Abstract: Method of curing inaccessible thermoset adhesive joints, comprising: forming structures to be bonded at mating surfaces when assembled, the shortest distance from the mating surfaces to the exterior of the assembly inhibiting the application of radio frequency heating by exterior electrodes; while forming the structures, molding into a least one of the structures, spaced from the surfaces to be adhered, a fiber or film-like electrode of sufficient thickness and spacing to project radio frequency waves through such one structure to the adhesive when energized; assembling the surfaces together with a thermoset adhesive therebetween in intimate contact of each of the surfaces; and connecting the fibrous or thin filmed electrode in a circuit for passing radio frequency waves across the adhesive to effect dielectric heating of the adhesive for a controlled period of time and at a predetermined temperature rise for curing.

Abstract: A retractable metal insert assembly for a core sand mold having at least one sand core element provided with walls to define an opening communicating with a molding cavity, the walls presenting a stepped neck which is dimensionally accurate within .+-.0.002 inches, the mold further including a metal support associated with the core element. The insert assembly comprises: (a) a metal guide detachably secured to the metal support; (b) a metal chill element extendible through the opening to present a metal molding surface which insert has walls mateable with the stepped neck for accurate alignment; and (c) biasing means acting between the guide and insert to urge the mating walls together for self positioning of the insert. The insert assembly can be repeatedly reused in a method of making castings.

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 system including a specifically-shaped probe and a complementarily-shaped hole formed in a surface of a part to be picked up ensures proper alignment between an end effector which picks up the part and the part itself. The probe includes first, second, third and fourth mutually converging locating surfaces terminating at a rounded tip at a free end of the probe. The probe is preferably diamond-shaped in cross-section along its entire length and the hole, consequently, is also diamond-shaped. The hole is defined by an inner peripheral diamond-shaped surface configured to be immediately adjacent and substantially parallel to each of the locating surfaces only when the end effector is in a proper pick up position and orientation with respect to the part. Preferably, the end effector is a gripper wherein the probe is adapted to be secured between gripping jaws of the gripper. In the preferred embodiment, the part comprises dunnage.

Abstract: A method of treating a light metal cylinder bore wall to adherently receive a thermally sprayed metallic coating, that comprises (a) honing the wall to produce a net cylinder shape surface by use of spiral overlapping cross-abrasions having certain peaks and valleys of the abrasions folded over and molded to create tears, folds and undercuts rendering a hook and ladder effect, the honing being carried out with the use of a machining coolant to prevent burnishing of the walls; (b) either concurrently or shortly after step (a), washing the honed surface with a hot alkaline solution comprising (i) a non-soaping aluminate forming agent (sodium xanthate) that produces a residue on the walls, and (ii) surfactants that facilitate wetting of the walls even when some steam bubbles may be present; (c) rinsing the washed surfaces without disturbing the residue; and (d) thermally spraying a metallic bond coat and top coat on the honed and washed surface to render adhesion between the coating and prepared surface that is

Abstract: A method and apparatus for detecting misoriented wheel assemblies in wheel truing machine punch stations. The wheel assemblies for which determination of proper orientation is sought are provided with at least one reference hole, preferably a valve stem hole extending therethrough at a predetermined location. The apparatus includes a light emitting source which is provided in electrical communication with a light detecting target. The light emitting source and the light detection target are disposed in predetermined positions and orientations on opposing sides of the wheel assemblies when received within the punch station. When the light emitting source is engaged during proper wheel assembly orientation, the light beam will pass through the selected reference hole whereupon it will be received and detected by the light detecting target.

Abstract: An apparatus and method for soldering components to a circuit board. The apparatus includes a conveyor in a tunnel for transporting the board through a preheat zone, molten waves of solder including a turbulent wave and a laminar wave, and a cool down zone through which the board passes upon exit from the laminar flow wave of the solder wave. The improvement comprises at least one distributing manifold mounted in the tunnel having an inlet port for receiving a cold gas under pressure and at least one outlet nozzle for directing the cold gas to the circuit board, thereby rapidly cooling the circuit board and the components.

Abstract: Apparatus for measuring the velocity of shaping air in a rotary bell atomizer for a paint sprayer, including a funnel that collects substantially all of the shaping air, a means for straightening the collected shaping air and a means for measuring the velocity of the straightened shaping air. These techniques enable the average velocity of the shaping air to be calibrated from a single velocity sample.

Abstract: An apparatus and method are provided for washing machining debris from machined parts. The apparatus includes a machine transfer housing with front and rear sidewalls, a top, a bottom, an entrance sidewall defining an entrance, and an exit sidewall defining an exit. A transfer line enters the housing at the entrance, extends through the housing and exits the housing at the exit to transport the machined parts through the housing. A header is attached to the top housing wall for delivering a wash solution to the housing. A solenoid valve controls the flow of the wash solution in the header. One or more rotating nozzles are connected to the header for spraying the wash solution in the housing to remove machining debris from the machined parts and the housing walls.

Abstract: An apparatus for testing the adhesion quality of a coating on the interior surface of a hollow cylindrical substrate, and a method for its use, the apparatus comprising an element joined to the coating, the element having a joining face at one end, a neck at the other end for pulling in a direction perpendicular to the joining face, and a channel through the element aligned with the direction of pulling; a non-adhering plug present in the channel of the element effective to be maintained in contact with the coated surface while extending through and out of said element; a die cut adhesive disc gluing the face of the element to the coated surface as a result of pressure and heat, said disc having a die cut circumference and inner opening commensurate with the size of the plug extending therethrough; a piston and piston housing assembly in which the piston housing is slidable on the piston in response to pressure and has an extension circumferentially overlapping the neck of the element to place a substantially

Abstract: A method of making coated engine blocks by (a) casting a metallic engine block having one or more cylinder bores; (b) fabricating a thin walled liner for each bore, the liner being constituted of extruded metallic tubing having a cleansed inner surface, a wall thickness controlled to a thickness of 1-3 mm.+-.

Abstract: An iron or copper based metal powder useful for plasma deposition of a coating that has a dry coefficient of friction 0.75 or less and readily conducts heat through the coating. The powder comprises (a) H.sub.2 O atomized and annealed particles consisting essentially of (by weight) carbon 0.15-85%, oxygen 0.1-0.45%, an air hardening agent selected from manganese and nickel of 0.1-6.5%, and the remainder iron or copper, with at least 90% of the particles having oxygen and iron or copper combined in the lowest atomic oxygen form for an oxide of such metal.A method of making anti-friction iron powder that is economical, selectively produces FeO and promotes fine flowable particles. The method comprises (a) steam atomization of a molten steel that excludes other oxygen, the steel containing carbon up to 0.4% by weight to produce a collection of comminuted particles, and (b) annealing the particles in an air atmosphere for a period of time of 0.25-2.0 hours in a temperature range of 800.degree.-1400.degree. F.

Abstract: A system and method for characterizing a machining process using techniques of mechanical signature analysis produces discriminants based on vibrational activity, measured at various positions on a machine tool. The system and method provide a complete characterization of an industrial machine tool including the machining structure, tooling, fixturing, workpiece, and operating environment under transient and steady state conditions both with and without machining loads. The method includes selection of appropriate sensors (24), sensor locations (24), mounting methods (24), signal conditioning (26), and data acquisition (28) and analysis (30) based upon the particular type of machine and machining process. The vibration signature analysis includes both time and frequency domain analysis.

Abstract: Method of making a rapid tool, comprising: making a plastic pattern of the tool by free form fabrication techniques following a computer aided design, the design having a base and no undercuts taken in a direction perpendicular to base; constructing a ceramic mold as the inverse of the pattern; separating the pattern from the mold by a separating movement in a direction perpendicular to the base to leave a surface defining a casting cavity within the mold; and thermally spraying tool steel particles against the casting cavity surface is a thickness exceeding 1 inch while rapidly cooling the sprayed particles to effect a net shape tool without the need for further working or heat treatment.

Abstract: Methods and apparatus for representing a three-dimensional object by means of a High Density Point Data Model (HDPDM) consisting of a large number of individual data values, each of which specifies the coordinates of a point on the surface of a three dimensional object. An initial HDPDM is produced by scanning a physical object, tessellating the elements of a CAD representation of the object surface, or evaluating mathematical expressions which describe the surface. Further data values define a virtual tool surface which is spaced from the modeled object surface. The projection of the virtual tool surface on the object surface along projection lies parallel to a defined axis of projection identifies selected points on the surface which are modified by effectively moving them to the tool surface.

Abstract: A method and apparatus for forming a rigid circuit board uses a circuit board with a reduced thickness in a bend region. The bend region may have several layers of laminate and conductive material. The circuit board is heated to the glass transition temperature which allows the circuit board to become flexible. The apparatus has two rollers used to form the bend region to a predetermined shape. When the circuit is cooled, the circuit board again becomes rigid in its predetermined shape.

Abstract: A method of applying a surface coating to promote gas carburization of a highly alloyed steel. The method includes the step of coating the highly alloyed steel with a layer of iron or an iron alloy to form a coated steel before carburizing the coated steel in a conventional gas carburizing atmosphere.

Abstract: A lightweight thermally responsive mold for use with a resin transfer molding process is provided. The mold includes first and second support frames including a plurality of upstanding intersecting support ribs. First and second substrates are supported by the first and second support frames, respectively, for carrying heating tubes therein. First and second hard shells are supported by the first and second substrates, respectively. The shells cooperate to form a mold cavity therebetween. Each shell is less than approximately 10 mm thick in order to provide a low thermal mass and high thermal responsiveness.

Abstract: Method of attaching an insert to a valve seat location of an engine involves forming an engine valve seat location with a circular conical face surface constituted of a light metal; forming an insert with a circular conical bonding surface for mating with the face surface, the bonding surface being constituted of a metal dissimilar to the light metal and having a higher hardness and a higher melting temperature than the light metal of the face surface; aligning the axes of the face surface and bonding surface and gradually rotationally driving the insert into the valve seat with sufficient pressure and for a controlled period of time frictionally melt or plasticize a film of the face surface; and thereafter ceasing the rotational driving while holding the surfaces together with sufficient forging pressure and for a period of time to allow the melted film to recrystallize and create a metallurgical bond between the surfaces.

Abstract: A method of preparing the surface of a conductive metal to be non-smooth and non-passivated for reception of thermal sprayed coatings. The method comprises melting and rapidly solidifying globules of the surface by electrical discharge by bring an electrode (anode) in close gap-sparking proximity to the surface, filling the gap with an electrolyte containing a halogenated hydrocarbon fluid present in an amount of 2-5% of the electrolyte, and imposing a pulsed DC voltage (i.e. 20-100 volts at 40-200 amps) on the electrode to provide cyclical sparking between the electrode and the surface through the electrolyte resulting in a breakdown of the hydrocarbon to release nascent halogen atoms which attack the surface to prevent passivation during melting and solidification of the globules. The electrolyte is preferably cooled to a temperature below 65.degree. F.