Abstract: Aluminum coated ferritic base metal foil formed by cold reduction of hot dip aluminum coated ferritic steel strip containing from 10% to about 35% chromium, up to 3% aluminum, and up to 1% silicon, the foil having a ratio of aluminum coating thickness on both sides to base metal foil thickness of at least 1:10, with at least 4% by weight total aluminum. The method of production includes heating the foil in an oxidizing atmosphere within specified temperature and time limitations to provide a porous surface having a thin layer of aluminum oxide. The foil is adapted for fabrication into monolithic support structures for catalytic converters for internal combustion engine exhaust systems.

Abstract: A method and apparatus for cooling metal wire or strip being drawn vertically from a hot dip bath and between a pair of refractory wiping pads. The wire or strip passing between the wiping pads directly into a chamber containing a cooling liquid which is supported above and at least in part by the wiping pads. The chamber having inlet and outlet means for the cooling liquid and a removable wall to allow more rapid draining of the chamber and access to the inside of the chamber for changing the wiping pads and/or re-threading the wire.

Abstract: The invention relates to a process for manufacturing a strip of hot galvanized sheet steel devoid of a coating of pure Zn or a coating based on Zn on at least one side of the strip, comprising passing the strip continuously in a conventional dipping galvanization bath, wiping by pneumatic means a part of the coating of liquid Zn deposited on the strip, and subjecting at least one side of the strip to a mechanical action for completely eliminating the coating based on zinc which is not alloyed to the iron, by allowing to subsist only a thin iron-zinc alloy layer, said mechanical action on the layer of coating based on zinc which is still liquid being exerted by means of a brush at least the bristles of which are energetically cooled. The invention also provides a cooled brushing device (10) for carrying out the process.

Abstract: A cadmium electrode for a rechargeable alkaline cell comprises a rigid substrate having particle-receiving recesses therein into and upon which are pressed a particulate mix of binder coated cadmium oxide particles and cadmium particles which constitute an active precharge anti-fading constituent of the mix. The binder coating may be a substantially insulating material, in which case the cadmium particles in various places are pressed into the substrate so that they penetrate through the binder coating to make direct contact with the cadmium oxide particles. The binder is most advantageously a curable butadiene polymer binder coating on the cadmium oxide particles preferably formed by heating an initial slurry of an emulsion of the binder and cadmium oxide particles to vaporize the liquid carrier and at least partially cure the binder material.

Abstract: Disclosed are processes and articles for the preparation of composite electroless coatings which comprise a metal and/or metal alloy, plus particulate matter, the latter having at least two distinct nominal sizes.

Abstract: A plastic substrate is injection molded to provide a pattern of channels in at least one of its sides to define a predetermined set of conductive paths. Both the surfaces of the channels and the non-channel surfaces therebetween are metalling through one or more steps of flame spraying, a combination of electroless plating and electroplating, gas plating or vacuum deposition. In one form of the invention the metallization over the non-channel surfaces is removed by abrading. In another form of the invention the initial metallization over the non-channel surfaces is coated with a resist prior to the deposition of another metal layer. The metal covering the channels is subsequently removed by stripping the resist and etching away the initial metallization.

Abstract: A metallic layer is applied to a substrate by flame spraying or arc spraying an alloy containing iron, chromium, and aluminum onto a substrate under conditions sufficient to produce a deposited layer containing from 10 to 30% by weight chromium, 1 to 12% by weight aluminum, 0.008 to 0.025% by weight nitrogen, 0.01 to 1.25% by weight oxygen predominantly as oxides of aluminum, iron, and chromium, with the balance substantially iron.

Abstract: In connection with a coating method and apparatus for one-sided coating of a continuous metal strip, a method and apparatus are provided for the mechanical removal of the oxide layer which forms on the uncoated side of said metal strip after said metal strip leaves the protective environment within which the coating occurs.

Abstract: A coated article and method for producing the coated article are described. The article is coated with a system which provides protection against oxidation and corrosion and which significantly reduces the substrate temperature. An MCrAlY layer is applied to the article to be protected and a columnar grain ceramic is applied by vapor deposition to the MCrAlY coated article. An alumina layer which exists between the MCrAly layer and the columnar ceramic layer provides for the adherence of the columnar layer to the MCrAlY layer.

Abstract: Disclosed is a method of preparing a permionic membrane by contacting the permionic membrane with a plasticizer and an electroconductive material, and hot pressing the permionic membrane, the plasticizer, and the electroconductive material.

Abstract: Disclosed are processes and articles for composite electroless coatings comprising at least two distinct layers, the first layer comprising a metal and/or a metal alloy plus particulate matter and the second layer comprising a metal and/or a metal alloy and being substantially free of particulate matter.

Abstract: Disclosed are processes and articles for composite electroless coatings comprising at least two distinct layers, the first layer comprising a metal and/or a metal alloy plus particulate matter and the second layer comprising a metal and/or a metal alloy and being substantially free of particulate matter.

Abstract: A process of making printed circuit boards in which the individual substrates involved are hot set formed from a suitable thermosetting resin and filler composition, with the cure being limited to the resin B stage. The side surfacing of the individual substrates that is to bear the metallic electrically conductive circuiting is catalyzed and then electrolessly plated with copper or the like electrically conductive metallic material to a thickness in the range of from about 50 to about 100 millionths of an inch, and thereafter the thusly plated substrates are hot set to fully cure same and perfect the bond between the substrate and its plating.

Abstract: A cladding process and apparatus in which steel strip or sheet is cladded with a metal of lower melting point, e.g. lead, by maintaining a bank of constant level of the molten cladding material between a belt and the strip or sheet substrate which passes along an inclined path and is cooled to harden the molten material thereon. During the cooling process the applied material is compressed against the substrate.

Abstract: The application discloses a method of terne coating, and a terne coated product, wherein the tin content of the terne is substantially lower than in conventional terne, without the need for other alloying elements in substitution for tin, such as zinc, antimony, silver, and phosphorus. The tin content of the terne bath is lowered below conventional percentages, to between about 2% and about 6.5% and the terne coated product, upon emerging from the coating bath, is jet finished. Such a terne coat has improved solderability and appearance with no change in pinhole frequency. Coating weight control is easier than with a terne coat having 7% or more tin in the bath.

Abstract: The occurrence of defects on wire coated with an aluminum-zinc alloy coating applied by hot dipping in a molten coating bath is substantially decreased by preventing the deposition of zinc powder particles upon the surface of the molten aluminum-zinc coating prior to solidification of the coating. The deposition of metallic zinc powder particles upon the molten aluminum-zinc coating may be alleviated in several different manners, including preventing the formation of the zinc powder, preventing the accumulation of the zinc powder upon the surface of the molten aluminum-zinc bath, decomposing the zinc powder before it accumulates and exhausting or removing the zinc powder from the vicinity of the molten metal coated wire as it leaves the molten bath. Several novel apparatus arrangements for accomplishing the above are disclosed.

Abstract: Corrosion resistant coatings are applied to metal tubing while substantially continuously moving the metal tubing through a series of stations. The process comprises the sequential steps of flowing by gravity a zinc-rich thermosetting coating suspended in a volatile carrier onto the tubing, the viscosity of the coating composition being such that it flows around and completely covers the external surface of the tubing, removing excess coating by means of an air blower arranged circumferentially around the tubing and sequentially heating the coated tubing first to volatize off the carrier and then more rapidly to crosslink the thermosetting coating composition.

Abstract: In this process there is determined, as a function of the conditions of the environment or other conditions, the distance from the surface of the bath at which the temperature of the zinc coating on the sheet or strip is in the range in which the zinc passes through a liquid-solid transitory state which is characterized by its friability. There is exerted at this point a mechanical action on at least one of the sides of the sheet or strip so as to completely remove away the whole of the non-alloyed zinc and allow to remain only a thin iron-zinc alloy coating whose thickness is between 1 and 2 .mu.m, which represents an amount of alloy of between 7 and 15 g/m.sup.2.

Abstract: A method is disclosed for depositing a thick layer of copper upon a copper base wherein the base is heated and flame sprayed with molten copper until globules are observed. The globules are mechanically removed from the base and the flame spraying and globules removing steps repeated.

Abstract: In the preferred embodiment, a method is presented for filling depressions in fabricated steel surfaces by applying a metallic body solder consisting of 15 to 20 weight percent copper, 2 to 3 weight percent zinc and the balance tin. The body solder alloy is heated to a temperature above about 210.degree. C. to form a workable thixotropic paste that is applied with spreading onto the steel surface. Upon cooling, the body solder forms a dense, tightly adherent fill that is grindable and paintable in conjunction with the surrounding steel surface.

Abstract: An article with an improved MCrAlY coating is disclosed wherein a plasma sprayed MCrAlY coating is provided with a metallic envelope and then hot isostatically pressed to densify the coating and interdiffuse the envelope. Thus, the substrate is provided with a coating which in its bulk is the densified plasma coating with an outer surface zone which is enriched in a metal which enhances the oxidation-corrosion protective properties of the coating. Preferred coatings have a standard CoCrAlY bulk with a metal-enriched surface zone of about 0.02 mm depth. When aluminum is added the surface zone is comprised by weight percent of about 60 Co, 20 Cr and 22 Al. With chromium the surface zone is about 50 Co, 43 Cr and 8.5 Al.

Abstract: An article comprising: (1) an interpolymer which comprises crosslinked (meth)acrylate, crosslinked styrene-acrylonitrile, and uncrosslinked styrene-acrylonitrile components; and (2) an adherent metallic coating on said interpolymer. The article is useful as a plated component in motor vehicles, for example, as trim, grille work, wheel covers, and the like, or as plated appliance parts or plumbing components.

Abstract: A process and apparatus for coating only one side of a metal strip with a molten metal, by continuously conveying a cleaned and heated strip of metal through a protective gas atmosphere above the level of a melting bath of the molten metal. The metal strip is supported on a reverse side thereof in the area of contact with the molten metal, and with the obverse side of the strip out of contact with the bath itself. The molten metal is conveyed by means of a scoop roller towards the supported area of the strip and only the scoop roller is immersed in the melting bath and only for a part of its surface area.

Abstract: By the process of this invention, printed circuits are prepared containing an electrically conductive wiring trace from materials having adherent and non-adherent surface areas, e.g., printed circuit substrates bearing an imaged photoadhesive layer. Onto the adherent surface areas of the material are applied ductile metal or alloy particles, and any excess particles are removed from the non-adherent areas. The metallized areas are conjoined, e.g., with silicon carbide brush or rounded metal rod. The conjoined areas can be electrolessly plated, electroplated or soldered. Multilayer printed circuits can also be prepared by repeating these steps with additional layers of photoadhesive material adhered to underlying printed circuits.

Abstract: A process for forming metallic articles involves generating a stream of atomized molten metal particles, directing this stream of particles at a substrate to form a deposit of the metal thereon having a desired form, and simultaneously directing at the metal as it is deposited on the substrate, a stream of rounded particles so as to consolidate the deposited metal. Apparatus for forming metallic articles includes means for generating a stream of atomized molten metal particles and means for producing a stream of rounded particles both of said means being so arranged as to cause the streams to converge on an area, and means for maintaining a substrate arranged to coincide with the area and adapted to receive thereon a deposit of the metal. The substrate may be incorporated into the metallic article product e.g.

Abstract: A method for producing a one-side zinc plated steel sheet, comprising;(a) a step of coating a steel sheet with zinc,(b) a step of heating the zinc-coated steel sheet to alloy at least the coated zinc on one side of the steel sheet with the steel sheet, and(c) a step of mechanically removing the coated zinc thus alloyed.

Abstract: A method of wiping hot dipped metal coated wire or strip, and an apparatus for performing the method, involving drawing the wire or strip upwardly from a bath of molten metal through a wiping bed located at the point of emergence from the bath, with an interference device being positioned adjacent the wire or strip below the surface of the molten bath such as to restrict the lamella flow of molten metal entrained by the moving wire or strip. The interference device wholly or partly surrounds the wire or strip and is located below the wiping bed, which bed in turn may be laterally confined or unconfined. The interference device may be of any convenient configuration such as in the form of a horizontally disposed flat plate provided with one or more slots, grooves or other apertures through which the wire or strip passes.

Abstract: A method and apparatus utilized in conjunction with a wire galvanizing apparatus assures a bright finish on the coated wire. This method and apparatus includes passing the wire through a water quenching bath immediately following the emergence of wire from the molten zinc galvanizing bath of a conventional galvanizing apparatus. A pair of pressure pads grips the wire at its entrance to the water quenching bath for substantially sealing the water quenching bath against water leakage into the adjacent molten zinc galvanizing bath. A heating apparatus is directed at the wire prior to its entrance to the pressure pads to assure that the zinc coating is still in a molten condition as the wire enters the water quenching bath.

Abstract: Process for depositing a thin conducting metal layer on an insulating support comprising the steps of applying on said support a layer of nonconducting ink loaded with a powder of metal, alloy or metallic derivative, heating said support and said layer to harden said ink layer, treating the surface of said layer so as to lay the particles forming said powder bare and immersing said thus coated support into a bath containing, in the form of particles, the conducting metal to be deposited, under conditions which are known per se and such that said conducting metal particles are deposited on the powder particles laid bare, wherein is used as insulating support a support made of an inorganic material provided with an enamel coating and the ink used being a compound formed of an enamel and a carrier, the melting point of said enamel being substantially equal to, and preferably slightly lower than, the softening point of the outer layer of said coating.

Abstract: A method for metalizing the surface walls of a printed circuit board through hole to produce an electrically conductive path from one metallic layer of the board through the insulating plate to another metallic layer. A drill bit is forced through the board and into a block of soft conductor material. While the bit is turning the conductive cuttings from the block are carried to the hole in the insulating plate and smeared on the wall surface by the bit. The smeared conductive material creates an electrically conductive path between two metallic layers of the printed circuit board.

Abstract: A method and apparatus utilized in conjunction with a wire galvanizing apparatus assures a bright finish on the coated wire. This method and apparatus includes passing the wire through a water quenching bath immediately following the emergence of wire from the molten zinc galvanizing bath of a conventional galvanizing apparatus. A pair of pressure pads grips the wire at its entrance to the water quenching bath for substantially sealing the water quenching bath against water leakage into the adjacent molten zinc galvanizing bath. A heating apparatus is directed at the wire prior to its entrance to the pressure pads to assure that the zinc coating is still in a molten condition as the wire enters the water quenching bath.

Abstract: The invention contemplates a method and means for making a dryer or the like roll having a ferrous metal surface provided with a surface coating of a hardfacing alloy, the ferrous metal surface having a thermal conductivity relative to silver taken as 1 cal/cm.sup.2 /cm/.degree.C./sec of at least about 0.06 the hardfacing alloy being a hardfacing heat, corrosion and wear resistant iron-group metal-base alloy mechanically and metallurgically bonded to said ferrous metal surface which is preferably made of cast iron, the hardfacing alloy coating having a thickness ranging from about 0.01 to 0.15 inch, the thermal conductivity of said coating being at least 0.05.

Abstract: Method of making a high power laser mirror. Essentially the mirror consists of a refractory composition substrate which is polished to an optical finish and overcoated with a high reflectivity metal and a dielectric film disposed to cover the high reflectivity metal.The method includes the hot pressing of the refractory composition, especially silicon carbide, to form a substrate following which an optical finish is polished on one surface thereof. Thereafter, a metal film with a high reflectivity is applied to cover the optical surface and then a dielectric film is deposited over the high reflectivity metal film. Both films are deposited employing process of vacuum evaporation for deposition on the substrate. As thus combined, the mirror exhibits low optical absorptivity, high thermal conductivity, low weight, and low coefficient of thermal expansion. Since the substrate is formed of a hard refractory composition, an excellent optical finish can be polished on the surface thereof.

Abstract: A method of continuously producing a one-side-only zinc coated ferrous metal strip initially having zinc coated on both wide surfaces, as by differentially hot-dip coating, and with the zinc on one of the wide surfaces being in the form of a thin film which is transformed into a thin zinc-iron intermetallic layer by applying heat to only the wide surface of the strip having the zinc in the form of a thin film and abrading the surface of the intermetallic layer thus formed by brushing to effect complete removal thereof, leaving the other wide surface of the strip coated with zinc.

Abstract: Substrate such as relatively porous, low thermally conductive materials are coated with molten lead, lead-base alloys, zinc, zinc-base alloys, tin, tin-base alloys, cadmium, cadmium-base alloys, aluminum, aluminum-base alloys and the like by spreading the molten metal by means of a low thermally conductive roll to provide products useful in sound attenuation, moisture and corrosion proofing and radiation shielding.

Abstract: A carbon fiber reinforced metal matrix composite is produced by depositing a metal boride coating on the surface of the fibers and subsequently immersing the fibers in a molten bath of the metal matrix material. The boride coating is formed by passing carbon fiber through a gaseous mixture of chlorides of the metal and boron in the presence of zinc vapor at elevated temperatures. The subsequent reaction deposits out a submicron lamina of metal boride on the carbon fibers serving to enhance wetting of the fibers by the molten metal, with the lamina preventing chemical reaction between the fibers and metal matrix materials and also providing a strong mechanical bond therebetween.

Abstract: A briquetting machine including a pair of compacting rolls, a pair of cheek plates enclosing the nip of the rolls, a generally rectangular feeding chute having a damper, means for automatically regulating the damper to control the roll force and a rectangular off-gas conduit extending upwardly from the nip, all designed to uniformly feed the rolls, minimizing feed entrainment in the off gas, and when hot materials are fed, to minimize exposure of the rolls to heat. Also included are cooling enclosures for the rolls and other parts exposed to high temperature and means for measuring the temperature of each roll and automatically regulating the flow of the cooling fluids and the positions of the cooling enclosures so as to maintain the temperature of the roll surfaces within predetermined ranges.

Abstract: A plate or plating comprising a matrix of a thermosetting synthetic resin and, optionally, Portland cement, and particulate metal elements filling the interior interstices of the matrix. The metal elements are bound to the matrix and completely surrounded by the matrix. The plate or plating maybe manufactured by intimately mixing the metal elements with a synthetic resin of low to average viscosity and Portland cement. The resultant viscous mass is placed into a mold or applied to a substrate and hardened in situ.

Abstract: A process of slurry coating particularly adapted to coatings less than one mil thick wherein a basis metal is coated with particles of a second metal dispersed in a liquid containing alkali-stabilized silica sol as the predominate film forming ingredient. The coated basis metal is dried; the coating is sintered thereon and then is worked. Provided that the silica to metal ratio is within a special range, residual silica in the coating metal does not interfere with working.

Abstract: Coating of steel articles with zinc-tin alloys by hot-galvanizing with addition of aluminum to improve the applicability and adhesion of the coating as well as the corrosion resistance, coated surface appearance and formabilities thereof.

Abstract: The improved hot dip metallizing process of this invention comprises passing the article to be metallized, such as a ferrous metal article, through a bath of a molten heavy metal, such as lead, and conducting the article therefrom through a layer of molten coating metal, such as zinc, confined in a stack-like structure of a cross-sectional area being a small fraction of the surface area of the heavy metal bath. The molten coating metal is continuously supplied to the stack, preferably through orifices or nozzles so as to remove any droplets of molten heavy metal adhering to the surface of the article, thereby causing metallizing of the article and continuous overflow of excess molten coating metal at the top of the stack. Before hot blasting the coated metallic article it may be passed through mechanical removal means, such as counterrotating rollers to remove the major part of excess coating metal, while the remainder is removed by hot blasting.

Abstract: A vapor deposited aluminum metallizing film is transformed into a transparent insulating oxide at selective locations at which a film of bismuth or sodium is vapor deposited either beforehand on the substrate or afterward on the aluminum. The oxide forms at only the selected locations to the full depth of the layer and has insulating qualities of interest for electrical components. The use of a pigmented substrate which will show through the transparent oxide areas is useful for providing visible legends, symbols, scales, and reference margins, marks or rasters.