Alliedsignal Inc.

Allied Corporation

Other

Metglas, Inc.

Honeywell International Inc.

Richard L Bye, Jr

Santosh K Das

Colin M Adam

David J Skinner

Chin-Fong Chang

Derek Raybould

Amitava Datta

Debasis Bose

Dung Anh Ngo

Nicholas J DeCristofaro

Gordon Edward Fish

James F Stevenson

Kenji Okazaki

Peter Joseph Stamatis

Clyde R Taylor

Douglas J Steinke

Michael L Briggs

Jeng S Lin

Alexander Loboysky

Nicholas De Cristofaro

Allen H Simpson

Manuel G Koucouthakis

An amorphous metal stator for a high efficiency radial-flux electric motor has a plurality of segments, each of which includes a plurality of layers of amorphous metal strips. The plural segments are arranged to form a generally cylindrical stator having a plurality of teeth sections or poles protruding radially inward from the inner surface of the stator. In a first embodiment, the stator back-iron and teeth are constructed such that radial flux passing through the stator crosses just one air gap when traversing each segment of the stator. In a second embodiment, the stator back-iron and teeth are constructed such that radial flux passing through the stator traverses each segment without crossing an air gap.

Amorphous metal stator for a radial-flux electric motor

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.

High stack factor amorphous metal ribbon and transformer cores

An amorphous metal strip having a sheet thickness ranging from about 50 to 75 .mu.m and a sheet width of at least 20 mm is produced by a casting process utilizing a single nozzle orifice and a high thermal conductivity, large diameter wheel as a casting substrate. The strip has a fracture strain of 0.01 or more, a lamination factor of 0.8 or more, and a core loss of less than 0.2 W/kg at 60 Hz and 1.4 T.

Thick amorphous metal strip having improved ductility and magnetic

An apparatus for melting and rapid solidification casting of metal alloys has a crucible for molding a metal charge. The crucible has side walls, a top and a bottom having an orifice therein. Collectively, the side walls, top and bottom define an interior of the crucible. A portion of the dimensions of the side walls of the side walls and bottom is divided by longitudinal slits into at least two segments. A nozzle is disposed partially within the crucible and extends through the orifice. The nozzle has a first end in communication with the interior of tune crucible. A second end of the nozzle has a nozzle orifice therein for defining a stream of molten metal alloy. A cooling mechanism cools the top, side walls and bottom of the crucible. The apparatus has mechanisms for inducing alternating electrical currents within the metal charge and within the nozzle, and for establishing and maintaining pressure within the interior of the crucible. A positioning mechanism positions the crucible and nozzle means relative to a quenching mechanisms that includes a rapidly moving chill substrate. The crucible, nozzle and quenching mechanism are housed within an enclosure that provides there within a controlled atmosphere having positive or negative pressure.

Induction skull melt spinning of reactive metal alloys

The present invention provides a process for making high strength, high ductility, low density rapidly solidified aluminum-base alloys, consisting essentially of the formula Al.sub.bal Zr.sub.a Li.sub.b X.sub.c, wherein X is at least one element selected from the group consisting of Cu, Mg, Si, Sc, Ti, U, Hf, Be, Cr, V, Mn, Fe, Co and Ni, 'a' ranges from about 0.2-0.6 wt %, 'b' ranges from about 2.5-5 wt %, 'c' ranges from about 0-5 wt % and the balance is aluminum. The alloy is given multiple aging treatments after being solutionized. The microstructure of the alloy is characterized by the precipitation of a composite phase in the aluminum matrix thereof.

High strength, ductile, low density aluminum alloys and process for

A rapidly quenched Fe-Si Alloy containing 6 to 7 wt % is heat treated to promote and control an order-disorder reaction, thereby improving its ac core loss and exciting power at induction levels about B=1.2 T. The alloy has a substantially &lt;100&gt; texture, a grain size of about 1 to 2 mm, a R2 domain size of 100 to 850 nm, a DO3 domain size of about 5 to 25 nm, an ac core loss of about 1.2 to 1.6 W/kg and an exciting power of about 15 to 46 VA/kg, the core loss and exciting power being measured at an induction level of B=1.4 T and a frequency of f=60 Hz.

Heat treatment of rapidly quenched Fe-6.5 wt % Si ribbon

Apparatus is provided for fabricating continuous metal strip composed of a low density, readily oxidizable aluminum based alloy. The allow is cast directly from the melt through a slotted nozzle onto a moving chill substrate. A scraping mechanism located upstream of the nozzle is adapted to ride on the substrate and remove therefrom the gaseous boundary layer associated therewith. Disposed between the scraping mechanism and the nozzle is a gas supply mechanism adapted to introduce a replacement gas that is carried by the substrate to the nozzle. A shielding means configured to form a semi-enclosed chamber around the nozzle and the substrate apparatus to direct and confine the replacement gas in the vicinity of the nozzle. The alloy preferably has the form of a foil and a composition consisting essentially of about 10 to 13 weight percent silicon, 0 to 3 weight percent magnesium, 0 to 4 weight percent copper, 0 to 0.2 weight percent of at least one of bismuth, phosphorous, strontium, lithium, scandium, yttrium, sodium and calcium and 0 to 2 weight percent of at least one of the rare earth elements, the balance being aluminum and incidental impurities.

Low temperature aluminum based brazing alloys

A rapidly solidified aluminum-base alloy consists essentially of the formula Al.sub.bal Fe.sub.a Si.sub.b V.sub.c, wherein 'a' ranges from 3.0 to 7.1 atom percent, 'b' ranges from 1.0 to 3.0 atom percent, 'c' ranges from 0.25 to 1.25 atom percent and the balance is aluminum plus incidental impurities, with the provisos that (i) the ratio (Fe+V): Si ranges from about 2.33:1 to 3:33:1 and (ii) the ratio Fe:V ranges from 11.5:1 to 5:1. The alloy exhibits high strength, ductility and fracture toughness and is especially suited for use in high temperature structural applications such as gas turbine engines, missiles, airframes and landing wheels.

Rapidly solidified aluminum based silicon containing, alloys for

A rapidly solidified aluminum-base alloy consists essentially of the formula Al.sub.bal Fe.sub.a Si.sub.b X.sub.c wherein X is at least one element selected from the group consisting of Mn,V,Cr,Mo,W,Nb,Ta, 'a' ranges from 2.0 to 7.5 atom percent, 'b' ranges from 0.5 to 3.0 atom percent, 'c' ranges from 0.05 to 3.5 atom percent and the balance is aluminum plus incidental impurities, with the proviso that the ratio {Fe+X}:Si ranges from about 2.0:1 to 5.0:1. The alloy exhibits high strength, ductility and fracture toughness and is especially suited for use in high temperature structural applications such as gas turbine engines, missiles, airframes and landing wheels.

Rapidly solidified aluminum based, silicon containing alloys for

A rapidly quenched Fe-Si alloy containing 6 to 7 wt % Si is heat treated to promote and control an order-disorder reaction, thereby improving its ac core loss and exciting power at induction levels above B=1.2 T. The alloy has a substantially &lt;100&gt; texture, a grain size of about 1 to 2 mm, a B2 domain size of 100 to 850 nm, a DO3 domain size of about 5 to 25 nm, an ac core loss of about 1.2 to 1.6 W/kg and an exciting power of about 15 to 46 VA/kg, the core loss and exciting power being measured at an induction level of B=1.4 T and a frequency of f=60 Hz.

Apparatus is provided for fabricating continuous metal strip composed of a low density, readily oxidizable aluminum based alloy. The alloy is cast directly from the metal through a slotted nozzle onto a moving chill substrate. A scraping mechanism located upstream of the nozzle is adapted to ride on the substrate and remove therefrom the gaseous boundary layer associated therewith. Disposed between the scraping mechanism and the nozzle is a gas supply mechanism adapted to introduce a replacement gas that is carried by the substrate to the nozzle. A shielding means configured to form a semi-enclosed chamber around the nozzle and the substrate apparatus to direct and confine the replacement gas in the vicinity of the nozzle. The alloy preferably has the form of a foil and a composition consisting essentially of about 10 to 13 weight percent silicon, 0 to 3 weight percent magnesium, 0 to 4 weight percent copper, 0 to 0.2 weight percent of at least one of bismuth, phosphorous, strontium, lithium, scandium, yttrium, sodium and calcium and 0 to 2 weight percent of at least one of the rare earth elements, the balance being aluminum and incidental impurities.

Production of low temperature aluminum based brazing alloys

A rapidly solidified aluminum-base alloy consists essentially of the formula Al.sub.bal Fe.sub.a Si.sub.b V.sub.c, wherein 'a' ranges from 3.0 to 7.1 atom percent, 'b' ranges from 1.0 to 3.0 atom percent, 'c' ranges from 0.25 to 1.25 atom percent and the balance is aluminum plus incidental impurities, with the provisos that (i) the ratio [Fe+V]:Si ranges from about 2.33:1 to 3:33:1 and (ii) the ratio Fe:V ranges from 11.5:1 to 5:1. The alloy exhibits high strength ductility and fracture toughness and is especially suited for use in high temperature structural applications such as gas turbine engine components, automotive engine components, missiles and airframes.

An apparatus for casting magnesium based alloy containing dispersed magnesium intermetallic phases comprises scraping means and shielding means to form a semi-closed chamber around a casting nozzle. Gas supply means is provided for supplying inert gas to the chamber.

Apparatus for casting high strength rapidly solidified magnesium base

The invention provides an aluminum based alloy consisting essentially of the formula Al.sub.bal Fe.sub.a V.sub.b X.sub.c, wherein X is at least one element selected from the group consisting of Zn, Co, Ni, Cr, Mo, Zr, Ti, Hf, Y and Ce, 'a' ranges from about 7-15 wt %, 'b' ranges from about 2-10 wt %, 'c' ranges from about 0-5 wt % and the balance is aluminum. The alloy has a distinctive microstructure which is at least about 50% composed of a generally spherical, intermetallic O-phase. Particles composed of the alloys of the invention can be heated in a vacuum and compacted to form a consolidated metal article have high strength and good ductility at both room temperature and at elevated temperatures of about 350.degree. C. The consolidated article is composed of an aluminum solid solution phase containing a substantially uniform distribution of dispersed intermetallic phase precipitates therein. These precipitates are fine intermetallics measuring from about 10 nm to about 100 nm in diameter with an average interparticle spacing ranging from 50-500 nm.

Aluminum-iron-vanadium alloys having high strength at elevated

A rapidly solidified magnesium based alloy contains finely dispersed magnesium intermetallic phases. The alloy has the form of a filament or a powder and is especially suited for consolidation into bulk shapes having superior mechanical properties and corrosion resistance.

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Morristown, NJ, United States of America

Richard L Bye, Jr