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.

Abstract: A method for manufacturing electrical connectors (22) which include rows of contact members (78, 90) held in a housing (24) includes feeding contact members in a wire form in parallel (74, 90), trimming such contact members to provide a partial form therefore at a trim station A, insert-molding such contact members to form a housing (62) and provide a carrier to tie such contact members together at a station (B), trimming said contact members to appropriate lengths, forming said contact members at further stations (C, D) into a multiple contact connector with rows of contact members in common planes held by the housing formed by insert-molding. Stamped and formed contact members (78', 90') are also contemplated utilized in an alternative method and both methods contemplate plating of the contact members either prior to molding or thereafter in alternative constructions, facilitated partially by the forming of the contact members into common planes.

Abstract: A radial inflow rotor for a gas turbine engine has a dual structure for improving the low cycle fatigue life of the saddle region. The interior core or hub of the rotor is a high strength polycrystalline alloy while a series of outer blade segments is individually cast as single crystals and bonded so that their low modulus (100) crystallographic axis is aligned substantially tangential to the rotor's circumference at the saddle.

Abstract: A mixer impeller made up of paddle shaped blades, which near their tips (e.g., at 90% of the radius of the impeller from its axis of rotation) are of a width at least 40% of the impeller's diameter. The blades also having camber and twist. They are formed by establishing bending moments which form the blades into sections which are curved and flat, with the flat sections being at least in the center area of the base of the blades.

Abstract: Extended stators for pumps or motors with eccentric shafts are made by machining. These stators are provided in the direction of their long axis with a dual- or multi-thread inner bore profile having periodically repeated profile pitches of predetermined lead as interior stator work faces. The course of the following method steps are utilized: (a) partial segments of the inner bore profile are produced by means of machining on rod-like work pieces as exterior working surfaces; (b) the work pieces are then separated in the direction of their long axes into a predetermined number of partial work pieces in such a way that each partial work piece has a partial segment of the inner bore profile, and (c) these partial work pieces are subsequently assembled together in such a way that the partial segments are combined into a complete inner bore profile.

Abstract: A method and apparatus for making a globoid screw for use as a mainrotor in a compressor or expander wherein a cylindrical rotor body is mounted for rotation about the longitudinal axis thereof, a cutter having a pluality of teeth at spaced locations around a circumference disposed in a plane and having an axis of rotation disposed perpendicular to that plane is mounted for rotation about its axis and is disposed so that the plane thereof is parallel to the rotor body longitudinal axis and so that the cutter rotational axis is perpendicular to the rotor longitudinal axis, and the rotor body and the cutter are rotated at synchronized speeds.

Abstract: An improved process for forming objects such as turbine nozzles (10) with internal geometries without requiring machining of the internal geometry to produce a smooth complex internal surface (16, 18 and 19) is disclosed. The process includes forming a mandrel (30) containing a negative image of the internal geometry; coating the mandrel with a material (32) which is not chemically reactive with the material from which the mandrel is formed, capturing the mandrel in a mold or form (34) which is to receive the material from which the object is to be formed, the material (36) from which the object is to be made not being chemically reactive with the coating; filling the mold or form with the material to capture the mandrel and coating in solidified material contained in the form; and removing the form and the mandrel. If the material is a cast metal, the melting point of the material for forming the object should be below the melting point of the coating on the mandrel.

Abstract: In a marine drive having a tapered propeller shaft section (14) and a tapered propeller hub (20, 60) matching and fitting therearound in flush contact, a relief inner diameter section (28, 66) is provided in the hub, spaced from the propeller shaft, to prevent flush contact and facilitate removal of the propeller hub from the propeller shaft. In a further embodiment, a thrust collar (50) with a substantially steeper tapered section (56) further facilitates removal.

Abstract: A process for manufacturing an improved flight assembly for a vertical centrifugal separator. e.g., of the type used to dry coal, is disclosed. The flights are first welded to the cone on which they are to be carried, then the outside edges of the flights are machined, for example on a vertical mill, after which a hard facing is applied to at least a portion of each flight. Preferably a stabilizing ring is welded to the bottoms of the flights before machining. A machining tolerance of plus or minus 1/64 inch (with respect to the gap between each flight and the surrounding conical screen with which the flight assembly is to be used) is preferred. The hard facing may be a weld having a hardness of at least about 40 Rockwell (C scale).

Abstract: A torque converter part having a three dimensional configuration and adapted to be assembled together with a series of torque converter pump blades is formed by a process which includes forming, within a press, slits, for receiving ends of the blades, in a flat blank within a press, deburring, within the press, to remove the burrs formed during slitting, so as to form half-finished work. The half-finished work is cut from the blank and deep drawn thereby obtaining a toroidal torque converter part. Since the deburring is conducted on the work while the work is still flat, burrs are removed easily and promptly with a high degree of uniformity.

Abstract: A method of manufacturing a pad for pressing a magnetic recording tape of a magnetic recording tape cassette against a magnetic head comprises steps of intermittently feeding a metal strip to a plastic injection mold, successively molding pad bodies on the metal strip by injection molding of synthetic resin, cutting the metal strip at the middle points between the pad bodies, and forming mounting portions for mounting the pad on the casing on opposite ends of the metal strip of each pad body-metal strip assembly thus obtained.