Olin Corporation

Osprey Metals Limited

International Telephone and Telegraph Corporation

Swiss Aluminium Ltd.

Alumax, Inc.

Harvey P Cheskis

Sankaranarayanan Ashok

Derek E Tyler

W Gary Watson

William G Watson

Paul D Tungatt

Ashok Sankaranarayanan

Michael J Pryor

Kenneth P Young

Stanley Shapiro

Deepak Mahulikar

Eugene Shapiro

Jacob Crane

Szuchain F Chen

Ronald N Caron

Brian Lewis

Brian Mravic

William C Setzer

Jeffrey S Coombs

George J Muench

James F Rooney

Charles R Pratt

Richard P Vierod

Thomas J Melillo

Peter F Chesney

Louis P Stone

Debabrata Gupta

Gary W Watson

WGary Watson

George A List

Richard J Slusar

James A Scheuneman

A flexible circuit to interconnect two components of an electrical device is formed with a flexible polymeric substrate. A copper alloy is laminated to the flexible substrate. This copper alloy is processed to have relatively high strength, an ultimate tensile strength in excess of about 80 ksi, by either alloying additions, by processing or by a combination of the two. When such an alloy is laminated to the polymeric substrate, the resultant flexible circuit has improved (more cycles to failure) dynamic fatigue performance when compared to both pure copper and dilute copper alloys.

Copper alloy foils for flexible circuits

There is provided a component for use in electronic packaging. The component is a composite having a graphite matrix which is infiltrated with a metal or a metal alloy and the external surfaces of the composite then coated with a metallic layer to provide environmental and mechanical protection. The packaging components are lightweight, have a coefficient of thermal expansion close to that of a silicon based integrated circuit device and further, have a high coefficient of thermal conductivity.

Graphite composites for electronic packaging

Spray cast copper-manganese-zirconium alloys are disclosed. In one embodiment, the alloy is spray cast in nitrogen and contains from about 1 ppm to about 20 ppm of dissolved nitrogen. In a second embodiment, the alloy contains an addition selected from the group consisting of chromium, titanium, erbium and mixtures thereof. The alloys are useful for sound damping as the combination of zirconium and the addition inhibits degradation of the specific damping capacity of the alloy.

Spray cast copper-manganese-zirconium alloys having reduced porosity

There is disclosed methods for the manufacture of a metal matrix composite having a metal or metal alloy matrix and a uniform dispersion of a second phase. The second phase is either a refractory metal or a nonmetal. An element which reacts with both the matrix and the second phase is added to increase the loathing density of the second phase and to improve adhesion between the components of the composite. When the metal alloy matrix is copper or a copper based alloy, suitable reactive elements include zirconium, titanium, chromium and mixtures thereof.

Spray cast copper composites

There is provided an apparatus and method for the manufacture of metallic articles. A molten metal stream is disrupted, such as by gas atomization, to form a plurality of molten metal droplets. The molten metal droplets pass through a cooling zone having a length sufficient to allow up to about 30 volume percent of each of the droplets to solidify. A mold then receives and completes solidification of the metal droplets. When under about 30 volume percent of the droplets is solid, the droplets retain liquid characteristics and readily flow within the mold.

Vertical casting process

Metal is spray cast onto a moving substrate using at least two sprays, the first of which has a solid fraction greater than 20% at the time the spray contacts the substrate, but less than the solid fraction of the second spray.

Metal spray forming using multiple nozzles

A method of casting metal material wherein metallic metal is deposited on a foil moving underneath the feeding means for the molten metal and is supported on a supporting substrate. The foil is formed with side edges before receiving a deposit of molten metal to contain the flow of molten metal thereon in a direction transverse to the direction of movement of the foil.

Casting of metal strip

A method of casting metal wherein molten metal is deposited on a moving planar substrate to form a strip thereon. The strip is removed from the moving substrate onto an open mesh support prior to the strip becoming completely solidified throughout its thickness. Ideally, the strip is removed as soon as it forms a solidified shell on its bottom which is thick enough not to fracture under the weight of the remaining molten metal. This arrangement overcomes the problem of cooling the bottom surface of the cast metal due to an air gap forming between a solid supporting substrate and the cast metal.

A molten metal gas-atomizing spray-depositing apparatus has an atomizer which employs a pressurized gas flow for atomizing a stream of molten metal into a spray pattern of metal particles being initially hotter than the solidus temperature of the metal. The apparatus also has a substrate system which includes an outer substrate of metallic foil and an inner substrate for supporting the outer substrate. The outer foil substrate is movable relative to the metal particles in the spray pattern thereof and disposed below the atomizer for receiving on a surface of the foil a deposit of the particles in the spray pattern to form a product on the outer foil substrate. The outer foil substrate is of a thickness which is less than a predefined maximum thickness at which the capacity of the foil to absorb heat from the deposit is equal to the latent heat and super heat, if present, of the deposit. The foil thickness precludes reduction in temperature below the solidus temperature, and thereby complete solidification, of the metal particles forming the deposit upon initial contact with the foil surface whereby a reduction of porosity is achieved in the deposit.

Substrate for spray cast strip

A method and apparatus for the casting of metals in which a molten stream of metal is atomized into a spray of highly liquid droplets. The droplets are deposited on a moving substrate such as an endless belt provided with side dams. The droplets flow in a direction transverse to the direction of movement of the substrate and are contained by the side dams. The droplets may have an average size of 300 microns and the spray may have a liquid to solid ratio of at least 50%. This arrangement overcomes the problems of splashing and turbulence caused by the relative flow between the melt and the belt in regular belt casting and overcomes porosity problems associated with spray casting.

Belt casting of molten metal

Spray cast alloys having reduced porosity and increased ductility are provided as well as a process for the manufacture of the alloys. An effective amount of a reactive metal which reacts with the spray casting atmosphere but not with the desired alloy is dissolved into the alloy prior to spray casting. Preferred reactive metals readily form a nitride which is finely dispersed throughout the spray cast alloy.

Copper alloys with dispersed metal nitrides and method of manufacture

A method of producing a grain refined copper base alloy containing iron in the amount of less than 2.3% by weight and which is cast into an ingot by conventional direct chill casting. Calcium is added to the melt before casting, preferably in the form of a copper-clad or iron-clad calcium feedwire.

Grain refinement of a copper base alloy

A metal extrusion process and apparatus in wich a semisolid material is fed into a passageway formed between first and second members, with one of the members being moved toward a die such that the moveable member draws the semisolid material through the passageway and through the die means.

Extrusion of metals

A metal extrusion process and apparatus in which a semisolid material is fed into a passageway formed between first and second members, with one of the members being moved toward a die such that the semisolid material is drawn through the passageway and solidifies before passing through the die means.

The present invention relates to a technique for forming silicon carbide coated porous filters for use in filtering molten metal, especially copper and copper alloy melts. The technique comprises preparing a silicon carbide containing slurry having a viscosity in the range of about 1 to about 50, preferably from about 5 to about 30, centipoise and impregnating a rigid porous substrate material with the slurry. In a preferred embodiment, the slurry contains mono-aluminum phosphate as a binding agent, ethylene glycol as a wetting agent, powdered silicon carbide having a maximum settling rate of about 0.1 mm./min. and the balance essentially water. After draining of the excess slurry, the coated substrate material is heated to substantially prevent foaming of the coating during firing and fired to bond the silicon carbide coating to the substrate material.

Growing community of inventors

North Haven, CT, United States of America

Harvey P Cheskis