Abstract: An electrical submersible pump runner having a core layer and a wear layer affixed to the core layer. One embodiment of the invention provides an electrical submersible pump that includes a motor section and a centrifugal pump section. A seal section and rotary gas separator may also be included. The pump is powered by an electric cable that connects the pump, located in a bore hole, to a power source on the surface. A thrust runner coated with a wear layer (e.g., polymer) is provided in the motor and/or seal section to reduce bearing temperature, provide longer bearing life, reduce costs, and facilitate overhaul. The runner may also function as a rotating up-thrust bearing when the runner is coated with a wear layer on one side that is formed with a bearing geometry. In this case, the up-thrust bearing may be eliminated.

Abstract: A thrust bearing assembly comprising a bearing runner and a bearing carrier, the carrier defining a plurality of thrust pad sites annularly around the carrier, with a thrust pad disposed at a site and with the carrier limiting movement of the thrust pad in a direction generally radial to the longitudinal axis of the runner while allowing the thrust pad to move in a direction generally parallel to the longitudinal axis. Though the range of movement is limited, the pads can tilt under load to form a hydrodynamic wedge as is known in the art. An embodiment comprises a bearing runner having a wear resistant face and a bearing carrier defining thrust pad sites disposed annularly around the carrier. In one implementation, at each site, a deflection element (e.g., Belleville washer) is disposed in a cavity and a pad is disposed over the deflection element. The pad can be at least partially disposed within the cavity. The wear resistant face contacts the pad.

Abstract: This disclosure describes sintered bodies comprising about 90 wt % to about 99 wt % of boron carbide, having a B:C atomic ratio ranging from 3.8 to 4.5:1; 0 to 1 wt % free carbon; 0 to 1 wt % BN or AlN, remainder an oxide binder phase; said sintered body having a uniform microstructure composed of substantially equiaxed grains of said boron carbide; the oxide binder phase comprising at least a rare earth aluminate and optionally Al2O3 or other ternary or binary phases of rare earth oxide-alumina systems; the binder phase being present in form of pockets at the multiple grain junctions and the density of no more than 2.6 g/cm3. Also described is a manufacturing process for the above described substantially pore-free, sintered boron carbide materials with high strength and fracture toughness, which can be used for production of large-area parts. This is achieved by liquid phase low temperature-low pressure hot pressing of boron carbide in an argon atmosphere.

Abstract: A method and apparatus for shaping the radial surface of a roller or other cylindrically shaped part in a single cycle. The preferred embodiment forms a crown geometry on one roller at a time using a CNC system to control a grinding surface in three axes. The grinding surface is controlled in two linear orthogonal directions (x and y) and around a circular axis (c) through corresponding stepper motors. In addition, the axial pressure applied by the grinding surface of the radial surface of the roller is controlled by an air pressure programmable regulator acting through a pneumatic cylinder. These four individually controlled, precise degrees of motion of the grinding surface, operating with a single rotating roller, permits extremely accurate crown shaping. The shaping is, in fact, so precisely controlled and so accurate that only one “cycle” of the grinding surface against the roller is required to achieve the desired crown profile.

Abstract: A light-weight armor hard-face component with elastomer encapsulation and lateral confinement to effectively improve multi-hit performance. The preferred embodiment is an integrated package consisting of a large elastomer plate, which contains confined, shock isolated ceramic tiles. This plate can be formed to a variety of sizes and shapes by cutting the elastomer along the gap between ceramic tiles. The attachment of this integrated package to a vehicle structure can be easily accomplished by bolting or adhesive bonding. Elastomer encapsulation limits lateral damage, increases ballistic efficiency and allows multiple impacts without ballistic performance degradation. The armor component is an integrated package, containing a continuous elastomer phase around segmented ceramic tiles. The elastomer is used to (1) attenuate stress waves, (2) accommodate the lateral displacement of ceramic fracturing, and (3) isolate adjacent tiles during the backing vibration stage.

Abstract: A pigmented silicon nitride composition suitable for hot pressing into near shape articles of manufacture having a cosmetically uniform color. The composition comprises high purity, sub-micrometer, alpha silicon nitride powder mixed with a sintering aid and a pigmenting material. In a preferred embodiment the pigmenting material comprises molybdenum carbide, although carbides of other elements are applicable as well. The resulting hot pressed article is cosmetically superior to non-pigmented silicon nitride. Such articles are especially useful for processing semiconductor components where appearance in the form of color uniformity is a strict requirement for the manufacturer and the customer.

Abstract: An orthodontic bracket includes a ceramic body having an elongated channel, and a metallic archwire slot liner that is received in the channel. The liner is affixed to the ceramic body by a brazing process using a brazing material such as platinum, silver, an active metal or a mixture of molybdenum and manganese. Alternatively, the liner is formed in situ in the bracket body.

Abstract: A golf club putter head made of a wear resistant and highly polished, aesthetically pleasing silicon nitride material in a manufacturing process which obviates labor intensive machining and finishing. Except for the optional addition of high density material weights at the toe and heel portions of the putter head, the present invention provides a putter head which is made of a monolithic silicon nitride ceramic which has a relatively low density of 3.3 grams per cubic centimeter and which is provided with a polished surface appearance along most of its surfaces. The present invention is preferably fabricated using a process of which the most important step is a high pressure, dry pressing step in which the unique shape of the golf club head described herein facilitates bi-axial symmetric pressure application resulting in what is known as a green part.

Abstract: A method is disclosed of fully densifying a plurality of preformed ceramic plates by axial compression of the billets along a wall defining a cylinder and cavity. A series of the plates are stacked along the wall with the smallest dimension of the billets aligned with the axis of the cavity. The billets have a ratio of the smallest dimension to the largest dimension in the range of 1:3 to 1:40. The largest dimension of each of the plates is less than the lateral dimension of the cavity to leave an annular space; the space is filled with a pseudo isostatic pressing medium. The assembly is hot pressed under sufficient pressure and heat to convert the plates to billets of substantially full density.

Abstract: A reservoir dispenser cathode structure having improved thermal efficiency is provided by inner and outer subassemblies. The inner subassembly has a molybdenum heater cup to which a tungsten-rhenium alloy cap is laser seam-welded. The outer subassembly has a tantalum support cylinder within which the inner subassembly is supported by means of a three-point suspension in the form of tabs that are lanced from the tantalum cylinder and spot-welded to the heater cup. The heater has a coiled-coil design wherein the coils are coated with Al.sub.3 O.sub.3 and small particle tungsten powder to increase the coil's thermal emissivity. This thermally-efficient structure permits the achievement of high current density (greater than 3 Amperes per square centimeter) with heater power that is less than 1.3 Watts.

Abstract: An orthodontic bracket or similar orthodontic appliance is made of a polycrystalline ceramic having a translucency which minimizes visibility of the appliance when mounted on a tooth. The ceramic is formed by pressing a powder material, such as high purity aluminum oxide, and sintering to yield a single phase appliance having substantially zero porosity and an average grain size preferably in the range of 10 to 30 microns. The substantially color-free ceramic appliance has desirable strength and other mechanical properties combined with a translucency which permits the natural color of the tooth to diffusely show through in a fashion tending to make the appliance blend with and disappear against the tooth.

Abstract: A method of making a silicon nitride comprising object by use of a low density reaction bonded body is disclosed. An uncompacted mixture of silicon powder and a fluxing agent is heated in a nitrogen atmosphere to react the mixture with the atmosphere to form a body consisting essentially of silicon nitride and having a dimension greater than and a density less than the finished product. The nitrided mixture is then hot pressed to produce a silicon nitride comprising object of desired dimension and density, which material is useful as a cutting tool material for machining metals.

Abstract: A dampening system roll which may be used in an offset printing press, is made of porous rebonded, fused silica, the pores of which are impregnated and sealed by a silicone resin. In a typical embodiment of the invention disclosed herein, a dampening system roll is fabricated by providing a 3 3/4 inch diameter 42 1/2 inch long fused silica cylinder infiltrated with a silicone resin and ground and polished to a 30 microinch Ra exterior smoothness. The ends of the cylinder are drilled out to provide a 1 3/4 inch diameter by 4 inch deep hollow core on each side which is adapted to receive a pair of shafts or end caps typically made of stainless steel or other low expansion metal alloy material and the end shafts or caps are bonded into the drilled ends of the fused silica cylinder for interfacing the printing press system. In an additional embodiment, the ends of the cylinder are core drilled to provide a pair of axial sockets each about 2 inches in diameter and about 2 inches deep.

Abstract: A process for soldering without using flux and producing a void-free joint comprises the steps of melting the solder in a reducing gas atmosphere such as hydrogen, evacuating the gas to permit the solder joint to expell any trapped gas, then reintroducing the reducing gas and cooling the solder joint. The reducing gas obviates the use of flux to avoid oxidation from interfering with the wetting of the materials to be joined. The materials may be metalized prior to soldering to permit wetting of certain materials such as ceramic.

Abstract: A method of making a reaction bonded/hot pressed silicon nitride comprising object is disclosed. Second phase crystallites are formed prior to hot pressing. A mixture of silicon, SiO.sub.2, and 0.4-2.3 molar percent (by weight of the silicon) of oxygen carrying agents, i.e., Y.sub.2 O.sub.3 and Al.sub.2 O.sub.3, is performed and reaction nitrided to form discs or billets having at least 60% alpha Si.sub.3 N.sub.4 and a high proportion of second phase crystallites which displace substantially all silicate glass except for a controlled small quantity. The reactive amounts of Y.sub.2 O.sub.3, Al.sub.2 O.sub.3 and SiO.sub.2 are controlled to assure formation of substantially Y.sub.1 SiO.sub.2 N as the second phase crystallite. Al.sub.2 O.sub.3 is controlled in an amount of 0.4-4% by weight to ensure that the small proportion of glass serves to protect the oxynitrides against linear oxidation kinetics. The hot pressed material has no visual mottle porosity associated therewith.

Abstract: A method of providing fastener holes in extremely hard ceramic armor comprises the steps of:(a) providing a billet of precompacted ceramic powder material;(b) drilling the desired holes in the billet;(c) preparing a plug of non-sintering material that is chemically compatible with and has compaction characteristics similar to the ceramic powder material;(d) pressing the plugs into the billet holes;(e) hot pressing the billet and plugs at conventional temperature and pressure for manufacture of a ceramic armor structure, and;(f) removing plugs by conventional tooling or sandblasting.

Abstract: A four-piece, easily manufactured dispenser cathode capable of current densities up to and exceeding 10 Amperes per square centimeter is particularly adapted for CRT applications because of its surprisingly low cost. A refractory material reservoir contains a pellet of tungsten and barium calcium aluminate and is sealed by a pellet of porous tungsten or tungsten mixture. The reservoir/pellet assembly is contained in a support cylinder to which the porous tungsten pellet may be welded. The inventive process includes the steps to prepare the pellets and assemble the four elements of the cathode.

Abstract: A method of enhancing the bondability of ceramic orthodontic brackets or other dental attachments for improving the bonding strength between such attachments and the tooth engaging surface utilizing an intermediate bonding agent such as an acrylic resin. The method of the present invention results in the application of a silicious glass-like material coating of the bonding surface of the dental appliance. The silicious glass-like material provides three functions: (1) the proper surface chemistry for the use of organofunctional silanes that act as adhesion promoters or primers to enhance the bond between the adhesive and the orthodontic bracket; (2) a medium whereby second phase particulates can be adhered to the bracket to form irregular surface projections to enhance bonding; and (3) a surface that can be etched to yield macro and micro pitting to enhance the bond between the appliance and the intermediate bonding agent.

Abstract: A spall shield for armor plate for restraining at least a portion of flying fragments resulting from impact of a projectile with said armor plate, comprises a plasticized resin of the type commonly used as an interlayer of safety plate glass such as for example, plasticized polyvinyl acetal resin or plasticized polyvinyl butyral resin. The novel spall shield replaces nylon cloth, rubber, felt or resin impregnated glass fabric of the prior art while being at least as thin and light as the adhesive commonly used to adhere such prior art spall shield materials to the armor plate. The spall shield of the present invention is substantially lower in weight and substantially more efficient in performance than conventional spall shields.