With Concurrent Bonding Patents (Class 228/265)
  • Patent number: 5564620
    Abstract: Industrial applications of composites often require that the final product have a complex shape. In this invention intermetallic or ceramic phases are formed from sheets of unreacted elemental metals. The process described in this invention allows the final product shape be formed prior to the formation of the composite. This saves energy and allows formation of shaped articles of metal-intermetallic composites composed of brittle materials that cannot be deformed without breaking.
    Type: Grant
    Filed: October 22, 1993
    Date of Patent: October 15, 1996
    Inventors: James C. Rawers, David E. Alman, Arthur V. Petty, Jr.
  • Patent number: 5562245
    Abstract: A method of producing a circular metal article reinforced by fibres in selected parts of its cross-section is described in which a metal blank of the article is formed and provided with at least one annular groove opening in the axial direction, preforms of reinforcing fibre and filler metal are placed in the groove which is then closed by a metal plug, and the assembly is isothermally forged to produce the article in a single forging step which serves to compress the preforms, weld the assembly together, and shape the article. Such articles may be used for machining high performance rotors for turbojet engines. Apparatus for use in the method is also described.
    Type: Grant
    Filed: December 8, 1994
    Date of Patent: October 8, 1996
    Assignee: Societe Nationale d'Etude et de Construction de Moteurs d'Aviation "Snecma"
    Inventors: Jean-Claude Berthelemy, Gilles J. Bessenay, Gerard P. Gauthier, Daniel G. Girault, Ludovic E. C. Molliex
  • Patent number: 5551623
    Abstract: Process for welding two blade parts (9, 10) by a means such as a linear friction welding machine, in which a collar or flange (15) of material to be sacrificed is placed between the contact surfaces (16) or around the latter in order to increase the heat produced by the friction at the leading and trailing edges of the blade. As a result of this arrangement it is possible to start with two blade parts (9, 10) having the dimensions of the finished product, possibly with the exception of the area around the contact surfaces, so that the final machining is very significantly reduced.
    Type: Grant
    Filed: February 17, 1995
    Date of Patent: September 3, 1996
    Assignee: Societe Nationale d'Etude et de Construction de Moteurs d'Aviation "SNECMA"
    Inventors: Andre C. F. Collot, Jean-Pierre Ferte, Roger Jolly
  • Patent number: 5544805
    Abstract: A method of producing a fibre-reinforced metallic circular part having a tral hollow, wherein the reinforcing fibres are disposed in the part in the vicinity of the hollow, comprises providing an annular metallic blank with a channel-sectioned groove opening towards the axis of the blank, placing uncompressed concentric layers of the reinforcing fibres and additional metal alternately in the groove followed by a more rigid expansion ring, evacuating the groove and sealing it by a deformable closure member which covers the groove, placing this assembly in an autoclave and subjecting it to a temperature and pressure sufficient to effect superplastic forging of the layers of additional metal whereby the fibre layers and the additional metal layers are compressed and welded to the blank in a single operation, and machining the resulting assembly to obtain the required shaped part.
    Type: Grant
    Filed: February 10, 1995
    Date of Patent: August 13, 1996
    Assignee: Societe National d'Etude et de Construction de Moteurs d'Aviation "SNECMA"
    Inventors: Philippe L. A. Alassoeur, Andre C. F. Collot, Xavier J. M. A. Guyonnet, Gilles C. C. Klein, Ludovic E. C. Molliex
  • Patent number: 5449109
    Abstract: A high gas pressure material capable of producing 50-300 psi gas pressure at forming temperature is placed in an enclosed area surrounding and sealing the blanks to be superplastically formed, without the use of argon gas. The blanks are formed under tensile stress by the internal pressure produced by the high gas pressure material. The method can be performed concurrently with diffusion bonding to obtain a metallic structure from a plurality of workpieces, and also can be used to manufacture perfectly spherical hollow bodies by a dieless method.
    Type: Grant
    Filed: November 15, 1993
    Date of Patent: September 12, 1995
    Inventors: Tung-Han Chuang, Jing-Shin Shyu
  • Patent number: 5439165
    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.
    Type: Grant
    Filed: February 4, 1994
    Date of Patent: August 8, 1995
    Assignee: Cartossi S.r.l.
    Inventor: Ferdinando Cartossi
  • Patent number: 5427304
    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.
    Type: Grant
    Filed: May 31, 1994
    Date of Patent: June 27, 1995
    Assignee: Avco Corporation
    Inventors: Harlan L. Woods, Richard C. Lewis, Peter Nagy, Stephen A. Kraus
  • Patent number: 5413271
    Abstract: A method of superplastically forming a metal article and an article formed by such a method are provided. The method includes the steps of placing sheet material including at least one sheet of superplastically formable material (2, 3) and a sheet of reinforcing material (10) adjacent a said sheet (2) of superplastically formable material within a mold tool having a male former (18) protruding from the tool surface positioned to contact the sheet of reinforcing material during forming and causing the at least one superplastically formable sheet (2, 3) adjacent the reinforcing sheet (10) to be superplastically formed into conformation with the surface (28) of the mold tool and simultaneously to urge the sheet of reinforcing material (10) against the male former (18).
    Type: Grant
    Filed: February 25, 1994
    Date of Patent: May 9, 1995
    Assignee: British Aerospace Public Limited Company
    Inventors: Martin H. Mansbridge, David Irwin
  • Patent number: 5397050
    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.
    Type: Grant
    Filed: October 27, 1993
    Date of Patent: March 14, 1995
    Assignee: Tosoh SMD, Inc.
    Inventor: John J. Mueller
  • Patent number: 5368661
    Abstract: Composite parts of Ni-Ti alloys joined to a different metal have a melt forged structure obtained through the reactive fusion of both metals, initiated by the fusion of at least one metal bordering on the joint interface and the application of pressure; a hot forged structure of Ni-Ti alloy obtained through softening the alloy at high temperature and applying pressure on the Ni-Ti alloy side of the joint; and a hot forged structure of the different metal obtained by softening the metal at high temperature and applying pressure on the different metal side of the joint.
    Type: Grant
    Filed: June 15, 1993
    Date of Patent: November 29, 1994
    Assignees: The Furukawa Electric Co., Ltd., Masunaga Menlo Park Co., Ltd.
    Inventors: Masayuki Nakamura, Kaisuke Shiroyama, Satoru Masunaga, Kazuo Murata
  • Patent number: 5360156
    Abstract: A welding management apparatus for use with a tube production machine. A workpiece fed from a roll of metal strip is formed in a tubular formation having side surfaces opposite to each other. An upsetting pressure is applied to joint the opposite side surfaces of the workpiece at a jointing point. A high frequency power is supplied to the workpiece to weld the opposite side surfaces at the jointing point so as to produce a metal tube member. The welding management apparatus comprises a camera positioned to have a visual field including the jointing point for producing a video signal indicative of an image including an area luminous with a pre-arc produced in the visual field. An image processor converts the video signal into a luminance distribution pattern. An inference unit is provided for inferring a defective welding condition based upon the luminance distribution pattern. The inference unit includes an alarm unit for producing an alarm when a defective welding condition is inferred.
    Type: Grant
    Filed: August 9, 1993
    Date of Patent: November 1, 1994
    Assignee: Kabushiki Kaisha Meidensha
    Inventors: Yuji Ishizaka, Takashi Katanosaka, Osamu Masuda, Hiroyasu Kimura
  • Patent number: 5323951
    Abstract: In this invention, a back end portion of a preceding sheet bar and a front end of a succeeding sheet bar are cut in a transfer line at an entrance side of a finish rolling mill so that at least both side edge regions of these sheet bars are contacted with each other at a butted contact state thereof and a gap is formed between both end portions and then portions to be joined int he preceding and succeeding sheet bars are locally heated and pushed to join them while gradually enlarging a joining area, whereby the required time is largely reduced as compared with the conventional technique and also it is attempted to miniaturize the heating apparatus and shorten the length of the apparatus.
    Type: Grant
    Filed: April 2, 1992
    Date of Patent: June 28, 1994
    Assignee: Kawasaki Steel Corporation
    Inventors: Toshisada Takechi, Masanori Ebihara, Fujio Aoki, Kunio Yoshida, Naoki Hatano, Hiroshi Sekiya, Toshiaki Amagasa, Kuniaki Sato, Takashi Kawase, Hideo Takekawa, Norio Takashima, Takashi Ishikawa, Masanori Kitahama
  • Patent number: 5323536
    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.
    Type: Grant
    Filed: August 6, 1993
    Date of Patent: June 28, 1994
    Assignee: Rolls-Royce plc.
    Inventors: John O. Fowler, Brian Richardson
  • Patent number: 5271546
    Abstract: Clad metal plate comprising a layer of cladding metal bonded to a first substrate metal layer is produced by a method comprising initially metallurgically bonding a thin layer of substrate to a thick layer of cladding metal and bonding further layers of substrate metal to the first substrate layer in at least two roll bonding steps wherein the cladding layer is reduced to the desired thickness. The initial metallurgical bonding step may advantageously be a bonding method such as explosive bonding which is free from metal compatibility restrictions encountered in roll-bonding. The method enables a base metal such as carbon steel to be clad economically with a metal, for example titanium, with which it is incompatible for roll-bonding.
    Type: Grant
    Filed: October 5, 1992
    Date of Patent: December 21, 1993
    Assignee: Imperial Chemical Industries, PLC
    Inventor: Roy Hardwick
  • Patent number: 5265791
    Abstract: This invention relates to the solid state joining of metal alloy pieces in order to form an integral structure. Such structures of this type, generally, allow the metal alloy pieces to be joined by local interfacial strain control.
    Type: Grant
    Filed: November 2, 1992
    Date of Patent: November 30, 1993
    Assignee: General Electric Company
    Inventors: Herman A. Nied, Robert E. Sundell
  • Patent number: 5261591
    Abstract: This invention relates to a method of manufacturing bi-metallic tubing by the successive steps of explosive bonding, hot extrusion and co-extrusion. Bi-metallic tubing, having an inner wall made from a corrosion resistant material, is of particular use in the oil and gas industries. The invention offers a number of advantages over previously known manufacturing methods, such as increased cladding capacity, reduction in the number of joints required, and an improvement in dimensional accuracy. These are achieved by explosively bonding a tube 3 of a first metal to a substantially incompressible billet 1 of a second metal. A length of the bonded composite 15 so formed is subsequently hot extruded to form a bi-metal shell 25. A length of the shell 25 is then placed within the bore of a hollow billet 33, the interface 35 formed between the shell 25 and billet 25 sealed, and the assembled composite 39 so formed co-extruded to form a bi-metal tube 41.
    Type: Grant
    Filed: April 11, 1991
    Date of Patent: November 16, 1993
    Assignee: Imperial Chemical Industries PLC
    Inventor: Roy Hardwick
  • Patent number: 5257717
    Abstract: A method of manufacturing a cooking utensil comprising a round container for the food. The container comprises a container, a plate made of heat-conducting material and a cap enclosing the plate, the cap being made from a sheet-metal disk and having a base provided with a convex curvature towards the container and also having collar which bears against the round container in a curved transition region between the container base and the container jacket. The container and the cap are made of stainless steel. The plate is intermetallically bonded to the container base and the cap. The plate, the sheet-metal disk and the container base are centered and connected by a central spot weld, using electric resistance welding. Next, the intermetallic bond is produced by single or multiple impulse pressure and permanent deformation and the cap collar is formed on the sheet-metal disk and its rim is placed around the container.
    Type: Grant
    Filed: July 30, 1992
    Date of Patent: November 2, 1993
    Assignee: AMC International Alfa Metalcraft Corporation AG
    Inventor: Alfred Galle
  • Patent number: 5242102
    Abstract: A method of forming metallic structures that consists of immersing shaping dies with a blank workpiece sandwiched between them in a molten metal or alloy bath at a temperature within the superplastic temperature range of the workpiece. The pressure necessary for forming the workpiece is then applied by using weights or other means disposed over the dies. The workpiece is allowed to be formed by the gravitational force of the weights while it is maintained in a superplastic state. A metal or alloy that is free of harmful elements and contaminants that cause damage to the physical properties of the workpiece and that has a melting point below the superplasticity range of the workpiece is suitable for the molten bath. The molten metal serves the dual purpose of displacing all contaminants from the surface of the workpiece and of providing a conductive source of heat for raising the temperature of the workpiece to its superplastic range.
    Type: Grant
    Filed: December 14, 1992
    Date of Patent: September 7, 1993
    Inventor: Raymond G. Nicolas
  • Patent number: 5238177
    Abstract: Disclosed is a flexible hinge pin, and a method and apparatus for forming the hinge pin, wherein a cable is twisted and heated with sufficient torque and heat to sever the cable into shorter hinge pins. The heating and twisting causes the portions of the cable in proximity with the severed ends to have a tight spiral and to be reduced in diameter, and the strands which comprise the cable to be bonded to one another both internally and at external portions of the cable. The reduced diameters of the formed ends facilitates easier threading of the hinge pins through belt fastener hoops. The bonding of the cable strands in the region of the ends serves to both maintain the tight spiral and the reduced diameter, and to prevent the ends of the hinge pin from separating.
    Type: Grant
    Filed: August 10, 1992
    Date of Patent: August 24, 1993
    Assignee: Flexible Steel Lacing Company
    Inventors: William L. Nakulski, Thomas J. Bubula, Richard J. Behrends
  • Patent number: 5234154
    Abstract: A trailing end of a preceding bar is arranged slantingly by an angle .theta. relative to a succeeding bar such that the lower edge of the leading end face of the succeeding bar is vertically shifted from the lower edge of the trailing end face of the preceding bar with the leading end face of the succeeding bar abutting against the trailing end face of the preceding bar. After that, the succeeding bar is vertically depressed by applying a predetermined force. Since the trailing end face is inclined by .theta. relative to the leading end face, the depression causes a relative slide between surfaces of both the end faces and, at the same time, a pressure P is also produced by the wedge effect, the pressure P causing a compression force and a plastic deformation between both the end faces.
    Type: Grant
    Filed: April 27, 1992
    Date of Patent: August 10, 1993
    Assignee: Hitachi, Ltd.
    Inventors: Toshiyuki Kajiwara, Tadashi Nishino, Tadayuki Watanabe, Yasutsugu Yoshimura, Takao Funamoto
  • Patent number: 5230459
    Abstract: Methods of preparing a sputter target/backing plate assembly and assemblies so prepared are disclosed. The methods comprise forming a plurality of grooves in one of the metal surfaces to be joined in the bonding process. The grooves are each provided in a closed, loop configuration or pattern. The target and backing plate to be bonded are adjacently positioned to form an assembly with the grooved surface forming one of the interfacial joint surfaces. The assembly is then placed in a controlled atmosphere, such as a vacuum, heated to a temperature just below the melting point of the lower melting metal to be joined, and pressed until the grooves are substantially filled with metal or alloy from the other, non-grooved interfacial surface.
    Type: Grant
    Filed: March 18, 1992
    Date of Patent: July 27, 1993
    Assignee: Tosoh SMD, Inc.
    Inventors: John J. Mueller, David E. Stellrecht
  • Patent number: 5217155
    Abstract: A method of continuously hot-rolling sheet bars in which a roughly rolled leading sheet bar and a trailing sheet bar are abutted prior to a hot finish rolling step. Plastic deformation of either or both of the cut rear and front end portions of the leading and trailing sheet bars is applied. End portions are brought into contact with each other due to metal flow, forming a gap portion between the sheet bars. The thickness of the sheet bar around the gap portion is enlarged in comparison to the thickness of the contact portions, and hot finish rolling fills the gap so that the bars are strongly joined over their width.
    Type: Grant
    Filed: August 10, 1992
    Date of Patent: June 8, 1993
    Assignee: Kawasaki Steel Corporation
    Inventors: Masanori Kitahama, Kunio Isobe, Norio Takashima, Toshisada Takechi, Fujio Aoki
  • Patent number: 5213252
    Abstract: A method for producing fiber reinforced titanium alloy articles which comprises casting a plurality of segments which can be joined to provide a unitary article, wherein at least one-half of the segments comprise at least one shallow cavity, treating the cast segments in such manner as to refine the microstructure of the segments, filling the cavity or cavities with reinforcing fibers and superplastic forming/diffusion bonding the segments into the desired article.
    Type: Grant
    Filed: May 15, 1992
    Date of Patent: May 25, 1993
    Assignee: The United States of America as represented by the Secretary of the Air Force
    Inventor: Daniel Eylon
  • Patent number: 5205470
    Abstract: A method and apparatus for superplastic and diffusion bonding of hollow metal parts which are generally surfaces of rotation. A hollow frangible ceramic die having an interior shaping surface is provided. A metal part to be shaped is placed against the shaping surface (together with any other metal components to be diffusion bonded to the part during forming) and the remainder of the die is covered with sheet metal pieces, all of which are sealed together and to the part to form a gas-tight enclosure for the die. The enclosure is flushed with an inert gas and/or evacuated through an opening in the enclosure. The assembly is placed in an autoclave and exposed to an appropriate pressure and temperature to superplastic form the part outwardly against the shaping surface. The assembly is cooled and removed from the autoclave, then the enclosure is removed. The die is broken away, freeing the formed part.
    Type: Grant
    Filed: October 31, 1988
    Date of Patent: April 27, 1993
    Assignee: Rohr, Inc.
    Inventor: Gilbert C. Cadwell
  • Patent number: 5205471
    Abstract: Methods and apparatus for joining conveyed steel pieces in a hot rolling mill are disclosed. A joining apparatus having a series of fusing torches extending laterally across the steel path is used, either before a rough rolling stage or between rough rolling and finish rolling. The fusing torches which operate at the side edges of the pieces to be joined are controlled to have independent movement by a controller, in such a way that the time elapsing between fusing and pressing together of portions at the lateral edges of the join line does not exceed a critical time for regrowth of oxide scale. Various mounting and control techniques for the fusing torches are proposed, including the possibility of two independently-driveable sets the controller can base its control of the torches on steel strip width information obtained from the processing path.
    Type: Grant
    Filed: March 9, 1992
    Date of Patent: April 27, 1993
    Assignee: Hitachi, Ltd.
    Inventors: Ryohei Kinose, Yasutsugu Yoshimura, Teruo Sekiya
  • Patent number: 5184769
    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.
    Type: Grant
    Filed: November 13, 1991
    Date of Patent: February 9, 1993
    Assignee: Avco Corporation
    Inventors: Donald J. Moracz, Gordon S. Doble
  • Patent number: 5163604
    Abstract: A method for forge welding or the like of a first and a second metal part, wherein at least one joint is established between opposed bounding surfaces on the two parts to be joined, and wherein preferably a reducing gas is passed through the joint or joints before the parts are pressed together. In order to make the weld less sensitive to remaining oxides, the bounding surfaces are provided with generally matching corrugations of somewhat different height.
    Type: Grant
    Filed: July 26, 1991
    Date of Patent: November 17, 1992
    Inventor: Per H. Moe
  • Patent number: 5156327
    Abstract: The procedure of the present invention may be applied to mold a composite material having a predetermined configuration. The first step of the present procedure is to form the dimples of the core in accordance with a super-plasticizing molding procedure, so that the dimples may exhibit a height higher than that in its final configuration which corresponds with the above-described predetermined configuration, and its top surface is formed in a convexed configuration. Then, pressure is applied to the core to flatten it by forcibly deforming it prior to or at the moment of jointing the skins of the predetermined configuration, so that the dimples may come into contact with the internal surface of the skin at their top surfaces. Thereafter or simultaneously with this operation, the skins of the predetermined configuration are jointed.
    Type: Grant
    Filed: April 2, 1991
    Date of Patent: October 20, 1992
    Assignee: Mitsubishi Jukogyo Kabushiki Kaisha
    Inventors: Akio Takahashi, Syoji Shimizu, Takayuki Tsuzuku
  • Patent number: 5147086
    Abstract: A process for preparation of capsule for use in isostatic pressing treatment, the process comprising a first step of enclosing a material to be treated, such as ceramic, metal, resin, etc. with metallic foil having a thickness of from 30 to 300 .mu.m, and a second step of welding the metallic foil so as to seal the material to be treated in the metallic foil thus welded, thereby preparing a capsule, wherein the welding is carried out by means of TIG welding. Alternatively, the welding may be carried out by means of seam resistance welding. It is posible, by the process, to seal the material to be treated in a capsule easily and economically. The capsule thus obtained is in a good sealed condition, permits effective isostatic pressing treatment, and enables the treated material to be taken out easily. A ceramic or metal layer covers the material to be treated to prevent adhesion between the material and the metallic foil.
    Type: Grant
    Filed: April 11, 1991
    Date of Patent: September 15, 1992
    Assignee: Kabushiki Kaisha Kobe Seiko Sho
    Inventors: Takao Fujikawa, Yasuo Manabe, Kazuhiko Nakajima
  • Patent number: 5143276
    Abstract: The present invention provides a method of making a domed structure using superplastic forming and diffusion bonding techniques. The dome is of a deep and/or irregular shape that cannot be achieved by creep forming. The method includes the step of forming a stack of two or more sheets made of superplastic material and the sheets of the stack being joined together in face to face contact by metallic bonds such that no sheet in the stack is bonded to more than one of its neighbouring sheets; the metallic bonds preferably lie on lines extending radially from and/or circumferentially around the said peak. The resulting stack is heated to superplastic termperatures and a pressure differential is established across the stack to form it into a domed shape.
    Type: Grant
    Filed: April 19, 1991
    Date of Patent: September 1, 1992
    Assignee: British Aerospace Plc
    Inventors: Martin H. Mansbridge, David Stephen, John Norton
  • Patent number: 5137203
    Abstract: A drum brake shoe is provided by fine blanking the brake shoe web (50) so that the web (50) has radially extending weld projections (60) at a circumferential edge (52), with a radial recess (62) disposed on each side of a weld projection (60). As a brake shoe rim (40) is fed through a welding and forming mechanism (65), a flat surface (41) of the rim (40) engages a radially extending weld projection (60) and a weld is effected. Welding wheels (90, 100) of the mechanism (65) rotate to bend the rim (40) and engage the rim (40) with the next weld projection as a weld is effected between the rim (40) and web (50). The manufacturing method will provide a more consistent welding process that will result in a higher percentage of quality welds and less scrappage.
    Type: Grant
    Filed: May 13, 1991
    Date of Patent: August 11, 1992
    Assignee: Allied-Signal Inc.
    Inventor: Donald D. Johannesen
  • Patent number: 5111572
    Abstract: A method of mechanically imparting a surface texture to a bland surface of sheet metal, especially soft aluminum, in which an adherent foil is applied at least to one surface of the sheet metal and is pressed into and against a surface by a roll so that the sheet metal is deformed and the pattern of the deformed foil is pressed into the sheet metal surface.
    Type: Grant
    Filed: February 22, 1991
    Date of Patent: May 12, 1992
    Assignee: Austria Metall Aktiengesellschaft
    Inventors: Gottfried Haiml, Johann Langgartner
  • Patent number: 5106012
    Abstract: Two pieces of metal are bonded together at a surface by placing the two pieces into contact at the surface and forging the two pieces in a die which causes substantial displacement of the metal originally at the surface in a direction parallel to and outwardly from the edges of the surface. In this way, many of the defects which are potentially present at the original surface are displaced with moving metal away from the original contact between the two pieces of metal into sacrificial ribs and the remaining defects are exposed to significant strain. A portion of the displaced metal which contains many of the defects and which forms the sacrificial ribs is removed from the resulting bonded work piece as the sacrificial ribs are removed from the work piece. The result is a bond with superior properties and with a bond surface which can be located very precisely.
    Type: Grant
    Filed: July 29, 1988
    Date of Patent: April 21, 1992
    Assignee: Wyman-Gordon Company
    Inventors: John M. Hyzak, Timothy E. Howson, Wilford H. Couts, Jr., Steven H. Reichman, Hugo E. Delgado, Daniel D. Kruger, Michael E. Sauby, Sulekh C. Jain, Bruce P. Bardes, Richard G. Menzies, Swami Ganesh
  • Patent number: 5100050
    Abstract: An article of manufacture having at least a first and a second part, each part having different mechanical properties, compositions, microstructures or combinations thereof, being joined together using a forging process to yield a substantially defect-free joint region. The article in the form of a turbine disk is particularly suited for use in a gas turbine engine in which the hub or inner portion must be resistant to low cycle fatigue and have high strength, while the rim or outer portion must be resistant to stress rupture failure and creep failure.
    Type: Grant
    Filed: October 4, 1989
    Date of Patent: March 31, 1992
    Assignee: General Electric Company
    Inventors: Daniel D. Krueger, Michael E. Sauby, Sulekh C. Jain, Bruce P. Bardes
  • Patent number: 5083697
    Abstract: A method for joining a first metal surface to a second metal surface employs metallized particles or protuberances disposed between said surfaces. The metallized particles include a core particulate composed of a material having a hardness greater than that of the metals to be bonded. By compressing the metal surfaces together in a generally normal or perpendicular direction, one or both of the metal surfaces is compressed into a metal region formed around the particulate core. In this way, very high local regions of stress are created which cause the metal to elastoplastically deform, enhancing the ability to form diffusion bonds. Alternatively, temporary electrical or other junctions may be formed by bringing the surfaces together under less rigorous conditions and/or using metals which are incapable of forming diffusion bonds.
    Type: Grant
    Filed: February 14, 1990
    Date of Patent: January 28, 1992
    Inventor: Louis Difrancesco
  • Patent number: 5046657
    Abstract: A tape automated bonding structure (10) includes a copper flexible tape (12) with a plurality of conductive leads (14) having tips (16) arranged in a generally rectangular pattern corresponding to gold bumped contacts (18) on semiconductor die (20). The tips (16) of the conductive leads (14) are configured as bumps extending from the remainder of each conductive lead (14). The tips (16) of the conductive leads (14) are gang bonded to the bumped contacts (18) on the semiconductor die (20) by positioning the tips (16) in registration over each bumped contact and applying heat and pressure to urge the tips (16) and the bumped contacts together, thus forming a thermocompression bond. The harder copper tips (16) penetrate into the gold bumped contacts. The bumped contacts (18) and the remainder of the tips (16) that has not penetrated into the contacts (18) space the conductive leads (14) above surface (22) of the semiconductor die (20).
    Type: Grant
    Filed: January 5, 1990
    Date of Patent: September 10, 1991
    Assignee: National Semiconductor Corporation
    Inventors: Venkat Iyer, Jagdish Belani, Hem P. Takiar, Rajenda Pendse
  • Patent number: 5024369
    Abstract: Processes for producing titanium alloy SPF/DB components, particularly structural panels, are provided.In one embodiment, the process comprises providing rapidly solidified titanium alloy sheetstock, providing a plurality of rapidly solidified titanium 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 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.
    Type: Grant
    Filed: May 5, 1989
    Date of Patent: June 18, 1991
    Assignee: The United States of America as represented by the Secretary of the Air Force
    Inventors: Francis H. Froes, Daniel Eylon
  • Patent number: 5007577
    Abstract: Heat-radiating substrate material characterized by a matrix of Ni-Fe alloy or Ni-Co-Fe alloy where a plurality of Cu elements penetrating cross-sectionally and the metals being mutually bonded by diffusion bonding to form multiple-core material.A method of manufacturing multiple-core complex material including process steps of manufacturing clad complex core member with a circular cross section, followed by formation of multiple-core complex billets composed of a plurality of complex core members filled in a metallic tube within the extent that the ratio of the inner diameter (D) of the metallic tube to the outer diameter (d) of the core member D/d is not less than 12, and then, after heating the complex billets, the core members are diffused and bonded together by a hot working at a reduction of area being not less than 20%.
    Type: Grant
    Filed: November 21, 1989
    Date of Patent: April 16, 1991
    Assignees: Sumitomo Metal Industries Ltd., Sumitomo Special Metals Co., Ltd.
    Inventors: Kazuyuki Nakasuji, Chihiro Hayashi, Yoshiyuki Suzushima
  • Patent number: 5005756
    Abstract: The method according to the invention relates to the production of a bimetallic tube, the cross-section of which comprises an outer annular zone and an inner annular zone, these zones being of different compositions. The method resides in preparing a blank (1) comprising two tubular components (2, 3) housed one inside the other and of different compositions and separated by an annular space (4) which is filled with divided metal. The whole assembly is made rigid by two end pieces (7, 8) and coextrusion is carried out at a suitable temperature to ensure a metallurgical bond between the inner component (2) and the outer component (3). The bimetallic tube obtained is particularly suitable for uses in which one of its two outer or inner walls is exposed to a medium which is more aggressive than the other.
    Type: Grant
    Filed: January 3, 1990
    Date of Patent: April 9, 1991
    Assignee: Valinox
    Inventors: Alain Muggeo, Denis Vuillaume
  • Patent number: 5004143
    Abstract: The present invention relates to a method of manufacturing a clad bar and is basically characterized in that a columnar core member is fitted in a cylindrical outside layer member and the resulting assembly is heated, and then the heated assembly is rolled by a rotary mill provided with three or more cone type rolls to integrate the core member and the outside layer member by diffusion bending. The method is additionally characterized in that, in order to prevent unnecessary substances, such as oxides, from being formed on an interface between the core member and the outside layer member, the assembly is sealed at both ends thereof under reduced pressure or under vacuum or the assembly is cold drawn, the assembly thus welded or cold drawn is then heated and subsequently rolled by a rotary mill. Thus, an intermetallic compound layer formed between the core member and the outside layer member can be thinned, whereby improving bond strength.
    Type: Grant
    Filed: July 28, 1987
    Date of Patent: April 2, 1991
    Assignee: Sumitomo Metal Industries, Ltd.
    Inventors: Kazuyuki Nakasuji, Chihiro Hayashi
  • Patent number: 4988037
    Abstract: A method and apparatus for superplastic forming and diffusion bonding of hollow metal parts. A forming assembly is prepared by surrounding a hollow tool (typically having a frusto-conical exterior) with a part blank having a corresponding shape, attaching parts, such as rings, to the exterior of the blank, then surrounding those parts with a skin blank. The forming assembly is placed in a pressure chamber, a heater is placed within the assembly and the chamber is sealed. The assembly of parts is heated to the diffusion bonding temperature of the parts while subjecting them to high gas pressure. The skin blank is deformed into intimate contact with the adjacent surfaces of the other parts and all of the parts are diffusion bonded together at all interfaces to form a unitary product. Gas pressure is released and the product is cooled and removed from the chamber and hollow tool. Any desired finish machining is accomplished and the productive is complete.
    Type: Grant
    Filed: October 31, 1988
    Date of Patent: January 29, 1991
    Assignee: Rohr Industries, Inc.
    Inventor: Gilbert C. Cadwell
  • Patent number: 4978054
    Abstract: A method of forming diffusion bonds between aluminum and aluminum alloy saces by coating the surfaces with molten AgNO.sub.3 and then decomposing the AgNO.sub.3 to form a thin uniform layer of silver on the surfaces before forming the diffusion bond. The AgNO.sub.3 coating and decomposition in treatment permanently breaks up the Al.sub.2 O.sub.3 coatings on the aluminum or aluminum alloy surfaces, making diffusion bonding possible.
    Type: Grant
    Filed: July 3, 1990
    Date of Patent: December 18, 1990
    Assignee: The United States of America as represented by the Secretary of the Navy
    Inventors: William A. Ferrando, Amarnath P. Divecha, Subhash D. Karmarkar
  • Patent number: 4896818
    Abstract: A method of fabricating light-weight sections consisting in uncoiling a strip (20), levelling it, slitting it in a zigzag course into at least two members (5, 6, 7), changing the path of travel of at least one member, matching the members (5, 6, 7) at the edges in the same plane so as to obtain units with an alternating cross-sectional area, and welding units together.
    Type: Grant
    Filed: September 21, 1988
    Date of Patent: January 30, 1990
    Assignee: Opytnoe Proizvodsyvenno- Tekhnicheskoe Predpriyatie "Energotekhprom"
    Inventors: Lev Z. Shteinbok, Igor L. Shteinbok, Alexandr V. Sagirov, Leonid S. Davydov
  • Patent number: 4896816
    Abstract: A process for producing a fluidtight seal between a body of a vitroceramic material and a metal element intended to be part of the construction of a gas laser and in particular a laser gyrometer includes interposing between the surfaces of the body of vitroceramic material and the metal element to be sealed a joining member of a metal capable of diffusing into the vitroceramic material, and subjecting the assembly thus formed to a thermo-compression operation so as to result in a superficial diffusion of the material of the joining member into the facing surfaces of the body of vitroceramic material and the metal element.
    Type: Grant
    Filed: November 6, 1987
    Date of Patent: January 30, 1990
    Assignees: Quantel S.A., Societe Francaise d'Equipements Pour la Navigation Arienne-S.F.E.N.A.
    Inventors: Guy Lascar, Jean-Jacques Roland
  • Patent number: 4889276
    Abstract: A method and apparatus for forming and bonding metal assemblies using an internally heated chamber. The parts can be both superplastic formed and diffusion bonded to other parts. A closable chamber contains a heating element near the chamber center. A ceramic die at least partially surrounding the heating element has a forming surface toward the heating element. The inner wall of the chamber is lined with a pressure bladder. A granular material, conical ceramic support, or extensible bladder fills the space between ceramic die and chamber inner wall. With the chamber closed, the heater is activated while an inert gas under pressure is introduced between heater and die and the bladder if used is pressurized. The bladder or packed granules support the outer die surface while the gas pressure presses metal parts on the die forming surface against the die. The metal parts are formed and bonded together by the substantially isostatic forces thereon.
    Type: Grant
    Filed: November 7, 1988
    Date of Patent: December 26, 1989
    Assignee: Rohr Industries, Inc.
    Inventors: Gilbert C. Cadwell, Paul M. Phillips
  • Patent number: 4861954
    Abstract: For simplified and more rapid production of a switch component (1) with a bimetallic element (3) and a switch (6) which can be actuated by this via a transmission element (15), the carrier or feed parts (4) are connected to the contact parts (5) by welding. For this purpose, each carrier or feed part (4) has a vertical weld section (8) passed through the insulating body (2) and having a smaller cross sectional surface than the remaining portion of the carrier or feed part (4).
    Type: Grant
    Filed: December 18, 1987
    Date of Patent: August 29, 1989
    Assignee: Electrovac, Fabrikation, Elektrotechnischer Spezialartike
    Inventors: Helmut Bayer, Peter Sekira
  • Patent number: 4834281
    Abstract: A porous metallic material of the present invention is constructed of a laminate consisting of an expanded metal and a fibrous metallic fiber both of which are pressed to be joined to each other under pressure. This porous metallic material is excellent in bending strength and workability. The porous metallic material may be laminated to a honeycomb structural element and a rigid plate so as to form a porous structural material. To this porous metallic material may be also laminated a decorative layer so as to form a porous decorative sound absorbing material. The present invention provides the above-mentioned products and method for manufacturing the same.
    Type: Grant
    Filed: February 19, 1988
    Date of Patent: May 30, 1989
    Assignees: Unix Corporation Ltd., Toru Morimoto
    Inventors: Toru Morimoto, Fumihiro Nakagawa
  • Patent number: 4792081
    Abstract: A novel method and apparatus for forming an aluminum container with an exposed metallic insert in the closed end thereof with the aluminum and the secondary metal being coextruded during forming of the container. A particularly synergetic combination is achieved by selecting a spherical insert member and providing concave or depressed region in the bottom of the extrusion die mold to partially receive the spherical element. The aluminum flows around the major diameter of the spherical insert during coextrusion but leaves a bottom portion of the insert exposed for external welding to another component.
    Type: Grant
    Filed: September 13, 1982
    Date of Patent: December 20, 1988
    Assignee: Duracell Inc.
    Inventor: Gordon E. Kaye
  • Patent number: 4782993
    Abstract: A process for the application of twin layer bottoms on the pots, wherein the filling material of the hollow space is located on the bottom of the pot and kept at a certain distance from its profile, being a covering layer located above it, by operating them according to the Italian Pat. No. 965,732. The process is characterized in that the height of the filling material is at least 20% higher than the average thickness that the same material has at the end, and in that in the first phase of the deformation of this material a pressure is gradually applied from the center to the periphery, and in the second phase wherein the covering layer is kept in a mould and the filling material fills all the hollow space, said impact acts on said filling material in all the directions.
    Type: Grant
    Filed: February 1, 1988
    Date of Patent: November 8, 1988
    Assignee: AMC-International Alfa Metalcraft Corporation AG
    Inventor: Ferdinando Cartossi
  • Patent number: 4756465
    Abstract: A method of cold welding of workpieces formed as axially symmetric bodies of rotation, wherein the workpieces are pressed into each other by applying an axial stress to at least one of the workpieces, and the workpieces are imparted a relative turn in a plane perpendicular to the direction of the axial stress.
    Type: Grant
    Filed: September 9, 1986
    Date of Patent: July 12, 1988
    Assignee: Latviisky Gosudarstvenny Institut
    Inventors: Anatoly S. Pranch, Pavel I. Gursky, Vasily I. Averkin, Petr S. Neminuschy, Vladimir N. Smirnov, Evgeny A. Baranov, Dmitry V. Leontiev, Jury I. Goroshkov, Vladimir N. Lozinsky