Abstract: The cylinder walls of light metal engine blocks are thermally spray coated with a ferrous-based coating including aluminum using an HVOF device. A ferrous-based wire is fed to the HVOF device to locate a tip end of the wire in a high temperature zone of the device. Jet flows of oxygen and gaseous fuel are fed to the high temperature zone and are combusted to generate heat to melt the tip end. The oxygen is oversupplied in relation to the gaseous fuel. The excess oxygen reacts with and burns a fraction of the ferrous-based feed wire in an exothermic reaction to generate substantial supplemental heat to the HVOF device. The molten/combusted metal is sprayed by the device onto the walls of the cylinder by the jet flow of gases.

Abstract: A fuel cell system and process using an organic Rankine cycle to produce shaft work to operate a fuel cell system component such as an air compressor. The air compressor delivers compressed air to a fuel cell stack. The steps of the Rankine cycle include pumping a liquid working fluid to an elevated pressure, heating the fluid to a gas, expanding the high temperature and high-pressure gas through an expander to produce shaft work used to drive a fuel cell system component such as an air compressor, and then removing energy from the cooling fluid to change the gas back to a liquid, and repeating the cycle. The liquid fluid can be heated by an external boiler, or one of the components of the fuel cell system such as the combustor and/or the fuel cell stack.

Abstract: A diesel engine intake cam profile creates two intake valve events separated by a short dwell period each engine cycle. A relatively low valve lift during an engine exhaust event allows a portion of the exhaust gas to flow into an intake manifold and mix with intake air. The intake valve is then nearly closed for a dwell period until a normal intake valve opening occurs, drawing the mixture of air and exhaust gas back into the combustion chamber for compression and burning, upon closure of the intake valves.

Abstract: A heat exchanger design is provided for optimal transfer of thermal energy between a primary reactor-out reformate and a primary reactor-in steam and air. In particular, one embodiment of the present invention comprises a prime-surface true counterflow heat exchanger positioned around the primary reactor. It is emphasized that this abstract is provided to comply with the rules requiring an abstract, which will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure. It is submitted with the understanding that is will not be used to interpret or limit the scope or meaning of the claims. 37 CFR 1.72(b).

Abstract: A turbocharger rotor has a turbine wheel and shaft, a compressor wheel and adapter and a separate thrust runner clamped together by a fastener rod. The adapter is piloted on the shaft and the thrust runner is piloted on the adapter, which has annular ends engaging the shaft and adapter for torque transmission between the turbine and compressor wheels. An anti-rotation coupling relates the phase angles of the shaft with the adapter and the thrust runner during assembly. Opposed radial thrust faces on the thrust runner and adapter are disposed at opposite ends of a compressor bearing journal on the adapter to allow placement of mating bearings on a single element of a turbocharger housing. Advantages include simplification of manufacture and assembly of the rotor in a turbocharger housing.

Abstract: A sensor for monitoring the lambda of a component of a reactant feed stream flowing through a fuel cell stack. The sensor comprises one or more fuel cells that are sensitive to a change in lambda of a specific component of a reactant feed stream flowing through the fuel cell. The sensitivity of the fuel cell causes a voltage produced by the lambda sensing fuel cell to vary in response to variation in the lambda of the specific component. The variation of the voltage output can be modeled and/or compared to empirical data to correlate the voltage output to the lambda of the specific component. Based on the lambda of the specific component, the operation of the fuel cell stack can be optimized.

Abstract: The present invention relates to an electrochemical cell having a catalytic electrode and an electrically conductive contact element facing the electrode. The electrically conductive contact element conducts electrical current from the electrode and has a surface comprising a plurality of passivated regions, and a plurality of non-passivated regions dispersed among the passivated regions. The surface further is coated with an electrically conductive, corrosion resistant coating. Other preferred aspects of the present invention include methods of treating the electrically conductive contact element by passivation to resist corrosion while still maintaining electrical conductivity.

Abstract: Method and apparatus for supplying extra/booster steam and/or fuel vapor to the fuel processor of a fuel cell system during surges in power demanded from the fuel cell. Hot water and/or liquid fuel is/are stored under pressure until needed. When needed during power surges, the pressure is rapidly reduced on the hot liquid(s) causing it/them to flash vaporize and supplement the normal, steady state supply of steam/fuel-vapor to the fuel processor.

Abstract: A method for starting a frozen fuel cell stack includes discontinuing reactant humidification before shutting down the fuel cell stack. The anode and cathode are purged with the dry reactants. The fuel cell stack is soaked at freezing temperatures. During subsequent startup, dry reactants are initially delivered. An outlet temperature of the anode and a current load of the fuel cell stack are measured. The dry reactants are shut off when the temperature of the anode outlet or the current load reach predetermined values. The open circuit voltage potential of the fuel cells is monitored and compared to a first voltage value. When the open circuit voltage exceeds the first value, the fuel cell stack begins supplying current load. The current load of the fuel cell stack is increased or decreased based on a difference between the minimum voltage and a second voltage value.

Abstract: A bipolar plate assembly for a proton exchange membrane fuel cell stack advantageously connects electrically conductive plate surfaces, without the requirement to weld or braze the plate pairs. Each plate has alternating coolant channels and lands formed on an inside facing surface. An electrically conductive layer is deposited over at least the coolant channels and lands. Pairs of plates are aligned having facing electrically conductive layers. A fluid seal is disposed between the inside facing surfaces about a perimeter of the coolant channels. Each plate pair is compressed to form a plurality of electrical bond lines between adjacent lands within the perimeter seal. The perimeter seal prevents stack reactant gas oxygen from contacting and oxidizing the electrically conductive layer. A dielectric coolant is also used to reduce oxidation of the electrically conductive layer.

Abstract: A nozzle assembly for a HVOF thermal metallic spray coating system includes an inner tube, a middle tube and an outer tube which are concentrically arranged about an axis of the nozzle assembly and are spaced to provide annular, concentric gas flow passages for oxygen and gaseous fuel along with a central wire feed passage in an efficient, compact arrangement. A slotted nib and plug are fitted to the discharge end at the assembly and defined, together with the middle tube, an annular premix chamber for the combustible gases, and a plurality of circumferentially spaced mixing slots and a downstream mix end portion of the nib where complete mixing of the gases occurs prior to entry into the combustion chamber provided in an air cap. An annular passage between the air cap and outer tube communicates with a high pressure air source for establishing an envelope of air against the inside surface of the air cap to serve as a protective barrier layer from the atomized metal.

Abstract: A fuel cell system and process using an organic Rankine cycle to produce shaft work to operate a fuel cell system component such as an air compressor. The air compressor delivers compressed air to a fuel cell stack. The steps of the Rankine cycle include pumping a liquid working fluid to an elevated pressure, heating the fluid to a gas, expanding the high temperature and high-pressure gas through an expander to produce shaft work used to drive a fuel cell system component such as an air compressor, and then removing energy from the cooling fluid to change the gas back to a liquid, and repeating the cycle. The liquid fluid can be heated by an external boiler, or one of the components of the fuel cell system such as the combustor and/or the fuel cell stack.

Abstract: An improved diesel engine water pump includes three main features that aid in extending the maintenance-free life of the pump. The impeller shaft is carried by tapered roller shaft support bearings of which the impeller bearing has a floating outer race that is urged axially by a preload spring to provide a prescribed axial preload that maintains concentricity of the shaft with the axis and prolongs bearing life. An improved oil seal combines an oil slinger, a stationary deflector and a lip oil seal with a return passage to the engine to more effectively limit oil leakage from the pump. An improved water seal includes pressurized water jets fed from the pump volute that flush wear particles from the water seal surface and increase water seal life. Further details of these features are also disclosed.

Abstract: One embodiment of the invention includes an MR fluid of improved durability. The MR fluid is particularly useful in devices that subject the fluid to substantial centrifugal forces, such as large fan clutches. A particular embodiment includes a magnetorheological fluid including a liquid, magnetizable particles, a stearate and a thiophosphate.

Abstract: An anti-bounce needle valve for a fuel injector, wherein the needle inherently incorporates the anti-bounce feature. The needle has a conventionally configured exterior for interfacing with a valve seat and a tip body of a conventional fuel injector. The needle is characterized by a needle body having an interior cavity which is filled with small diameter shot, preferably generally spherical tungsten carbide shot. In operation, when the needle impacts upon the valve seat at the conclusion of a fuel injection process, the shot causes the needle collision with the valve seat to be inelastic, thereby eliminating needle bounce.

Abstract: An arrangement for self-steering, radial bogie, truck or vehicle frame for locomotives and other railroad vehicles, which includes steering beams for and located behind their respective leading and trailing wheelsets, and whose rotary motions are coupled by an inter-axle link to provide opposite transverse movement of the first and third wheelsets upon traversing curves.

Abstract: Engine reconfiguration kits are developed for NOx emission reduction in Electro-Motive Division of General Motors Corporation model 645 diesel engines. The kits feature improved unit fuel injectors providing better fuel atomization with retarded injection timing and other improvements. Included new higher efficiency four pass counterflow aftercoolers provide reduced airbox inlet air temperatures. New connector pipes for the counterflow aftercoolers may also be included. Optional higher compression ratio pistons are available for increased fuel efficiency in some engine types. The kits reduce NOx emissions without increasing smoke, CO or particulate emissions or reducing performance.

Abstract: A membrane electrode assembly comprising an ionically conductive member and an electrode, wherein the electrode is a smooth, continuous layer that completely covers and supports the ionically conductive member. The electrode further comprises a central region and a peripheral region, wherein a gradient of electrochemically active material exists between the central region and the peripheral region such that a content of the electrochemically active material is greater in the central region than the peripheral region.

Abstract: A measurement technique that generates a number value identifying the width of a noisy pulse in an analog signal that has particular application for determining whether a defect exists in a cylinder valve of a locomotive diesel engine. The algorithm samples the analog signal, and then the samples are bunched into successive groups where each group includes a predetermined number of samples. A root mean square is taken of the samples in each group to generate a representative amplitude value for that group. Successive amplitude values are multiplied together to generate product values. The product values are averaged over a predetermined number of product values to generate the number value that can be analyzed to determine if a defect in a valve exists.

Abstract: A fuel cell system comprising a plurality of fuel cells, in particular in the form of low temperature fuel cells, which are assembled into a stack, the system having a cathode side with a cathode inlet and a cathode outlet, with oxygen or an oxygen containing gas, such as for example air, being capable of being supplied to the cathode inlet and also having an anode side which has an anode inlet and an anode outlet, with hydrogen or a hydrogen rich gas being capable of being supplied to the anode inlet and with a feedback loop being provided in order to return at least a part of the hydrogen containing exhaust gases which arise at the anode outlet back to the anode inlet, characterized by a line which leads from the anode side to the cathode side and is designed to supply anode exhaust gases to the cathode inlet which, after reaction of the hydrogen component with oxygen at the cathode side to form water, leave the fuel cell system with the cathode exhaust gases via the cathode outlet.

Abstract: A process and apparatus for the production of glass fiber is disclosed. The process and apparatus are directed to collecting filaments being drawn from streams of liquid glass into a plurality of loosely bound strands of filaments which additionally are not treated with any binders. The strands are then drawn off individually on separated but parallel rotating surfaces to provide the filaments with a desired diameter.