Abstract: Method of universally making waved parts by (a) providing a plurality of wave forming blocks each having a working surface in the form of a conical segment; (b) removably securing a plurality of such blocks to two arcuate supports (preferably discs) with the blocks spaced apart and with the axis of revolution of the block working surfaces aligned with the radius of the support to create a support-block assembly; and (c) facing and accurately bringing together such support-block assemblies with a deformable material (i.e., spring steel) therebetween, the blocks of one support being superimposed over the spaces between the blocks of the other support.

Abstract: A catalyst system for attaining high conversions of NO, HC, and CO in a fuel-lean emission flow (i.e., containing SO.sub.2, H.sub.2 O, H.sub.2, and considerable excess oxygen), the system comprising: (a) a first stage reducing catalyst for treating the nitric oxide emissions, the catalyst containing highly acidic gamma alumina (i.e., with a pH.sub.pzc of less than 3); (b) means for injecting gaseous or liquid reductants into the emission stream prior to entering said first stage catalyst, said first stage catalyst temperature being selected to be in the range of 550.degree.-650.degree. C.; and (c) an oxidation catalyst effective for treating the effluent from the first stage catalyst.Another aspect of this invention is a method of treating the exhaust gas from a fuel-lean emission flow from a fossil-fueled internal combustion engine having a redox ratio of 0.02-0.

Abstract: A solenoid assembly for an anti-lock braking system includes a housing having a cavity, a plurality of solenoids, each of said solenoids being received within the cavity, and an overmold disposed between the housing and each of the solenoids to provide a resilient force for each of the solenoids.

Abstract: A method of preparing a stereolithographically produced prototype for experimental stress analysis. The method includes creating a 3-D solid model prototype through a stereolithographic process. The prototype is cleaned in an alcohol bath and cured by exposing the prototype to a bath of ultraviolet light. Further, curing of the prototype is accomplished by placing the prototype in a thermal oven at an elevated temperature for a period of time. Upon removal and after cooling of the prototype, the prototype can be tested using several different experimental stress analysis procedures.

Abstract: A method of using an amorphous carbon-based coating to extend the operating life of a fuel injector having a needle operating within a valve body, the valve body, the valve and body having steel surfaces subject to repeated impact and sliding friction contact over the operating life of the injector. The method comprises (a) providing the steel surfaces of at least one of the needle and body with an ion implanted stabilized amorphous carbon-based coating in a thickness of 1-10 micrometers, the coating having low internal stresses and low coefficient of friction independent of humidity and being stabilized by the presence of up to 30% by weight of carbide forming material selected from the group of silicon, titanium and tungsten, and (b) repeatedly and rapidly actuating the fuel injector in time periods of 0.5-1.

Abstract: A method of coating an area of an electrode with an erosion resistant material. The method comprises bringing into contact with the area a web which contains the erosion resistant material and which carries an adhesive so that the web adheres to the electrode. The electrode and the adhered web are then heated to a temperature high enough to cause the adhesive to decompose, volatilize, or both such that the adhesive is substantially eliminated from the web and such that the erosion resistant material fuses and bonds to the electrode.

Abstract: A method of eliminating scrubbing noise between metal to metal (or metal to ceramic) contact members that experience articulating swiveling interengagement at high force levels in excess of 5,000 psi. The method comprises: (a) preparing the interface to present at least one fresh mechanically adherable stiff surface; (b) thermally spraying a top coating thereonto consisting of at least one of (i) a self-lubricating metal, ceramic material or metal alloy, and (ii) a compliant metal; and (c) placing the coating interface into service to subject it to repeating articulating swiveling contact that functions to microweld the coating to the surface under normal operating conditions.

Abstract: Method of depositing a metal base coating containing a self-lubricating oxide phase and one or more wear resistant phases, by: preparing at least one light metal substrate surface to be essentially oxide-free and in a condition to adherently receive the coating, plasma spraying a supply of metal (M) powder particles onto the substrate surface to produce a composite coating of such metal (M) and an oxide (MO.sub.

Abstract: A heat exchanger assembly includes at least one tube having an internal surface and an external surface, a composition cladding having at least lithium and magnesium applied to either one of the internal surface and external surface of the tube, and at least one component disposed adjacent the composition cladding, whereby the tube and component are joined together during a controlled atmosphere brazing process.

Abstract: A closed core box is provided with one or more inlets for receiving and passing gas fluidized resin-coated sand to fill the interior of such core box, and with one or more screened outlets for allowing egress of such gas. A closed cylindrical or angular sand-fluidizing chamber is provided for each of the inlets, the chamber having one end connectable to a pressurized gas supply and an opposite end communicating with an inlet. At least part of each chamber is filled with resin-coated sand and a non-porous piston is placed on the sand within each chamber, each piston providing an annular gap (i.e. about 1/16 of an inch) with the interior of such chamber to direct the gas supply along the periphery of the chamber interior.

Abstract: A vehicle traction control system is controlled in-part by a signal value indicative of estimated wheel torque. The estimated wheel torque value is produced within the vehicle's electronic engine control (EEC) module by summing a first value which indicated the estimated torque attributable to engine combustion and a second value which is proportional to engine acceleration/deceleration which indicates the amount of torque attributable to the inertial movement of engine and drive train masses. Before summing the two signal components, the signal which indicates combustion torque is delayed with respect to the signal indicating inertial torque by a delay interval whose duration varies with engine speed to take into account the delay between intake fuel rate changes and combustion forces as well as delays attributable to the timing of the calculations themselves.

Abstract: An apparatus for dispensing solder includes a nozzle body having a plurality of flow channels formed therein. Each flow channel includes an inlet end and a dispenser end for dispensing solder. The nozzle body forms a nipple surrounding each dispenser end, and the nozzle body further forms a shielding chamber in communication with each dispenser end for protecting the respective nipple, and optionally providing flow of inerting gas and/or excluding ambient oxygen from the soldering area. The nozzle bodies comprise micro-machined silicon. Various flow channel configurations are provided for improved flow characteristics.

Abstract: An adaptive CAD system, comprising: (a) gathering data consisting of at least one of (i) human generated information and techniques, and (ii) machine generated information and rules; (b) processing the gathered data by instructions to produce processed knowledge containing script without a product or part design; (c) recursively editing the processed knowledge to continuously improve the script to form an executable part design, such processing being carried out by inputting into the editing process at least one of (i) recently learned data, (ii) associative techniques, relations and features, and (iii) knowledge-based rules and instructions and (d) inputting the history of step (c) into processed knowledge, such inputting creating captured improvement criteria, that is iteratively and recursively feeding back into either the recursive editing process or into processing of step (b) to effect evolvement of an executable design form.

Abstract: A solder dispensing apparatus for depositing fluid solder into and around a pin-in-through-hole joining zone of an electronic circuit board which comprises:a valve assembly defining a valve chamber with an inlet and an outlet, and having the valve member actuated by the pin of said pin-in-through-hole joining zone when the valve is positioned at the zone against the board, the valve member moving from a first position closing off fluid flow from the outlet to a second position permitting fluid flow through the outlet; means for measuring a predetermined body of fluid solder that is released from the chamber when said valve member is in the second position with the assembly positioned at the zone against the board; and means to contain the released fluid solder in a predetermined shape and in and around the pin-in-through-hole joining zone while the solder solidifies.

Abstract: A three dimensional multi-layer circuit structure is formed by partially etching a foil having a coating. A pre-circuit is formed by providing a metal foil, applying a photodefinable photoresist to each side of the metal foil, selectively exposing and developing the photoresist leaving exposed areas and unexposed areas and, plating the unexposed areas with a second metal. The pre-circuit is placed in an etching solution and removed after the etching solution partially etches the metal foil to undercut the second metal. The partially etched pre-circuit is then bent into a predetermined shape. The partially etched pre-circuit is then inserted into a mold cavity so that at least one surface of the circuit structure is adjacent to the mold. The mold is filled with a polymer resin so that the polymer resin encapsulates at least a portion of the partially etched pre-circuit and substantially fills the undercut.

Abstract: A method of inertial bonding of a conductive metallic member to a fragile non-conductive member, comprising: (a) depositing a thin adherent conductive pad onto the fragile member to present a first friction creating surface: (b) forming the conductive metallic member with a second friction mating surface conforming essentially to the first friction creating surface; (c) bringing the first and second friction surfaces together with high relative movement transverse to the surfaces and with a gradually increasing forging force along an axis perpendicular to the surfaces to generate sufficient frictional heat therebetween to effect at least a galling or smearing of melted particles of said surfaces; and (d) abruptly ceasing the relative rotation and increasing forging force upon the attainment of such melted particles at the engaging interface between the surfaces.

Abstract: A copper core weld gun assembly is provided with a substantially omega (.OMEGA.) shaped cross-section taken through each arm of the assembly. Concentric copper tubes are provided to carry cooling water and electric current to the electrodes of each arm. Special fittings are provided to insure that cooling water is carried directly to and from the electrodes without contacting the body, thereby eliminating galvanization in aluminum bodies. The design includes wedge-shaped barrel locks, crown-tipped incoming water tubes, thimble-shaped female electrode caps, and provides modular design capability. A modular gun design separates the gun into three fundamental areas: (a) the electrode system; (b) the body/frame system; and (c) the moment arm design.

Abstract: A computer controlled reconfigurable fixture mechanism having a base, rotatively and pivotably supporting a plurality of fixture linkages. Each linkage has at least two arms connected by a wrist assembly. The wrist assemblies are motor-driven and permit the arms to be rotated and pivoted relative to each other and to the base. A control computer includes a keyboard. Using a keyboard an operator can individually move the arms to a desired location and orientation. Angle sensors associated with each wrist assembly generate feedback signals indicative of the current configuration of the linkages which can be stored in the control computer. The computer can generate position signals for each linkage to return them to the stored configuration. The control computer may also use the physical data of the part generated by a CAD system to configure the linkages to hold the part at the desired location and orientation.

Abstract: A method of bonding a thermally sprayed coating to a non-roughened light metal (i.e. cast aluminum-based) surface. The method comprises the steps of (a) depositing a flux material (i.e. potassium aluminum's fluoride containing up to 50 molar % other fluoride salts) onto such cast surface which has been cleansed to be substantially free of grease and oils, such deposition providing a dry flux coated surface, the flux being capable of removing oxide on the cast surface and having a melting temperature below that of the cast surface; (b) thermally activating the flux in the flux coated surface to melt and dissolve any oxide residing on the cast surface; and (c) concurrently therewith or subsequent to step (b) thermally spraying metallic droplets or particles onto the flux coated surface to form a metallic coating that is metallurgically bonded to the cast surface.

Abstract: A hermetically protected electronic assembly that has (a) a housing having walls defining a shallow impervious cavity with a depth no greater than 6-12 mm and with an cavity bottom surface; (b) conductor pins extending through integrally said housing walls and along the cavity bottom surface; (c) an insulating supporting platform resting on the cavity bottom surface with ends of the conductor pins extending therethrough to secure the position of the platform, the platform carrying an electrical circuit integrated to at least the top surface of the platform and connected to the conductor pins; (d) at least one electronic sensor component supported in the housing by the platform and operatively secured to the circuit; and (e) a water-proofing silicon gel filling the entire space within the housing including surrounding the circuit, platform, sensor and pin connections therein.