Abstract: A method for preparing a Ni base superalloy inner wall surface of a body open end, such as an end of a turbomachinery blade, and an end plate, such as a blade tip cap, for brazing together at a rim of the end plate includes electrochemically removing oxides from the inner wall surface. The end plate is prepared, at least at its rim, by first removing surface and subsurface oxides, for example by mechanical abrading or a combination of such abrading and acid cleaning. Then at least the rim is electroplated with Ni which is heated to diffuse the Ni into the rim substrate. This provides an improved combination of surfaces for brazing, for example with a Ni base brazing alloy. After brazing the rim to the inner wall, there is provided an article with an improved relatively low oxide brazed joint, including less than about 20 volume % oxides, and a plate rim of substantially Ni along with elements diffused from the brazing alloy and the rim.

Abstract: The present invention provides a method of making a frame, particularly for the aircraft industry, having a central member (34) and one or more cantilever ribs (32); such a frame can be made by forging or machining but these are time-consuming and expensive. According to the present invention such frames are made by diffusion bonding and superplastic forming techniques, whereby a pack of sheets are bonded together except in certain areas. Gas is injected into those areas to inflate the pack superplastically to form one or more closed cells (16). The top of the cells is then machined off along line 23, while the side walls of the cells are retained, to provide a frame having cantilever ribs (32).

Abstract: Articles are fabricated by collating and heating precursor metallic sheets of different compositions. The collated stack of sheets is heated with an applied pressure for a time sufficient to interdiffuse them either partially to produce a controllably modulated structure or completely to produce a homogeneous structure. The sheets may be collated in a form, and may be deformed during or after heating. The composition and structure of the final article is controllably varied from location to location by varying the composition, arrangement, or thickness of the collated sheets. In one embodiment, reinforcements such as fibers are positioned between the sheets.

Abstract: The invention concerns a method of bonding a diamond substrate to at least one metal substrate. According to the invention:at least one of the faces of the diamond substrate is covered with a piece of aluminum foil;said diamond substrate and said piece of aluminum foil are disposed in a chamber under a controlled atmosphere, and they are bonded together by a first thermocompression step under Argon or under a vacuum, thereby forming a composite multilayer substrate;said composite multilayer substrate is disposed on a metal substrate, the aluminum surface being in contact with the metal substrate; andsaid composite multilayer substrate and said metal substrate are bonded together by performing a second thermocompression step.

Abstract: A fabricated gas turbine engine component and method of manufacturing. In one embodiment the component having a structural member with a cover member metalurgically bonded thereto. The bonding of the cover member being controlled by an apparatus that sequentially applies a substantially non-unifrom bonding load across the components radius of curvature. The patterns utilized in the casting process are formed in one embodiment to a precision preformed geometry by a closed die forming operation.

Abstract: A method of making an expanded metal sandwich structure includes cleaning at least two metal superplastic core sheets to remove metal oxides and residues that would interfere with diffusion bonding of the sheets. The core sheets are placed face-to-face and a gas pressure line fitting is inserted between one edge and is welded into place. The fitting has a through bore through which gas can flow under pressure into the space between the core sheets. The core sheets are pressed together and laser welded together into a core pack along lines which will form junction lines between the core sheets when the core pack is superplastically expanded. The core pack and the two metal face sheets having superplastic characteristics are each chemically cleaned, and the face sheets are placed over and under the core pack.

Abstract: A method for controlling the interface in a titanium matrix composite between the titanium matrix material and a silicon carbide reinforcing filament or fiber which comprises treating such filament or fiber with a phosphorus-containing compound, and thereafter incorporating the treated fiber into a titanium matrix composite. The quantity of phosphorus remaining on the fiber, following treatment, can be miniscule, so long as at least a trace amount of phosphorus remains on the fiber.

Abstract: A turbomachine rotor stage having a thin annular body comprising a metal alloy part reinforced by at least one fibrous ring which has a radial height h of at least 1.5 times its axial width l and which is embedded in the metal alloy part so that it projects radially outwardly from the inner wall thereof in order to stiffen the body and reduce the quantity of fibre material to be used.

Abstract: In a method for fastening electronic components on a substrate by means of pressure sintering, which includes providing a layer of sinterable metal powder on a surface of one component, assembling the components engaging the layer and then, while exerting a pressure on the components, applying heat to sinter the layer of material, an improvement comprises forming the layer of sinterable metal powder by vaporizing a metal and condensing the metal as a nanocrystalline metal powder on the surface. Preferably, the metal powder is silver and is applied in a precipitation chamber.

Abstract: A bushing base plate comprised of a bushing base raw plate containing a circular or irregular aperture having inner surfaces and inner diameters; and a hollow tube having outer surfaces and out diameters which is inserted into the aperture and bonded thereto by thermal diffusion. Prior to insertion of the tube in the aperture, the outer diameters are greater than the inner diameters, thereby producing a pressing force between the outer surfaces of the tube and the inner surfaces of the aperture.

Abstract: A method of forming a sputter target/backing plate assembly comprises the steps of: providing a target fabricated from a first material having a coefficient of thermal expansion; providing a backing plate fabricated from a second material having a coefficient of thermal expansion; providing a block fabricated from a third material having a coefficient of thermal expansion; positioning the block on one side of the backing plate; positioning the target on the other side of the backing plate; and subjecting the target, backing plate and block to elevated temperature and pressure to bond the target, backing plate and block together. The third material is selected so as to have a coefficient of thermal expansion which counteracts the effects of the coefficients of thermal expansion of the first and second materials. The third material may be selected so as to have a coefficient of thermal expansion which is approximately the same as the coefficient of thermal expansion of the first material.

Abstract: A cold-worked titanium material subjected to isostatic material and a backing plate are brought into contact with each other and subsequently hot-pressing. By such working the titanium material and the backing plate are bonded with each other by mutual diffusion and simultaneously the titanium material is recrystallized. The isostatic pressing is performed under a pressure of 50 to 200 MPa at a temperature of 300.degree. to 450.degree. C. The surface of the titanium material is preferably subjected to a surface roughening treatment to provide with a roughness level of 6S to 12S prior to the isostatic pressing.

Abstract: Described is a method of making high purity copper sputtering target. The method avoids melting and casting and involves stacking segments of high purity copper plates, and heating, forging and annealing to produce a diffusion bonded unitary structure.

Abstract: An optical module and method in which an optical element (32) and an optical waveguide (34) are formed on a silicon substrate (31) so that an optical axis of the optical element coincides with an optical axis of the optical waveguide. Metallized films (41, 42) are formed on the silicon substrate and on the optical waveguide respectively, and these metallized films are bonded to each other by mutual diffusion of their atoms.

Abstract: A process for joining two parts of which at least one is made of an intermetallic material comprises:mixing elemental powders to form an intermetallic compound of the same type as that of the intermetallic part or parts;compacting and forming an intermediate part from the said compound at a temperature below that of the reaction sintering temperature of the compound;placing the intermediate part in position between the two parts to be joined;subjecting the assembly of parts to a first thermal cycle so as to effect a reaction sintering of the intermediate part and a consolidation of the assembly; and,subjecting the assembly to a second thermal cycle at a temperature above 0.8 of the fusion temperature of said intermetallic compound so as to effect a diffusion treatment and mechanical consolidation of the assembly.The process may also be adapted to form a coating or a repair of a part using an intermetallic material.

Abstract: This invention relates to a method for producing a metallic catalyst carrier used for a catalytic convertor for an automobile, for example, and calcines a metallic catalyst carrier element obtained by alternately winding or laminating metallic plates in vacuum, and in integrally combining the connecting parts of the metallic plates by diffused junction, the metallic catalyst carrier element being calcines at 1200.degree. C. or above and a pressure of 1 Pa to 10 Pa, preferably l.5 Pa to 10 Pa, to obtain a strong metallic catalyst carrier having oxidization resistance.

Abstract: In method of forming a hermetically sealed electrical feedthrough comprising, a feedthrough is positioned in a hole, the hole passing through a structure. The feedthrough includes a first material and the structure including a second material. A compressive force directed at the structure is applied to the feedthrough, and an equal force directed at the feedthrough is applied to the structure. The equal force is applied in a direction opposite the compressive force. The feedthrough and the structure are heated to a diffusion temperature whereat the first material and the second material undergo diffusion so as to cause a hermetically sealed bond between the first and second materials, and the hermetically sealed bond is thereby formed between the feedthrough and the structure.

Abstract: A method of fabricating a structural panel having a predetermined shape features forming an inflatable envelope assembly from at least a pair of superplastically formed and diffusion bonded metallic core sheets. The inflatable envelope assembly can be disposed between first and second metallic face sheets which are generally superplastically formed into the predetermined shape prior to being assembled. Thereafter, the assembled face sheets and the inflatable envelope assembly can be superplastically formed and diffusion bonded to form an integral structure, such as structural panel having a compound curvature. Alternatively, the inflatable envelope assembly can be disposed between a pair of reinforced titanium composite sheets. The reinforced titanium composite sheets can also be joined to adjacent face sheets, such as by welding or diffusion bonding, such that an integral structural panel having the predetermined shape can be readily fabricated.

Abstract: Solder bonding of first and second contact pad arrays is accomplished by forming contact structures, such as posts with vertical or tapered sides, on the contact pads of the first array and solder bumps on the second array. The respective contact structures should have an average cross-sectional area that is less than the average cross-sectional area of the corresponding solder bumps. The contact structures and solder bumps are then bonded by a bonding process at a temperature and pressure where the solder bumps deform and envelop at least a portion of the respective contact structures. It is possible to employ the contact structures as a compression stop during the bonding process. The temperature should be below the melting points of the contact structures. In this manner, solder bump spreading can be reduced during bonding which correspondingly reduces electrical shorting of adjacent formed interconnect bonds.

Abstract: Platelet assemblies are formed from bondable platelets, such as diffusion-bondable, brazable, or adhesive-bondable platelets, with void regions in the platelets to form channels or open spaces in the finished platelet assembly. To improve the response of the platelet assembly to pressure bonding as well as to post-bonding fabrication processes such as forming, machining and welding, the void regions are filled with a sacrificial material which transmits the load of the applied pressure in the same manner as the remainder of the platelet, and yet which is removable from the finished platelet assembly by either thermal or chemical liquefaction after all potentially damaging fabrication procedures have been performed on the platelet assembly.

Abstract: Disclosed herein is a method for electrically conductive metal-to-metal bonding. The method for bonding flat metal surfaces comprises the steps of depositing a thin layer of titanium on a first surface of a first metal surface, placing the first surface of the first metal surface in contact with a first surface of a second metal surface in an inert ambiance, heating the inert ambiance to a temperature substantially below the melting point of the metal surfaces, and forming a titanium metal bond between the first metal surface and the second metal surface to provide a low resistive path between the first metal surface and the second metal surface.

Abstract: A target, target backing plate, and cover plate form a target plate assembly. The sputtering target assembly includes an integral cooling passage. A series of grooves are constructed in either the target backing plate or the target backing cooling cover plate, which are then securely bonded to one another. The sputtering target can be a single monolith with a target backing plate or can be securely attached to the target backing plate by one of any number of conventional bonding methods. Tantalum to titanium, titanium to titanium and aluminum to titanium, diffusion bonding can be used.

Abstract: A method for determining the generation of a diffusion bond between two articles is disclosed. The two articles are sealed together to define a cavity therebetween. A vacuum is drawn in the cavity by means of an evacuation tube having a passageway. The passageway is then sealed and the articles are subjected to a temperature and pressure to diffusion bond the articles together. A successful diffusion bond can be determined if the evacuation tube sidewall is collapsed.

Abstract: A continuous fiber-reinforced Ti-based composite material comprises a Ti alloy matrix containing 3 to 7% by weight of Al, 2 to 5% by weight of v, 1 to 3% by weight of Mo, 1 to 3% by weight of Fe, 0.06 to 0.20% by weight of 0, and the balance of Ti and unavoidable impurities, and SiC continuous fibers arranged within said matrix in one direction.

Abstract: An electronic assembly (100) includes multiple solder connections (101) coupling faying surfaces (202, 204) of two substrates (106, 108). A solder connection (201) is fabricated by reflow heating of a first, less compliant solder paste (312, 314) and a compliant preform (210) so as to cause compliant material of the preform (210) to dissolve into the solder paste (312, 314). Upon solidification of the solder paste (312, 314), blended regions (520, 522), having a gradual, changing concentration of compliant material form between resulting fillets (212, 214) and the preform (210). The blended regions (520, 522) transfer temperature induced shear stresses, caused by thermal cycling of the electronic assembly (100), from the fillets (212, 214) into the compliant preform (210).

Abstract: Methods of making an improved high performance x-ray system having a rotating anode therein are available. The anode includes an improved target/stem connection which reduces tube failure due to anode assembly imbalance. Methods of bonding a metallic target and a metal stem to form a composite rotating x-ray tube target are also available. In these procedures an insert of an alloy, for example, tantalum or its alloys , is placed between the target and the niobium-alloy stem and then bonded thereto to produce a composite x-ray tube target/stem having a high remelt temperature and bond strength which retains its balance throughout the manufacturing process and during x-ray tube operations.

Abstract: An airfoil and its sub components for a gas turbine engine have a convex wall and a concave wall that are connected at leading and trailing edges. Internal supports extending from the convex and concave walls define a series of airfoil supports that have at least one primary cavity between them. Internal supports in the proximity of the edges define material absorption cavities that have a smaller cross-section than the cross section of the primary cavities. Pressure applied to the walls during the diffusion bonding process forces material inside the airfoil, and most particularly the airfoil edges, to yield towards the center of the airfoil. The material absorption cavities absorb material that yields during the diffusion bonding process and prevent buckling of the walls.

Abstract: A metal foil substrate material 50 for catalytic converters 54 and method of making the material in which layers (10, 12, 14) of ferritic stainless steel and aluminum are solid state metallurgically bonded together forming a composite material 24. Such composite material 24 is further rolled to the final foil gauge with no heat treatment and then subjected to a thermal in situ reaction to form a resulting uniform solid solution foil material 50 with superior high temperature corrosion resistance.

Abstract: In a method and apparatus for forming a hermetically sealed bond for use in implantable medical devices, a first structure, made from a first material, is positioned against a second structure, made from a second material. A compressive force directed at the second structure is applied to the first structure, and an equal force directed at the first structure in a direction opposite the compressive force is applied to the second structure so that the first and second structures are isodynamically pressed together. The first and second structures are heated to a diffusion temperature whereat the first material and the second material undergo diffusion, thereby forming a hermetically sealed bond between the first and second materials.

Abstract: An improved method for forming fluid inflatable metal structures is taught. The improvement concerns the patterning of the portion of the structure to be inflated. Patterning is accomplished by first applying a strippable flexible mask coating and then scoring this coating so that a patterned portion may be removed therefrom. The parent portion is the portion of the sheet article to be inflated by subsequent processing. After the patterned portion has been removed, a stop-off is applied to the exposed surface of the first sheet. After the stop-off material has been applied, the remainder of the strippable mask is removed and washed with a detergent to remove the residue from the mask. The sheet having stop-off applied in the pattern to the first sheet is then superposed over a second sheet, and heat and pressure are applied to cause diffusion bonding between the exposed surfaces of the two sheets.

Abstract: An airfoil includes preformed first and second sides joinable together at a bond line extending between first and second opposite edges thereof. The first side includes a first extension having a proximal end forming a first end of the bond line, an intermediate section, and a distal end. The second side includes a second extension extending from the airfoil first edge which is fixedly joinable to the distal end of the first extension. The intermediate section of the first extension is spaced from the airfoil first edge to define therewith a working void so that pressure loading on the intermediate section is carried in part through the bond line first end for diffusion bonding thereof.

Abstract: An electronic package comprises a component mounted on a substrate, such as a printed circuit board, by a solder connection that is based upon a tin alloy containing zinc. The connection is formed to copper faying surface on the substrate, and includes a first layer formed of a zinc-free tin metal bonded to the copper surface and a second layer formed of the tin-zinc solder alloy bonded to the first layer. The first layer provides a zinc-free barrier between the copper and the tin-zinc alloy to retard zinc migration to the copper interface that would otherwise result in dezincification of the solder alloy and reduce the mechanical properties of the connection.

Abstract: A metal foil substrate material for catalytic converters and method of making the material in which layers of ferritic stainless steel and aluminum are solid state metallurgically bonded together forming a composite material. Such composite material is further rolled to the final foil gauge with no heat treatment and then subjected to a thermal in situ reaction to form a resulting uniform solid solution foil material with superior high temperature corrosion resistance.

Abstract: The method enables a stainless steel cooking utensil to be formed with a decorated base, the base being of the type comprising three layers, of which one is an intermediate layer of a good heat conducting metal and the other two layers are of stainless steel. Compared with traditional methods for forming normal utensils of the aforesaid type, there is a further step of positioning on the outer stainless steel layer at least one sheet portion of a metal having a melting point not less than that of the metal forming the intermediate layer. An aluminum foil is interposed between the sheet portion and the outer stainless steel layer if the metal of the sheet portion does not enable a direct permanent connection to be achieved between the sheet portion and the outer layer. A decoration can also be obtained on the inside of the utensil base in a similar manner.

Abstract: Methods for and preforms for making fiber reinforced composites are disclosed. According to the invention, preforms which allow composites to be machined are provided. Also, preforms with a uniform debulking ratio are provided with non-uniform fiber placement. In addition, methods of forming composites have less material waste and allow more than one composite to be consolidated at one time.

Abstract: An aluminum body having diamond bonded thereto with a diffused interlayer of silicon is described.

Abstract: A method for preparing a machined surface of a composite article for diffusion bonding is provided. The method includes removing most of the exposed fibers by shot peening followed by acid etching. The acid etch may be followed by grit blasting and then another acid etch. After the method is applied to the surface, the article can be diffusion bonded to other composite article to form complex shapes.

Abstract: There is provided by the present invention method and apparatus for damping vibrations or other unwanted motions of a brush seal, the apparatus including a damper having a plurality of individual plates that are bonded directly to the inlet rows of bristles of the seal. Methods for producing a damped brush seal in accord with the present invention contemplate brazing damping plates to the bristles, absorbing a melting point suppressor into the surface of the damping plates and then heating the damping plates until the treated surface melts and bonds with the bristles, or sintering a braze alloy to the bristles such that the braze alloy functions as a damping plate.

Abstract: A method of producing a sputter target assembly including a tungsten-titanium target attached to a titanium backing plate. The method includes consolidating a tungsten-titanium powder composition to form a target while simultaneously bonding the powder composition to the titanium backing plate to form an interdiffusion-type bond between the target and the backing plate such that the target assembly possesses extremely high temperature operating capability.

Abstract: The diffusion bonding of aluminum and aluminum alloys presents problems because, when left exposed to the atmosphere even for a short time, they acquire an extremely tenacious surface oxide layer that inhibits or prevents satisfactory diffusion bonding. Unlike titanium, this oxide layer is not absorbed at diffusion bonding temperatures. The present invention comprises a method of reducing oxidation of a surface of aluminum or aluminum alloy by causing a nitride film to form on the surface. This film is believed to prevent oxidation of the aluminum or aluminum alloy, but to be absorbable into it at diffusion bonding temperatures. In the preferred embodiment shown in FIG. 1, the nitride film is applied to the piece of aluminum or aluminum alloy (10) in a vacuum chamber (4) by sputtering with nitrogen ions, or by heating the piece (10) in a nitrogen gas atmosphere.

Abstract: A composite article is manufactured by preparing a machined surface of the composite article for diffusion bonding. The method includes removing most of the exposed fibers by shot peening followed by acid etching. The acid etch may be followed by grit blasting and then another acid etch. After the method is applied to the surface, the article can be diffusion bonded to other composite article to form complex shapes.

Abstract: A metal foil substrate material for catalytic converters and method of making the material in which layers of ferritic stainless steel and aluminum are solid state metallurgically bonded together forming a composite material. Such composite material is further rolled to the final foil gauge with no heat treatment and then subjected to a thermal in situ reaction to form a resulting uniform solid solution foil material with superior high temperature corrosion resistance.

Abstract: A component made of superalloy is provided with a localized coating formed from three layers by a brazing heat treatment, the layers comprising an outer layer having a composition adapted to the specific surface properties sought, an inner layer having a composition which includes flux elements, and an intermediate layer obtained by the deposition of a mixture of the materials used for the other two layers.

Abstract: Two pieces (42, 46) are Joined together by providing a gold bonding layer (44) overlying a nickel layer (40) on a first piece (42) to be bonded and providing a gold bonding layer (50) on a second piece (46) to be bonded. The gold layer (50) on the second piece (46) may optionally overlie a nickel layer (48) on the second piece (46). The gold layers (44, 50) are pressed together in a facing relation at a temperature of from about 125 C. to about 250 C. for a time sufficient to permit the layers (40, 44, 50, 46) to interdiffuse.

Abstract: This invention relates to a process of forming components having selectively thickened regions from superplastically formable and diffusion bondable materials. The said selected thickening is achieved by positioning metal matrix composite plies between the interior surface of each of the formed skin sheets of the component and the sheets which will form the internal cells, superplastically forming the cells, and then diffusion bonding the component to form a metallurgically bonded structure.

Abstract: A method for soldering a ceramic body of an electric component, such as a microwave resonator, into a metal housing, includes applying a tin layer over the ceramic body provided with an electrically conductive layer. A high-melting-point lead-tin passivation layer is applied to a surface of the housing to be soldered to the ceramic body.

Abstract: Described herein is a method of manufacturing components having "warren girder" or "X" core structures, i.e. those having internal support walls extending between their outer surfaces, from superplastically formable and diffusion bondable materials having different flow stress characteristics. By using materials of relatively high flow stress characteristics for the outer skin sheets of the component, and relatively low flow stress characteristics to form the internal support walls, the tendency for the sheets outer skin to bow outwards during superplastic formation at a faster rate in regions where they are the greatest distance from support walls is reduced. Consequently, the exterior of the outer skin sheets is less susceptible to the formation of recesses thereon at the point where the corresponding interior surface meets the inner support walls, i.e. the phenomenon of quilting is substantially eliminated.

Abstract: A plurality of workpieces are assembled into a stack. Two of the workpieces are machined on one surface at predetermined positions from the edges of the workpieces. The workpieces are stacked so that the machined surfaces of the workpieces face away from each other. Two workpieces are provided with a stop off material on one of their surfaces to prevent diffusion bonding at predetermined positions. The edges of the workpieces are welded together and a pipe is welded to the stack to interconnect with the stop off material to form a sealed assembly. The workpieces are diffusion bonded together. The integral structure formed is heated and opposite ends of the integral structure are twisted relatively to contour the integral structure to a predetermined shape. The integral structure is heated and the machined portions on the workpieces are isothermally forged and then the twisted integral structure is internally pressurised to superplastically form one workpiece to produce an article, eg a fan blade.

Abstract: A metallic structural panel having a plurality of internal passages separated by supporting ribs and its method of fabrication. The fabrication assembly of the metallic structural panel is essentially comprised of a housing defining an internal cavity, a plurality of internal tubes, a means for segregating the internal cavity into a pressurized and an evacuation section and a means for establishing a pressure differential between the pressurized and evacuation sections. The metallic structural panel is superplastically formed and diffusion bonded such that independent passages are formed between supporting ribs within the internal cavity of the housing. Embodiments of the fabrication assembly for manufacturing metallic structural panel are also provided which produced a curved structural panel. These embodiments utilize a curved housing along with either curved end plates or curved internal tubes, depending on whether the supporting ribs are desired to be straight or curved, respectively.

Abstract: A method of making a titanium fan disc for a gas turbine engine comprises the steps of providing a pair of identical forged titanium cylinders each having a central bore and a flat end surface at right angles to its central axis, preparing the flat end surface of each cylinder to a high degree of smoothness, abutting the prepared surfaces of the cylinders one against the other in axial alignment, removing air from between said surfaces, and diffusion bonding the cylinders end-to-end by hot isostatic pressing to form the disc.