Currently, fiber/metal laminate sheets are limited in width due to restrictions in the width of thin metal sheets available. This invention solves that problem by providing an integral splice concept and a method for manufacturing a laminate employing the inventive concept. Specifically, a fiber/metal laminate sheet is provided having at least two metal plies and at least one fiber layer. Each of the metal plies comprises at least two metal sheets which are arranged side-by-side and have sheet metal breaks therebetween. All of the sheet metal breaks lie within the integral splice. An important feature of the invention is that the sheet metal breaks in each metal ply are staggered widthwise across the laminate with respect to the sheet metal breaks in the remaining metal plies, in accordance with a predetermined metal break staggering pattern, thereby maximizing the bond engagement of the discontinuous metal plies with the adjacent fiber layers. Another important inventive feature is that the fiber layers are continuous through the integral splice region. The resultant spliced laminate may have any desired width, and is strong, fatigue-resistant, durable, and easy to manufacture.

Fiber/metal laminate splice

An extrusion billet is fabricated from layers of soft magnetic material separated by one or more metal layers. The billet is coreduced and heat treated to impart the desired magnetic properties to the soft magnetic material and also to form intermetallic insulating layers between the magnetic layers. Electric field shield sections are formed in a similar manner by placing relatively thick layers of copper between adjacent layers of metal located adjacent to the layers of soft magnetic material. The layers of soft magnetic metal can also be separated by a layer of semiconductor material; or a metal foil having a semiconductor-forming or high electrical resistivity forming material deposited thereon. In the latter case no extrusion is required. Instead, pressure and heat cause the materials to react and form either a semiconductor layer or a layer with an electrical resistivity higher than about 10.sup. -4 ohm-cm between adjacent layers of soft magnetic metal. Even the deposition step is eliminated by separating and bonding the layers of soft magnetic metal with glass so long as the glass and soft magnetic metal have similar coefficients of thermal expansion.

Method of making laminated magnetic material

Systems and methods in accordance with embodiments of the invention implement bulk metallic glass-based strain wave gears and strain wave gear components. In one embodiment, a method of fabricating a strain wave gear includes: shaping a BMG-based material using a mold in conjunction with one of a thermoplastic forming technique and a casting technique; where the BMG-based material is shaped into one of: a wave generator plug, an inner race, an outer race, a rolling element, a flexspline, a flexspline without a set of gear teeth, a circular spline, a circular spline without a set of gear teeth, a set of gear teeth to be incorporated within a flexspline, and a set of gear teeth to be incorporated within a circular spline.

/pdf/systems-and-methods-for-implementing-bulk-metallic-glass-21n7iaup7v.pdf

Systems and Methods for Implementing Bulk Metallic Glass-Based Strain Wave Gears and Strain Wave Gear Components

Systems and methods in accordance with embodiments of the invention implement additive manufacturing techniques that employ different sets of deposition characteristics and/or material formation characteristics during the additive manufacture of an object so as to strategically build up the object. In many embodiments, material used to build up an object is deposited at different deposition rates during the additive manufacture of the object, and the object is thereby strategically built up. In one embodiment, a method of additively manufacturing an object includes: depositing material onto a surface at a first deposition rate so as to define a first region of the object to be additively manufactured; and depositing material onto a surface at a second deposition rate so as to define a second region of the object to be additively manufactured; where the second deposition rate is different from the first deposition rate.

https://ntrs.nasa.gov/api/citations/20180006279/downloads/20180006279.pdf

Systems and methods for additive manufacturing processes that strategically buildup objects

A method of laminating first and second metal sheets to one another, comprises the steps of superposing the metal sheets and including therebetween a layer of amorphous metal and laminating the sheets to one another. During the lamination a pressure is applied by cold rolling for bonding the first and second sheets together.

Laminating method and article

AN ALUMINUM-STEEL COMPOSITE AND METHOD FOR PRODUCING SAME WHEREIN A MATRIX COMPRISING AT LEAST TWO SHEETS OF ALUMINUM IS INTERNALLY REINFORCED WITH A PLURALITY OF LAYERS OF A PLURALITY OF THIN STEEL STIPS, WHEREIN THE LAYERS MAY OR MAY NOT BE SEPARATED BY ONE OR MORE SHEETS OF ALUMINUM, AND THE RESULTING MATRIX IS SUBJECTED TO ELEVATED PRESSURE TO FORM AN INTERMETALLIC BOND BETWEEN THE SHEETS AND THE STRIPS TO PROVIDE A COMPOSITE HAVING SUBSTANTIALLY ISOTROPIC PROPERTIES.

Aluminum-steel composite

Aluminium-Stahl-Verbundwerkstoff und Verfahren zu dessen Herstellung

1,235,973. Welding by rolling or pressing. COMPAGNIE PECHINEY. 21 Aug., 1969 [22 Aug., 1968], No. 41836/69. Heading B3R. A composite material comprising a matrix of aluminium or aluminium alloy a reinforced by parallel layers of steel strips b is formed by rolling or pressing. The width of the steel strips is from 30 to 200 times their thickness, which is from 0A05 mm. to 0A15 mm. The steel is preferably a stainless steel, a martensite steel, a maraging steel, or a steel having a good cold working capacity. The aluminium alloy is preferably an alloy of the Al-Si type, or a hardenable alloy of the Al-Zn-Mg, or Al-Cu-Mg, Al-Mg-Si or Al-Zn-Mg-Cu, type. The ratio of volume between the steel and matrix is from 10 to 50%. The steel strips are preferably encased in aluminium or aluminium alloy prior to rolling or pressing and may be placed with the axes of the strips in one layer parallel to, or across the axes of the adjacent layer.

Eric Anderson

Papers

Aluminum-steel composite

Aluminium-Stahl-Verbundwerkstoff und Verfahren zu dessen Herstellung

Aluminium-steel composite materials