Abstract: An emitter for a cathode of an X-ray tube is provided that includes a shaped emitting surface. The emitting surface is shaped in a suitable process in order to enable the emitting surface to focus electron beams emitted from the emitting surface on a focal spot on a target of less than 1.0 mm without the need for any additional focusing elements in the X-ray tube.

Abstract: An induction furnace for heating a workpiece includes a chamber and an insulation cylinder positioned therein, with the insulation cylinder including a base cover movable between first and second positions, and the first position positioning the workpiece within a heating zone and the second position positioning the workpiece within a cooling zone. A translation system in the furnace includes a first member coupled to the base cover of the insulation cylinder and extending through a wall of the chamber, an actuator coupled to the first member, the actuator configured to translate the first member to move the base cover of the insulation cylinder between the first and second positions, and an expansion member encircling a portion of the first member and configured to hermetically seal an interior volume of the chamber from an environment volume external to the chamber.

Abstract: An induction furnace for heating a workpiece includes a chamber and an insulation cylinder positioned therein, with the insulation cylinder including a base cover movable between first and second positions, and the first position positioning the workpiece within a heating zone and the second position positioning the workpiece within a cooling zone. A translation system in the furnace includes a first member coupled to the base cover of the insulation cylinder and extending through a wall of the chamber, an actuator coupled to the first member, the actuator configured to translate the first member to move the base cover of the insulation cylinder between the first and second positions, and an expansion member encircling a portion of the first member and configured to hermetically seal an interior volume of the chamber from an environment volume external to the chamber.

Abstract: A structure and associated process for joining dissimilar materials to form various components of an x-ray tube is illustrated that utilizes one or more intermediate or interfacial filler material members positioned between the primary welding or mating surfaces of the base material components to be joined. The use of the interfacial or intermediate filler material preserves the multiple benefits of friction welding, as well as enabling the joining of highly dissimilar material components, decreasing the required joining temperature, and providing increased microstructural control of the resulting weld or joint.

Abstract: Various methods and systems are provided for providing coatings and textures to surfaces of a bearing assembly in an x-ray system to control the wettability of the surfaces when components of the bearing assembly rotate during operation of the x-ray system. A lubricant is disposed in a gap formed between a shaft and a sleeve of the bearing assembly such that textured and coated surfaces of the shaft and sleeve alter wetting properties between the lubricant and surfaces. The coatings and textures can be wetting or anti-wetting to further enhance control over the behavior of the lubricant.

Abstract: An x-ray tube includes a frame enclosing a high vacuum, a cathode positioned within the enclosure, and a target assembly. The target assembly includes a target cap, a focal track material positioned on the target cap to receive electrons from the cathode, and a foam material positioned within a cavity of the target cap and positioned proximate the focal track. The x-ray tube also includes a bearing assembly attached to the frame and configured to support the target assembly.

Abstract: A structure and associated process for joining dissimilar materials to form various components of an x-ray tube is illustrated that utilizes one or more intermediate or interfacial filler material members positioned between the primary welding or mating surfaces of the base material components to be joined. The use of the interfacial or intermediate filler material preserves the multiple benefits of friction welding, as well as enabling the joining of highly dissimilar material components, decreasing the required joining temperature, and providing increased microstructural control of the resulting well or joint.

Abstract: Various methods and systems are provided for providing coatings and textures to surfaces of a bearing assembly in an x-ray system to control the wettability of the surfaces when components of the bearing assembly rotate during operation of the x-ray system. A lubricant is disposed in a gap formed between a shaft and a sleeve of the bearing assembly such that textured and coated surfaces of the shaft and sleeve alter wetting properties between the lubricant and surfaces. The coatings and textures can be wetting or anti-wetting to further enhance control over the behavior of the lubricant.

Abstract: A bearing assembly is disclosed that includes a sleeve having an opening formed therein and a shaft positioned within the opening of the sleeve such that a gap is formed between an inner surface of the sleeve and an outer surface of the shaft. A lubricant is disposed in the gap and a plurality of grooves are formed on at least one of the outer surface of the shaft and the inner surface of the sleeve. An anti-wetting coating is disposed on the at least one of the outer surface of the shaft and the inner surface of the sleeve between adjacent grooves of the plurality of grooves.

Abstract: An emitter for a cathode of an X-ray tube is provided that includes a shaped emitting surface. The emitting surface is shaped in a suitable process in order to enable the emitting surface to focus electron beams emitted from the emitting surface on a focal spot on a target of less than 1.0 mm without the need for any additional focusing elements in the X-ray tube.

Abstract: An induction furnace for heating a workpiece includes a chamber and an insulation cylinder positioned therein, with the insulation cylinder including a base cover movable between first and second positions, and the first position positioning the workpiece within a heating zone and the second position positioning the workpiece within a cooling zone. A translation system in the furnace includes a first member coupled to the base cover of the insulation cylinder and extending through a wall of the chamber, an actuator coupled to the first member, the actuator configured to translate the first member to move the base cover of the insulation cylinder between the first and second positions, and an expansion member encircling a portion of the first member and configured to hermetically seal an interior volume of the chamber from an environment volume external to the chamber.

Abstract: A system for applying a target track material to an x-ray tube target includes a controller configured to direct a beam of energy toward an x-ray tube target, and direct a solid stock material toward the beam of energy to cause the solid stock material to melt and deposit as a melted material on the x-ray tube target.

Abstract: A system and method for removing impurities in an induction furnace cooling system is disclosed. An induction furnace for heating a workpiece includes a chamber, an induction coil positioned in the chamber to provide for heating of the workpiece when a current is provided to the induction coil, and a cooling system fluidly coupled to an interior volume of the chamber, the cooling system including a heat exchanger, a blower fluidly coupled to the heat exchanger and configured to cause a gas to flow through the heat exchanger, and a filter assembly comprising a filtering device, the filter assembly fluidly coupled to the blower and configured to remove impurities from the gas flowing through the cooling system.

Abstract: A system and method for insulating an induction vacuum furnace is disclosed. An induction furnace for heating a workpiece includes a chamber, an insulation cylinder positioned within the chamber, and an induction coil positioned to surround at least a portion of the insulation cylinder. A susceptor is positioned within the insulation cylinder and inductively heated by the induction coil when a current is provided to the induction coil. An insulating jacket assembly including one of a carbide material and a refractory metal is positioned in a space between the insulating cylinder and the susceptor.

Abstract: A system and method for x-ray tube components is disclosed. The method of fabricating an x-ray tube component includes providing a powder into an electrically conductive die constructed to have a cavity shaped as the x-ray tube component being fabricated and simultaneously applying a mechanical pressure and an electric field to the die so as to cause sintering of the powder and thereby fabricate the x-ray tube component, wherein the electric field applied to the die directly passes through the die to the powder, so as to generate heat internally within the powder responsive to the applied electric field.

Abstract: A system and method for x-ray tube components is disclosed. The method of fabricating an x-ray tube component includes providing a powder into an electrically conductive die constructed to have a cavity shaped as the x-ray tube component being fabricated and simultaneously applying a mechanical pressure and an electric field to the die so as to cause sintering of the powder and thereby fabricate the x-ray tube component, wherein the electric field applied to the die directly passes through the die to the powder, so as to generate heat internally within the powder responsive to the applied electric field.

Abstract: A bearing assembly is disclosed that includes a sleeve having an opening formed therein and a shaft positioned within the opening of the sleeve such that a gap is formed between an inner surface of the sleeve and an outer surface of the shaft. A lubricant is disposed in the gap and a plurality of grooves are formed on at least one of the outer surface of the shaft and the inner surface of the sleeve. An anti-wetting coating is disposed on the at least one of the outer surface of the shaft and the inner surface of the sleeve between adjacent grooves of the plurality of grooves.

Abstract: A system for applying a target track material to an x-ray tube target includes a controller configured to direct a beam of energy toward an x-ray tube target, and direct a solid stock material toward the beam of energy to cause the solid stock material to melt and deposit as a melted material on the x-ray tube target.

Abstract: An x-ray tube includes a frame enclosing a high vacuum, a cathode positioned within the enclosure, and a target assembly. The target assembly includes a target cap, a focal track material positioned on the target cap to receive electrons from the cathode, and a foam material positioned within a cavity of the target cap and positioned proximate the focal track. The x-ray tube also includes a bearing assembly attached to the frame and configured to support the target assembly.

Abstract: Composite materials comprising ferroelastic ceramic particulates dispersed in a metal matrix are capable of vibration damping. When the ferroelastic ceramic particulates are subjected to stress, such as the cyclic stress experienced during vibration of the material, internal stresses in the ceramic cause the material to deform via twinning, domain rotation or domain motion thereby dissipating the vibrational energy. The ferroelastic ceramic particulates may also act as reinforcements to improve the mechanical properties of the composites. The composite materials may be used in various structural components in vehicles, aircraft, spacecraft, buildings and tools.