Abstract: A part is stamped from a steel sheet having a textured surface. The stamped part is coated with a zinc layer. The zinc layer is coated with a chromate conversion layer, either yellow-colored or black-colored. Preferably, the textured surface is produced by embossing the steel sheet. Alternatively, the textured surface is produced by etching, shot peening, or sand blasting the sheet steel. An exterior surface comprised of at least some of the textured surface of the part, as coated with such layers, has a finish simulating the similarly-colored, textured finish that the part would have if the part were stamped from a steel sheet so that the part would have a smooth, exterior surface and if the smooth, exterior surface were to be electrostatically coated with a black-colored, epoxy powder, which would be heat-cured.

Abstract: Treated copper foil produced by electrodepositing on a matte surface of a base copper foil a “corrective” copper layer having a surface roughness different from the surface roughness of the matte surface of the base foil and which has a peak count greater than the peak count of the matte surface of the base foil. In the electrodeposition there are used a unique electrolyte composition and plating conditions effective to control the micro-throwing process of the plating process so that the surface roughness of the corrective is substantially constant from one batch of base foil to another.

Abstract: The periodic stress and strain fields produced by a pure twist grain boundary between two single crystals bonded together in the form of a bicrystal are used to fabricate a two-dimensional surface topography with controllable, nanometer-scale feature spacings (e.g., from 50 nanometers down to 1.5 nanometers). The spacing of the features is controlled by the misorientation angle used during crystal bonding. One of the crystals is selected to be thin, on the order of 5-100 nanometers. A buried periodic array of screw dislocations is formed at the twist grain boundary. To bring the buried periodicity to the surface, the thin single crystal is etched to reveal an array of raised elements, such as pyramids, that have nanometer-scale dimensions. The process can be employed with numerous materials, such as gold, silicon and sapphire. In addition, the process can be used with different materials for each crystal such that a periodic array of misfit dislocations is formed at the interface between the two crystals.

Abstract: A plate shaped compression mold, a process for producing the same and a process for making laminate therewith. The plate-shaped compression mold for producing sheet laminate including synthetic resin with a metal coating on at least one surface thereof has a surface for contacting the metal coating of the sheet laminate, which surface has a Rockwell C hardness of higher than about 44 and a thermal coefficient of linear expansion which differs from that of the metal coating by not more than about 2.5×10−6/K, thereby substantially preventing warping or wrinkling of the metal coating during the compression molding process.

Abstract: There is provided a stainless steel sheet material, used for a semiconductor manufacturing device, to which it difficult for fine dust to be attached and from the surface of which the attaching dust can be easily washed away. Also, there is provided a method of manufacturing the stainless steel sheet material. A stainless steel sheet material characterized in that: the number of pinholes, the area of each pinhole exceeding 0.25 mm2, in the area of 10 cm2 on the surface of a skinpass-rolled stainless steel sheet material is not more than 10; and the average surface roughness Ra on the center line in the direction perpendicular to the rolling direction is not more than 0.15 &mgr;m. A method of manufacturing a stainless steel sheet material comprising the steps of: annealing a stainless steel cold-rolled sheet in a heat-treatment furnace having no support rollers in a temperature region exceeding 600° C.

Abstract: The invention relates to a printing plate substrate made of a rolled and embossed aluminum strip, wherein the surface has depressions with an average diameter of <25 &mgr;m and an aspect ratio of <1.5 (ratio length/width relative to the transport direction of the strip). The number of depressions is >2,500/mm2. The invention also relates to a method of making an aluminum printing plate substrate, wherein the surface of the aluminum strip is roughened using rollers. The surfaces of the rollers have microscopically small, stochastically distributed, dome-shaped projections. In cross-sectional view, the rollers have a round ridge-shaped roughness profile. The invention is also directed to an offset printing plate, wherein a printing plate substrate is produced with the method and provided with an anodically deposited oxide layer. A light-sensitive hydrophobic, oleophilic layer is deposited on the oxide layer.

Abstract: A metal fiber of titanium or titanium alloy has given equivalent area diameter and specific surface area and is produced by a bundle drawing method wherein mild steel is used as a material for covering layer and outer housing and a composite wire is subjected to a heat treatment at a given temperature.

Abstract: A rolled product of metal with at least one structured surface with light spreading structure. The structured surface exhibits a groove-type pattern in the form of a series of circular arc lengths that runs in the roiling direction and is wave-like in cross-section. The maximum angle of inclination of a tangent to the circular arc lengths with respect to a plane defined by the surface is 1 to 15°, and the radius of the arc lengths is between 0.1 and 20 mm.

Abstract: A stainless steel “fish tape” is disclosed. The tape is characterized by a steel formulation of 10 to 20 percent chromium, up to 18 percent nickel, up to 4 percent molybdenum, not more than 0.9% carbon and no more than 0.8% nitrogen. It is critical that the circumference of the tape relative to the cross sectional area of the tape be of a ratio of at least 1.30 and preferably greater than 1.55. In counter distinction to known prior art fish tapes which attempt to achieve a highly smooth surface, the tape of the instant invention is preferably roughened or abraded to improve the ability to carry for lubricants. The lubricant retaining characteristic functions both to reduce friction on insertion of the tape through a conduit and to leave traces of lubricant on the surface of surfaces which have been impacted against the tape whereby the wire which is then drawn through the conduit, will also be lubricated at the critical points in the conduit most likely to cause frictional contact with the wire.

Abstract: To establish a technique of further improving the oxidation resistance of the glossy surface of a copper foil that has a composite layer containing chromium, zinc, and phosphorus on its glossy surface is achieved by a copper foil having excellent oxidation resistance characterized by a composite layer containing chromium, zinc, phosphorus, and nickel formed on the glossy surface of the foil and also to a method of manufacturing the same by electrolysis.

Abstract: A metal fiber of titanium or titanium alloy has given equivalent area diameter and specific surface area and is produced by a bundle drawing method wherein mild steel is used as a material for covering layer and outer housing and a composite wire is subjected to a heat treatment at a given temperature.

Abstract: A thin, forged magnesium alloy casing is integrally constituted by a thin plate with projections on either or both surfaces, and the thin plate is as thin as about 1.5 mm or less. The thin forged casing can be produced by (a) carrying out a first forging step for roughly forging a magnesium alloy plate to form an intermediate forged product under the conditions of a preheating temperature of the magnesium alloy plate of 350-500° C., a die temperature of 350-450° C., a compression pressure of 3-30 tons/cm2, a compressing speed of 10‥500 mm/sec. and a compression ratio of 75% or less; and (b) carrying out a second forging step for precisely forging the intermediate forged product under the conditions of a preheating temperature of the intermediate forged product of 300-500° C., a die temperature of 300-400° C., a compression pressure of 1-20 tons/cm2, a compressing speed of 1-200 mm/sec., and a compression ratio of 30% or less.

Abstract: Disclosed is a metal pipe excellent in dimensional accuracy, which is suitably used for a development sleeve, a fixing roller, or a photosensitive drum for electrophotographic apparatuses or electrostatic recording apparatuses such as copying machines or printers, or a base body thereof. The metal pipe is produced by cutting a long-sized metal pipe body into a specific length, to obtain a raw pipe, and adjusting the surface state and the dimensional accuracy of the raw pipe by cutting and polishing the outer peripheral surface of the raw pipe, wherein the raw pipe has an inner stress of 20 N/mm2 or less.

Abstract: A method is provided for achieving an enhanced finish on a sputter target surface that results in good film uniformity, low particle counts, and little to no bum-in time. The method involves chemically etching the surface of the sputter target by immersing the surface one or more times in an etching solution, with intermediate rinsing steps. The result is a surface substantially free of mechanical deformation that exhibits a surface similar to a sputtered target with a surface roughness of 10-30 &mgr;in.

Abstract: The present invention relates to a porous electrode wire for use in electrical discharge machining and the method of manufacturing the same. The wire improves the machining speed at least 15% compared with a conventional zinc coated wire, which results from an increased cooling ability of the wire with a cooling liquid because of the increase in the surface area of the wire having porous surface morphology. Since the surface of the porous wire presents uniform profile of outer periphery rather than surface protrusions, it does not affect machining accuracy. Further, the porous nature of the wire is expected to improve flushability during the electrical discharge machining, providing spaces to eliminate particles of the machining. Therefore, in accordance with the method of the present invention, a zinc coated wire having improved performance of machining speed and flushability compared with a conventional coated wire can be provided without additional processes.

Abstract: The present invention relates to a high stack factor amorphous metal transformer core, and to a process for constructing a high stack factor amorphous metal transformer core. The process uses high lamination factor amorphous metal ribbon (the term lamination factor is generally used to express the smoothness and uniformity of the ribbon, whereas the term stack factor is applied to cores made from ribbon); that is, amorphous metal ribbon with a highly smooth surface and a highly uniform thickness as measured across the ribbon width. High stack factor amorphous metal ribbon can be efficiently packed, by winding or stacking operations, into compact transformer core shapes. The transformer core can then be clamped, to further reduce overall dimensions, and annealed, to relieve residual mechanical stresses and to generate a desired magnetic anisotropy, without detriment to the final magnetic properties.

Abstract: To provide an aluminum alloy member having a high machinability while keeping a sufficient mechanical strength and a sufficient wear resistance, and a method of producing the aluminum alloy member. In an aluminum alloy member formed from an aluminum-silicon alloy by casting, eutectic silicon grains are exposed from at least part of an exposed plane of the aluminum alloy member. A coating layer having a thickness nearly equal to or thinner than a diameter of each of the eutectic silicon grains is formed on the exposed plane from which the eutectic silicon grains are exposed.

Abstract: A process for producing an electrodeposited copper foil with its surface prepared, comprising the steps of: subjecting an electrodeposited copper foil having a shiny side and a matte side whose average surface roughness (Rz) is in the range of 2.5 to 10 &mgr;m to the first mechanical polishing so that the average surface roughness (Rz) of the matte side becomes 1.5 to 6 &mgr;m; and subjecting the matte side having undergone the first mechanical polishing to at least one further mechanical polishing so that the average surface roughness (Rz) of the matte side becomes 1.0 to 3.0 &mgr;m. The protrudent parts of the matte side are selectively polished by the first mechanical polishing, and the surface having undergone the first mechanical polishing is further subjected to the second and any ensuing mechanical polishings under milder conditions. Thus, a highly planar polished face with excellent surface properties can be obtained.

Abstract: The present invention is directed to a method of forming an electrically insulating layer on a steel article such as a stack of electrical steel laminations or an individual, unstacked electrical steel lamination, comprising exposing the article to an oxidation atmosphere, and to a temperature (such as at least about 800° F.) for a time sufficient to form on the article an electrically insulating layer comprising hematite. The hematite layer is effective to provide the article with a surface resistivity characterized by an F-amp value of not greater than about 0.85 at a test pressure of 50 psi and a transfer surface roughness of about 10 microinches (Ra). Also featured is a steel article having the electrically insulating layer formed thereon.

Abstract: The present invention relates to a porous electrode wire for use in electrical discharge machining and the method of manufacturing the same. The wire improves the machining speed at least 15% compared with a conventional zinc coated wire, which results from an increased cooling ability of the wire with a cooling liquid because of the increase in the surface area of the wire having porous surface morphology. Since the surface of the porous wire presents uniform profile of outer periphery rather than surface protrusions, it does not affect machining accuracy. Further, the porous nature of the wire is expected to improve flushability during the electrical discharge machining, providing spaces to eliminate particles of the machining. Therefore, in accordance with the method of the present invention, a zinc coated wire having improved performance of machining speed and flushability compared with a conventional coated wire can be provided without additional processes.

Abstract: In one aspect, the invention includes a processing method, comprising: a) providing a substrate having a high aspect ratio opening therein; b) forming a metal-comprising layer over the opening; c) providing a first pressure against the metal-comprising layer; and d) ramping the pressure that is against the metal-comprising layer to a second pressure at a rate of from about 1 atmosphere per second about 100 atmospheres per second.

Abstract: A steel sheet having an embossed pattern of straight parallel grooves along the longitudinal axis of the sheet which replicate an abrasively polished surface. Furthermore, a working roll with the embossing pattern comprised of matching channels is disclosed along with methods for imparting the embossed pattern to the steel sheet. Finally, a method for fabricating the channels within the working roll is disclosed utilizing an abrasive element against the periphery of the roll.

Abstract: A coating composition and process have been developed to provide an activated coating on nickel screen for use as cathodes in electrolytic cells for the generation of hydrogen and oxygen. Compared to the earlier Classical Pack Cementation process, the disclosed process is less expensive, reduces processing time from 20 hours to a few minutes, eliminates dusts and toxic gases, and provides improved performance in cells for hydrogen and oxygen generation. The coating is characterized by the presence of two activated layers with a high surface area, a multitude of fissures and a nickel to aluminum weight ratio greater than 20/1 in the top layer and greater than 4/1 in the bottom layer adjacent to the nickel substrate.

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

Abstract: A method for rendering a surface of a contact rough includes submerging the surface of the contact in an electroplating bath having a dissolved metal salt, and pulsing an electric current through the contact and the bath to form a rough metallic structure on the surface of the contact.

Abstract: A surface active, viscosity modifying agent is used to promote additional tunnel initiation during the etching of high purity cubicity anode foil, preferably aluminum anode foil, to render it suitable for use in electrolytic capacitors. The anode foil is etched in the electrolyte bath composition by passing a charge rough the bath, resulting in an anode foil having a higher capacitance than foils etched using known methods or etching compositions. The etched anode foil is suitable for use in an electrolytic capacitor.

Abstract: A slide surface construction is formed of a large number of truncated hexagonal pyramid-shaped metal crystals in a slide surface, with the area rate A of said truncated hexagonal pyramid-shaped metal crystals being in a range of 40%≦A≦100%. A top face of each of the truncated hexagonal pyramid-shaped metal crystals has a plurality of flat face portions, with a step provided between adjacent ones of the flat face portions. Each of the truncated hexagonal pyramid-shaped metal crystals is a (hhh) oriented metal crystal which has a body-centered cubic structure and whose (hhh) plane (by Miller indices) is oriented toward the slide surface.

Abstract: A sheet laminate for use in a press lay-up between printed circuit board panels having a steel substrate layer and a copper foil layer releasibly bonded to at least one surface of the substrate layer.

Abstract: In a process for the production of an electrolytic copper foil from a sulfurically acidic copper sulfate electrolytic solution, the sulfurically acidic copper sulfate electrolytic solution contains additives of 0.1 to 1.0 g/l of an oxyethylenic surfactant, 50 to 250 mg/l of a chloride, 1 to 10 mg/l of a glue or gelatin and 1 to 10 mg/l of a nitrogen-containing organic compound.

Abstract: The invention is a composite body panel, a sheet product from which the composite body panel is formed, and a vehicle incorporating at least one such composite body panel thereon. The composite body panel includes a substrate having an inner and an outer surface. A lamination is applied to at least the inner and, in an alternative embodiment, the outer surfaces of the substrate. The lamination includes a material having a uniform surface which is well suited for formation, but which is not as strong as the substrate. The formation of the composite body panel further includes the step of applying a coating to the lamination, and then, forming the substrate/lamination/coating material into the desired shape.

Abstract: The present invention is directed to a method of forming an electrically insulating layer on a steel article such as a stack of electrical steel laminations or an individual, unstacked electrical steel lamination, comprising exposing the article to an oxidation atmosphere, and to a temperature (such as at least about 800° F.) for a time sufficient to form on the article an electrically insulating layer comprising hematite. The hematite layer is effective to provide the article with a surface resistivity characterized by an F-amp value of not greater than about 0.85 at a test pressure of 50 psi and a transfer surface roughness of about 10 micro inches (Ra). Also featured is a steel article having the electrically insulating layer formed thereon.

Abstract: Embossed sheets having improved grain retention can be made from a polyolefin composition containing a propylene polymer material, a partially crosslinked thermoplastic olefin elastomer composition, and optionally, crystalline polyethylene. Large parts such as automobile door and instrument panels can be formed from these sheets.

Abstract: The contact material of the present invention comprises: an anti-arcing constituent consisting of at least one TiC, V and VC of which the content is 30˜70 volume % and whose mean particle (grain) size is 0.1˜9 &mgr;m; C whose content is 0.005˜0.5 weight % with respect to the anti-arcing constituent, whose diameter is 0.01˜5 &mgr;m when its shape is calculated as spherical, and which is in non-solid solution condition or condition in which it does not form a chemical compound; and a conductive constituent consisting of Cu and constituting the balance.

Abstract: A support for a lithographic printing plate in which uniform pits are efficiently formed by electrochemically graining treatment, always independently of electrolytic conditions to give excellent printing performance, which comprises an aluminum alloy plate containing 0.05% to 0.5% by weight of Fe, 0.03% to 0.15% of Si, 0.006% to 0.03% by weight of Cu and 0.010% to 0.040% by weight of Ti, wherein the Cu concentration of a surface layer portion of from a surface to a depth of 2 &mgr;m of the aluminum alloy plate is at least 20 ppm higher than that of a region deeper than the surface layer portion.

Abstract: A magnetic recording disk having on its surface a texture structure of fine surface irregularities with reduced variations, which is suitable for high-density magnetic recording, and a method of manufacturing such a magnetic recording disk are provided. The magnetic recording disk has a substrate 11, 12 (16) coated on a surface thereof with a magnetic layer 13, a carbon layer 14, and a lubricating film 15. The substrate has on a surface thereof a texture structure of fine surface irregularities for reducing friction when the substrate is brought into contact with a head and controlling an amount of lift of the head. The fine surface irregularities have a height of 20 nm or less and are formed from a pattern shape or profile of a shield with a high-speed atomic beam emitted from a high-speed atomic beam source.

Abstract: In order to secure stable magnetic properties in a magnet alloy ribbon obtained by a melt rapid cooling method, and obtain excellent magnetic properties and corrosion resistance in a bonded magnet, the area ratio of dimple-like recesses (22) present in the surface (roll surface) of the alloy ribbon in contact with a cooling roll during solidification is defined. As a result, an alloy ribbon for a magnet having stable magnetic properties can be obtained. The use of a powder obtained by grinding such an alloy ribbon enables formation of a bonded magnet having excellent magnetic properties and corrosion resistance.

Abstract: A decorative roll-patterned metal strip or sheet, preferably aluminium strip or sheet, having: a thickness of about 0.05-1.0 mm, preferably about 0.1-0.8 mm, with a surface having a plurality of indentations of a depth of about 0.001-0.05 mm, preferably about 0.02-0.035 mm, and optionally having a layer of a paint of a thickness of about 3-30 microns, preferably about 10-15 microns, on the surface and within its indentations, the ratio of the depth of the indentations to the thickness of the strip or sheet being in the range of about 1:5 to about 1:100. A process is provided for making the decorative roll-patterned metal strip.

Abstract: Lightweight flexure-resistant thin metal sheet is produced by passing flexible thin metal sheet between rolls having defined teeth, the teeth having radiused corners so that rows of projections are formed on both faces of the sheet without damage to the surface material or the rolls.

Abstract: The present invention is directed to polishing the surface of an airplane part to an improved specularity by adding the additional step of sanding prior to the polishing step.

Abstract: Carbon—carbon composite parts are joined with minimum surface preparation. A reactive-bonding joint interlayer having thickness greater than 1 mil is formed of fine particles of carbide-forming metallic ingredients and carbon. The joint interlayer is sandwiched between the two carbon—carbon parts to be joined and the assembly is heated under a compressive pressure to a temperature sufficient to complete the bonding reaction. No special surface preparation is required for the carbon—carbon parts due to the nature of the reactive-bonding. The mechanical properties of the joint are assured by selecting the metal-carbon ingredients so that thermal expansion mismatch is minimized. Shear strength exhibited by the resulting joints is greater than the interlaminar shear strength of the carbon—carbon composite material.

Abstract: A coated aerospace aluminum alloy part, such as a lipskin of a nacelle or a leading edge of a wing or tail, is disclosed which part is protected from corrosion due to severe environmental stresses, including high and low temperatures, and rain drop erosion, by a multilayer coating comprising a phosphate bonded metal containing basecoat and a resin based topcoat. A method of coating the part is disclosed.

Abstract: Aluminum anode foil is etched using a process of treating the foil in an electrolyte bath composition comprising aluminum chloride hexahydrate, hydrochloric acid, sulfuric acid and perchloric acid or perchlorate. The anode foil is etched in the electrolyte bath composition by passing a direct current (DC) through the bath, resulting in an aluminum anode foil having a higher capacitance and/or metal strength than using known methods or etching compositions. The etched anode foil is suitable for use in an electrolytic capacitor.

Abstract: An electrode substrate comprises a backing substrate carrying thereon a metal electrode layer and/or a recording layer, the layer or layers having a smooth surface area with a surface roughness of less than 1 nm by more than 1 &mgr;m2. The smooth surface of the metal electrode layer and/or the recording layer is formed by firstly forming the layer on another substrate having a corresponding smooth surface and then peeling another substrate off the layer after the layer is bonded to the surface of the backing substrate, whereby the smooth surface profile of another substrate is transferred to the surface of the layer formed on the backing substrate.

Abstract: Embossed sheets having improved grain retention can be made from a polyolefin composition containing a propylene polymer material, a partially crosslinked thermoplastic olefin elastomer composition, and optionally, crystalline polyethylene. Large parts such as automobile door and instrument panels can be formed from these sheets.

Abstract: Non-directional and diffuse reflecting photometric properties may be imbued to a metal sheet stock, particularly aluminum alloy sheet stock, by directly creating a textured surface on one or more surfaces of the sheet stock through mechanical texturing with at least one textured work roll in a cold roll reducing mill. A textured metal sheet surface thus produced is characterized by having over its entire surface randomly formed imbricated depressions transversely arranged, such that each depression has a substantially transverse width dimension relative to a longitudinal axis of the sheet and a longitudinal dimension greater than its width. The depressions formed are substantially equiaxial. Surface properties of both the textured work roll and the textured metal sheet may be controlled. The metal sheet stock are subjected to finishing steps such as chemical brightening and anodizing, or organic coating to provide lighting sheets with high total reflectance.

Abstract: The surface roughness of a sputtering target is controlled and the amount of residual contaminants, the hydrogen content, and the thickness of a surface damage layer are reduced, in order to homogenize the thickness of a film formed on a substrate by sputtering and prevent and suppress nodule production to reduce particle production during sputtering. A sputtering target with the surface roughness (Ra) not more than 1.0 .mu.m, the total amount of contaminants, metal elements with a high melting point other than the major component and alloy components and Si, Al, Co, Ni, and B, not more that 500 ppm, the hydrogen content of the surface not more than 50 ppm, and the thickness of a surface damage layer not more than 50 .mu.m is provided, which is manufactured by precision machining, preferably, with the use of a diamond turning tool.

Abstract: A bond coat and method of forming a bond coat for a thermal barrier coating system are set forth. The bond coat is a roughened bond coat and comprises a layer possessing an uneven, undulated, and irregular surface. The layer is formed of a metal powder mixture disposed on a substrate, such as a turbine component, by high velocity oxygen fuel spraying. The metal powder mixture comprises at least one of a first powder having a first melting point and a second powder having a second melting point that is higher than the first melting point. The bond coat's uneven, undulated, and irregular surface enhances prevention of de-bonding of elements in a thermal barrier coating system.

Abstract: Grain oriented electrical steel sheet with a very low iron loss and a method for producing the same, wherein the surface of the iron substrate of the grain oriented electrical steel sheet is subjected to an enhancement treatment of crystal grain orientation or surface smoothing to a mean roughness of about 0.20 .mu.m or less, electroplating a chromium plating layer on the substrate with heterogeneous growth, and applying a tension coating film to the plating layer.

Abstract: A sheet laminate for use in a press lay-up between printed circuit board panels having a steel substrate layer and a copper foil layer releasibly bonded to at least one surface of the substrate layer.

Abstract: A corrosion resistant sheet alloy separator sheet for use in a press lay-up between printed circuit board panels.