Method of securing an insert in a shell

A method of joining an insert to a shell at an interface and simultaneously sealing the interface therebetween, the insert being of the type including a body section disposed within and extending axially along an insert-receiving aperture extending axially through the shell from a forward end to a rearward end thereof, the insert body section including an outwardly facing surface peripherally surrounded by a continuous portion of the shell upon assembly, and the insert including a flange section extending transversely outwardly from the outwardly facing surface of a rearward portion of the body section and peripherally therearound and having a forwardly facing surface section abutting a rearwardly facing surface section of a rearward portion of the shell continuously around the insert flange section, comprising the steps of:

• forming a channel in said forwardly facing surface section of said insert flange section extending transversely outwardly from said insert body section and opposing said rearwardly facing shell surface section;
• forming an opposing recess in said rearwardly facing shell surface section opposed from said channel when said insert is placed within said shell, said recess and said channel defining a seal set peripherally surrounding said body section of said insert and shaped cross-sectionally to eventually contain a bead of cured sealing material;
• selecting uncured material having low melt viscosity and good ability to flow along surfaces upon being liquefied, and having good adhesive characteristics upon curing;
• disposing said selected material in one of said channel and said recess substantially entirely therearound prior to assembling said insert and said shell, obviating any need for openings providing access to said seal seat for injection of material;
• placing said insert within said shell with said forwardly facing insert surface section at least adjacent said rearwardly facing shell surface section;
• and
• melting said selected material so that it liquefies, flows along all surfaces defining said seal sat, and cures thereby bonding said insert to said shell both defining the inert-to-shell joint and defining a hermetic seal entirely peripherally around the interface therebetween.