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Well, the cooling drum is held at 38 deg F by a chiller,the foil wraps half way around the drum,drum is 20" dia. drum is polished 6061 aluminum, foil is 32 finish nickel .0007 thick X 5" wide. The heat problem. e-beam crucible temp is 550deg C and distance is 8" from foil...

Copper was considered BUT copper is reactive with Lithium and cannot be used without very big problems. Due to the properties of the material I am using, I am limited in choice of metals. Thanks Woody Ebersold Consulting Engineer "AN EXPERT IS ALWAYS SOMEONE FROM OUT OF TOWN"

All of the information given here is good but if you want the best possible fit, then you need to make a change in the design and add an adjustable gib to the groove. This will allow a true sliding fit with no side to side play. Otherwise follow GD&T guidelines for fits and dimensional tolerance...

I checked all my old stuff including a asme reference and f4 is a ground surface corresponding to the common 32 finish of today. Woody Ebersold Consulting Engineer "AN EXPERT IS ALWAYS SOMEONE FROM OUT OF TOWN"

Thanks for the input. The process is working but I was looking for a way to increase yield. The foil I am using is very thin .0007 and at least a 32 finish as it comes from the supplier. Contact is probably at it's max right now.I was hoping that someone had a new type of coating that could be...

Guys, you are all on the right track but helicoils can and do pull out of aluminum. I would use an item called a thread-sert. They are made just for such soft materials and do hold up much better. Woody Ebersold Consulting Engineer "AN EXPERT IS ALWAYS SOMEONE FROM OUT OF TOWN"

I have a heat transfer problem. I use an electron beam vacuum deposition system to coat lithium on a nickel foil substrate in a continous web operation. Yes this is for making batteries! The problem: The foil collects heat by radiation from the e-beam guns,sufficient to melt the lithium back off...