Abstract: A method of making an austempered ductile iron article is disclosed. The method includes providing a melt of a ductile iron alloy composition. The method also includes casting the melt into a mold to form a casting. The method further includes cooling the casting to an austempering temperature by circulating a coolant through the mold; wherein cooling comprises solidifying the melt and forming a ductile iron article. Still further, the method includes heating the casting to maintain the austempering temperature for an interval sufficient to form an austempered ductile iron article that comprises a microstructure comprising ausferrite.

Abstract: Casting preforms are provided comprising a casting preform assembly; and a plurality of geometrically shaped bodies, wherein the plurality of geometrically shaped bodies are arranged or interconnected to form the casting preform assembly. Also provided is a method of using a casting preform, comprising forming a casting preform assembly, wherein the casting preform assembly comprises a plurality of geometrically shaped bodies; anchoring the casting preform to an outer surface of a casting mold; introducing a fluid casting material into the casting mold; applying centrifugal force to the casting mold; forming a molded article, wherein at least a portion of the surface of the molded article is reinforced with the plurality of geometrically shaped bodies.

Abstract: A method of making an austempered ductile iron article is disclosed. The method includes providing a melt of a ductile iron alloy composition. The method also includes casting the melt into a mold to form a casting. The method further includes cooling the casting to an austempering temperature by circulating a coolant through the mold; wherein cooling comprises solidifying the melt and forming a ductile iron article. Still further, the method includes heating the casting to maintain the austempering temperature for an interval sufficient to form an austempered ductile iron article that comprises a microstructure comprising ausferrite.

Abstract: A method for making an equiaxed investment casting. The method utilizes an ultrasonic generator to send an ultrasonic pulse into molten metal in an investment casting mold. The investment casting mold is positioned within a working zone of furnace having low output induction coils for generating a convection current in molten metal. The ultrasonic pulse separates dendrites growing from the face of the mold inward into the molten metal. Instead, equiaxed grains can nucleate within the molten metal. In addition, the ultrasonic pulse and the low output induction coils circulate the molten metal as solute is rejected from solidifying equiaxed grains. The mixing reduces the effects of segregation in the solidifying alloy and assists in nucleating equiaxed grains.

Abstract: A method for estimating an operating temperature of component in turbo machinery includes providing body detachably affixed to component, operating machinery, stopping operation of machinery, and removing body. The method includes obtaining concentration profile by determining final concentration of at least one species in first material and in second material, and determining a transient concentration of at least one species between first material and second material. The method includes determining an operating temperature by correlating concentration profile to corresponding operating temperature for system. A system including body is also provided. Body includes at least one species, a first material having a starting first concentration of the species, a second material arranged to permit migration of the species from first material to second material. Species migrates from first material to second material during operation of turbo machinery allowing body to estimate temperature during operation.

Abstract: A casting system, mold, and method are disclosed for electromagnetically stirring sand castings. In an embodiment, the casting mold includes a mold body having a cavity therein, and a passageway fluidly connecting the cavity with an exterior of the mold body. The passageway allows for introduction of a molten metal into the cavity. The mold body further includes at least one induction coil embedded in a cope of the mold body; and at least one induction coil embedded in a drag of the mold body. The induction coils are configured to generate an electromagnetic field for stirring a molten metal casting while it solidifies inside the mold.

Abstract: A method of making a ductile iron article is disclosed. The method includes providing a ductile iron article preform. The method also includes deforming the ductile iron article preform by hot-working to provide a hot-worked portion of the article. The method further includes cooling the article to an austempering temperature. Still further, the method includes austempering the ductile iron article preform for a predetermined time sufficient to provide an austempered article preform comprising an austempered microstructure, wherein the austempered microstructure of the hot-worked portion is different than in other portions of the article. A ductile iron wind turbine shaft is also disclosed. The ductile iron wind turbine shaft has an austempered microstructure comprising an ausferrite matrix and a plurality of graphite nodules. The austempered microstructure has a deformed portion, the deformed portion has a microstructure that is different than the microstructure of the other portion of the shaft.

Abstract: A method for brazing a component in a power generation system, the brazed power generation system component, and braze are provided to improve repairing power generation systems. The method includes providing the component having a feature in a surface of the component and coating a particulate material with a filler material to obtain a coated particulate material. The method includes preparing the feature to obtain a treatment area and filling the treatment area in the surface of the component with the coated particulate material. The method includes heating the treatment area and surrounding component to a brazing temperature and applying oxidation protection to the treatment area. After the brazing temperature is obtained, the method includes brazing the treatment area and the screen and cooling the component to obtain a brazed joint.

Abstract: A mold system and method for producing a casting. The mold system utilizes multiple channels, each channel comprising a sprue and gating system, to feed the mold cavity at different heights. When a lower portion of the mold is filled, a controller is signaled to initiate filling of the mold through a second channel positioned above the lower portion. This mold system desirably provides the hottest molten metal to the last portion of the casting to freeze with or without the use of risers, eliminating casting defects. The system also enables the controlled pouring of dissimilar metal castings.

Abstract: A wind turbine component having a lightweight structure is provided and includes a metallic matrix defining a cavity, metallic foam enclosed within the cavity and a solidification metallurgical bond formed at an entire interface between the metallic matrix and the metallic foam.

Abstract: A battery holder having plates disposed between parallel oriented batteries, and holds batteries in specified positions. The battery holder is provided with L-shaped holders each having the form of a first plate and a second plate connected at a right angle corner and having an L-shaped lateral cross-section, and flat-plate holders that connect with the L-shaped holders and have an overall planar form. The L-shaped holder has connecting holes on the outside of the corner between the first plate and second plate. Further, the outer edge of the first plate opposite the corner is provided with first connecting tabs that can connect with connecting holes of another L-shaped holder. The flat-plate holder is provided with second connecting tabs on at least one side edge that connect with connecting holes of an L-shaped holder.

Abstract: Various turbine component preforms are disclosed having near-net shape features. In one embodiment, a turbine casing preform is disclosed. The turbine casing preform includes an as-cast body comprising a partially cylindrical wall section of a turbine casing, the wall section having an inner surface and an outer surface. The turbine casing preform also includes a circumferentially-extending vane slot formed in the wall section on the inner surface. In another embodiment, a turbine nozzle diaphragm preform is disclosed. The turbine nozzle diaphragm preform includes an as-cast body comprising a partially-cylindrical wall section of a turbine nozzle diaphragm having an inner surface and an outer surface. The turbine nozzle diaphragm preform also includes an as-cast, circumferentially-extending seal member projecting from one of the outer surface or inner surface.

Abstract: A battery pack that enhances the reliability and coupling force of a connection member electrically connecting two protective circuit boards is disclosed. The battery pack includes: a secondary battery including a positive electrode and a negative electrode; a first protective circuit board electrically connected to the battery; a second protective circuit board electrically connected to the first protective circuit board; and at least one conductive plate coupled to one surface of the first protective circuit board and one surface of the second protective circuit board.

Abstract: A battery pack that enhances the reliability and coupling force of a connection member electrically connecting two protective circuit boards is disclosed. The battery pack includes: a secondary battery including a positive electrode and a negative electrode; a first protective circuit board electrically connected to the battery; a second protective circuit board electrically connected to the first protective circuit board; and at least one conductive plate coupled to one surface of the first protective circuit board and one surface of the second protective circuit board.

Abstract: A method by which properties of a component (18) formed of a ductile iron alloy and having thick sections can be promoted with an austempering process. The method entails casting a ductile iron alloy containing iron, carbon, silicon and alloying constituents. The casting is solidified at a rate that inhibits segregation of the alloying constituents to grain boundaries of the casting, and so that the casting contains graphite nodules having a count of greater than 100 nodules per mm2. The casting is then austempered by heating to an austenitization temperature to yield a microstructure having a single-phase matrix of austenite that contains carbon, and then quenching the casting to an austempering temperature. The casting is held at the austempering temperature for a duration sufficient to yield a microstructure whose matrix is mostly ausferrite and essentially free of martensite and pearlite.

Abstract: Systems and methods are provided for improved brazing. A system includes a gap filling compound (GFC). The GFC includes a brazing alloy. The system also includes a GFC retention screen. The GFC retention screen configured to be disposed over the GFC to retain the GFC within the gap during brazing. The GFC retention screen is also configured to enable gas to escape from the GFC during brazing.

Abstract: A wind turbine component having a lightweight structure is provided and includes a metallic matrix defining a cavity, metallic foam enclosed within the cavity and a solidification metallurgical bond formed at an entire interface between the metallic matrix and the metallic foam.

Abstract: Methods of forming a compressor article such as a cast airfoil, a stator, a blade, a gas turbine, and a gas turbine shell via casting are presented. The methods include: preparing an iron-manganese-aluminum-silicon-carbon (Fe—Mn—Al—Si—C) based alloy; casting the Fe—Mn—Al—Si—C based alloy, wherein a cast has a shape of the compressor article; and performing post-casting finishing thereby forming the compressor article.

Abstract: A component for wind turbines includes cast austempered ductile iron containing about 3.0 to about 3.8 weight percent carbon, about 1.9 to about 2.8 weight percent silicon, up to about 0.3 weight percent manganese, up to about 0.8 weight percent copper, up to about 2.0 weight percent nickel, up to about 0.3 weight percent molybdenum, about 0.03 to about 0.06 weight percent magnesium, less than about 0.05 weight percent chromium, less than about 0.02 weight percent vanadium, and less than about 0.01 weight percent sulfur. The component is preferably a drive shaft or gearbox component having a mass of more than about 3 tons. A method of manufacturing the component is also provided.

Abstract: A circuit board apparatus of a battery pack in which tape is attached to low priced flexible printed circuit boards (FPCB) so that it is possible to prevent cracks from being generated in the FPCBs when the FPCBs are bent. The circuit board apparatus includes a first board, a second board, and a bendable third board with one side electrically connected to one side of the first board, and the other side electrically connected to one side of the second board. The first board is oblique to the second board, or the first board is substantially perpendicular to the second board. Protective tape is provided on a first region where the first board and the third board overlap, and in a second region where the second board and the third board overlap.