Abstract: A method includes shrink fitting a ring member about a railroad wheel body and metallurically bonding the ring member to the railroad wheel body. A wheel assembly includes an inner portion obtained from a worn railroad wheel, a ring member disposed about the inner portion, and suitable electroplating material disposed on at least one of the faying surfaces. The wheel assembly may be heated under suitable conditions to provide diffusion bonding across interfacing faying surfaces to produce an integral wheel structure. Appropriate quenching, tempering, and finishing processes may be utilized to obtain desired properties. An article formed thereby includes an inner body portion obtained from a worn railroad wheel and a metallurically bonded outer circumferential portion. The outer portion may comprise a composition selected for desired wear characteristics.

Abstract: A method for repairing a rotor of a turbine includes providing a rotor having a groove portion defined by a circumferential portion of the rotor. The circumferential portion of the rotor is removed to create an opening to provide access to the groove such that the opening, immediately adjacent the groove, is narrower than the groove. A guide block may be extended into a receiving slot separating a first protruding surface from a second protruding surface of the rotor such that a weld area slot of the guide block extends over at least a portion of the opening. The opening may be welded adjacent the guide block to close at least a portion of the opening.

Abstract: A method of refurbishing components such as brake rotors and drums is disclosed. The method may involve identifying, sorting and cleaning used or worn components. The components may then be blasted with an abrasive material to prepare them for a metal deposition process. Metal may then be added to the components using an arc spray gun, for example. The component may then be cryogenically treated to improve the wear characteristics of the component. The component may then be machined to place the component within a specified configuration. Components may be refurbished repeatedly in this manner so as to utilize resources more efficiently and reduce waste. Moreover, the components may exhibit improved wear characteristics over components manufactured by other methods.

Abstract: A method is provided for joining blades to blade roots or rotor disks when manufacturing and/or repairing gas turbine blades or integrally bladed gas turbine rotors. A blade and a blade root or rotor disk that is to be joined to the blade are supplied, and provided with a thickening in sections that are to be joined together. The sections of the blade and the blade root or rotor disk that are to be joined together are machined so as to form recesses and; c) are then aligned relative to each other, opposite recesses defining at least one groove-shaped seam preparation. The blade and the blade root or rotor disk are joined in the area of the or each seam preparation by means of laser power build-up welding and the joined blade and blade root or rotor disk are machined so as to provide a gas turbine blade or an integrally bladed gas turbine rotor having a predefined geometrical profile.

Abstract: A method of repairing a case for a gas turbine engine includes identifying areas of damage on its internal holding structures in a gas turbine case, and utilizing cold metal transfer to deposit weld material to the internal holding structures.

Abstract: A method for forming a dense coating on a limited region of a subject body is disclosed. The method is composed of the steps of: applying one selected from the group of a compressed body of a powder of a metal and a sintered compressed body of a powder of a metal to a working electrode; executing discharge deposition to deposit a first coating from the working electrode on the subject body by applying the subject body as a workpiece of the discharge deposition; executing discharge deposition to deposit a second coating from the working electrode on the first coating by applying the subject body as a workpiece of the discharge deposition; and heating the subject body in one selected from the group of a vacuum, an air and an oxidizing atmosphere so as to densify the second coating or oxidizing the second coating at least in part to generate a solid lubricant substance.

Abstract: A method of hole defect repair includes removing one or more defects at or near a desired hole shape in a substrate by removing a non-concentric portion of the substrate proximate the desired hole shape, and welding a filler material to the substrate after removing the non-concentric portion of the substrate.

Abstract: A method for repairing a heat recovery steam generator (HSRG) header to tube attachment damage, includes providing an access window in the header opposite the damaged header to tube attachment location; removing the header to tube attachment damage; inserting a tapered stub tube into a header penetration centered axially immediately over the tube; effecting a profile weld between the header and the tapered stub tube at the header penetration from the inside surface of the header; welding the tapered stub tube to the existing tube through the header inside diameter; welding shut the access window; and completing a post weld heat treatment of all the welds.

Abstract: A process for repairing a metallic shroud of a gas turbine blade includes a step of removing a portion of an anti-wear layer to a removal depth that is greater than a depth of wear of the anti-wear layer. Further, the process includes a step of leaving a trace of the anti-wear layer to subsist, wherein the trace of the anti-wear layer extends at least in a re-entrant zone of the Z profile of the blade. The process also includes a step of depositing a new layer of anti-wear material on the trace of the anti-wear layer.

Abstract: A method for metallurgically bonding a stator bar to a coupling to reduce the incidence of leak paths resulting from corrosion. The stator bar comprises strands through which a liquid coolant can flow. Adjacent ends of the strands are received in an interior cavity of the coupling through an opening in the coupling. A joining material is provided on a first portion of the stator bar within the coupling opening and adjacent the ends of the strands. The first portion is heated to melt the joining material. At essentially the same time, a second portion of the stator bar outside the coupling is also heated. Once the joining material is suitably molten, the first portion is allowed to cool while the second portion remains heated, thereby causing the joining material nearest the ends of the strands to solidify first.

Abstract: A defect in a splitter fairing of a turbine engine is repaired by removing a forward portion of the splitter fairing and salvaging the remaining original portion of the splitter fairing. The forward portion includes an inner flange and outer surface that create a channel. A replacement ring is provided and welded to the original portion. The replacement ring has minimum dimensions equal to the maximum height and width of the removed forward portion. Material from the replacement ring is then removed to obtain a profile with essentially the same profile for the inner flange, outer surface, and channel as the original dimensions of the splitter fairing before the defect occurred.

Abstract: A gas turbine rotor and a method for manufacturing a gas turbine rotor having integral blading, is disclosed. A rotor blade has a blade pan and a blade footing connected to the blade pan. The blade footing is designed with a V-shaped cross section in at least some portions and the blade footing is welded to a rotor mount by capacitor discharge welding.

Abstract: A method for repairing a turbine engine component comprises the steps of providing a turbine engine component formed from a nickel-based superalloy, removing any defects from the turbine engine component, the removing step comprising subjecting the turbine engine component to a solutioning heat treatment using a heating rate in the range of from 29 degrees Fahrenheit/minute to approximately 40 degrees Fahrenheit/minute as the component passes through a temperature in the range of from 1100 degrees Fahrenheit to 1600 degrees Fahrenheit, and welding the turbine engine component to effect the repair. A deliberately slow post-solution treatment cooling rate is used to substantially prevent weld cracks.

Abstract: A simple and low cost method of replacing an abradable portion on the fan casing of a turbojet includes an inside heating belt together with holding sectors therefor are put into place against the abradable portion, each holding sector including an inflatable bladder, and the abradable portion and the inside heating belt being sandwiched in full between the fan casing and the bladders, the holding sectors themselves being held in place by a plurality of straps attached to the fan casing by fixing points.

Abstract: In manufacturing a speaker, ultrasonic complex vibration welding is applied at least to: a process of fixedly putting together a magnet, a pot yoke a the pole piece; a process of fixing, to a portion of an inner circumference of a frame, an outer periphery of a spider, which has its periphery fixed to a bobbin; a process of fixing to a portion of the frame an outer circumferential edge of a surround, which has its inner circumferential edge fixed to an outer periphery of a diaphragm whose inner periphery is fixed to the bobbin; and a process of fixedly connecting both ends of each of tinsel leads respectively to terminations of a voice coil and to terminals.

Abstract: A process for refurbishing a worn surface of a shroud support component of a turbomachine, as well as a shroud support component refurbished with the process. The process generally entails removing a surface region of the worn surface so as to define a repair surface on the component. A braze tape formed from a slurry to comprise a braze material and a wear-resistant alloy is then applied to the repair surface, followed by a heat treatment to cause the braze tape to diffusion bond to the repair surface so as to define a built-up surface. The built-up surface is then machined to define a wear-resistant coating on the component.

Abstract: A method for repairing a stationary turbine nozzle segment having at least one vane disposed between outer and inner structural bands includes providing an engine-run turbine nozzle segment having at least one vane disposed between outer and inner bands, wherein the outer band and the vanes are previously replaced components of the segment and the inner band is an original component of the segment; separating the inner band from the nozzle segment; repairing damage in the outer band and/or the vane; and joining the outer band and the vane to a newly manufactured replacement inner band segment. The replacement inner band segment includes: a structural inner band; and an integral structural collar adapted to receive an inner end of the at least one vane.

Abstract: This invention relates generally to a method for repairing a casting, and more specifically to a method of repairing a casting by pouring melted filler material into a damaged portion of the original casting. Damaged cast metal components, such as a cylinder head of an internal combustion engine are repaired by preheating the component to a first preheat temperature. The damaged area of the casting is then heated to a higher temperature using a torch and melted filler material is poured into the casting. The torch is used to maintain the temperature of the melted material for thirty seconds to two minutes. The temperature of the filler material is then cooled using compressed air.

Abstract: A method of repairing a crack (14) in a component (12). The method includes preparing a surrounding surface (22) of the crack (14) for repair and welding a first portion (24) of the component (12) on a first side (26) of the crack (14) to a second portion (28) of the component (12) on a second side (30) of the crack (14) to form a fused crack area (50). The method may also include applying a patch (78) over the fused crack area (50) for additional strength.

Abstract: An improved generator rotor (30) and a method of repairing an existing generator rotor (12) are disclosed. Methods consistent with the present invention provide techniques for repairing existing stress-damaged rotors (12) to remove stress-induced cracks (29), without requiring new retaining rings (16), to significantly extend the useful life of a generator without the cost and complexity of conventional repair techniques. Improved generator rotors (30) consistent with the present invention provide a tooth-top design that is more resistant to stress-induced cracking than conventional designs, resulting in new generators with longer useful lives.

Abstract: The method facilitates sealing a control rod drive (CRD) housing to a stub tube in a reactor pressure vessel of a nuclear reactor, if any cracks develop proximate a heat affected zone of the stub tube at a CRD housing re-attachment weld. The method includes cutting the CRD housing to separate an upper portion of the CRD housing from a lower portion of the CRD housing. The lower portion remains in place and in substantial alignment with the upper portion of the CRD housing. A lower portion member, which may be the lower portion that was cut, is re-attached to the reactor vessel by a re-attachment weld at a location below potential differential leakage paths along the CRD housing. The heat affected zone (e.g., at the re-attachment weld) is covered with a corrosion resistant material to prevent future leaking, and to protect the weld from inter-granular stress corrosion cracking (IGSCC).

Abstract: An ultrasonic rotary horn is repaired by removal of deteriorated metal condition from the horn energy transfer surface, and application and consolidation of metal powder to the horn radial surface. An ultrasonic rotary horn having a repaired radial energy transfer surface.

Abstract: An inspection and sorting system for part repair includes at least one sensor for inspecting a part. The sensor is configured to obtain inspection data for the part. A comparison module is configured to receive the inspection data, to generate a repair profile for the part using the inspection data, and to compare the repair profile with a baseline to arrive at a repair recommendation for the part. A method includes inspecting a part with at least one sensor to obtain preliminary inspection data for the part. The method further includes generating a preliminary repair profile from the preliminary inspection data, comparing the preliminary repair profile with a baseline, and arriving at a repair recommendation for the part based on the comparison.

Abstract: An improved rework method and rework wiring structure for repairing and reworking multilayer printed circuit boards utilizing ball grid array (BGA) solder pads are described. The repair method includes the steps of locating a solder pad to be rewired, removing the identified pad, installing a repair wire through a via hole in a multilayer printed circuit board, and forming a replacement solder pad on the end of the repair wire and positioning it in place of the removed pad. Once thus installed, the method includes the step of connecting the other end of the repair wire to a corrected circuit interconnection point.

Abstract: A process of brazing cracks and gaps in a single crystal article which takes places isothermally under the following conditions: the temperature of the isothermal solidification is between TLiqidus, Braze+5*(wt-%BBraze) and (Tsolidus, base material−70*(wt-%BBraze)), while (wt-%B*wt-%Cr) is between 15 and 40 and (Tsolv.&ggr;′, base material−TLiqidus, Braze) is above 140° C. This results in an homogeneous &ggr;/&ggr;′-microstructure of the isothermal solidified, brazed joint with mechanical properties similar to those of the base material.

Abstract: The present invention relates to a method of converting box car from having a sliding door to having a plug door. In addition, the roof may be removed and the storage capacity within the box car may be increased by raising the roof of the box car and adding extensions to the sides of the box car. Moreover, the door opening may be increased by increasing the height of the roof. Further, the present invention relates to a method of creating a sealing surface around the perimeter of the door opening of the box car wherein the sealing surface is coplanar.

Abstract: A method of repairing a defect in a casting or cast article, where the defect comprises at least one of a manufacturing, intentional, or service-related defect. The cast article can comprise a casting core and a casting, the casting core comprising a bumper that creates a thin region, namely the defect. One method of repairing the bumper hole defect comprises locating the defect area in the cast article; removing an area of the casting at the defect area; removing an area of the casting core including the bumper at the defect area, where the removing the area of the casting at the defect area and removing an area of the casting core including the bumper at the defect area create a hole; positioning repair material in the hole; heating the defect area, the repair material and the area of the casting at the defect area to melt the repair material and area of the casting at the defect area into a molten material; and re-solidifying the molten material to form a repaired casting.

Abstract: A framework of magnet pods and beams or strongbacks can be quickly and easily assembled to plug a leak in a ferromagnetic container wall. The magnet pods are located on either side of the leak. One or more beams extend between the magnet pods. Each magnet pod has a yoke with plural holes therethrough. The yoke loosely receives the beam. Each beam has lines of holes therethrough all along the beam length. The plurality of holes in the yokes and beams simplifies the alignment of at least one set of holes between the yoke and beam, wherein a pin is inserted to couple the beam to the magnet pod. A clamp is pinned to the beam so as to be adjacent to the leak. The clamp is tightened to exert removable pressure on a patch over the leak.

Abstract: A method of correcting defects in a metal workpeice. A location of a defect in a workpiece is determined. The defect comprising a void or an inclusion in a workpiece substrate. The workpiece substrate is comprised of a metal alloy. Material of the workpiece substrate at the location of the defect is removed to form cleaned area in the workpiece substrate. The cleaned area in the workpiece substrate is coated with a high-density coating. A sintering heat treatment is performed on the coated workpiece substrate to remove entrapped gas from the coating material prior to a step of hot isostatic pressing treating. Then, hot isostatic pressing treating is performed on the coated workpiece to produce diffusion bonding bewteen the workpiece substrate and the high-density coating. The material can be removed by techniques such as sandblasting or grinding.

Abstract: A method and apparatus for in situ refurbishment of valve seats are disclosed in which a worn valve seat is initially ground to a flat surface, a buildup of weld metal is deposited on the flat surface, and the weld buildup is machined to the final dimensions of the valve seat. The apparatus comprises a machining apparatus for machining and machining of the valve seat, a gas metal arc welding apparatus for deposition of weld metal, and support structures to support the weld buildup as it is being formed. Preferably, the support structures are in the form of metal chill blocks which act both to support the buildup of weld metal and to act as heat sinks and remove excess heat from the buildup, resulting in a higher quality buildup of metal.

Abstract: A mold assembly including moveable mold parts, one of which includes a plurality of hollow cavities. Each hollow cavity forms an outer wall of an elongated, generally annular portion of a molded part and the other mold part includes a corresponding plurality of core elements, which form an inner wall of the same portion of the molded part. Each core is disposed within a corresponding cavity to define a generally annular mold chamber portion for receiving molten material to be molded to form the shape of the portion of the molded part. Each core element includes a cooling apparatus and each cavity includes an outside cavity-cooling device. Each core element includes a first portion made of high strength material and a tip portion made of material having a greater heat diffusivity and heat transfer coefficient than said first portion.

Abstract: The invention relates to a process for the production of a clamping means for clamping a component (20) in a holder (16), especially for the production of moulding tools for the manufacture of precision articles. Spring-action clamping elements (72), for example tightening discs or clamping sleeves (72), are inserted into a recess of the holder (16) and final working thereof takes place in a position that corresponds to the subsequent position when the component (20) to be clamped is clamped. With this process, very good centricity and coaxiality of the clamped components (20) is achieved, whereby the manufacturing tolerances to be maintained for the individual components are not critical.

Abstract: A method for repairing worn brake assembly holes on a highway trailer axle assembly including a cam shaft hole, and first and second anchor pin holes and including an axle stub extending from an end thereof, comprising the steps of aligning a boring tool, having a tool axis, with each brake assembly hole axis by aligning the tool axis parallel with the stub axis; positioning the tool axis at a distance from the stub axis equal to the distance of the brake assembly hole axis from the stub axis; and positioning the tool axis at an angular position relative to the brake assembly hole axis that is equal to the angular position of the brake assembly hole axis relative to the axis of another of the brake assembly holes. The aligned boring tool is then driven to bore an oversize hole through the worn brake assembly hole such that the worn brake assembly hole, including any worn extremities thereof, is consumed by the oversize hole, leaving a substantially cylindrical oversize hole.

Abstract: A PCB assembly which allows economical and reliable rework. The PCB assembly contains a soldermask and a trace with a portion of the trace exposed by a soldermask relief When one needs to rework the PCB assembly, one bonds a rework wire, using conventional intermetalic bonding materials, to the portion of the trace exposed by the soldermask relief There is no need to bond a rework wire to a component. Further, there is no need to scrape a off the soldermask and possibly damage the traces and/or vias. The bonds are high reliability bonds, and the labor required to perform such bonds are minimal.

Abstract: The instant invention provides an inexpensive method of repairing the hollow drive shaft hub of a torque converter impeller housing. The impeller hub is turned to a smaller outer diameter and a sleeve having a wear resistant surface is fitted to the turned outer hub diameter. The sleeve may be further secured by mechanical interference, bonding, or welding.