Ford Motor Company Limited

Materials Resources International

S-bond Technologies, LLC

Ronald W Smith

Robert C McCune

Randall Redd

Michael R Kim

An active solder alloy, an electronic device package including the active solder alloy bonding an electronic device to a substrate, and a method of forming high-strength joints by soldering using the solder alloy. The alloy contains up to about 10% by weight of an element or a mixture of elements selected from the group consisting of titanium, zirconium, hafnium, vanadium, niobium, or tantalum; between about 0.1 and 5% by weight of an element or a mixture of elements selected from the group of the lanthanides (rare earths); between about 0.01 and 1% by weight of gallium up to about 10% by weight of silver; up to about 2% by weight of magnesium; and a remainder consisting of tin, bismuth, indium, cadmium, or a mixture of two or more of these elements. The alloy enables low-temperature (less than about 180&#xb0; C.) soldering within relatively narrow melting ranges (less than about 10&#xb0; C.).

Electronic package formed using low-temperature active solder including indium, bismuth, and/or cadmium

A process for joining workpieces by active soldering. The process includes cleaning the surfaces of the workpieces to be joined; heating the workpieces to be joined; placing an active, low-temperature solder material on at least one of the surfaces of the workpieces to be joined; mechanically activating the molten solder material, to break oxide films on the solder material, while the solder material contacts the surfaces of the workpieces to be joined; assembling the surfaces of the workpieces to be joined; and applying pressure to the surfaces of the workpieces to be joined both while the solder material is molten and as the solder material cools to a solid.

Process of using an active solder alloy

A method for coating the internal cylinder bores of a cast aluminum engine block comprising the steps of casting an engine block of aluminum alloy, thermally spraying a wear-resistant coating onto cylinder walls in the engine block by melting the tip of a rotating iron-based alloy rod with a plasma torch within cylinders in the engine block, and honing the cylinder walls to a chosen size.

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Blue Bell, PA, United States of America

Ronald W Smith