounts of stabilizing copper may be added to a superconducting core using an economical cladding process. One or more cladding strips of copper are bonded directly to the core without the use of a bonding agent. The copper cladding is fused to the core at a late stage in the fabrication of the superconductor by the simultaneous application of heat and pressure using conventional rolling apparatus. Multiple cladding layers may be sequentially applied to further increase the volume of copper present in the superconductor.

Abstract: An apparatus for making cable including an elongate core and a surrounding longitudinally welded tube includes one or more pairs of opposing tube forming rolls which form a tape into a generally tubular shape surrounding the advancing core. A pair of tube forming rolls define exit tube forming rolls mounted to have an adjustable spacing therebetween. A first sensor generates an exit roll spacing signal which is one parameter that may be displayed to the operator or used to directly to control the spacing. Downstream from an induction welding coil, a pair of opposing weld rolls are mounted to have an adjustable spacing therebetween for permitting setting of a desired pressure between the heated opposing longitudinal edges of the advancing tape. A second sensor generates a weld roll spacing signal which may also be displayed or used to directly control the spacing within a desired range. An associated method is also disclosed.

Abstract: The object of the invention is a corrosion-resistant composite wire with diameters <10 mm, which has a concentric, homogeneous high-grade steel coating, wherein this coating, depending on the diameter of the wire and the application, can vary 15-30% by volume, and its strength can vary, depending on the core wire used and the degree of forming, up to .ltoreq.2000 N/mm.sup.2. To produce such a composite wire, for example, a high-strength, patented and surface-pretreated steel wire is sheathed with a strip of high-grade steel. In the first forming step, the longitudinally welded high-grade steel sheath is pressed tightly onto the core wire and in subsequent drawing steps, the composite wire is drawn to the final dimensions. At least between two forming steps, there is a selective annealing treatment of the composite wire by means of a rotary arc, whereby only the high-grade steel layer is heated to the annealing temperature.

Abstract: A method of cladding a medium or high steel core rod with another metal includes a hot water quench at a temperature of about 160.degree. F. to boiling temperature and preferably about 195.degree. F. to 205.degree. F. with a subsequent quench in water at a temperature below a level of the first temperature and preferably at about ambient temperature. The clad material is found to be substantially devoid of objectionable oxide particles or surface sponge particles and the steel core substantially devoid of acicular transformation products permitting continued processing by deformation processes, such as wire drawing.

Abstract: A multiple sheath cable for telemetry, heating and communications and methods of manufacturing such cable in long lengths with high tensile strength. The telemetry and communications cable may be of the wire type for conducting electrical signals or fiber optics for conducting laser or other optical signal, the conductors being typically insulated by mineral insulation material or organic insulation material. These insulated conductors are provided with concentric multiple layers of metal tubular sheaths having staggered weld joints for increasing tensile strength while protecting the conductors and the insulation from extreme environmental conditions such as heat, pressure and corrosion.

Abstract: The specification discloses manufacture of clad rod and the like by rolling cladding strip on to the core rod. By matching the core rod cross section, cladding strip cross section, and roll pass design a composite clad rod of improved concentricity may be produced.

Abstract: In the manufacture of mineral insulated cable, by a continuous process in which the tubular sheath is formed by bending and seam welding travelling metal strip, and insulating powder and conductor wires are continuously delivered into the sheath, one wire is fed through a guide tube extending into the sheath beyond the weld point, and having an aperture in its wall adjacent to the weld area. The wire so exposed directly to the heat from the weld conducts excess heat away from the weld, thus preventing thermal damage, in particular to a powder delivery tube if present. The guide tube is so arranged that powder is excluded from the weld area. When the sheath is formed of an oxidizable metal such as copper, a continuous stream of rare gas is delivered to the underside of the weld area. Forms of apparatus for carrying out vertical and horizontal processes are described.

Abstract: A clad product having predetermined closely-toleranced shape and dimensions. The product is made by first preforming a base material and a cladding of dissimilar material in dimensions substantially the same as the clad product, with at least the base or cladding being preformed with an additional dimensional profile. At least the cladding material is then heated to a solid-phase bonding temperature, achieved in one embodiment by laser-heating. The base material and cladding material are subsequently passed together through pressure rollers with application of a pressure for solid-phase bonding the cladding material against the base material to form the clad product. The bonding pressure of the rollers deforms the preformed additional dimensional profile to compensate for non-uniform material flow in the respective base or cladding material during solid-phase bonding for obtaining the predetermined closely-toleranced shape and dimensions of the clad product.

Abstract: A metal rod is supplied to a pair of bonding rolls provided with peripheral grooves forming a substantially circular roll pass that also receives at opposite sides of the rod a pair of metal strips of a different metal than that of the rod. The rolls press the strips against the rod and pull all three together through the roll pass, with the strips bent around the rod to enclose it. Before the strips reach the pass, an electric current passes through a length of each one to heat it to a solid-phase bonding temperature and to burn off contaminants. Also, before the rod reaches the rolls, it is heated to a solid-phase bonding temperature by means of an electric induction coil encircling it while it is passing through an enclosure maintained full of a gas providing a controlled atmosphere around the heated portion of the rod. The diameter of the roll pass is small enough to reduce the diameter of the product therein and simultaneously cause solid-phase bonding together of the heated strips and heated rod.

Abstract: A method of producing a copper clad steel wire, which comprises the steps of preparing a 5 to 15 mm diameter steel rod and a 21 to 66.7 mm width copper tape; continuously supplying the steel rod and the copper tape separately and cleaning the surfaces thereof; forming the copper tape in tubular form such that the copper tape can cover the steel rod while supplying the steel rod and the copper tape in parallel, and welding the edges of the copper tape in a non-oxidizing atmosphere; sinking the tubular copper tape sufficiently for the copper tape to substantially come into contact with the steel rod to form a copper clad steel rod; cold-drawing the copper clad steel rod and/or hot working the clad rod at a temperature of 400.degree. to 800.degree. C. to reduce its cross-sectional area by more than 20%; and then annealing the copper clad steel rod at a temperature of 300.degree. to 1050.degree. C.

Abstract: Copper-clad steel wire is produced by forming a copper tube around the wire, and drawing down the copper tube and wire to reduce the cross-section of the wire by at least 30%. The wire is annealed, slowly cooled and the cross-section further reduced by at least 10%.

Abstract: There is disclosed a process and apparatus for manufacturing flexible, shielded coaxial cable exhibiting improved magnetical screening capabilities wherein a tubular outer conductor is concentrically formed about an inner conductor with spacer means being disposed in the annulus between conductors. Accordingly, about the inner conductor including spacer means therefore, there is formed an inner component tube of a conductive material by the continuous forming in a lengthwise direction of a metal band into a tube having longitudinal edges welded together in a continuous, longitudinal welded joint. Concurrently, at least one further component tube is formed concentrically about the inner component tube by the lengthwise deformation of a second metal band of a ferromagnetic material into a second tube having opposed longitudinal edges which are also welded in a longitudinal direction in a continuous, longitudinal welded joint.

Abstract: Manufacturing of a soft metal sheath formed of aluminum or copper, for example, is improved by suitably selecting the apparatus composing the shaping means employed therein and arranging the capstan and the sinking die in a novel manner. The apparatus selected is made from a wear-resistant synthetic resin such as a molybdenum bisulfide-included nylon. The sheath is manufactured from a metal tape of aluminum or copper through the working stages of applying a cylindrical tube shaped from the tape onto a cable core, butt welding the seam, and then reducing the diameter of the metal tube to connect it to the core.