Abstract: A pair of sheets of a metal capable of exhibiting superplasticity, such as Titanium, are placed in overlapping relationship and the peripheral edges of the sheets are joined, such as by welding, to provide a gas impervious seal. The joined metal sheets are lowered into a press so that they extend vertically between a pair of horizontally spaced apart, vertically extending preheated ceramic dies. The dies are previously transferred inside insulating shrouds from a preheater station before being loaded into the press. At least one of the dies is moved horizontally toward the other one of the dies so that the joined metal sheets are positioned closely adjacent to the dies. As a result, the metal sheets are heated to a predetermined temperature at which they are capable of exhibiting superplasticity. Thermostatically controlled heating platens behind the dies offset any heat losses in the dies as they radiate energy to the joined metal sheets.

Abstract: A vacuum-insulated, double-walled metal structure comprises inner and outer shells made of a metal and seamed together to form a double-walled structure with a space between them, the space being exhausted of air. At least one of the inner and outer shells is provided with at least one activated foil of a metal selected from the group consisting of copper, titanium and zirconium. The inner shell may be wound with an activated titanium or zirconium foil, and covered by another metal foil selected from the group consisting of copper, aluminum, titanium and zirconium, except for a part of its bottom. The metal foil wound on the metal structure is activated by preliminarily exhausting air from the space so that a pressure therein becomes reduced to a low vacuum of the order of 10.sup.-2 Torr, and then heating the double-walled structure at not less than about 400.degree. C.

Abstract: A composite electrode based on a valve metal with a layer of a platinum foil securely adhering thereto is produced by hot isostatic pressing of the valve metal base and platinum foil between separating sheets; the separating sheet which comes in contact with the platinum foil during hot isostatic pressing is a metal with a melting point of at least 100.degree. C. above the hot isostatic pressing temperature.

Abstract: A technique for assembling semiconductor devices in which semiconductor elements, especially lasers or LEDs, are mounted on a first packaging element such as a heat spreader that is mounted on a second packaging element such as a heat sink. Handling of solder preforms is avoided by coating at least one of each of the pairs of surfaces to be brought into contact with a layer of solder and heating the assembly to melt both solder layers in a single operation. In a preferred embodiment a heat spreader is coated in solder on both sides and interposed between a semiconductor element and a heat sink and the assembly is heated. Molybdenum may be used as a layer to aid wetting and adhesion and gold/tin solder may be used. Slightly different solidification temperatures and compositons for the layers may result from different take up of metallization layers from the components into the solder.

Abstract: Insert 1 comprises thin substrate made by cold-rolling, and two bonding alloy layers formed by plating on the upper and lower surfaces of substrate, respectively. Both layers is extremely thin, and is made of an alloy having a melting point lower than that of substrate. Insert 1 is used to achieve liquid phase diffusion bonding of first and second base metals. Insert 1 is interposed between first base metal and second base metal. Then, insert 1 and base metals are clamped together with a pressure of, for example, 0.5 kgf/mm.sup.2, and are placed in a atmosphere of a low pressure of about 10.sup.-4 Torr and heated to the melting point of alloy layers or to a temperature above this melting point but below the melting points of substrate and plates.

Abstract: The present invention provides a process for producing a clad plate which comprises a first step of forming a coil by taking up two or more metal sheets as clad materials and a thin sheet of heat-resistant steel which works as a separator material while these members are overlaid on one another and a second step of vacuum heat-treating the resultant coil.

Abstract: A fiber reinforced metal laminate and method of preparation. The metal layers are of aluminum or aluminum alloy. An aluminum containing solder layer is disposed on inner surfaces of the metal layers. The fibers are silicone-carbide, boron or silicon-carbide coated boron and located between the solder layers. These layers are heated under pressure to a temperature above the melting point of the solder and below the melting point of the metal layer.

Abstract: A method for making multi-colored composite laminates comprises stacking a plurality of colored strips in a predetermined pattern and bonding the strips into a composite laminate by continuous bonding. The composite laminate is then rolled before being passed through a deep steel pattern roll which forms a raised pattern on its surface. Next, the laminate is passed through a skiving table where the raised pattern is skived off to expose the multi-colored pattern formed by the underlying layers. The laminate is than flat rolled to a finished dimension and may be reeled up into a cylindrical roll.

Abstract: A method of explosion welding magnesium-alloyed aluminium to high strength material.

Abstract: A process for producing a heating plate involves fastening a tubular heating element (1) to a plate (2) made of metal or metal alloy. A plate (2) made of rolled metal or metal alloy is used, and cold-stamped in this plate is a shoulder (3), the contour of which corresponds substantially to the contour of the tubular heating element (1). The tubular heating element (1) is placed against the shoulder (3) and fastened to the plate by soldering. The thickness of the central part of the plate (2) is sufficient to withstand the thermal stresses which it must undergo. The process is especially useful for producing a heating sole of a steam-operated smoothing iron.

Abstract: An improved method of forming a filamentary reinforced article includes forming a preform of metal and filament layers by winding material around an axis. The resulting layered preform is enclosed in a fluid tight housing. The housing has a rigid frame which bounds the periphery of the preform. The housing also has flexible panel sections which extend inwardly from the frame across the preform. To bond the layers of the preform together and increase the density of the preform, the housing is subjected to a hot isostatic pressing operation. During the hot isostatic pressing operation, fluid pressure forces against the housing plastically deform the panel sections of the housing inwardly in a direction parallel to the axis around which the layers of the preform were wound to apply axial deformation forces to opposite sides of the preform.

Abstract: A combination of unique properties of (i) high strength and stiffness at temperatures up to about 1500.degree. F., (ii) good room temperature mechanical properties including good ductility and (iii) improved resistance to matrix cracking is achieved in a titanium structure by forming a hybrid titanium alloy matrix composite in which the matrix consists of layers of at least two alloys, i.e. a high temperature-resistant titanium aluminide alloy and a ductile, lower modulus titanium alloy, that are bonded metallurgically to each other in various embodiments. A reinforcing material in the form of filaments, fibers or whiskers, e.g. silicon carbide, can be embedded within either or both types of the titanium layers.

Abstract: Processes for producing titanium aluminide SPF/DB components, particularly structural panels, are provided. In one embodiment, the process comprises providing rapidly solidified titanium aluminide alloy sheetstock, providing a plurality of rapidly solidified titanium aluminide alloy ribbons or strips, forming the ribbons into waveform structures, assembling a plurality of these waveform structures to produce a honeycomb core, positioning this core between face sheets, and bonding the core to the face sheets. In another embodiment, the process comprises providing rapidly solidified titanium aluminide alloy sheetstock, superplastically forming at least one piece of sheetstock into a shaped piece having spaced apart, parallel bonding regions, positioning this shaped piece between two face sheets, and bonding the shaped piece to each face sheet.

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: A method is set forth of forming a hollow structure having a varying mass distribution. Two sheets of a diffusion bondable and superplastic formable material are formed with one flat surface and an opposite surface contoured to have a selected mass distribution. A stop-off material is applied between selected non-peripheral portions of each of the flat surfaces whereat diffusion bonding is to be prevented and superplastic forming is to be required. An intermediate flat core sheet may also be present. The flat surfaces are positioned in abutting relation to each other or to the intermediate flat core sheet. The sheets are subjected to diffusion bonding conditions. The sheets are superplastically formed to expand them apart against a die. The invention also provides a method of preinflating contoured sheets prior to superplastically forming them to avoid truss core rupture. Hollow aircraft engine components are formed by the methods.

Abstract: A first surface of a first metal component of an ink jet print head is bonded to a second surface of a second metal component of the ink jet print head, the first and second surfaces being of materials having the same or similar coefficients of thermal expansion. A layer of filler material is electroplated or otherwise placed on at least one of these surfaces. The filler material has a melting point which is below the melting point of the first and second components, and the total thickness of the filler material on the surfaces together is in the range of from approximately one-sixteenth micron to approximately five microns, with one-eighth micron to two microns being a preferred range. These surfaces are placed together and subjected to heat and pressure to diffusion bond the surfaces without melting the filler material. The diffusion bonding is performed in one approach until no more than approximately one micron of filler material remains between the surfaces.

Abstract: The method of making a heterogeneous, Damascus-type cutting blade, comprising forming an open metal enclosure, placing a stack of metal foils in the enclosure, placing a metal plate in the enclosure on top of the stack of foils, folding in portions of the enclosure on said plate to compress the latter and stack of foils, heating and hammering the enclosure and foils to bond the same together, removing the enclosure from the bonded foils, and finish-griding the bonded foils.

Abstract: A first surface of a first metal component of an ink jet print head is bonded to a second surface of a second metal component of the ink jet print head, the first and second surfaces being of materials having the same or similar coefficients of thermal expansion. A layer of filler material is electroplated or otherwise placed on at least one of these surfaces. The filler material has a melting point which is below the melting point of the first and second components, and the total thickness of the filler material on the surfaces together is in the range of from approximately one-sixteenth micron to approximately five microns, with one-eighth micron to two microns being a preferred range. These surfaces are placed together and brazed under low pressure. Preferably, the braze pressure is from about one-half psi to no more than about one hundred psi, with about ten psi being most preferred.

Abstract: Two soft magnetic core halves of amorphous metal are connected together via a non-magnetic gap and the core halves are supported bilaterally by two core supports. The core supports have a connection member at the gap area and at the short-circuit area of the head block thus constructed on both sides of the head gap. The parts of the head are welded by means of the connection members to form a mechanically stable unit.

Abstract: In a method for producing a clad plate by rolling an improvement comprises: a base material, a cladding material, and a cover material overlaid one on another to form a multi-layer structure, and after cleaning joining surfaces of the materials, the cover material is welded to the base material along the periphery thereof, thereby sealing and fixing the cladding material between the cover material and base material, and forming a multi-layer assembly. A member for preventing warp is overlaid over an outer surface of the cover material via a separating agent, and the member for preventing warp and the base material are fixed to one another by welding along the periphery thereof, thereby forming a blank for rolling. The blank is hot-rolled, a rolled article is cut along its periphery to separate the means for preventing warp, and subsequently, the cover material is removed by machining, grinding, or pickling.

Abstract: Relatively large structures are fabricated from oxide dispersion strengthened platinum or alloys by working a plurality of pieces to thin, wide layers, and then laminating the layers such as by hammer welding so as not to disturb the grain structure or oxide dispersion.

Abstract: A method for fabricating an improved titanium alloy composite consisting of at least one high strength/high stiffness filament or fiber embedded in an alpha-beta titanium alloy matrix which comprises the steps of providing a rapidly-solidified foil made of a lean metastable beta titanium alloy, fabricating a preform consisting of alternating layers of the rapidly-solidified foil and the filamentary material, and applying heat and pressure to consolidate the preform, wherein consolidation is carried out at a temperature below the beta-transus temperature of the alloy.

Abstract: A method for forming fiber reinforced titanium alloy composite is taught. The composite is formed with an inner and outer high density skin of titanium base alloy prepared by RF plasma spray depositing larger size particles of the alloy. The first skin is formed on a substrate, the fiber reinforcement is applied over the inner portion of the first skin and then a second skin is RF plasma deposited over the reinforcement and outer or edge portions of the first skin to seal the contents of the composite. The composite is then hot isostatic pressed to densify its contents without being enclosed in any auxilliary container such as the conventional HIPing container.

Abstract: An apparatus for the in-line annealing of amorphous strip includes feed rolls for substantially continuously feeding the strip during annealing. The strip is first fed into a nip of cooperating heated pressure rolls. The heated pressure rolls rapidly heat the strip to an annealing temperature at a rate of substantially 10.sup.2 -10.sup.4 .degree.C./second while also subjecting the strip to localized plastic deformation. Where multiple ribbons are being fed simultaneously through the heating pressure rolls, bonding occurs to produce a composite strip. The strip is fed from the pressure rolls through an in-line annealer immediately downstream from the pressure rolls. During annealing, the strip is continuously fed and maintained under tension by operation of a winding roll. The strip is annealed at a temperature of between 420.degree.-510.degree. C. for 0.01-10.0 minutes.

Abstract: An improved method of forming an article includes providing continuous, woven, flat, helical tape of filaments and a continuous flat, helical tape of foil. The two helical tapes are interleaved to form a helical assembly having turns of filaments alternating with turns of foil. Deformation forces are applied against the turns of the helical assembly in a direction parallel to the central axis of the helix to bond the turns of the tapes off oil and filament together while maintaining the filaments free of axially extending forces. During the bonding of the turns of the helical foil and filament tapes, the tapes may be bonded to a housing or other component of an article to be reinforced. Radial reinforcing can be provided by including in the helical assembly a layer having filaments with central axes which are radial relative to the central axes of the filaments of the helical tape.

Abstract: A method for fabricating long-length and/or large-sized dense filamentary reinforced monotapes. The method comprises forming a layered sandwich of matrix foils or encapsulating sheets plus foils around a reinforcing mat of collimated fibers and sealing the edges of the assembly. The sealing step is carried out with the sandwich formed to a predetermined arcuate configuration such that the sandwich can be coiled after edge sealing without buckling the encapsulating sheets or disturbing the filament alignment and orientation. The formation of the sealed, encapsulated preform can be carried out using continuous processing techniques. Subsequent processing, such as densification, can be performed with the preform in the coiled condition or after it is uncoiled to approximately the arcuate configuration of the sealing step.

Abstract: Process for manufacturing reinforced panel, including corrosion resistant panel, comprising preheating a galvanized or zinc coated metal sheet, applying a molten aluminum coating to a strip or plate of metal mesh and pressing the thus heated materials together to effect interdiffusion of the zinc and aluminum. An embodiment of the process is characterized by the immersion of the mesh into an aluminum bath and the passing of the molten aluminum coated mesh and galvanized strip between pinch rolls. The molten aluminum coated mesh may also be sandwiched between two zinc coated strips.

Abstract: A lid for closing an electronics package exhibits a high corrosion resistance. The lid is formed of a metal substrate which is clad with rolled or worked nickel, and covered with a layer of gold or precious metal electroplate. At edges of the lid, which are not covered with cladding, a layer of nickel is electroplated, employing the dogbone effect to concentrate the metallization at the edges. The rolled or worked metal has a much smaller porosity than an electroplated layer, and the nickel cladding can be applied to the desired thickness in much less time than nickel electroplate.

Abstract: A method for fabricating an improved titanium alloy composite consisting of at least one high strength/high stiffness filament or fiber embedded in an alpha-beta titanium alloy matrix which comprises the steps of providing a rapidly-solidified foil made of an alpha-beta titanium alloy, fabricating a preform consisting of alternating layers of the rapidly-solidified foil and the filamentary material, and applying heat and pressure to consolidate the preform, wherein consolidation is carried out at a temperature below the beta-transus temperature of the alloy.

Abstract: The invention provides a method of manufacturing a metal-based composite material, in which the interfacial reaction between an inorganic fiber reinforcing material and a matrix metal such Al or Mg during press forming of the metal-based composite material is suppressed, and the resultant material has an excellent composite state.In the method of the invention, a preform laminate or sandwiched body consisting of the inorganic fiber reinforcing material and the matrix metal is packed in a sealing metal container. After the interior of the container is evacuated, the container is rapidly heated to a temperature higher than the solidus of the matrix metal. Immediately thereafter, while a vacuum pressure is kept unchanged, the container is pressed between a pair of platens kept at a temperature lower than the solidus of the metal, thereby obtaining a composite material of the reinforcing material and the metal.

Abstract: 1. A method of making a fuel-containing structure for nuclear reactors, comprising providing an assembly comprising a plurality of fuel units; each fuel unit consisting of a core plate containing thermal-neutron-fissionable material, sheets of cladding metal on its bottom and top surfaces, said cladding sheets being of greater width and length than said core plates whereby recesses are formed at the ends and sides of said core plate, and end pieces and first side pieces of cladding metal of the same thickness as the core plate positioned in said recesses, the assembly further comprising a plurality of second side pieces of cladding metal engaging the cladding sheets so as to space the fuel units from one another, and a plurality of filler plates of an acid-dissolvable nonresilient material whose melting point is above 2000.degree. F.

Abstract: A process for bonding together two or more pieces of material, at least one of which is an amorphous material, wherein an intermediate interlayer is placed between the two pieces and the assembly is hot pressed at a temperature above the melting point of the interlayer but below the crystallization temperature of the amorphous piece. The composition of the interlayer is chosen so that the elements diffusing into the pieces being bonded are compatible with retention of the amorphous structure. When the bonding operation is carried to completion, no evidence of the interlayer as a separate phase remains. Alternatively, the bonding operation may be halted before completion and the interlayer will remain as a separate, observable phase. For bonding hard metal amorphous materials, alloys of aluminum with silver, gold, silicon and germanium, and alloys of gold with silicon, with the addition of fluxing elements such as phosphorus and boron, have been found to provide particularly satisfactory results.

Abstract: A laminated aluminum fluidic device is constructed by sequentially coating the facing side surfaces of the aluminum laminae with layers of zinc, nickel and solder, positioning the facing pairs of solder layers in intimate contact, and heating the coated laminae to fuse the facing solder layers.

Abstract: This invention includes a continuous in-plane spiral of monofilament/metallic ribbon which forms a preform for metal matrix composite fabrication. The purpose is to provide continuous spiral filament reinforcement around a hole or central core. This spiral monolayer is fabricated by co-winding the filament and a ribbon or wire made from the intended composite material around a mandrel. Monolayers so constructed could then be stacked to form cylindrical or torus-shaped components and consolidated in a direction parallel to the axis of the shape.

Abstract: A method of bonding and shaping a plurality of pieces of material disposed in a fluid tight container includes providing a housing having components with different coefficients of thermal expansion. The container is positioned between upper and lower sections of the housing. The housing is then enclosed in an autoclave. The fluid in the autoclave and housing is heated with a resulting increase in the fluid pressure in the autoclave and housing. As the temperature and pressure in the housing is increased, the joint between the container and the housing sections is sealed by pressing the upper and lower sections of the housing against the container under the influence of forces resulting from different amounts of of thermal expansion of components of the housing. Thereafter, the fluid pressure in the autoclave is increased. Since the joint between the housing and the container has been sealed, the further increase in fluid pressure is applied to only the upper side of the container.

Abstract: To counteract magnetic forces arising in the operation of a dynamo electric machine, and more particularly a vehicular, especially automotive three-phase alternator, causing, in operation, noise due to shifting of laminations under the influence of magnetic forces, the stator laminations are connected together at a circumferential edge, preferably the outer circumference, by a welding seam or track applied by laser welding. More than one seam or track may be provided, the welding seams or tracks extending in undulating or zig-zag form from one end face of the stack to the other in a criss-cross or mesh pattern.

Abstract: Heat exchanger panel and process of making such panel comprised of selectively clad or bonded metal plates made of a material which cannot be cold roll bonded without great difficulty, if at all, with at least one channel disposed therebetween. An adhesive layer of an amorphous metal is provided between the plates for permanently joining the plates together by cold roll bonding in the area of the adhesive layer.

Abstract: In a method of producing heavy plate of steel, a prematerial is hot-rolled in several passes. As the prematerial at least two slabs of the same steel quality are superposed so as to form a pack and are welded by roll-bonding and reduced in thickness.

Abstract: A method is described for the manufacture of articles in defect-immunized materials in which the defects are eliminated, or broken up and oriented in such manner as to minimize their harmful effects on the article.Referring to FIG. 1e, a rotor disc for a gas turbine engine is formed to an approximate shape by stacking together "sticks" 5 of material in an evacuated container and bonding them together by a hot isostatic pressing process. The "sticks" 5 are produced by extruding a starting body, for example, of powder material, to produce an elongation of up to twenty times and then cutting them to the appropriate length. By this means any non-metallic inclusions in the powder are broken up, inspection of the sticks and rejection of defective ones becomes easier, and the sticks can be oriented so that the effects of any remaining defects can be minimized.

Abstract: A method of fabricating a fiber-reinforced metal matrix composite including the steps of mounting of a braided fiber tube on a substrate, wrapping a braze foil about the braided fiber tube to form an assembly that is encapsulated by a metal capsule which is creep collapsed onto the assembly at a temperature below the braze foil flowpoint. The encapsulated assembly is subsequently heated to a temperature sufficient to induce flow of the braze foil alloy and later cooled to allow solidification and annealing of the resulting fiber reinforced metal composite.

Abstract: A thermostatic metal comprises a layer of a low expansion metal bonded to a layer of a high expansion metal, the outer surface of one of the layers comprising a layer of similar composition but containing, in addition, a grain growth limiting additive.

Abstract: A method is described for the manufacture of articles in defect immunized materials in which the defects are eliminated, or broken up and oriented in such manner as to minimize their harmful effects on the article. Referring to FIG. 1e, a rotor disc for a gas turbine engine is formed to an approximate shape by stacking together "sticks" 5 of material in an evacuated container and bonding them together by a hot isostatic pressing process. The "sticks" 5 are produced by extruding a starting body, for example, of powder material, to produce an elongation of up to twenty times and then cutting them to the appropriate length. By this means any non-metallic inclusions in the powder are broken up, inspection of the sticks and rejection of defective ones becomes easier, and the sticks can be oriented so that the effects of any remaining defects can be minimized.

Abstract: This invention is a process for joining metals to ceramics to form very strong bonds using low brazing temperature, i.e., less than 750.degree. C., and particularly for joining nodular cast iron to partially stabilized zirconia. The process provides that the ceramic be coated with an active metal, such as titanium, that can form an intermetallic with a low melting point brazing alloy such as 60Ag-30Cu-10Sn. The nodular cast iron is coated with a noncarbon containing metal, such as copper, to prevent carbon in the nodular cast iron from dissolving in the brazing alloy. These coated surfaces can be brazed together with the brazing alloy between at less than 750.degree. C. to form a very strong joint. An even stronger bond can be formed if a transition piece is used between the metal and ceramic. It is preferred for the transition piece to have a coefficient of thermal compatible with the coefficient of thermal expansion of the ceramic, such as titanium.

Abstract: A titanium clad steel plate is formed by conversion rolling an explosively bonded composite which includes intermediate layer selected from tantalum or niobium in alloyed or unalloyed form. The process is particularly characterized by the inclusion of a second intermediate layer of cooper or nickel between the steel and the first intermediate layer. After explosion bonding of this four layered composite, the same may be preheated to for 1 hour at, e.g., 830.degree. C. before hot rolling to a thickness of one fifth that of the composite.

Abstract: A building roof, having an optimum strength to weight ratio, and method of constructing the roof wherein a horizontally disposed roof deck assembly particularly adapted to provide diaphragm shear strength and shear stiffness is formed comprising: a sheet (12) of steel corrugated material, a sheet (14) of optional insulation material, and a sheet (16) of rigid substrate material mechanically fastened together by screws (18). The sheet (12) of corrugated material is welded to purlins (20) by elongated welds (40) formed to resist rotation of the corrugated sheet (12) in a horizontal plane. The screws (18) extend through the rigid substrate (16) and through rigids (11) on the upper side of the corrugated sheet (12) to form a truss-like structure extending generally parallel to the purlins (20). Weld washers 30 having elongated slots (35) are used to secure high tensile strength symmetrically corrugated steel (12) having a thickness in a range of 0.0144 inch to 0.

Abstract: An improved method of making an airfoil includes stacking plies in two groups. A separator ply is positioned between the two groups of plies. The groups of plies and the separator ply are interconnected to form an airfoil blank. The airfoil blank is shaped, by forging or other methods, to have a desired configuration. The material of the separator ply is then dissolved or otherwise removed from between the two sections of the airfoil blank to provide access to the interior of the airfoil blank. Material is removed from inner sides of the two separated sections to form core receiving cavities. After cores have been placed in the cavities, the two sections of the airfoil blank are interconnected and the shaping of the airfoil is completed. The cores are subsequently removed from the completed airfoil.

Abstract: A method of producing a machine part of a fiber-reinforced composite material comprising forming a fibrous-shaped body by effecting a partial diffusion-bonding of a plurality of inorganic fibers by copper solder. The fibrous-shaped body is self-supporting and is of relatively high density of the order between 2.0 and 5.0 g/cc. The mechanical part is produced by integrating the fibrous-shaped body with a matrix metal by high pressure solidification.

Abstract: This invention relates to the production of large non-planar shapes of metallic glass fabricated from ribbon. The inventive method contemplates stacking the ribbon. The stacked ribbon is formed and held at temperatures of between 70 and 90% of the crystallization temperature for a time sufficient to facilitate permanent deformation of the stacked ribbons and to bond the ribbons.

Abstract: This invention relates to the production of large shapes of metallic glass fabricated from ribbon. The inventive method contemplates placing the ribbon and consolidating the alloy under a pressure or at least 1000 psi at a temperature of between 70% and 90% of the crystallization temperature for a time sufficient to facilitate bonding of the ribbons.

Abstract: A number of metal cores especially suitable for use in an electrical induction device such as a transformer are disclosed herein along with respective methods of making these cores. In accordance with each of these methods, the appropriate metal material is initially provided and thereafter formed into an unsolidified, preliminary shape. Thereafter, while the material is in its preliminary shape, it is densified, preferably by means of explosion bonding, whereby to improve its permeability and saturation field characteristics. In one embodiment, a metal material is initially provided as a continuous strip. In another embodiment, the metal material is initially provided as a number of plates and still in another, preferred embodiment, amorphous metal particulate material is utilized. In this latter embodiment, the orientation of the particulate material is controlled to further improve the permeability and saturation field characteristics of the ultimately formed core.