Abstract: A composition of matter for depositing a thin anti-friction film that has a coefficient of friction of 0.06 or less. The composition comprises (a) a mixture of solid lubricant particles, a thermoset resin, and a catalyst for setting the resin, and (b) an evaporative medium for carrying the mixture during deposition. A solid film lubricant system for protecting metal wear interfaces subject to high temperatures and wet lubrications, comprising an oil-attracting solid lubricant mixture with at least two elements selected from the group of graphite, MoS.sub.2 and BN; a support for the mixture to loads of at least 10 psi at temperatures of 600.degree.-800.degree. F. while being thermally stable; a thermally stable thermoset polymer matrix, the polymer having inherent hydrocarbon chemical attraction to form a tenacious oil film of the lubricating oil on the wearing surface.

Abstract: A method of preparing metal surfaces for thermally applied coatings by electrical discharge, which method controllably provides greater roughness for increased mechanical coating adhesion, avoids carbon deposits and is more economical to use. The method comprises melting and rapidly solidifying globules of the metal surface by spark erosion, the spark erosion occurring by incidence of an electrical discharge between an electrode and the metal surface closely spaced thereto, the spacing having an electrolyte with plasma forming capabilities, the discharge resulting from application of an electrical current to the electrode with a DC voltage in the range of 60-85 volts and amperage in the range of 50-110 amps, the current being pulsed on for periods of 150-300 micro seconds per spark.

Abstract: A paint spray booth including an air supply having a fan motor is controlled by first and second plenums and air restrictors that adjustably control the flow of air from the second plenum to first and second areas of the booth that require different velocities of airflow. A pressure sensor responsive to air in the second plenum controls the air supply to maintain constant pressure in the second plenum so that the speed of air in the first and second areas is adequately controlled.

Abstract: An extrudable brazeable corrosion resistant aluminum alloy, consisting essentially of, by weight percent, 0.1-0.2 titanium, 0.6-1.2 manganese, up to 0.1 silicon, up to 0.2 iron, and other impurities up to 0.15, with each such other impurity no greater than 0.03, and the remainder aluminum.A method of fabricating a heat exchange tube array, by (i) extruding aluminum alloy tubing of the above composition to a uniform wall thickness of about 0.4mm; (ii) bending and/or arranging the tubes to form a tube array for conducting a fluid medium therethrough; (iii) interposing an aluminum-based heat exchange means between and in contact with the tubes of the array to provide for heat transfer; (iv) brazing the heat exchange means to the tube array by heating to the temperature range of 595.degree. C. whereby the tube array will not be adversely affected metallurgically by the brazing operation.

Abstract: Heat engine piston and combustion chamber construction enclosing a gas combustion zone, comprising: a piston body having a crown facing said gas combustion zone; combustion chamber surfaces cooperating with said piston to complete enclosure of said zone; and a thermal diffusivity coating on said crown and combustion chamber surfaces having an effective thickness to operate as a thermal diode to restrict heat transfer to said piston body and combustion chamber and to restrict heat transfer to said combustible charge prior to combustion.

Abstract: A rotor for a disc brake assembly includes a centrally disposed hub and at least one friction surface disposed annularly about the hub, the friction surface including a single continuous spiral groove disposed between the hub and an outer radial edge of the rotor, the single continuous spiral groove including a first portion wherein the groove is disposed radially side-by-side relative to itself and concentrically about the hub with each adjacent segment of the first portion of the groove being spaced from itself by a first predetermined distance, the single continuous spiral groove also including a second portion wherein the groove is disposed radially in side-by-side relation relative to itself and concentrically about the hub with each adjacent segment of the second portion of the groove being spaced from itself by a second predetermined distance which is different from the first predetermined distance to improve braking of the rotor.

Abstract: A piston assembly operable within a fluid bathed, cylinder wall, comprising a piston body (10) having at least one annular land (36) adapted to be in close-fitting relationship to the cylinder wall (37) an abradable coating (15) tenaciously adhered to said at least the one land (36) effective to create and sustain substantially zero clearance with the fluid bathed cylinder wall and a heat sink in the form of at least one of (i) heat conductors (23) in the coating to conduct heat from the land (36) and (ii) a piston body interior (52) effective to receive a heat conducting fluid (26) moving along the interior to extract heat therefrom. The abradable coating comprises solid lubricants at least two of which are selected from the group consisting of graphite, molydisulphide and boron nitride The heat conductors in the coating preferably consist of copper particles distributed throughout the coating and constitute at least 70-90% by weight of the abradable coating.

Abstract: An apparatus for measuring kinematic errors in power transmission mechanisms with an input shaft and an output shaft. The apparatus comprises a pair of laser doppler velocimeters (LDV's) (16,34). Each generates a laser beam split into two equal-intensity parallel beams which are projected so as to strike a shaft while the shaft rotates. The shaft produces reflected beams having a frequency which is shifted from that of the incident beams, thereby producing returning beams which are heterodyne. A measuring (20,38) channel is in communication with each LDV. An attenuator (24) is in communication with one of the measuring channels (20) for decreasing the amplitude of a signal generated by the measuring channel (20). A summing and integrating amplifier (28) is connected to the attenuator, the amplifier generating a signal indicative of kinematic error in the gear mechanism.

Abstract: A die assembly (10) for shaping a workpiece (12). The die assembly (10) includes a die shoe (22) within which a channel (24) is provided. A hollow die head (32) may move within the channel. One or more passages are disposed within the die head (32). Within each passage is a locking member (46) which is seatable within a groove (52) defined within a head portion (50) of a shaft (48) which transmits a shaping force to the workpiece (12) or a driven or shaping force within the die assembly (10), thereby allowing the shaft (48) to rotate axially. The die assembly (10) permits the die head (32) and shaft (48) to move in unison during the initial stages of retraction. During later stages of retraction, the die head (32) becomes unlocked from the shaft ( 48).

Abstract: A method of making anti-friction coated surfaces subject to sliding wear, comprising: (a) forming grains of agglomerated solid lubricant particles and air-hardenable, fusable ingredients such as steel particles, the particles being agglomerated by a low melting medium such as wax; (b) providing a light metal-based component surface; (c) thermally spraying such grains onto said surface in a thickness range of 100-250 microns to form a coating substantially devoid of the low melting medium (the temperature of said thermal spraying liquifying and eliminating the wax by ash-free combustion); (d) removing at least a portion of the fusable particles by honing to expose edges of such particles; and (e) subjecting the exposed particles to air hardening (i.e., by available interfacing friction).

Abstract: An improved method of brazing of two unclad aluminum shapes, particularly for automotive heat exchangers, which brazing joint does not leave a physically apparent layer of brazing material and which effects a stronger, sounder autogenous joint. A thin film of aluminum eutectic forming material (Si, Al-Si or Al-Zn) is deposited onto a zone of at least one of the shapes to be brazed or joined. The shapes are placed in joining relationship to form an assembly with a joint at the zone. The assembly is heated to a temperature to diffuse the eutectic forming material into the aluminum members to form a sacrificial bond between the shapes at the joining zone. It is desirable that at least one of the unclad aluminum shapes to be joined is extruded tubing having a precise diametrical configuration and said film is deposited as a physically vapor deposited layer in a thickness range of 1-50 microns.

Abstract: A fluid bearing assembly for rotatably supporting a rotary-driven spindle having smooth bearing surfaces. Each bearing has a stationary housing holding an annular bearing race that presents a smooth continuous bearing surface facing a complementary bearing surface of the spindle; together the race and spindle define a continuous, thin, uniform crevice space. The smooth race bearing surface is interrupted by a plurality of circumferentially spaced pressure generating zones, each capable of dynamically compressing a fluid body contained in the zone into the crevice in either direction of rotation of the spindle at higher speeds. Pressurized fluid is supplied to flow through each zone and out of the crevice while exerting a predetermined hydrostatic force against the spindle at lower rotational speeds.

Abstract: Method for aiding sheet metal forming tool design, for use with a computer including memory, and forming tools including a draw die, punch and binder having surfaces designed to form the sheet metal into a part, the sheet metal being represented as a mesh including a plurality of nodes. The method includes evaluating an initial binder-set associated with an initial binder surface design during a first stage of forming the sheet metal in which at least one of the plurality of sheet metal mesh nodes is forced against the binder surface, and detecting an area of unacceptable deformation on the sheet metal mesh. The method also includes identifying the at least one of the plurality nodes forced against the binder surface associated with the unacceptable sheet metal deformation and releasing the at least one of the plurality of nodes identified, so as to allow the identified nodes to move as the sheet metal assumes a relaxed state.

Abstract: A system for measuring the gap between two surfaces is disclosed. The sensing apparatus comprises an actuator, an active sensor and a display. The actuator actuates operation of the sensing apparatus. The active sensor includes a transmitter for transmitting a wave signal beam reflectable off one of the surfaces and a receiver for receiving the reflected wave signal beam by the sensing apparatus. A signal processor is in electrical communication with the actuator, the transmitter and the receiver, for processing the reflected wave signal beam to determine the gap between the two surfaces. The display is in electrical communication with the signal processor for displaying the amount of gap between the two surfaces.

Abstract: A flux formulation for use in the assembly of electronic circuit boards having components to be joined by soldering. The formulation comprises a medium which acts as a carrier and solvent for the fluxing agent, which includes in a preferred embodiment supercritical carbon dioxide. The formulation also includes a fluxing agent, being at least partially soluble in the supercritical carbon dioxide which serves to transport the fluxing agent before deposition thereof upon a soldering site. The supercritical fluid is delivered through a nozzle to the circuit board, the supercritical condition being maintained until the supercritical fluid is discharged from the nozzle. The fluxing agent at least partially loses its solubility in the fluid thereupon and is transported to the board by a stream of carbon dioxide gas. Also disclosed is a method for delivering a flux formulation to the electronic circuit board.

Abstract: A no-VOC or low-VOC no-clean flux formulation for use in the assembly of electronic circuit boards having a conformal coating. The formulation comprises a solvent, a water-soluble weak organic acid, a halide-free, non-ionic surfactant, and a biocidal co-solvent. The formulation is compatible with the conformal coating, permits no or low VOC emissions into the environment, and eliminates post-soldering cleaning steps.

Abstract: A method is provided for verifying the accuracy of a part geometry with respect to a master geometry. The method begins with the step of providing a computer workstation including a computer and an output device attached to the computer. The method also includes the steps of generating a master HDPDM describing the geometry of the master and generating a part HDPDM describing the geometry of the part. The master HDPDM includes a plurality of points. The method further includes the step of aligning the master HDPDM and the part HDPDM within a coordinate frame. The method continues with the step of computing the distance from each point of the master HDPDM to the surface described by the part HDPDM to obtain signed distance data. The method concludes with the step of displaying an image on the output device based on the signed distance data.

Abstract: A detachable monorail system is provided for conveying articles between workstations wherein carriers may be disengaged and moved independently from the monorail. A carrier is provided with a load retainer, a hook, and a roller. A chain having a plurality of load bar assemblies is provided for supporting a pin extending transverse to the length of the chain. A guide track vertically adjacent the chain extends along a portion of the length of the chain. A disengagement station is defined at a location where the chain and the guide track converge vertically so that the hook disengages the load bar assembly as the roller contacts the guide track. An engagement station is defined at a location where the chain and the guide track diverge vertically so that the hook engages the load bar assembly to lift the roller off of the guide track.

Abstract: The invention relates to an improved emission control system. The system has particular applicability for use in an internal combustion engine (10) utilizing alternative fuels such as natural gas. More particularly, the invention provides an apparatus and method wherein hydrogen is removed by a conditioning catalyst (16) from the exhaust gas stream (21) to produce a conditioned exhaust gas (22). An exhaust gas oxygen (EGO) sensor (18) is in communication with the conditioned exhaust gas (22) and generates a signal in response to the sensed oxygen concentration of the conditioned exhaust gas (22). The A/F mixture entering engine (10) is adjusted by closed loop control means (14) in response to the signal generated by EGO sensor (18). The removal of hydrogen from the exhaust gas stream (21) eliminates lean shifts and allows oxygen sensor (18) and closed loop control means (14) to more accurately control the A/F ratio.

Abstract: Method of making a piston ring assembly by providing a metallic (i.e. cast aluminum) piston with a crown and an annular depending side wall; machining a stepped annular groove in the side wall having a total height of at least 4 mm (preferably having a combined total height equal to the groove height less 60 microns or less); fabricating a pair of metallic (i.e. aluminum based) split annular compression rings nestable within said groove and effective to operate together as a superimposed unit to seal against both said step and groove; coating said groove and the non-mating surfaces of said rings with solid film lubricants (i.e. graphite, BN and MoS.sub.2); and inserting said pair of coated rings into said coated groove with their split ends out of superimposed alignment.