Abstract: A forging die and a forging die manufacturing method for extruding helical gears wherein the lead end face of each die tooth is made up of harmonious S-shaped curves with each curve having maximized-radii contours. The shape of the S-shaped curves is formed by dividing the cylindrical surface at the lead end face and the full depth perimeter into an equal number of equally spaced points, connecting these points up into pairs so as to establish the shortest distance between the pairs of points and using these pairs as the end points for the S-shaped curves.

Abstract: A dual-phase zeolite having a transition metal-containing zeolite phase and a transition metal-containing oxide phase. The catalytic material may be an intimate mixture of a phase-layered structure of a first phase constituted preferably of a copper-containing high silica zeolite and a second phase constituted of copper-containing zirconia.Methods are also disclosed for making a single-stage catalyst for removing NO.sub.x and HC at high efficiency in an oxygen-rich automotive exhaust gas, and for treating the exhaust gas with the dual-phase catalyst above.

Abstract: A cooling system for cooling intake air in an internal combustion engine. The system comprised of a two-stage turbocharging subsystem having two turbine driven compressors in series with two intercoolers and a closed-loop refrigeration subsystem having cooling coils within or in close proximity to the insulated intake manifold of the engine. This cooled intake air results in a lower peak combustion temperature which results in lower levels of nitrous oxides emitted by the engine exhaust.

Abstract: A method of monitoring, while on board an automotive vehicle, one or more of catalyst performance, engine misfire, and combustion quality, the vehicle having an internal combustion engine equipped with a catalyst for converting noxious emissions of the engine, comprising: (i) exposing at least one pair of EGO sensors to substantially the same emissions either exiting from the engine or from the catalyst, one of the EGO sensors having its electrode highly catalytic, and the other sensor having its electrode low-to-noncatalytic; (ii) comparing the outputs of the sensor electrodes (amplitude, frequency, or phase shift) to determine if there is a sufficient differential to indicate a misfire or poor combustion in the case of the sensors being located downstream of the engine exhaust but upstream of the catalyst, or indicating poor catalyst efficiency in the case of the sensors being placed substantially immediately downstream of the catalyst. The catalyst may be a three-way catalyst (or an oxidation catalyst).

Abstract: A container (10) for compressed gas with a pressure relief member (18) made from a bimorph shape memory material. The bimorph (18) is impermeable by the gas. The bimorph (18) assumes a shape which changes depending on temperature. Below a critical temperature, the bimorph (18) lies in a first (deformed) state, and reverts to a second (remembered) state thereabove. The gas is entrapped within the container (10) when the bimorph (18) assumes the first state. When pressure rises due to temperature increase above the critical temperature, gas may escape from the container (10). This is because the bimorph (18) reverts to its second state, in which a relief gas passageway is opened, thereby relieving gas pressure.

Abstract: An engine cylinder block having a shallow water jacket in either a V-type, in-line, or opposed engine configuration. The engine cylinder block further having an isolation chamber below the shallow water jacket forming a cavity between the cylinder bore walls and the outer engine block wall. Additionally, ventilation passages are located between the crankcase and isolation chamber through the upper crankcase plate.

Abstract: A powertrain component (10) for use in an internal combustion engine, the powertrain component comprising a coating system including a film (30) selected from the group consisting of amorphous hydrogenated carbon, silicon-doped amorphous hydrogenated carbon, boron-, nitrogen-, boron nitride-, or metal-doped amorphous hydrogenated carbon, and mixtures thereof. The film (30) is formed on the powertrain component (10), and imparts the characteristics of low friction and wear resistance to the component. The powertrain component (10) also includes an interlayer (42) formed between the film and the component. The interlayer (42) accommodates stresses engendered by formation of the film (30), and thereby improves adherence of the film (30) to the substrate (10). To enable engineering of desired surface properties, the film (30), the interlayer (42), or both may be provided with a graded composition.

Abstract: A linear motor control system and method to increase apparent motor stiffness by providing linear motor resistance to perturbations caused by external forces exerted on a slide mass and a base mass. Primary and secondary sensors detect the accelerations of the slide mass and the base mass relative to ground and generate acceleration signals corresponding thereto. A position detector senses the position of the slide mass relative to the base mass and generates a position signal corresponding thereto. A signal processor processes the first and second acceleration signals and the position signal to determine deviations in the position, velocity and acceleration of the slide mass relative to the base mass from selected values caused by the external forces, and to generate a motor control signal to provide linear motor resistance against such deviations.

Abstract: A locating pin for positioning weld nuts relative to sheet metal pieces. The locating pin includes a heat and wear resistant ceramic base having a central opening. The locating pin also includes a heat and wear resistant elastomeric tip attached to the base by a shaft depending from the tip into the central opening of the base. The ceramic and elastomeric materials provide the locating pin with an electrically non-conducting characteristic.

Abstract: In order to deposit metal onto a surface such as a cylindrical surface, an arc spraying method is used with a consumable electrode (16), a non-consumable electrode (18) and a jet of atomising gas (22) blown through the arc (20) in a radial direction to propel the molten metal of the consumable electrode from the acr to the cylinder wall (12). The non-consumable electrode and the atomising gas jet both rotate about the cylinder axis so that the entire surface can be covered. The supply for the consumable electrode will normally come from a reel which can be stationary such that the consumable electrode does not rotate about its own axis.

Abstract: A low-friction piston construction for use in an oil-fed cylinder bore with the piston skirt relieved to define lands that are coated with SFL (graphite, MoS.sub.2, BN, and a special expoxy resin). A method of making such piston construction including provision of asperities on the skirt wall onto which the SFL coating is thermally sprayed and formation of small pockets at the mouth of the asperities to additionally act as oil replenishing reservoirs. A method of using such piston construction in an engine which comprises provisions of a slightly increased gap between the piston and cylinder wall and formation of a transferred SFL coating from the piston to the cylinder wall resulting in two polished microsmooth mating coatings, each attractive to oil films.

Abstract: Provided is a method and apparatus for in-situ measuring filament temperature and the thickness of a film deposited on a substrate disposed within a hot-filament chemical vapor deposition reactor. In accordance with the invention, white light which is emitted directly from the filament and that reflects from the top and bottom surfaces of a deposited film are collected and converted to monochromatic light through the use of simple narrow-banned interference filters operative over specific, yet different, optical banned widths. This information is thereafter used to mathematically calculate the filament temperature, film thickness and growth rate of the deposited film.

Abstract: A method for detecting defects (10) in a workpiece (12) non-destructively, comprising subjecting the workpiece (12) to a temperature difference in relation to ambient temperature. The method provides an infrared radiometric scanner (14) having a field of view (16) which includes the workpiece (12) being tested, the radiometric scanner (14) sensing an emitted temperature pattern representative of the internal structure (10) of the workpiece (12). The method for detecting defects (10) also communicates a controller (18) with the radiometric scanner (14), the controller (18) receiving an output signal (22) from the radiometric scanner (14) indicative of the emitted temperature pattern before the workpiece (12) is allowed to achieve thermal equilibrium with the ambient environment.

Abstract: A valve lifter of the roller type formed of a lightweight metal preferably aluminum or magnesium alloy. A roller formed of a wear resistant ceramic material is rotatably secured to the valve lifter. The wear/bearing surfaces of the valve lifter are impregnated with a solid film lubricant to provide reduced friction during operation.

Abstract: A molded workpiece is formed using a mold having an inner cavity, an injection port which communicates with the inner cavity for permitting molding material to be injected into the inner cavity, and at least one disposable vent line. The vent line has sidewalls which are substantially transparent to light and provides for venting gases from the inner cavity as molding material is injected into the cavity. A material injector is coupled to the injection port for injecting molding material into the inner cavity through the injection port. A removably sensor receives the disposable vent line for detecting when molding material has substantially filled the vent line and for generating a first signal indicating that the vent line is substantially filled.

Abstract: A powertrain component such as a valve lifter (10) for use in an internal combustion engine (12), the valve lifter (10) being positioned between a cam (14) and a valve stem (16). An amorphous hydrogenated carbon film (28) is formed on the component, the film (28) imparting the characteristics of low friction and wear resistance. Also disclosed is an interlayer which improves adherence by imparting the properties of improved absorption of mechanical stresses and chemical compatibility between the film (28) and the substrate (10). Methods for forming the film (28) and interlayer are also disclosed.

Abstract: A catalyst having high temperature (800.degree.-1050.degree. C.) stability and improved three-way automotive exhaust gas catalyst activity at high temperatures, comprising an outer catalytic coating of binary La-Pd oxide (La.sub.2 Pd.sub.2 O.sub.5 or La.sub.4 PdO.sub.7) calcined and supported on a catalyst-supporting substrate, the oxide being present in an amount to provide 15-150 g of Pd per cubic foot of the substrateA method of making binary La-Pd oxides useful as an automotive exhaust catalyst operative at high temperatures, comprising heating in an oxidizing atmosphere a mixture containing La compounds and Pd compounds in a La:Pd ratio of 1:1 or 4:1, the heating being staged to first heat slowly from about 50.degree. C. to start decomposition of the compounds and thereafter retaining the residue at an elevated temperature to stimulate growth of crystalline binary La-Pd oxides and to calcine the crystalline oxides.

Abstract: A balanced rotary assembly having an axis of rotation, comprising: (a) an aluminum-based driveshaft; (b) at least one cast aluminum-based connector having its weight substantially equally divided on opposite sides of the axis and coaxially secured to the driveshaft; (c) a uniformly thick iron-based band embedded in the outer surface of the connector locked against relative rotation with the connector; and (d) one or more iron-based members welded to the band to bring the assembly into a desired rotationally balanced conditions.

Abstract: A method of preparing a gear blank for roll-finishing, essentially comprising the step of: while supporting a gear blank with pitch-line chucking, finish-sizing the central axial opening of the gear blank to a desired concentricity to promote accurate subsequent roll-finishing. Also, a method of making roll-finished gears, comprising: (a) preparing a near-net-shape gear blank, with external gear teeth and a central axial opening, by intimately engaging and supporting the gear blank between two opposing roll-finishing gear dies, without teeth finishing pressure; (b) finish-sizing the sides of said axial opening to attain a concentricity between the gear blank's intended tooth pitch circle and said sized sides that is within the range of 0.

Abstract: An apparatus for providing a gas phase film lubrication between a reciprocal piston and a cylinder of an uncooled oilless internal combustion engine; the piston is effective to drive a rotary crankshaft in response to an expanding gas charge. The apparatus comprises: (a) means connecting the crankshaft to said piston for transferring reciprocal thrust into rotary thrust, such means aligning the piston concentrically within the cylinder wall to limit the imposition of side loads on said piston (i.e., less than 80 psi); (b) interfacing walls on the piston and cylinder (i) sized to provide a predetermined annular gap therebetween at ambient conditions that has a radial dimension in the range of 0.001.+-.0.