Metal working – Method of mechanical manufacture – Utilizing transitory attached element or associated separate...
Reexamination Certificate
1999-07-12
2001-10-30
Hughes, S Thomas (Department: 3726)
Metal working
Method of mechanical manufacture
Utilizing transitory attached element or associated separate...
C029S423000, C029S419100, C228S141100
Reexamination Certificate
active
06308392
ABSTRACT:
CROSS REFERENCE TO RELATED PATENT APPLICATIONS
There are no related pending patent applications filed by us.
BACKGROUND OF THE INVENTION
I. Field of the Invention
This invention is in the general field of manufacture of metallic wires;
The invention is more particularly in the field of manufacture of wire and other elongate members from high performance brittle alloys;
The invention is even more directly in the field of manufacture of such products by a specialized, novel, and unique version of the filled billet extrusion technique, and by a similarly novel and unique heat treating/cold roll system.
II. Description of the Prior Art
There is considerable prior art in this field. The following United States Patents reveal the state of the art prior to our present invention:
U.S. Pat. No. 4,209,122 discloses a method of making high performance alloy wire;
U.S. Pat. No. 3,788,820 discloses the making of high performance alloy members by the Filled Billet Extrusion Method;
U.S. Pat. No. 3,394,213 discloses the production of fine filaments through an interesting process involving some of the known extrusion processes and an acid solution process;
U.S. Pat. No. 4,606,884 combines a number of pressing, machining and acid solution steps;
U.S. Pat. No. 2,050,298 defines a process for reducing rods, wires, etc. by surrounding preforms with a brittle filler and performing a number of physical steps without using acid;
U.S. Pat. No. 4,209,122 defines a process to produce high performance alloy wires, etc. utilizing the principles set forth in many of the foregoing patents;
U.S. Pat. No. 4,777,710 includes the features of U.S. Pat. No. 4,209,122 particularly utilizing a chromium filler powder in the process.
SUMMARY OF THE INVENTION
High performance brittle alloy wires and the like are used extensively in various critical manufacturing processes and the like. They are particularly used in critical welding of various sensitive items, such as in aircraft welding and the like.
As will be understood by those skilled in the art, critical components must be addressed with the highest regard for performance and reliability since safety is a prime consideration. As a result, those engaged in production of high performance brittle alloy items are constantly seeking even the most minute improvement and innovation in manufacturing methods and the like.
We have previously mentioned some of the most important prior art in this field. Considering all of the innovations and improvements heretofore developed, we have still found deficiencies in the processes concerned.
The processes disclosed in U.S. Pat. Nos. 4,209,122; 3,394,213; and 3,505,039 are not efficient because the billets involved must contain a significant amount of filler at the expense of rod preforms. Also, where an acid solution is required to dissolve the filler an inordinate amount of time is involved.
The process of U.S. Pat. No. 3,788,820 is not efficient due to the high cost of producing lamina with desired perforations where needed which is prohibitive.
The process disclosed in U.S. Pat. No. 4,777,710 can be more effective and efficient for high performance wire manufacture than the other processes known to us. However, it, too, has deficiencies—primarily: 1) Performance of the glass coating on the preforms; and 2) Performance of the chromium filler powder around the preforms.
During preheating the glass particles coalesce to initially form a relatively uniform layer having truly liquid condition. This liquid condition, though, allows a significant portion of the glass to leave the surface of the preform rods and flow into the adjacent porous chromium filler powder due to gravity and capillary action. When the preforms no longer have the critical thickness of the protective coating of glass chromium atoms are able to diffuse into the surfaces of the preforms and the alloy constituents of the rods causing an undesirable alloy of sufficient thickness to require removal by centerless grinding. Also, variability of heating rates and times causes substantial variation of mechanical separation of the chromium, requiring manual separation of each strand. The overall result is a labor intensive process having an inherently low yield due to the centerless grinding of each strand of wire.
We have now conceived and perfected two methods for solving the problems concerned with the production of high performance brittle alloy wires.
1) In one of our methods we place brittle alloy rods coated with a slurry containing calcium fluoride and an acrylic polymer into a metal container which is specially treated as described and claimed below resulting in the ultimate efficiency of production and highest quality of the finished wire.
2) In our other method we feed brittle alloy wires through a high temperature clamshell furnace, into a liquid nitrogen quench, through a cold roll diameter reduction process and finally polish and solvent cleaning in special manner.
It is an object of this invention to provide improved and economical methods and means for manufacture of brittle alloy elongate shapes;
Another object of this invention is to provide such method and means wherein there is a minimum of lost product due to the necessity of machining of surfaces to eliminate contaminated material;
Another object of this invention is to minimize labor requirements in such method;
Another object of this invention is to maximize the quality of the brittle alloy products produced.
The foregoing and other objects and advantages of this invention will be clear to those skilled in the art upon reading the following description of preferred embodiments in conjunction with a review of the appended drawings.
REFERENCES:
patent: 3962373 (1976-06-01), Pertucelli
patent: 3994428 (1976-11-01), Li
patent: 4777710 (1988-10-01), Hunt
Mann L. E.
Simon R. E.
Hong John C.
Hughes S Thomas
Schulze Herbert C.
U.S. Welding International, Ltd.
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