Abstract: High-strength aluminum alloys and other hot-short-sensitive alloys can be extruded at rapid rates through a cooled, double reduction die (3) without hot-short cracking or scoring caused by die pickup. A primary reduction die (4) has a long, cooled primary land (5) and is followed by a secondary reduction die (6). A metal billet (15) may be extruded through the primary die (4) at about the solidus temperature of its lowest melting phase, then cooled as it passes through the primary die land (5) to reduce or maintain the temperature below the solidus temperature and, finally, the primary extrusion is reduced in cross section in the secondary die (6) by about 2-50%. The temperature, the back pressure caused by the second reduction, and the low friction through the primary land (5) contribute to eliminate hot-short cracks and minimize serious pickup scoring at surprising rates of at least about 18 meters per minute (60 ft/min) for 2024 aluminum rod.

Abstract: The disclosure relates to a method of insuring the tightness of a fastener including forming a three-dimensional annular member in an austenite phase using a press, cooling the annular member to a temperature lower than the temperature for starting an austenite transformation, fastening the fastener with the annular member to flatten the annular member, and returning the temperature of the annular member to a higher than austenite temperature so that the recovery power of the annular member for returning the annular member to the three-dimensional shape in the austenite phase generates a fastening force for the fastener.

Abstract: A method for producing cold rolled titanium strips having good surface quality. The cold rolling of a titanium strip is carried out under the conditions represented by the following formula:X.ltoreq.(48673/Y.sup.1.3283)where X is an average grain size (.mu.m) of the pre-cold rolled titanium strip and Y is a diameter (mm) of the roll for the cold rolling.

Abstract: An inner stainless-steel tube having an outer frustoconical faying surface is fitted into an outer carbon-steel tube having a matching inner frustoconical faying surface, and these tubes are friction welded over their entire faying surfaces by pressing the tubes together in their axial direction to obtain a high contact pressure due to a wedge action and, at the same time, imparting rotation thereto relative to each other thereby to obtain an integrally bonded, laminated, tubular blank, which is then extended by a suitable process such as rolling into a clad steel tube. The tubular blank can also be slit in its axial direction and flattened into a laminated flat blank, which can be rolled into a clad steel plate. The inner tube may be replaced by a solid core metal. In this case, an integrally bonded blank made up of the inner core metal and the outer tube is extended into a clad steel tube or into a clad steel shape.

Abstract: A steel strip having distributed thereon powder containing aluminum as its main ingredient is cooled to a temperature range of less than 15.degree. C. below room temperature. The cooled material is immediately subjected to cold rolling and then to sintering, to produce multilayer sliding material. By cooling the steel strip and the powder distributed thereon together to a temperature range of less than 15.degree. C. below room temperature, occurrence of seizure between the powder and rolls of a rolling mill can be avoided.

Abstract: This invention relates to a resistive or semiconducting coating for use on current conductors in cryogenic applications. This includes copper-clad superconductor wire, copper wire used for stabilizing superconductor magnets, and for hyperconductors. The coating is a film of cuprous sulfide (Cu.sub.2 S) that has been found not to degrade the properties of the conductors. It is very adherent to the respective conductors and satisfies the mechanical, thermal and electrical requirements of coatings for the conductors.

Abstract: An electrically conductive part with an insulation material which withstands high temperatures and a method of manufacturing such a part. Its conductive core is formed by drawing a copper billet coated with a copper-aluminium alloy.

Abstract: Low carbon steel strip is cold rolled with rolling reduction of 15 to 35% in final cold rolling step and annealed in form of tight coil at temperature of 520 to 600.degree. C. to provide product having grain size number of 4 to 7 and coercive force of not greater than 2.0 Oersted as measured with initial magnetization field of 25 Oersted. The product is especially suitable for manufacturing shadow mask of Braun tube for color TV.

Abstract: A process for producing self-tapping screws from an austenitic 300 series stainless steel material wherein a blank of such material is chilled prior to a thread rolling operation so that the threads are formed while the blank is in a chilled condition. A preferred apparatus for practicing such a method utilizes an insulated tunnel surrounding the feed track which leads to the thread roller. Fluid refrigerant is fed to the interior of the tunnel to chill the blanks immediately prior to the thread rolling operation.

Abstract: A process for producing self-tapping screws from an austenitic 300 series stainless steel material wherein a blank of such material is chilled prior to a thread rolling operation so that the threads are formed while the blank is in a chilled condition. A preferred apparatus for practicing such a method utilizes an insulated tunnel surrounding the feed track which leads to the thread roller. Fluid refrigerant is fed to the interior of the tunnel to chill the blanks immediately prior to the thread rolling operation.

Abstract: A process for producing thermoformed articles from thin-walled blanks composed of aluminum or magnesium alloys, the present invention particularly provides for forming a layer of alumina or magnesia on the surfaces of the respective aluminum or magnesium blank. The alumina or magnesia layers so formed are artificially formed in order to obtain desired thicknesses, the regular layers allowing ready removal of the articles from thermoforming molds. The present process is particularly intended for the production of thin-wall packaging members and motor vehicle components.

Abstract: This invention provides a method for cold extruding 18% nickel maraging steel to form an article of manufacture, such as a sub projectile blank for the manufacture of cannon rounds which includes performing a series of cold extrusion operations on an extrusion blank with a tapered punch to produce a combination forward extrusion and backward extrusion. On the first cold extrusion operation a tapered hole is formed in the extrusion blank and the extrusion blank is elongated. Subsequent cold extrusion operations progressively elongate both the extrusion blank and the tapered hole. The punch and die geometry are such that the tapered hole is elongated by penetration of the punch into the blank and additionally backward extrusion of the material around the punch. Additionally, as the tapered hole becomes increasingly longer, a floating punch is employed wherein at least a portion of the punch is supported by the walls of the tapered hole.

Abstract: A method and apparatus of manufacturing wire rod having a content of silicon and manganese greater than 1.5% is described, wherein the average final rolling temperature in processing the rod is from 870.degree. C. to 970.degree. C. and the rod is cooled in an extended position. The composition of steels utilized in the method is also described.

Abstract: A method for continuously relieving residual stresses in hot extruded then cold drawn brass sections, particularly leaded yellow brass. In the disclosed method, the residual stress is localized near the surface of the brass section during cold draw by limiting the percentage reduction in cross-sectional area for the section as it passes through a smaller angle cold draw die. This is accomplished by using a cold draw die having a relatively small attack angle which minimizes the stress at the center of the brass section and localizes the residual stress to an area near the surface of the section. The configured extruded, cold drawn rod is mechanically worked by passing it through mechanical benders which are set to alternatively bend the rod out of alignment first relative to a horizontal longitudinal axis and then relative to a vertical longitudinal axis.

Abstract: A method of hot forming bends or deflections in preconsolidated metal matrix composite panels comprised of unidirectional filaments of boron, borsic, alumina, or graphite in aluminum or titanium base metals without limitation of orientation of the filaments relative to axes of the formed bends or deflections.

Abstract: In a method for cryogenically forming a sheet of aluminum or a solid solution strengthened aluminum alloy wherein the sheet has a maximum thickness of about 0.2 inch, said method comprising forming said sheet into a shaped article of desired configuration by deforming said sheet at a cryogenic temperature in the range of about minus 100.degree. C. to about minus 200.degree. C.,the improvement comprising:(a) work-hardening the sheet to at least about 25 percent of maximum hardness prior to the cryogenic deformation; and(b) conducting the cryogenic deformation in such a manner that (i) at least part of the sheet is deformed by tensile stresses, (ii) the thickness of said part is reduced by at least 2 percent by said deformation, and (iii) the smallest dimension of the area of the part to be deformed is at least equal to the thickness of the sheet.

Abstract: A forging compound particularly adapted for hot die dwell forging of titanium and its alloys comprises boundary layer particles (boron nitride or graphite) and a major quantity (more than 60% by weight) of vitreous components. The vitreous components comprise diboron trioxide and silica frit containing a metal oxide wetting agent. In a preferred form, the forging lubricant comprises about 14 to 25% by weight boron nitride particles, balance, vitreous components. The latter comprise about 60% to 75% by weight diboron trioxide, balance silica glass containing cobalt oxide wetting agent in an amount of 1.0 to 3% by weight of the vitreous components. All the foregoing ingredients may be dispersed in a coatable carrier preferably comprising a solvent, e.g., xylene, in which a resin binder is dissolved.

Abstract: A method according to the present invention comprises the formation of metallic materials by translating metal wire between working tools, that is, a striker and an anvil, which are arranged in a closed space with a medium inert to both the wire metal and material of the tools. The wire is then heated to a temperature high enough for plastic deformation of the metal, while ultrasonic vibrations are simultaneously applied to the working tools, propagating at an angle to the longitudinal axis of the wire. An apparatus for carrying out the proposed method comprises, in addition to the working tools, sources of ultrasonic vibrations which are rigidly coupled to the tools, and a mechanism for heating the working tools and wire.

Abstract: A unique alloy comprising lead with small additions of zinc and tin is used to make grids for lead acid cells. The alloy as produced is softer than is desirable. It is hardened by mechanical working. When properly worked, it has a strength and stiffness approaching that of other low alloy lead materials currently in use as storage battery grids.

Abstract: A method for producing zircaloy tubes from hollows or workpieces which are in the form of tubes having greater wall thickness than the finished tubes. The method is carried out upon a mill of the general type known as a McKay rocker which has a stationary tapered mandrel, but the mandrel is cylindrical and is moved with the workpiece.

Abstract: Improvements in a plastic working process for face-centered cubic metals, and titanium and zirconium having close-packed-hexagonal lattice, which process utilizes a phenomenon that the ductility of these metals is increased at sub-zero temperatures, i.e., temperatures below 0.degree. C. This process includes the steps of (i) imparting plastic flow including at least a uniaxial tensile stress field a metal at a temperature below zero, (ii) subjecting the metal to plastic flow to an extent that the strain of the metal is within the limit of uniform elongation of the metal, and then to plastic flow including at least a uniaxial tensile stress field continuously thereafter, or (iii) using frost as a lubricant for plastic working at temperatures below 0.degree. C according to either one of the foregoing steps.

Abstract: A process of precision forging of titanium or a titanium alloy in which the forging stock and a segmented die are first heated to forging temperature while separated, and are then assembled together and heated again to that temperature, with the stock being covered by a protective coating preferably containing glass grit, and the die sections being coated with lubricant. The heated die and contained heated forging stock are then inserted in a heated holder and the stock subjected to forging force, to partially but not completely deform the stock to the shape of the die cavity, following which the die and stock are separated and the stock allowed to cool, flashing is removed from the stock, the die is cleaned, the die and stock are recoated and then reheated separately and then together, and the stock is forged again to assume more closely the shape of the die cavity.

Abstract: There is disclosed a process for producing strip material useful for making lead frames which includes preparing a ferritic stainless steel substrate as a thin strip and, before subjecting it to finish rolling, electroplating it with a first layer of copper and an outside layer of nickel or tin, after which the strip is precision rolled to final gauge. There is also disclosed the product from this process which is a precision rolled strip having a core of ferritic stainless steel and a continuous surface layer of nickel or tin with an intermediate layer of copper.

Abstract: Anisotropic permanent magnets of Mn-Al-C polycrystalline alloy are produced by warm extrusion at a temperature of 530.degree. to 830.degree. C utilizing converging or tapered dies with lubricant interposed between the polycrystalline body and the converging die. With dies of rather small semiangles, alloys with improved magnetic properties with regard to (BH)max, and especially Br are obtained.

Abstract: Graphite having a compressive strength at room temperature of at least 10,000 psi is an improved die material useful in the forging of high strength alloys which are in a temporary condition of low strength and high ductility in hot die means.

Abstract: Apparatus and related process steps are disclosed for manufacturing titanium alloy sheet metal parts over a die form using radiant heating, particular mechanical motions, and differential fluid pressures in specific sequences of operations. The resulting parts have configurations with substantial depths and are produced both at accelerated rates and with reduced alloy contamination in comparison to known titanium sheet metal forming practices.

Abstract: Production of tapered titanium alloy tube performed by subjecting uniformly dimensioned tube to multiple swaging steps interspersed with vacuum annealing, heat hardening in the presence of atmospheric gases producing high yield strength in the final product.

Abstract: A method of manufacturing low energy-loss waveguide circuit elements in which a film of metal with a low resistivity is joined to a base metal by thermal pressing or electric plating, and a hard male die of a desired shape is pressed into the base metal from above the metal film, whereby a plastic strain is caused in the base metal thereby to form a recessed portion in the base metal having an internal surface covered with the low resistivity metal.

Abstract: A method of expanding the diametric size of coins and retaining the impressions, embossings, stamping definitions, or the like, thereon for use in jewelry, medallions, and the like, and which comprises initially placing a coin between two layers of carrier metal having a fluidity different from the fluidity of the metal of the coin whereby the carrier metal expands faster or flows more readily than the coin metal, applying pressure against the coin and carriers until the carrier material and coin metal begin to flow from the center out, removing the slightly enlarged or expanded coin from the initial carrier members and placing the enlarged coin between two additional layers of carrier material for repeating the process until the coin has been enlarged or expanded to the desired end size.

Abstract: A method of producing long length articles from hot-rolled carbon steel is disclosed. A distinctive feature of the method, is that the operations of cold and warm plastic deformation of a wire rod alternate in succession at least twice.

Abstract: Stable wrought lead-calcium-tin alloys can be prepared by casting an alloy of lead having a calcium content of from about 0.02% or 0.03% to about 0.1% by weight and having a tin content such that the tin to calcium weight ratio or relative tin content is from about 7:1 to 10:1 and preferably is more than 10:1 up to about 100:1, with the proviso that the absolute tin content be from about 0.3% to about 2.0%; and thereafter cold working the casting at a time period of within about 24 hours after casting for the lead-calcium-tin alloys having a tin to calcium weight ratio of from about 7:1 to 10:1 and within about 48 hours after casting for the lead-calcium-tin alloys having a tin to calcium weight ratio of from more than 10:1 up to about 100:1.Aged work pieces heated sufficiently to dissolve the precipitated calcium phases can be similarly treated.