Abstract: The invention describes a temperature-stable protective coating over a metallic substrate surface (1), which coating includes at least one layer of material (4) consisting of MCrAlY, where M represents at least one of the elements selected from the group of materials consisting of Fe, Co and Ni. The invention also describes a production process for this coating.

Abstract: The present invention describes a method for fabricating an embossing tool or an x-ray mask tool, providing microstructures that smoothly vary in height from point-to-point in etched substrates, i.e., structure which can vary in all three dimensions. The process uses a lithographic technique to transfer an image pattern in the surface of a silicon wafer by exposing and developing the resist and then etching the silicon substrate. Importantly, the photoresist is variably exposed so that when developed some of the resist layer remains. The remaining undeveloped resist acts as an etchant barrier to the reactive plasma used to etch the silicon substrate and therefore provides the ability etch structures of variable depths.

Abstract: The present invention is generally directed towards a carrier of a motor vehicle. The carrier is formed of a first portion and the second portion. The first portion is made of aluminum having ceramic particles reinforcing the aluminum matrix. The second portion is made of unreinforced aluminum metal or metal alloy. Preferably the second portion is present in form of discrete pockets in the first portion and is adapted to be machined or welded.

Abstract: A hybrid composite reinforced metal matrix in which the metal is aluminum, aluminum alloy, or a magnesium alloy containing a relatively high percentage of aluminum. In addition to the reinforcement, which is typically alumina, the metal matrix also includes a hardening agent which is at least one intermetallic compound of aluminum with at least one second metal chosen from iron, nickel, titanium, zirconium, cobalt and niobium. The intermetallic compound(s) can be added as a powder to the metal matrix during formation of the composite, or can be created in the composite by adding the at least one second metal as a powder to the molten metal matrix during composite preparation. When the intermetallic compound(s) are created in the composite, during the addition step the second metal powder should be protected from oxidation. If the intermetallic compound is created in the composite, the composite when made initially can be readily machined and is self hardening through repeated heating cycles.

Abstract: A cast article from an aluminum alloy, which has improved mechanical properties at elevated temperatures, has the following composition in weight percent: Silicon 14-25.0, Copper 5.5-8.0, Iron 0.05-1.2, Magnesium 0.5-1.5, Nickel 0.05-0.9, Manganese 0.05-1.0, Titanium 0.05-1.2, Zirconium 0.05-1.2, Vanadium 0.05-1.2, Zinc 0.05-0.9, Phosphorus 0.001-0.1, and the balance is Aluminum, wherein the silicon-to-magnesium ratio is 10-25, and the copper-to-magnesium ratio is 4-15. The aluminum alloy contains a simultaneous dispersion of three types of Al3X compound particles (X═Ti, V, Zr) having a L12 crystal structure, and their lattice parameters are coherent to the aluminum matrix lattice. A process for producing this cast article is also disclosed, as well as a metal matrix composite, which includes the aluminum alloy serving as a matrix and containing up to about 60% by volume of a secondary filler material.

Abstract: Wires and cables made from ceramic oxide fibers encapsulated within a matrix that includes aluminum.

Abstract: Fibrous monolith composites having architectures that provide increased flaw insensitivity, improved hardness, wear resistance and damage tolerance and methods of manufacture thereof are provided for use in dynamic environments to mitigate impact damage and increase wear resistance.

Abstract: A multilayer material comprising a backing material (10) and a obverse material (12) made of a metal different from the backing material, said obverse material being bonded to the backing material, said obverse material having a rapidly cooled dendrite structure extended substantially vertically to the backing material, said dendrite structure having a grain size not more than 0.02 mm in a cutting plane in parallel to the backing material and/or a dendrite arm spacing not more than 0.02 mm in a cutting plane vertical to the backing material.

Abstract: The present invention provides a tailored blank having a pair of sheet metal constituent parts each having a pair of oppositely directed major surfaces. The first constituent part has an aperture while the second constituent part has an embossment to fit the aperture. The first and second constituent parts are then secured to one another to form the tailored blank. The blank may then be subsequently formed into a component of varying material characteristics.

Abstract: The present invention provides a metal matrix composite having stable performance without extremely weak portions and capable of assuring strength with a simple structure, the metal matrix composite being formed by hot-pressing or hot-isostatic-pressing a flat formation of reinforcing fibers 10 sandwiched between metal matrices 12 and comprising a joined end part 11 in the longitudinal direction of reinforcing fibers 10 which is joined obliquely at a joining angle of 5 to 60 degrees with respect to the longitudinal direction of reinforcing fibers or more preferably wherein a plurality of metal matrices 11 and a plurality flat formations of reinforcing fibers 10 are lapped each other to form layers of metal matrices and flat formations of reinforcing fibers so that the adjacent upper layers of flat formations of reinforcing fibers and the adjacent lower layers of flat formations of reinforcing fibers to a layer having a joined part of flat formations of reinforcing fibers are continuous and have no joined part

Abstract: A method for manufacturing a Sn-based alloy containing a finely dispersed Sn—Ti compound includes melting Sn by heating to a temperature in a range from 1300 to 1500° C. in vacuum or an inert gas atmosphere, adding 0.1 to 5% by weight of Ti followed by melting by heating, and casting the molten alloy into a copper mold directly or through a pouring cup. The Sn-based alloy obtained by this method contains the Sn—Ti compound having a maximum particle diameter of 30 &mgr;m and a mean particle diameter of 5 to 20 &mgr;m. A precursor of a Nb3Sn wire is also obtained by an inner diffusion method using this Sn-based alloy. The Nb3Sn wire manufactured by using the Sn-based alloy of the present invention exhibits excellent superconductive characteristics. The method of the present invention enables the ingot to be free from a shrinkage cavity appearing during prior art manufacturing processes.

Abstract: The invention concerns a process for manufacturing a composite material comprising a matrix component made from one or more metals, or their alloys, chosen from groups IVb to VIb of the Periodic Table, and a strengthening or reinforcing component. According to the invention, the matrix components are processed to form foils, sheets and/or wires and coated with a 1 &mgr;m to 10 &mgr;m thick layer of the strengthening or reinforcing component. A plurality of these coated foils, sheets and/or wires are then combined and permanently joined together by pressure and/or heat.

Abstract: A porous preform includes at least one kind of preform-forming materials of ceramic particles, ceramic fibers and ceramic whiskers, and a film of a binder formed on a surface of said at least one kind of the preform-forming materials and comprising magnesium or a magnesium alloy. The preform is used for producing a metal matrix composite material.

Abstract: The present invention relates generally to a joined structure of dissimilar metallic materials having different characteristics. More specifically, the invention relates to a joined structure of a current-carrying contact or arching contact which are used for, e.g., a power breaker, or a coating end structure of a metal base and a coating material for improving conductivity and heat resistance.

Abstract: Often, metal matrix composites (MMC's) lack adequate machinability and possess excessive abrasiveness because hard ceramic materials, such as silicon carbide, are used as the reinforcement phase. To make a metal matrix composite body having a more machinable and less abrasive surface, an MMC comprising an aluminum nitride reinforcement is formed on the surface of the body. In one embodiment, a layer is provided to a permeable mass or preform at the surface at issue, the layer featuring at least a reduced loading of ceramic filler material, and sometimes no ceramic material at all. The reduced loading is achieved by incorporating a fugitive material into the coating layer. Molten matrix metal is caused to infiltrate the permeable mass or preform and the coating layer to produce a macrocomposite body comprising a metal matrix composite coating and substrate.

Abstract: The invention described herein provides an organic-inorganic multilayer coating system comprising an advanced nanostructured layer-by-layer hybrid coating for the corrosion inhibition of metals. Electrochemically-active corrosion inhibitors are adsorbed onto a layer-by-layer assembled organic-inorganic multilayer coating, preferably used in combination with a topcoat sol-gel barrier layer, to provide enhanced corrosion protection of metal substrates.

Abstract: A superconducting conductor and method for its production. The conductor is formed of least one superconducting core and an aluminum based cryogenic stabilizer which is a high purity Al—Fe—Ni aluminum alloy having a composition, in % by weight: 200 ppm≦Fe+Ni≦1500 ppm; 0.20≦Fe/(Fe+Ni)≦0.65; optionally, B<100 ppm; impurities other than Fe, Ni and B<0.01% total; and remainder aluminum.

Abstract: The present invention is generally directed towards a carrier of a motor vehicle. The carrier is formed of a first portion and the second portion. The first portion is made of aluminum having ceramic particles reinforcing the aluminum matrix. The second portion is made of unreinforced aluminum metal or metal alloy. Preferably the second portion is present in form of discrete pockets in the first portion and is adapted to be machined or welded.

Abstract: A preform for use in a metal matrix composite, particularly for a magnesium metal composite, and a metal matrix composite, typically made by squeeze casting, using the preform. In the preform the reinforcing material typically is silicon carbide, boron nitride, carbon or graphite. The binder used in the preform is magnesium fluoride, which avoids the known problems which result from the high reactivity of magnesium metal with other binders, such as silica and alumina, which results in the formation of magnesium oxide in the reinforced composite. The presence of magnesium oxide crystals in the metal matrix adversely affects the properties of the composite.

Abstract: In an electrodeposited hard-chromium coat, particularly for a piston ring, which is substantially formed of an electrolyte containing hexavalent chromium, wherein there are cracks in the coat and diamond particles are embedded in these cracks, the diamond particles have a size ranging from 0.25 to 0.5 &mgr;m.

Abstract: The present invention provides a unique method for the electroless co-deposition of metal and hard particles on an electrical contact surface to provide electrical, thermal, and mechanical connections between the particle enhanced contact surface and an opposing contact surface, and to enhance the thermal and electrical conductivity between the contact surfaces and their corresponding substrates. The innovative method is able to uniformly deposit metal and particles of any shape, and with a wide range of density and sizes, on contact surfaces, and can be adjusted to provide any desired surface area coverage in desirable deposition patterns. The co-deposited contact surface can, for example, be easily joined to another surface of any type by nonconductive adhesive, resulting in a connection that is mechanically robust, chemically inert, and inherently electrically conductive.

Abstract: Ion exchange membrane-based sensors, actuators and sensor/actuators and methods of making same for applications requiring sensing, actuating and controlling displacement. Sensors, actuators, and sensor/actuators are useful in biological as well as other applications. Encapsulation of the sensors, actuators, or sensor/actuators further increases the utility of the present invention. Devices according to the present invention made using lithium are preferred over those made using only sodium.

Abstract: A method to form a sealed, partially or fully densified fiber reinforced composite preform which comprises: impregnating said preform with a major portion of a liquid, ceramic-forming precursor; initiating cure of the outer surface of said precursor with radiation, such as actinic radiation; a thereby forming a sealing barrier or skin on the surface of said preform. In a second embodiment the preform is infiltrated with a thermoplastic as liquid, frozen, excess frozen infiltrate optionally removed from the preform surface, then the preform is coated with a liquid which is curable with radiation, cure is initiated with radiation and the preform is sealed with a barrier coat.

Abstract: A method for fabricating an abrasive tool. A tool substrate is provided. A surface of the substrate is coated with an electroplatable bonding material. The electroplatable bonding material comprises a mixture of a conductive material and an adhesive material. Abrasive particles are adhered to the bonding material. The abrasive particles are adhered so as to have a predetermined distribution over the coated surface of the substrate. A metal layer is electroplated to the electroplatable bonding material to secure the abrasive particles to the substrate. Thus, in accordance with the present invention, the fabricated abrasive tool has abrasive particles having the predetermine distribution and fixed to the substrate by the adhesive material and the electroplated metal layer.

Abstract: A composite metal matrix formed of polycrystalline &agr;-Al2O3 fibers encapsulated within a matrix of substantially pure elemental aluminum, or an alloy elemental aluminum and up to about 2% copper is disclosed. The resulting materials are characterized by their high strength and low weight are particularly well suited for applications in various industries including high voltage power transmission.

Abstract: A method of producing an Nb—Sn compound superconducting wire precursor includes forming composite filament materials, each filament including a niobium material of an Nb-based metal and a titanium material of pure Ti enveloped in the niobium material; forming a composite rod in which composite filament materials are arranged in a matrix of a Cu-based metal but not in contact with one another, the matrix containing Sn diffused by heat treatment to combine with the niobium material to form a compound; and drawing the composite rod.

Abstract: A part of a piston is composed of a metal matrix composite. The metal matrix composite is composed of a matrix of a light metal alloy and reinforcements formed of metallic fibers mixed in the matrix. The reinforcements are formed of an alloy that consists mainly of Fe and Cr and contains Al and/or Si. The Cr content and the Al and/or Si content of the reinforcements range from 5 to 30% and from 3 to 10%, respectively. The fiber diameter of the reinforcements ranges from &phgr;20 &mgr;m to &phgr;100 &mgr;m. The reinforcements are formed by the melt extraction method and have irregular peripheral surfaces. Solution-treatment of the metal matrix composite is carried out within a temperature range from 470° C. to 500° C. such that formation of intermetallic compounds is restrained.

Abstract: An apparatus and method for welding members that are formed at least in part of aluminum. A welding assembly is constructed and arranged to position a welding material in electrically conductive relation between exterior surface portions of first and second weldable members at a location where the first and second weldable members are to be joined. The welding material assembly includes at least one welding material member mounted on a flexible carrier sheet in a predetermined arrangement with each welding material member being constructed of an electrically conductive metallic welding material capable of melting when heated by application of an electrical current. A welding method includes alternatively attaching the welding material members to a weldable member without a carrier sheet, by a welding process.

Abstract: Positioning arms for positioning and assembling systems are subjected to high accelerations and must therefore be made lightweight but nevertheless resistant to bending and twisting. The use of composite materials based on metal or ceramic foams and non-expanded materials for positioning arms in positioning and assembling systems allows these positioning arms to be lightweight and nevertheless to have high rigidity. Semifinished products are arranged in the non-expanded material, since a better connection between the semifinished product and material is ensured there than in the metal or ceramic foam.

Abstract: A tailored blank is provided by welding a pair of constituent parts to one another in juxtaposition. The parts are laser welded together to form a unitary blank that is subsequently formed into a shaped finished component.

Abstract: Composite wear component produced by casting and consisting of a metal matrix whose working face or faces include inserts which have a very high wear resistance, characterized in that the inserts consist of a ceramic pad, this ceramic pad consisting of a homogeneous solid solution of 20 to 80% of A12O3 and 80 to 20% of ZrO2, the percentages being expressed by weights of the constituents, and the pad then being impregnated with a liquid metal during the casting.

Abstract: A surface of an article, for example an external fluid flow surface, includes a plurality of metal wires lengthwise of the wires along the article surface. The article can be in the form of a component of an apparatus, for example a component of a gas turbine engine, the wires being bonded along and modifying surface characteristics of the article. Also, the article can be in the form of a bonding layer, for example a brazing tape, including the metal wires carried along a surface of the layer.

Abstract: A turbine combustion system comprises at least one turbine combustion component that is provided with a protective coating on the outer surface otherwise known as the non-flame surface of at least one turbine combustion component. The at least one turbine combustion component comprises an inner surface that defines a hot flame path area and an outer surface. The coating on the outer surface of the combustion components provides protection for the components from at least one of oxidation, nitridation, and hot corrosion.

Abstract: A method for molding a molded substance to a substrate is provided. A substrate connected to a fixing portion by a connecting portion is prepared. The substrate is placed in a mold, wherein a portion of the fixing portion is protruding from the mold. The fixing portion is fixed by a fixing device outside the mold. Then, the molded substance covering the substrate is formed within the mold.

Abstract: A metal matrix composite includes a plurality of fibers having an average diameter of about eight micrometers with a coating, and a metal or alloy distributed with said fibers, a fibers-to-metal or alloy ratio has a range is has a range of about 9:1 to less than about 1:1.

Abstract: An array of nanowires having a relatively constant diameter and techniques and apparatus for fabrication thereof are described. In one embodiment, a technique for melting a material under vacuum and followed by pressure injection of the molten material into the pores of a porous substrate produces continuous nanowires. In another embodiment, a technique to systematically change the channel diameter and channel packing density of an anodic alumina substrate includes the steps of anodizing an aluminum substrate with an electrolyte to provide an anodic aluminum oxide film having a pore with a wall surface composition which is different than aluminum oxide and etching the pore wall surface with an acid to affect at least one of the surface properties of the pore wall and the pore wall composition.

Abstract: A slide member is made of an aluminum alloy and compositely reinforced at its sliding surface by a reinforcing material. The reinforcing material is a mixture of alumina short fibers consisting of not less than 80 wt. % alumina and the remainder silica and having 5-60 wt. % alpha alumina content, and non-spherical mullite particles consisting of 40-86 wt. % alumina and the remainder silica and having 3-60 microns mean diameter. The volumetric percentages of the alumina short fibers and the mullite particles are 2-12% and 5-25%, respectively, on the basis of the volume of the reinforced portion.

Abstract: Electronics packages having a primary metallic material, such as a titanium metallic material, metallurgically bonded to one or more secondary regions within the primary metallic material, the composite regions having desirable thermal conductivity properties and having a coefficient of thermal expansion (“CTE”) that generally matches the CTE of the primary metallic material are provided. Electronics packages comprising titanium having heat sinks comprising a metal matrix material such as aluminum silicon carbide or a composite metallic structure such as titanium aluminide/copper, are described. Methods for manufacturing electronics packages having a composite structure are also disclosed.

Abstract: Metal matrix composite wires that include at least one tow comprising a plurality of substantially continuous, longitudinally positioned fibers in a metal matrix. The fibers are selected from the group of ceramic fibers carbon fibers, and mixtures thereof. The wires have certain specified characteristics such as roundness values, roundness uniformity values, and/or diameter uniformity values.

Abstract: A wrapped slide bearing bushing consists of a composite bushing material including a metal bearing layer, a porous support layer sintered thereon, and a PTFE-based sliding layer, forming the sliding surface of an associated sliding member, said sliding layer also filling the pores of said support layer, and including at least 60 vol % of PTFE, 15-25 volume percent of a metal filler, preferably lead, and optionally 8-12 volume percent of PVDF. To obtain a low coefficient of friction, only varying in a narrow range over a long time period, said slide bearing bushing is formed such that the sliding layer includes 1-3 volume percent of carbon fibers, said carbon fibers being oriented substantially in a preferred direction relative to said composite bushing material, while the relative movement of said bearing bushing and said associated sliding member is substantially transverse to said preferred direction.

Abstract: A metal-infiltrated ceramic for use in tribological applications, such as in mechanical face seals, beatings and other sliding or rubbing components, which provides excellent durability and wear characteristics. The metal-infiltrated ceramic is useful in both the “harder” and “softer” one of two relatively sliding members which is in, or may come into, contact with each other during the motion of one of the members relative to the other. The material is a porous ceramic which has been infiltrated with a metal.

Abstract: A target mark member having a mark pattern with a plurality of marks and a controlled width of the marks provides accuracy and efficiency in electron beam shape measurement and focus of the electron beam. The target mark member for adjusting a focus of an electron beam and measuring a shape of said electron beam in an electron beam processing apparatus includes a metal mark portion having a predetermined mark pattern, said metal mark portion comprising an epitaxial metal material; and a substrate that supports said metal mark portion.

Abstract: Metal matrix composite wires that include a plurality of substantially continuous, longitudinally positioned fibers in a metal matrix. The wire exhibits zero breaks over a length of at least 300 meters when tested according to a specified test.

Abstract: The present invention discloses a conductive injection molding composition. The thermally conductive composition includes a metallic base matrix of, by volume, between 30 and 60 percent. A first thermally conductive filler, by volume, between 25 and 60 percent is provided in the composition that has a relatively high aspect ratio of at least 10:1. In addition, an alternative embodiment of the composition mixture includes a second thermally conductive filler, by volume, between 10 and 25 percent that has a relatively low aspect ratio of 5:1 or less.

Abstract: A method of producing a silicon based alloy is described which comprises melting a silicon alloy containing greater than 50 wt. % silicon and preferably including aluminium. The melted alloy is then inert gas atomized to produce powder or a spray formed deposit in which the silicon forms a substantially continuous phase made up of fine, randomly oriented crystals in the microstructure. The alloy produced by the method has particularly useful application in electronics packaging materials and a typical example comprises an alloy of 70 wt. % silicon and 30 wt. % aluminium. Such an alloy is an engineering material which, for example, is machinable.

Abstract: A part of a piston is composed of a metal matrix composite. The metal matrix composite is composed of a matrix of a light metal alloy and reinforcements formed of metallic fibers mixed in the matrix. The reinforcements are formed of an alloy that consists mainly of Fe and Cr and contains Al and/or Si. The Cr content and the Al and/or Si content of the reinforcements range from 5 to 30% and from 3 to 10%, respectively. The fiber diameter of the reinforcements ranges from ø20 &mgr;m to ø100 &mgr;m. The reinforcements are formed by the melt extraction method and have irregular peripheral surfaces. Solution-treatment of the metal matrix composite is carried out within a temperature range from 470° C. to 500° C. such that formation of intermetallic compounds is restrained.

Abstract: Composite materials are composed of a primary metallic base material, such as a titanium metallic material, metallurgically bonded to one or more secondary materials having desirable thermal conductivity properties and having a coefficient of thermal expansion (“CTE”) that generally matches the CTE of the primary metallic material. An exemplary composite material is composed of a titanium primary material metallurgically bonded to a secondary metal matrix composite material having a high thermal conductivity, such as aluminum silicon carbide. Methods for manufacturing such composite materials are disclosed.

Abstract: The bonding material for an electronic component comprises a metal material and fine resin particles dispersed in the metal material. Such a material may form an electrical “bump” for the component.

Abstract: In a case where a welding of a member is performed through a friction stir welding, to restrain the generation of a clearance in a portion to be joined by the welding and to provide a joint having a good joining portion, abutting faces of members are formed with slanting surfaces. A friction stir welding is carried out from an upper portion. The welding is carried out with the slanting surfaces resisting the forces produced in forming the welding bead. Since the slanting on surfaces are provided, a flow-out of the material in the welding bead can be restrained, and further a bending of the joining portion can be restrained. Further, a tab is arranged at a beginning end and a finish end of the welding and then the welding is carried out starting at one tab and ending at the other tab.

Abstract: A metal-based composite material is formed by impregnating a matrix metal of Al or Al alloy into ores of a porous preform of a hydrogenatable metal having a metal hydride in at least a part of its surface.