Abstract: A very fine pixel pattern can be formed by first screen printing a conductive paste and electron-emitting carbon paste material in sequence before removing a predetermined portion of the screen-printed layers simultaneously such that remaining portions become a fine pixel pattern. This method not only enables fine pixel pattern formation but also provides an electrode/emitter structure that increases electron emission. Furthermore all these improvements can be made with less manufacturing time and cost.

Abstract: A method for improving the thermal fatigue life of a thermal barrier coating (TBC) deposited on an aluminide bond coat through a process by which the surface morphology of the aluminide bond coat is modified to eliminate or at least reduce oxidation and oxidation-induced convolutions at the alumina-bond coat interface, as explained more fully below. The bond coat is deposited to have generally columnar grains and grain boundary ridges at its surface, and is then peened at an intensity sufficient to flatten at least some of the grain boundary ridges, but insufficient to cause recrystallization of the bond coat when later heated, such as during deposition of the thermal barrier coating. In so doing, the original surface texture of the bond coat is altered to be smoother where the grain boundaries meet the bond coat surface, thereby yielding a smoother bond coat surface where the critical alumina-bond coat interface will exist following oxidation of the bond coat.

Abstract: A filling squeegee and a scraping squeegee are provided. The filling squeegee is moved in a state without contact with a surface of a mask thereby to fill a solder paste in openings of the mask, then the unnecessary solder paste on the surface of the mask is scraped by the scraping squeegee. The solder paste is prevented from being filled in the openings improperly or scraped improperly even if a speed of the squeegee is increased, so that the solder paste is printed stably on circuit boards.

Abstract: A process for reclaiming aluminum alloy donor from a vapor phase deposition process used to form a diffusion aluminide coating on a component, such as the high-temperature superalloy components of gas turbine engines. The process generally entails recycling a particulate aluminum alloy donor material that, as a result of having been used as the donor material for depositing a diffusion aluminide coating on an article by vapor phase deposition, particles of the donor material comprise an aluminum alloy core encased in an aluminum-depleted shell. The process generally entails tumbling the donor material in a manner that removes the aluminum-depleted shell, followed by sieving the donor material to remove shell fragments and undersized particles.

Abstract: A method for producing cylinder linings in an aluminum or magnesium engine block for an internal combustion engine utilizes plasma spraying of a mixture of powdered molybdenum and powdered steel containing from about 10 to about 70 wt. % molybdenum and from about 90 to about 30 wt. % steel. The resulting slide layer has good adhesion to the engine block and has high wear resistance.

Abstract: A method of making an oil scraper piston ring includes the following steps of providing a base ring body including a circumferential web having flanks and an outer circumferential surface; galvanically depositing on the web a wear resistant hard chromium layer having solid particles embedded therein; applying a break-off resistant cover layer to the hard chromium layer; and grinding the cover layer to provide the outer circumferential surface of the web with sharp bounding edges

Abstract: Method of manufacturing a thin-film magnetic head comprising an inductive transducing system. A non-magnetic, insulating material for forming a first insulation layer (13), on which an inductive transducing element (15) is formed, is deposited on a plane basic surface (11). Subsequently, a non-magnetic, insulating material for forming a second insulation layer (19) is deposited on the first insulation layer and the inductive transducing element formed thereon. Subsequently, material is removed in an area proximate to a head face (30) to be formed for forming an aperture extending through the first and the second insulation layer and reaching as far as the basic surface, whereafter a non-magnetic, insulating material for forming a gap layer (29) is deposited in the aperture.

Abstract: In a melt deposition painting station, a solid body of paint is fed onto an endless belt conveyor, incorporating a substantially planar belt flight, a head pulley, and turn round means adjacent to the contact point of the paint block and the moving steel strip and consisting of a stationary guide and an idler pulley. The turn round means is so constructed that the direction of the belt movement after the turn is at least parallel to that of the continuously moving strip and preferably at an angle away from it. The head pulley is preferably coated with a high friction material such as natural rubber. The planar belt flight is adapted to support one or more blocks of substantially solvent-free paint composition, which becomes bonded to the pliable, durable heat-resistant material of the belt. The belt causes continuous movement of the paint block towards one end of the flight to affect melting of some portion of a solid body of paint composition onto a moving strip.

Abstract: Structural steel profiles such as channels, having a material thickness greater than 2 mm, are roll-formed to a preform profile with corners partial bent, in-line galvanized, and then further roll-formed to final shape. The preform profile has upwardly facing convex surfaces allowing rapid shedding of excess galvanising material. By preforming corners before galvanising, surface elongation in the galvanising layer is minimized and cracking eliminated. This is enhances by constant length bending of corners over preform and final roll-forming operations.

Abstract: A method of fabricating a metal matrix composite containing electrically isolated areas and the MMC formed from the method. The method comprises: (a) providing a liquid pool of unreinforced aluminum alloy; (b) infiltrating the unreinforced aluminum alloy into a stack comprising upper and lower porous preforms and an electrical insulator material placed between the preforms; (c) solidifying the liquid-phase metal to form a metal matrix composite product that completely surrounds the stack; and (d) forming at least one groove in the solidified metal, the groove extending downward to the insulating substrate so as to electrically isolate at least one region on the surface of the metal matrix composite.

Abstract: The invention is a method of plating a nonmetallic substrate comprising the steps of depositing an adhesion enhancing film on the substrate, treating the adhesion enhancing film to make the film catalytic, and forming an outer coating and passivating plate on the adhesion enhancing film. The resulting plated, nonmetallic substrates may comprise any number of materials used as an inner substrate such as compounds of oxide, nitride, phosphide, carbide, glass, ceramic, and mixtures thereof. In use, the resulting substrate may find application in any number of data storage and retrieval application.

Abstract: A microembossable coating for paper substrates containing: (i) a cross-linked sealing layer provided on the paper substrate, wherein the cross-linked sealing layer has a glass transition temperature above an embossing temperature; (ii) a microembossable layer provided on the cross-linked sealing layer, wherein the microembossable layer comprises, in admixture, a) a cyclohexanone aldehyde resin, b) chlorinated rubber; c) a vinyl terpolymer resin and d) an anti-blocking aid; (iii) an image intensifying layer provided on the microembossable layer; and (iv) a protective layer provided on the image intensifying layer. Optionally, the microembossable layer may contain: a) at least one of methyl methacrylate or ethyl methacrylate, b) polyvinyl acetate maleate copolymer, c) carboxyl vinyl terpolymer, and d) an antiblocking aid. A microembossed paper and process for microembossing paper substrates utilizes the above coatings.

Abstract: A method is disclosed of protecting a land or roadway vehicle body from surface corrosion which causes pitting, blistering, and other defects in paint at the joints in the skin, where the body surface is comprised of dissimilar metals in its skins and stringers and in the fasteners therefor. Roadway vehicles such as ambulances and fire trucks often have aluminum skins fastened with stainless steel screws, bolts, or rivets to aluminum structural members to save weight, but corrosion thereof is a persistent problem. The new method comprises using an anti-oxidant, a heavy grease compound with metallic zinc dispersed therein as dust or powder, such as electrical joint compound, as a bedding compound applied to surfaces of the fasteners or to the insertion apertures therefor before assembly. In one commercial form, the compound comprises about 51-53% by weight zinc, about 36% by weight refined heavy paraffinic distillate, and about 11-13% by weight aluminum stearate.

Abstract: In a method of forming a mold release film on at least molding surfaces of a mold comprising an upper die, a lower die, and a cylindrical die for press molding of an optical element, a TiAlN film is formed on the molding surfaces of the mold and is polished so as to yield a center-line mean roughness of about 1 nm or less, thereby improving the mold in terms of durability, heat resistance, specular characteristic, and the like while improving releasability of the mold and a molded article with respect to each other. A TiAlN film (1) is formed on molding surfaces (31a, 32a) of upper and lower dies (31, 32) by a sputtering technique or the like. Thus formed TiAlN film (1) is polished till its center-line mean roughness becomes about 1 nm. Accordingly, the molding surfaces (31a, 32a) are prevented from being discolored or becoming rough due to heat, whereby the mold can be improved in terms of durability, heat resistance, and the like.

Abstract: A magnetic recording medium is constructed with a substrate made of glass, one or two underlayers, and a magnetic film. In order that the easy magnetization axis of the magnetic film is parallel to the magnetic film, an underlayer having an NaCl crystallographic structure is superposed on the substrate. A magnetic film made of a Co based alloy having a hexagonal close packed crystallographic structure is formed on this underlayer, putting an underlayer made of a material having a body centered cubic crystallographic structure therebetween at need. Magnetic anisotropy of the magnetic film is increased by forming grooves in a predetermined direction in a surface portion of the substrate. These grooves play a role also for defining the orientation of the underlayer made of the material having an NaCl crystallographic structure.

Abstract: A method of manufacturing a terminated ceramic capacitor comprises forming the capacitor in the configuration of a parallelepiped having end surfaces joining the major base portions which define an acute angle with one base and an obtuse angle with the other. Electrodes of opposite polarities are exposed at the opposite end surfaces. A conductive coating, generally of metal or metal frit is applied to the entire end and base surfaces, the side surfaces being maintained clear of termination material. By removing termination materials from the acute angle junctions of end and base surfaces there is provided a capacitor which may be inserted into a circuit by contact with the opposite bases or the opposite ends. the invention relates also to the unique resultant capacitor.

Abstract: A continuously advancing workpiece (e.g., a steel rod) is treated prior to size reduction by drawing. The rod is preheated and then a liquid (such as a borax solution) is applied to the surface of the rod. The preheating of the rod provides sufficient residual heat within the rod to rapidly and evenly dry the liquid such that the rod is provided with a thick and uniform coating. Also disclosed is a system for conditioning the coating liquid.

Abstract: This invention discloses processes and articles for the manufacturing of composite plated articles comprising finely divided particulate matter dispersed within metallic matrices and having light emitting properties, such articles being useful in the metallization of articles and their reuse through subsequent rejuvenation, without damaging the base metal of said articles.

Abstract: Protection of a metal surface is carried out by applying a coating of vitreous enamel to the surface so that the enamel forms a strong bond with the metal and then spraying a coating of an atomized protective metal on the enamel. Preferably a peening operation is carried out on the surface of the sprayed metal simultaneously with or immediately after the spraying of the metal. The method is particularly advantageous in protecting steel marine structures against corrosion and, where the protective metal is cupro-nickel, fouling by marine creatures. The vitreous enamel forms an electrically insulating layer preventing galvanic action between the steel and the cupro-nickel in the presence of sea water.

Abstract: A laminated polyester film comprising a polyester film and a layer comprising an antistatic agent and formed on at least one side of the polyester film, the antistatic agent being a high-molecular-weight antistatic agent having a nitrogen atom-containing group and a sulfonic acid or sulfonate group.

Abstract: The present invention provides a method for metallizing vias in co-fired ceramic green tape. A vacuum operated pick and place anvil comprising a porous block is used to pick up conductor balls from a bed. Air pressure is used to create a vacuum which pulls the conductor balls to the porous block. A stencil having openings is placed on a contact surface of the anvil, thereby permitting only one conductor ball to attach to each opening in the stencil. With the conductor balls attached to the anvil, the anvil is lowered onto the green tape. Next the anvil pushes the conductor balls into the tape until the conductor balls break through the opposite side of the tape. The anvil is retracted leaving the conductor balls lodged in the tape. It is possible to provide a green tape with pre-formed vias so that forcing the conductor balls into the tape is a simpler task. The locations of the openings in the stencil determines the location of the vias or must correspond to the vias in a tape having pre-formed vias.

Abstract: A maskless process for forming a protected metal feature in a planar insulating layer of a substrate is disclosed. A first barrier material is disposed in a recess in an insulating layer, a conductive metal is disposed on the first barrier material such that the entire metal feature is positioned within the recess below the top of the recess, a second barrier material is disposed on the metal feature such that the second barrier material occupies the entire portion of the recess above the-metal feature and extends above the top surface of the insulating layer, and the second barrier material is then polished until the top of the second barrier material is in and aligned with the top of the insulating layer. As a result, the metal feature is surrounded and protected by the first and second barrier materials, and the substrate is planarized.

Abstract: The method for metallizing the surface of dielectric materials according to the invention comprises a first step wherein a metal powder, the size of the grains of which is comprised between 10 and 5000 nm, is deposited and then incorporated into the surface of the dielectric material. In a second step of the method, the dielectric material which is so impregnated with metal, is immersed into an autocatalytic bath to coat the impregnated zones of the material with a layer of the metal contained in the bath in a thickness which is proportional to the immersion time. This method enables to metallize materials such as oxides, polymers and composites containing these oxides and/or these polymers. The characteristics of the metal deposits are controlled, on the one hand, by the type of metal, and the size and the geometry of the metal powder grains and, on the other hand, by the type and the structure of the dielectric materials coated with these deposits.

Abstract: A cold process for laying a textured or polished coat of bronze, copper, brass, pewter or other metallic substance over a mineral or organic surface comprises the step of mixing a sintering metal powder with a polyester resin and a ketonic catalyst for forming a spreadable, moldable or sprayable paste that hardens to a coat having essentially the mechanical and chemical characteristics of the selected metallic substance, but exhibiting no electrical conductivity.

Abstract: A maskless process for forming a protected metal feature in a planar insulating layer of a substrate is disclosed. A first barrier material is disposed in a recess in an insulating layer, a conductive metal is disposed on the first barrier material such that the entire metal feature is positioned within the recess below the top of the recess, a second barrier material is disposed on the metal feature such that the second barrier material occupies the entire portion of the recess above the metal feature and extends above the top surface of the insulating layer, and the second barrier material is then polished until the top of the second barrier material is in and aligned with the top of the insulating layer. As a result, the metal feature is surrounded and protected by the first and second barrier materials, and the substrate is planarized.

Abstract: The invention relates to a coating composition based on a polyester resin, an amino resin and an epoxy resin.The polyester resin is a carboxyl-functional polyester with a molecular weight of between 12000 and 25000.

Abstract: For the purpose of preventing reductions of wall thickness due to erosion-corrosion in parts (2, 3, 7) of a system made of carbon steel, and which constitute a wet steam system, a feedwater and condensate system, and a drain system of a thermal or nuclear power plant, a coating (17) of metal or ceramic which is chemically stable against a fluid flowing in the systems is formed by spraying on the surface of the devices which are exposed to the fluid.

Abstract: The oxidation resistance of MCrAlY-type overlay coatings is improved by incorporating small discrete oxide particles into the coating. The particles are preferably yttrium oxide, and the coating is applied by simultaneously plasma spraying MCrAlY-type powder particles and oxide particles onto a substrate in a nonoxidizing atmosphere. Improvements in resistance to rumpling has also been observed in coatings applied according to this invention.

Abstract: A stainless steel gas turbine engine compressor blade is protected against corrosion by providing a thin sacrificial coating in the form of a coherent aluminum body in electrically-conducting contact with the blade surface, then overcoating the aluminum coat with a phosphate-chromate mixture in organic vehicle and drying and heating to cure and repeating the overcoating step several times to harden and densify the resulting ceramic body.

Abstract: A process for the production of engraved rolls and plates for printing operations wherein there are applied to a base member of metal, after it has been engraved, at least two layers of a metal and, respectively, a metal compound for increasing the hardness and the corrosion protection in order to achieve surface hardness values of at least 2000 HV.

Abstract: The invention relates to a method of producing an X-ray rotary anode having a focal track region composed of refractory metals. The focal track region is manufactured by means of powder-metallurgy methods or by means of CVD or PVD methods. According to the invention, the focal track region is posttreated using high-energy electrons or photons by means of local, superficial melting to a depth of less than 1.5 mm. This reduces, in particular, the residual porosity in the focal track region. That results in improved mechanical properties, higher X-ray yield and markedly improved service life of such rotary anodes.

Abstract: An improved high performance x-ray tube having a rotating graphite anode therein and method of preparation thereof. The surface of a graphite anode body is oxidized in air for removing the surface damage caused during the machining of the anode body. The anode body is provided with a diffusion barrier layer of rhenium contiguously disposed on the substantially damage free surface of the anode body. An anode target layer is then deposited on top of the barrier layer.

Abstract: The method of forming a high temperature resistant copper coating on a ceramic and/or enamel substrate, includes the steps of chemically depositing a copper layer having a thickness of at least 3 .mu.m on the substrate, heating the copper layer formed thereon at a temperature of from 200.degree. to 450.degree. C., mechanically treating the copper layer with brush and polishing means to consolidate an upper surface thereof and galvanically depositing an additional copper layer having a thickness of 3 .mu.m on the upper surface. The high temperature resistant copper coating for the ceramic or enamel substrate can stand a higher thermal load for a longer time than similar conventional coatings and can act to rapidly dissipate heat generated by electronic components.

Abstract: A metallic "close-out" layer is applied to the surface of a thermal barrier coating system to seal the ceramic material in the coating. The "close-out" layer is glass-bead preened to densify the surface.

Abstract: There is provided a method of spray deposition in which a stream of liquid metal or metal alloy is atomized inside a spray chamber into a spray of atomized droplets. A metal or metal alloy collector is rotated about an axis transverse to the mean axis of the spray and in the path of the spray so that a deposit is formed about the collector with a bond between the deposit and the collector sufficient to isolate the interface from oxygen penetration. The collector is then retained as an integral part of the final product and further processed to substantially eliminate porosity in the region of the bonded interface. The collector and the deposit may be the same or different materials, and the bond between the deposit and the collector is preferably enhanced by plasma heating in the region disposition. The invention also provides a plant for carrying out the preferred method arc plasma heating.

Abstract: A composite lead sheet product comprising a layer of lead or lead alloy having first and second surfaces. A first layer of a porous, non-metallic material is mechanically bonded to the first surface of the lead layer, and a second layer of porous, non-metallic material is mechanically bonded to the second surface of the lead layer. The method of making the composite of this invention comprises supporting a first layer of a porous, non-metallic sheet material on a heat sink. Molten lead or lead alloy is dispensed transversely across the first layer. A second layer of a porous, non-metallic sheet material is applied over the dispensed molten lead. The second layer is pressed into the molten lead, and the molten lead is pressed into the first layer with a roller, to mechanically bond the first and second layers to the lead.

Abstract: A ceramic-based coating is provided on a sealing surface of a sealing assembly component by processing and applying a powder mixture of ceramic particles and metal binder, encasing the coating of powder on the sealing surface by applying a metallic cover thereover, evacuating the atmosphere between the cover and coating, hot isostatic pressing the component and coating, cooling the component and coating, and after cooling thereof removing the cover from the coating.

Abstract: Metal filler compositions and methods of employing the same are disclosed, in which the compositions are copper base with the addition thereto of tin and silicon. For thermal spraying applications, aluminum is included in the formulation. By practice of the invention, substantial improvements in bond strength and quality of the surface finish are achieved.

Abstract: Manufacture of glass mold plungers utilizes a thermal spray gun having combustion chamber with an open channel for propelling combustion products into the ambient atmosphere at supersonic velocity. The method comprises injecting into the chamber a combustible mixture of combustion gas and oxygen at a pressure in the chamber of at least two atmospheres above ambient atmospheric pressure, feeding into the chamber a powder comprising self-fluxing alloy particles, and combusting the combustible mixture in the chamber means whereby a supersonic spray stream containing the powder is propelled through the open channel. The spray stream is directed toward a glass mold plunger substrate such as to produce a coating thereon which is ground and polished. The coating may be fused prior to grinding.

Abstract: A conductive metal layer is formed on a substrate by depositing copper or nickel particles on the substrate, contacting the metal particles with a specified developing agent, and heating the metal particles and the developing agent. The coated substrates have conductive surfaces and are useful for a variety of uses such as EMI shielding and printed circuit boards.

Abstract: This invention concerns a mechanical plating process comprising: shaving metal off from a pure metal or alloy block and plating an object to be plated with the shaved off metal by the use of at least a single metal brush, wherein the metal block and the metal brush are in frictional contact with each other, and the object to be plated and the metal brush are concurrently in frictional contact with each other.

Abstract: An improved method for inhibiting inland atmospheric corrosion of steel by a sacrificial coating of aluminum, galvanically activated by small surface deposits of metallic indium is disclosed.

Abstract: A continuous method of forming a repetitive pattern on a metallized film substrate is disclosed as including the steps of continuously feeding a web of metallized film substrate at a predetermined web speed, selective dry removal of predetermined metallized areas from the metallized film substrate during continuous movement thereof, and collecting metallized dust and flakes removed from the metallized film substrate during the aforementioned dry removal of predetermined metallized areas from the metallized film substrate. Unlike existing wet systems which remove metallized areas from a metallized film substrate, the present invention employs selective dry removal, along with the collection of dust, in a continuous in-line system. Following the selective removal of metallized areas from the metallized film substrate, metallized dust is collected in a closed dust removal system providing removal, transport and collection of the metallized dust in a storage unit.

Abstract: A process for hermetically sealing defects in a porous ceramic substrate comprising the steps of evaporating or sputtering a malleable metal layer onto the defective porous ceramic surface, swaging or smearing the malleable metal layer over the defects and depositing a second metal film over the swaged first film to provide a smooth defect free surface.

Abstract: The quality or durability of an oxidation protective coating produced by alitizing or aluminizing on the surface of a structural component made of titanium or titanium alloy, is improved by adding niobium to the surface of the structural component. The addition may be accomplished prior to the aluminizing or during the aluminizing. Prior application may involve, for example, vapor deposition of the niobium. Simultaneous application involves including a niobium donator powder in the aluminizing powder mixture.

Abstract: A transfer-metallization method in which a metal coating is applied to a top layer of a metallizing film, and the film is then brought into contact with a substrate such that the metal coating is transferred from the top layer to the substrate. The film is a three-layer biaxially-oriented transfer film produced by coextrusion and having a base layer of a polypropylene homopolymer and top layers applied to the two surfaces thereof. The base layer contains an additive depot of migrating monomers in an amount of 0.01 to 2.0 percent by weight, relative to the weight of the polymer constituting the base layer. The top layers are comprised of polypropylene that has a lower viscosity than the polypropylene of the base layer.

Abstract: Negative correction of gravure printing plates by filling undesirable depressions in the printing layer of the gravure printing plate with a correcting agent is carried out by a method in which the correcting agent used is a pasty material which is viscoplastic at room temperature and is based on a dispersion of a solid, highly fluorinated olefin polymer powder in an inert, sparingly volatile, organic dispersing liquid.

Abstract: A cold rolled solid solution iron-aluminum diffusion alloy foil and a method of making the foil are described. The foil has good room temperature formability and high temperature oxidation and corrosion resistance with useful electrical and magnetic properties and is adapted for use as a tool wrap, as an electrical steel, and as a support for a catalyst after a coating of spine-like aluminum oxide whiskers is grown on the surface thereof. The foil is made by hot-dip aluminum coating a titanium stabilized low carbon steel strip, cold rolling the aluminum coated strip to effect between about a 40 and 99 percent reduction in thickness, and diffusion heating the cold rolled aluminum coated steel strip to form a solid solution iron-aluminum diffusion alloy foil containing between about 2 and 12 wt. % aluminum.

Abstract: A method and apparatus for vacuum coating of materials having a three-dimensional surface structure is disclosed that provides cooling, to prevent heat destruction of those materials during vacuum coating. The web is moved back and forth across the coating area, between rolls. A cooling film is rolled onto each roll with the web. As the web is unrolled, the film is unrolled and recooled before being rolled up again with the web.

Abstract: A method of cladding an internal cavity surface of a metal object is disclosed. The method includes the steps:(a) applying a powder metal layer on said internal surface, the metal powder including metal oxide or oxides, borides and carbides,(b) filling a pressure transmitting and flowable grain into said cavity to contact said layer,(c) and pressurizing said grain to cause sufficient pressure transmission to the powder metal layer to consolidate same.