Abstract: A welding filler metal is manufactured by casting a nickel-base alloy as an extrusion rod having a diameter of from about 0.2 inch to about 0.5 inch. The extrusion rod has at least about 12 grains in the cross section of the extrusion rod. The extrusion rod is extruded in a single extrusion operation to a filler-metal diameter of less than about 0.1 inch and using an areal extrusion ratio of at least about 9:1 to form the welding filler metal. Preferably, the process is used to make a nickel-base superalloy welding filler metal of a diameter of about 0.05-0.06 inch from an extrusion-rod casting of about ¼ inch diameter and having at least about 12 grains in the cross section.

Abstract: A housing configuration for a liquid filter in which the housing is cup-shaped and is produced by a molding technique. The housing lid or lid is secured to the housing (10) by a course of threads (28) which can be produced without forming any undercuts. This is achieved inside an area (30) around the mold parting plane (29) by providing recesses (31) on the course of threads in the horizontal areas. As a result, the thread can be produced directly on the housing by the initial molding technique without any post-molding processing measures, so that manufacturing costs are reduced.

Abstract: A golf club head has a face portion, a crown portion, a sole portion, a side portion and a hosel portion. Each portion is made of titanium or a titanium alloy. The side portion is formed integrally entirely from its toe side to its back side and its heel side. The side portion and the hosel portion are cast integrally. The face portion, the crown portion and the sole portion are molded separately from one another. The face portion, the crown portion, the sole portion and the side portion are welded integrally so as to form a golf club head. The Young's modulus of the crown portion is lower than any Young's modulus of the face portion, the sole portion, the side portion and the hosel portion.

Abstract: A cooling unit adapted for use in a freezing mechanism, which is composed a metallic cylindrical evaporator housing and a metallic freezing pipe helically wound on an outer periphery of the evaporator housing for thermal contact with the evaporator housing, wherein the freezing pipe is embedded in a metal layer formed by slip casting of a low melting point alloy such as aluminum alloy, tin alloy or magnesium alloy on the outer periphery of the evaporator housing.

Abstract: A magnetic marker comprises a magnetically switchable wire and a magnetic casing that covers the magnetically switchable wire. The magnetically switchable wire is formed of a magnetic material that undergoes occurrence of sharp magnetic inversion when an alternating field of intensity higher than its coercive force is applied to it. The magnetic casing is formed of a magnetically hard or semihard magnetic material and can apply a bias magnetic field to the magnetically switchable wire to prevent magnetic inversion of the magnetically switchable wire. Heat-treated portions and high-coercivity regions, which are not heat-treated, are formed alternately in the longitudinal direction on the magnetic casing. The heat-treated portions are given magnetic properties different from magnetic properties essential to the magnetic casing by heat treatment such as annealing.

Abstract: A combustor for a gas turbine engine includes a deflector assembly that enhances heat transfer from the combustor and minimizes low cycle fatigue stresses induced within the combustor. The deflector assembly includes a plurality of deflectors secured to a spectacle plate. Each deflector has tapered edges and includes a plurality of cylindrical projections extending outward from the deflector to facilitate heat transfer. The projections include rounded edges and are arranged in a high density pattern. The deflector is coated with a thermal barrier coating and a bondcoat to minimize exposure to hot combustion gases or flame radiation.

Abstract: The invention relates to a method of strengthening a mould manufactured from aluminium or its alloys. One method of strengthening a mould having mould body and mould walls as an integral unit is to include at least one insert into each of the mould walls. These inserts are of stronger material or materials as compared to the mould material. Each of these inserts is of the same height as that of the mould wall at the position where it is located. Another method uses reinforced walls which are separate units, with the reinforced walls made of a higher strength material or materials than that of the mould body. The reinforced walls are coupled to the mould body either by fasteners or by welding or bonding or by any other suitable means. The invention also relates to moulds including strengthening according to one or more of these methods.

Abstract: A tire molding apparatus and technique is provided for the ventless molding of tires. According to the invention, a series of pitches is formed in an appropriate REN board, plaster, or like material with the implementation of a CNC machine. An aluminum pour casting is made from the model in which the various pitches are separated by voids which allow for the entry of a cutting tool such that each individual pitch or tire tread segment can be cut from the aluminum casting. Sipe locations are then cut into the model. Master rubbers or foundry tooling is then created and the castings poured. The individual pitches are then matingly interengaged in a puzzle-like fashion along the interior of a tire mold to define the tread portion of the mold. Venting of the mold is achieved at the pitch line formed at the intersection of each of the pitches.

Abstract: A method of manufacturing a golf club head comprises: hot forging a material of a beta titanium alloy into the face plate, slow cooling the forged face plate; and assembling a golf club head from the face plate and other component(s).

Abstract: A method of fabricating a mailbox is disclosed comprising the steps of obtaining an extruded metal bar having a generally L-shaped cross section defining an elevation flange and a base flange, wherein the length of the elevation flange is selected to correspond to the desired height of the side walls of the mailbox and the length of the base flange is selected to correspond to one-half of the desired width of the mailbox floor. The outside face of the elevation flange has one or more areas shaped as a decorative molding detail to create the appearance of a case mailbox. The base flange has an inside face in a pattern of raised longitudinal ribs that define a grooved surface. The open channel of the mailbox is created by cutting two equal-length billets from the extruded bar, welding them together facing each other, attaching a back pate, a hinged door plate and an ornamental cast metal roof. The appearance of the finished box creates the illusion of a cast metal mailbox.

Abstract: A bearing member manufacturing method manufactures a bearing member 20 formed of a light-metal-base material and capable of stably supporting a rotational shaft at a reduced manufacturing cost. The bearing member manufacturing method manufactures a bearing member 20 including a bearing body 21 formed of a first material, a light-metal-base material, and a bearing part 22 formed of a light-metal-base material different from that forming the body part 21, the bearing part 22 having a bearing surface 23 and bonded to the body part 21. A first workpiece 30 having a cylindrical inside surface 30a serving as the bearing surface 23 is placed in a mold 50. The molten first material is poured into a cavity 56 surrounding the first workpiece 30 to cast a second workpiece 32. The first workpiece 30 and the second workpiece 32 are bonded metallurgically along the interface between the first work-piece 30 and the second workpiece 32 to form a primary workpiece 34 in the form of a semifinished workpiece 33.

Abstract: To adopt die casts product as parts of a vehicle body frame. A vehicle body frame is provide with an alumite treating, showing that brightness and appearance of pivot plates which are die cast products differ from those of non-die cast products, head pipes, longitudinal pipes and cross pipe. By carrying out a local coating treatment on the pivot plates, the pivot plates are provided with a color the same as that of the pipe, the longitudinal pipes and the cross pipe. By making die cast products portion of constituent parts, the fabrication cost of the vehicle body frame can be reduced.

Abstract: A golf clubhead containing a main body and a face member, the main body including a main shell portion having a hollow and a tubular inner extension of a hosel protruding in the hollow, and at least a part of the tubular inner extension separating from the inner surface of the main shell portion. A method of making the golf clubhead which includes making a first lost form corresponding to the main shell portion, making a second lost form corresponding to the tubular inner extension, fixing the second lost form to the first lost form to make a third lost form corresponding to the main body, making a casting mold using the third lost form, and casting a metallic material into the main body using the casting mold.

Abstract: A golf club head has a face portion, a crown portion, a sole portion, a side portion and a hosel portion. Each portion is made of titanium or a titanium alloy. The side portion is formed integrally entirely from its toe side to its back side and its heel side. The side portion and the hosel portion are cast integrally. The face portion, the crown portion and the sole portion are molded separately from one another. The face portion, the crown portion, the sole portion and the side portion are welded integrally so as to form a golf club head. The Young's modulus of the crown portion is lower than any Young's modulus of the face portion, the sole portion, the side portion and the hosel portion.

Abstract: A method of manufacturing sliding bearings of the type in which a sliding guide surface is formed by using a resin liner, including fixing a thermosetting resin, which constitutes the resin liner, on the whole or a part of a sliding guide surface of a first member by an injection molding operation using the first member as a core, thereafter molding a second member, which covers a sliding guide surface of the first member, by a metal molding operation with the resin liner-fixed first member placed firmly as a core in a metal mold, and thermally curing the resin liner with the heat working on the sliding surface of the first member during the molding of this second member.

Abstract: An alternator assembly 10 having a pair of housing members 11, 12 which cooperatively contain a stator 24, rotor 18, and bearing 29. The housing member 12 includes an integrally formed bearing sleeve member 40 which receives the bearing 29 and allows the rotor 18 to rotate within the assembly 10.

Abstract: A lightweight detachable air coupler for an air seeder comprises an aluminum frame having two steel sleeves die cast into the frame. The frame is provided with two circular apertures each being defined by a rim having an internal cylindrical surface. The steel cylindrical sleeve has a first end having an exterior surface that is diagonally knurled. Two steel sleeves are mounted in the mold for the aluminum frame and cast aluminum is injected into the mold. The liquid aluminum adheres to the knurled exterior surface of the steel sleeves. The aluminum frame has a front surface from which the rims project and a rear surface from which the sleeves project.

Abstract: Disclosed herein is a golf club head comprising a forged face cup, which comprises a hitting face and at least one sidewall, a cast member, and a stamped member, wherein the face cup, the cast member and the stamped member are welded together to form the golf club head. The hitting face and the at least one sidewall form a face cup. The hitting face may have a thickened central portion and a relatively thinner intermediate region. The hitting face defines a rectangular area of about 0.5 inch by 1.0 inch, and wherein initial ball speeds generated by the golf club head impacting golf balls are within 2% of a peak initial ball speed within the rectangle.

Abstract: A continuously cast copper ingot is made by a procedure in which turbulence is imparted to the metal/solid interface during the casting operation. The ingot is then hot worked to form a billet having a smaller average grain size and a larger diameter than possible in the past. The billet is especially useful for making electroplating anodes used in the damascene process for making copper interconnects in silicon wafers.

Abstract: A metal ingot (1) solidified through unidirectional forced-cooling from a cooling member (100) to an end surface of a stopper (13), by the cooling member, of molten metal (1′) teeming via a molten metal inlet (101) of a closable mold (12) into a mold cavity (16) is plastic-worked at percent working equl to or higher than a predetermined level to obtain a plastic-worked member. The end surface of the stopper and the cooling member partially define the mold cavity. The plastic-worked member is improved in mechanical characteristics that have heretofore been inferior on the side of the end surface of the stopper and is increased in entire strength.

Abstract: Membrane electrode assemblies are described that include an ion conductive membrane a catalyst adjacent to the major surfaces of the ion conductive membrane and a porous particle filled polymer membrane adjacent to the ion conductive membrane. The catalyst can be disposed on the major surfaces of the ion conductive membrane. Preferably, the catalyst is disposed in nanostructures. The polymer film serving as the electrode backing layer preferably is processed by heating the particle loaded porous film to a temperature within about 20 degrees of the melting point of the polymer to decrease the Gurley value and the electrical resistivity. The MEAs can be produced in a continuous roll process. The MEAs can be used to produce fuel cells, electrolyzers and electrochemical reactors.

Abstract: The invention is directed to an expandable or self-expanding stent for implantation in a body lumen, such as an artery. The stent is made from a centrifugal casting process in which liquid casting material is placed within a female mold which includes an elongated cavity having a angular wall formed of grooves cooperating to form a predetermined stent configuration and rotating the female mold to distribute the casting material throughout the network of grooves. The stent can also be made from a rotational molding process in which dry cold powder resin is placed in a female mold and rotated at low speeds and heated to allow the charge of cold powder material to sinter to form the shape of the stent. The invention is also directed to the method for making such stents made from either centrifugal casting or rotational molding processes.

Abstract: A ceramic metal-reinforced metal-based composite material produced by impregnating, under pressure, a semi-molten alloy having a solid phase and a liquid phase coexistent with each other into a preliminarily molded body composed of ceramic whiskers or ceramic particles.

Abstract: This invention is directed to a method for manufacturing metal which includes a step of melting a forged material, and a step of casting a molten forged material to obtain a preform made of forged material, and a step of forging the preform made of forged material, and an apparatus therefor. The preform made of forged material comprises one or more of standardized preforms made of forged material having an approximately cylindrical form with the same cross sectional shape, but a different length. According to the present method and the present apparatus, one may produce metal products to which excellent mechanical properties are impaired by subjecting standardized preforms to the forging treatment with an improved productivity and reduced production cost.

Abstract: A welding filler metal is manufactured by casting a nickel-base alloy as an extrusion rod having a diameter of from about 0.2 inch to about 0.5 inch. The extrusion rod has at least about 12 grains in the cross section of the extrusion rod. The extrusion rod is extruded in a single extrusion operation to a filler-metal diameter of less than about 0.1 inch and using an areal extrusion ratio of at least about 9:1 to form the welding filler metal. Preferably, the process is used to make a nickel-base superalloy welding filler metal of a diameter of about 0.05-0.06 inch from an extrusion-rod casting of about 1/4 inch diameter and having at least about 12 grains in the cross section.

Abstract: A method for producing a cylinder block capable of providing sufficient bonding between the cylinder liner and a block body. The cylinder block producing method includes an inner peripheral surface roughening process, outer peripheral surface roughening process, adiabatic particle adhesion process, and melt bonding process. In the inner peripheral surface roughening process, shot blasting is performed to the inner surface of the cylinder liner. In the outer peripheral surface roughening process, semi-spherical dimples are formed on the outer surface of the cylinder liner by sinking the shot balls by their semi-spherical amount into the liner by means of shot blasting. Zn balls and stainless beads each having diameter of 0.4 mm, or Zn balls having diameter of 0.8 mm are used as the shot balls. In the adiabatic particle adhesion process, BN particles are adhered to the inner surface of the cylinder liner.

Abstract: The subject matter of the present invention relates to perforating gun carriers and their methods of manufacture. In one embodiment of the present invention, high strength, uniform wall thickness carriers are manufactured through use of the electric resistance weld process.

Abstract: A method of making a bicycle crank arm bar by casting, forging, rolling, heat molding, and cold forging. The bicycle crank arm has an elongated cavity, an axle end, and a pedal end.

Abstract: The present invention relates generally to improved cathodes (24) for use in an electrotransport device (10) for transdermally or transmucosally delivering a beneficial agent (e.g., a drug) to, or extracting a body analyte (e.g., glucose) from, the body surface of a patient. Most particularly, the present invention relates to a cathodic electrode (24) in the form of a silver halide foil which can be made, e.g., by forging particulate silver chloride. The cathode (24) does not absorb agent (e.g., drug), eliminates the need for binders, solvents and processing aids during the manufacturing process, and increases dimensional freedom of design.

Abstract: A sacrificial plastic mold having an electroplatable backing is provided as are methods of making such a mold via the infusion of a castable liquid formulation through a porous metal substrate (sheet, screen, mesh or foam) and into the features of a micro-scale master mold. Upon casting and demolding, the porous metal substrate is embedded within the cast formulation and projects a plastic structure with features determined by the mold tool. The plastic structure provides a sacrificial plastic mold mechanically bonded to the porous metal substrate, which provides a conducting support suitable for electroplating either contiguous or non-contiguous metal replicates. After electroplating and lapping, the sacrificial plastic can be dissolved, leaving the desired metal structure bonded to the porous metal substrate. Optionally, the electroplated structures may be debonded from the porous substrate by selective dissolution of the porous substrate or a coating thereon.

Abstract: The invention relates to a method for producing a solid molded article, in particular a ceramic and/or metallic article made of pulverized particles. The invention also relates to stable dispersions of pulverized particles in an aqueous fluid medium, solid molded articles made of pulverized particles, and sintered ceramic and/or metallic molded articles.

Abstract: A method of manufacturing a camshaft used in an internal combustion engine. The method of manufacturing the camshaft produces a camshaft which has reduced weight and added wear resistance at a lobe of the camshaft. The camshaft is manufactured to provide increased efficiency of the internal combustion engine. The method of making the camshaft includes mixing wear resistant material with a base material and metering the mixture into a rotating die. The rotating die rotates at a predetermined speed and forces the wear resistant material to the outer surface of the lobes.

Abstract: A golf club which has a clubface of desired shape comprising an alloy metal is provided. The golf club has excellent strength properties as well as excellent ball hitting properties. The clubface is free from casting defects such as cold shuts, and preferably, free from the crystalline phase formed from crystal nuclei through nonuniform nucleation since the club face is produced in a simple, highly reproducible, one-step process by selectively cooling the molten metal at a temperature above the melting point at a rate higher than the critical cooling rate, and the product comprises a single amorphous phase.

Abstract: The present invention provides a cast iron component for enveloped casting which is characterized by that the cast iron component has a surface to which enveloped casting is applied and which has a surface roughness such that a maximum height Ry is from 65 to 260 &mgr;m and a mean spacing of profile irregularities Sm is from 0.6 to 1.5 mm; an enveloped casting product using it; and a method for its production.

Abstract: The invention relates to a method for manufacturing molds suitable for plastic injection consisting of a CAD geometry. To which parting lines are added, thereby obtaining a negative CAD insert is then converted into an STL file. The negative of the prototype is built in a stereolithographic machine and the refined and polished, the metal being manufactured in cooper or nickel by electrodeposition or galvanoplasty and the resulting cavity in the metal insert being filled with iron founding or the like.

Abstract: A golf club head has a weight compartment within a hollow interior, and a weight member that is injected into the weight compartment subsequent to formation of the body of the golf club head. The preferred weight member is bismuth. The golf club head has a body that has a volume between 140 cubic centimeters and 350 cubic centimeters. The body of the golf club head weighs between 140 grams and 215 grams.

Abstract: A spherical crown shoe is fabricated from an aluminum alloy. A cast shoe member is first fabricated by casting in such a shape having a substantially flat surface and a convex curved surface, which is similar to the shape of the shoe as a product. The cast shoe member is then formed into a formed shoe member substantially in the shape of a spherical crown, by pressing. The cast shoe member is smaller in diameter and greater in height than the formed shoe member, for example.

Abstract: A method for producing metal sputtering target, comprising a step of double V melting process, and a step of high temperature forging. The step of double V melting process produces a single metal of aluminum, titanium, or copper, or an alloy of the single metal associated with at least a different metal selecting from one of copper, silicon, titanium, zirconium, osmium, molybdenum, tungsten, platinum, gold, niobium, tantalum, cobalt, rhenium, and scandium. The step of high temperature forging treats the single metal or the alloy to form the metal sputtering target material with small crystal grains and a secondary phase of fineness and high homogeneity suitable for using in semiconductor and photoelectric industries.

Abstract: Aluminum alloy compositions are disclosed, which include small amounts of calcium that result in improved surface properties of the cast aluminum. The calcium, and up to 0.25% grain refiners, are added along with alkaline earth metals, transition metals and/or rare earth metals to the aluminum alloy as a melt. The addition results in improved appearance, substantially reduced surface imperfections and reduced surface oxidation in cast ingot aluminum and aluminum alloys. The addition of small amounts of these additives, surprisingly were found to substantially eliminate vertical folds, pits and ingot cracking in more than one ingot casting technique. The additions also improved the appearance of the ingots, including reflectance. As a result, the ingots could be reduced or worked essentially right out of the casting without first conditioning the surface by, for example, scalping.

Abstract: A base material of a peripheral wall and a vane rotor is formed by extrusion molding an aluminum alloy and cutting an extrusion molded article to the desired length. Further, the extrusion molded article can be molded with high accuracy by extracting the aluminum alloy after extrusion. Preferably, 6000 system of Al—Mg—Si is used as an aluminum alloy. The cutting process and polishing process are applied to the roughly molded base material to form the peripheral wall and the vane rotor. By varying the length to be cut, the volume of each retard hydraulic chamber and each advance hydraulic chamber are adjusted. When the volume of the hydraulic chambers are adjusted, the torque for relatively rotating and driving the vane rotor with respect to the housing member can be changed even pressure of working oil is the same.

Abstract: A crank arm for a bicycle includes a crank arm body formed of a first material and a core formed of a second material disposed in the crank arm body. The second material has a specific gravity less than a specific gravity of the first material. The second material may be a porous material such as volcanic glass or some other lightweight material. In the method used to form the crank arm body, a core having a specific gravity lower than a specific gravity of the metal forming the outer portions of the crank arm is positioned in a casting mold so that a melt space is formed around the core. Molten metal is poured into the casting mold, and the molten metal is solidified to form a crank billet such that the core is integrally formed with the metal.

Abstract: Metal products are taught that comprise integrally formed resin seals. The fastening strength of a rubber or synthetic resin seal is increased because the resin seal is formed during a casting operation. For example, an unvulcanized rubber or unhardened resin seal member (9′) may be temporarily secured to a metal mold (A1) and heat from the molten metal vulcanizes or hardens the seal member (9′), thereby integrally forming a rubber or synthetic resin seal and a metal molded body. Resin seals can be integrally formed on metal products having a variety of shapes, because the resin seal will melt and integrally form with the metal product during the die casting operation. That is, the resin seal is adhered to the metal product by a diffusion or seamless bond. In one representative embodiment, an engine head cover is die cast and a plurality of bolts protrude from the engine head cover.

Abstract: A golf club head is formed with a unitary, one-piece body including a top crown, sole plate, face plate and side skirt. The side skirt includes an opening, and a cap is configured to cover the opening. Preferably, the cap is connected to the side skirt by a snap fit or interference fit. The interior portion of the golf club head preferably includes a reinforcement structure which supports the face plate. Desirably, the reinforcement structure includes three vertical ribs which are connected to the top crown, face plate and sole plate to form part of the one-piece body.

Abstract: A process for sealing a ceramic filter by infiltrating a metal into an end of the filter. The process includes the steps of contacting the end of a porous ceramic filter with a molten metal, whereby the metal enters into the ceramic matrix to substantially fill the void space. The ceramic filter is cooled to form a filter having a ceramic-metal composite portion. The present invention also provides a filter having an infiltrated metal seal. Methods for joining infiltrated ends are also provided.

Abstract: A ratchet type one-way clutch in which an outer ring is made of aluminum is improved in durability. In order to solve such problems as an increase in the number of parts, complication, bulkiness, an increase in weight and an increase in cost, there is provided a one-way clutch with the lock-up function also having the function of idly rotating only in one direction and the function of blocking the rotation in both directions. In a ratchet type one-way clutch having an outer ring having a pocket in the inner periphery thereof, an inner ring disposed coaxially with the outer ring and having a notch in the outer periphery thereof, a pawl contained in the pocket and fitted in the notch of the inner ring for transmitting torque between the inner ring and the outer ring, and a resilient member for biasing the pawl toward the inner ring, the outer ring is made of aluminum, and the inner peripheral side surface of the outer ring is subjected to a hardening process.

Abstract: Surface activation is intended to ensure that a cylinder liner can be anchored in the casting material of a light-metal crankcase with greater bonding. For surface activation, the surface of the cylinder liner is roughened mechanically. Advantageously, copper particles are also implanted into the treated surface. It is necessary to ensure that the time span between surface activation and casting-in is short. Moreover, the activated surface, as far as possible, should not be touched by hand.

Abstract: A method of manufacturing a brake pad comprising casting a back plate in a mould. The plate is formed with at least one integral projection which overhangs an adjacent surface of the plate. The mould is formed from frangible material and has a recess in the shape of the projection. The mould is formed from particulate material compressed around a projection made of resilient material which deforms to the shape of the projection. The resilient material is withdrawn to form the recess. Metal is cast in the mould including the recess. After solidification of the metal, the mould is broken away from the projection. The method also comprises pressing a mixture containing friction material and curable material against the plate including pressing the mixture around the projection so that it extends beneath the overhang and curing the curable material to form a block of friction material adhered to the plate.

Abstract: A process for manufacturing hollow synthetic resin bodies or objects in which cores are produced in casting molds, then placed into molds of injection molding machines, and subsequently enveloped with injected synthetic resin material (35) which then solidifies. The molds are then heated up to a temperature at which the cores melt and at which the molten cores can be removed from the molds. The cores are made of shell halves (32, 33) which are assembled before the synthetic resin material (35) is injection molded around them.

Abstract: A PCB package for shielding electromagnetic radiation from exiting or entering the package. In one embodiment the package includes first and second electrically conductive covers and first and second electrically conductive frames. The first frame electrically connected to the first cover and the second frame electrically connected to the second cover. The first frame is then electrically connected to the second frame. The first and second frames can be made of electrically conductive plastics or metals or any other electrically conductive materials. Methods of assembling the packages of the various embodiments are also set forth.

Abstract: The present invention relates to a method for manufacturing a paving stone. The invention also relates to a paving stone.