Abstract: A method for chemical processing an internal cavity of an additive manufactured (AM) metal workpiece is disclosed in which a connector is provided in fluid connection with the internal cavity and a chemical polishing solution is flowed through the connector and the internal cavity to process the internal cavity to a desired finish.

Abstract: A highly reactive conversion coating chemistry is used during CAVF processing of high hardness steel alloys such as AMS 6509 and AMS 6517 steel alloys. This chemistry produces a hard, thin, black conversion coating that is not fully rubbed off by the media during the CAVF process. Distressed material regions on the surface of the alloys are not susceptible to forming the conversion coating and remain white. Visual inspection for the presence of such regions is facilitated.

Abstract: A method for chemical processing an internal cavity of an additive manufactured (AM) metal workpiece is disclosed in which a connector is provided in fluid connection with the internal cavity and a chemical polishing solution is flowed through the connector and the internal cavity to process the internal cavity to a desired finish.

Abstract: A highly reactive conversion coating chemistry is used during CAVF processing of high hardness steel alloys such as AMS 6509 and AMS 6517 steel alloys. This chemistry produces a hard, thin, black conversion coating that is not fully rubbed off by the media during the CAVF process. Distressed material regions on the surface of the alloys are not susceptible to forming the conversion coating and remain white. Visual inspection for the presence of such regions is facilitated.

Abstract: A wind-turbine gearbox system includes an input gear stage having mating gear surfaces finished to a surface roughness of less than 0.25 micron and at least one bearing supporting the input gear stage. A lubrication circuit is arranged to deliver lubricant to the input gear stage and the bearing during operation of the wind-turbine and includes an inline filter for removal of particles of less than 2 micron from the lubricant prior to delivery. A lubricant for use in the system may have a relatively low viscosity compared to conventional wind turbine gearbox lubricants.

Abstract: A method for finishing a surface of a metal component is carried out in a receptacle containing a quantity of non-abrasive media. The component is at least partially immersed in the media and a quantity of active finishing chemistry is supplied. The chemistry forms a relatively soft conversion coating on the surface. By inducing high energy relative movement between the surface and the media the coating can be continuously removed. The method may be carried out in a drag finishing machine.

Abstract: A fixture is provided for retaining a metal workpiece for contact by finishing media during operation of a media based finishing operation. The fixture comprises a body and a magnet for retaining the workpiece in contact with the body. By use of super-magnetic materials a significant holding force may be achieved.

Abstract: Refurbishing used or damaged engineering components is performed using a subtractive surface engineering process to remove material from worn or damaged critical surfaces. The method involves initially performing the process on the component to remove a first quantity of material from the surfaces, inspecting the surface of the component to determine the extent of damage and subsequently further performing the process to remove a further quantity of material if necessary.

Abstract: A method of superfinishing a large hollow wheel gear in a vibratory bowl having a center hub comprises at least partially filling the vibratory bowl with an amount of finishing media, laying the gear horizontally into the bowl over the center hub, supplying a quantity of an active chemistry into the bowl and agitating the vibratory bowl at a frequency such that the gear settles into and is fully supported by the media. By controlling the process parameters, the hollow wheel gear may be caused to rotate in the media and can be made to float at a desired level. The method is particularly suitable for hollow wheel gears for large wind turbines.

Abstract: Disclosed herein is a new improved large planetary gear system used on the input stage of wind turbine power generators. This improved planetary gear system reduces or eliminates lubricant debris traditionally generated from the gear teeth, thereby eliminating an initiating source for bearing failure. To achieve these results, some and preferably all of the gear teeth within the planetary gear system are superfinished using chemically accelerated vibratory finishing to a surface roughness of approximately 0.25 micron or less. Several objects and advantages of the invention are to provide a gearbox with reduced metal debris, improved bearing life, reduced wear, reduced vibro-frictional noise, improved contact fatigue, improved fretting resistance, improved lubrication, to simplify the run-in process, and to enhance the durability and efficiency of the gearbox.

Abstract: Disclosed herein is a new improved large planetary gear system used on the input stage of wind turbine power generators. This improved planetary gear system reduces or eliminates lubricant debris traditionally generated from the gear teeth, thereby eliminating an initiating source for bearing failure. To achieve these results, some and preferably all of the gear teeth within the planetary gear system are superfinished using chemically accelerated vibratory finishing to a surface roughness of approximately 0.25 micron or less. Several objects and advantages of the invention are to provide a gearbox with reduced metal debris, improved bearing life, reduced wear, reduced vibro-frictional noise, improved contact fatigue, improved fretting resistance, improved lubrication, to simplify the run-in process, and to enhance the durability and efficiency of the gearbox.

Abstract: A method for finishing a surface of a metal component is carried out in a receptacle containing a quantity of non-abrasive media. The component is at least partially immersed in the media and a quantity of active finishing chemistry is supplied. The chemistry forms a relatively soft conversion coating on the surface. By inducing high energy relative movement between the surface and the media the coating can be continuously removed. The method may be carried out in a drag finishing machine.

Abstract: A method for superfinishing a high density carbide steel component using chemically accelerated finishing is provided. The high density carbide steel component is vibrated in a vessel containing a plurality of media, with active chemistry being added to the vessel at a low flow rate. An active chemistry composition is also provided, consisting of one or more conversion coating agents having preferably a phosphate radical, and one or more chelating agents preferably including citric acid.

Abstract: The invention is an improvement in the metal finishing processes disclosed in U.S. Pat. No. 4,818,333. The improvement arises in the use of nonabrasive media, such as stainless steel or plastic, in combination with chemicals that are reactive to the metal surface processed. The invention also includes metal articles finished using this process.

Abstract: A low inductance bus bar arrangement suitable for industrial voltage levels, and for power applications contains two or more elongate electrical conducting bars having rounded edges. Strips of dielectric insulating material are located between two of the elongate electrical conducting bars. The conducting bars are oriented in substantially parallel relationship to one another with the dielectric insulating material having a height of the cross-section thereof substantially greater than the height of the cross-section of the conducting bars. The bus bar arrangement also provides low inductance to the connecting devices.

Abstract: A heart pump having a housing with a central longitudinal axis, inlet means and an outlet means is disclosed. A stationary shaft extends axially within the housing and the means are provided for supporting the shaft centrally located within the housing. A stator assembly is mounted about the stationary shaft and a shell assembly is rotatable about the stator assembly and shaft. The shell assembly is located between the housing and stator assembly and includes a spiral ridge located on the outerside thereof for pumping blood through the housing between the housing and shell assembly as the shell assembly rotates. Rotor laminations are located on an innerside of the shell assembly. The rotor laminations have a plurality of axially extending permanent magnets therebetween which are circumferentially spaced about the stationary shaft. A damper winding means is mounted within the rotor laminations. Blood may flow between the shell assembly and housing without exposure to magnetic fields.

Abstract: A rotor for a dynamoelectric machine, without windings and rotatable about a central longitudinal axis, having an axially extending rotatable body and a toroidal magnet coaxially mounted on the body is constructed to provide magnetic exitation for the rotor. The rotatable body contains a first set of circumferentially spaced axially extending salient poles with circumferentially spaced recesses therebetween and a second set of similar poles at an opposite axial location. The toroidal magnet is coaxially mounted on the body between the first and second set of salient poles. A second toroidal magnet may also be mounted on the body and a magnetic spacer placed in between both toroidal magnets.

Abstract: A support and positioning structure for a stator assembly of an inductor type dynamoelectric machine is disclosed. The stator assembly includes a plurality of stationary C-shaped armature elements circumferentially located about a central longitudinal axis and supported by end portions. The C-shaped armature elements include armature windings on a base portion extending parallel to the longitudinal axis and legs extending from each end in a radially inward direction. The support structure includes a nonmagnetic ring shaped member sized to be insertable over the bases of the circumferentially spaced C-shaped armature elements. The bases are in contact with an inner portion of the ring shaped member to thereby position the C-shaped armature elements. The ring shaped member may provide improved cooling effects if made of a heat conductive material and may allow air gap tolerances within the stator assembly to be minimized.

Abstract: A system for supporting conductors in a dynamoelectric machine having a stator assembly with a plurality of stationary armature elements spaced about a circumference positioned radially about a central longitudinal axis, where each armature element includes an armature winding on a base portion and a leg extending from each of the base portions in a radially inward direction, includes a spacer for supporting one or more electrical conductors and for insulating the one or more conductors for an armature element. The spacer is mountable on the armature element and may comprise one or more grooves for supporting one or more interconnecting bars which are capable of connecting the armature windings of two or more armature elements. The spacers may be fastened to the stator assembly and allow the stator assembly to be equipped with conductors which may be oriented in a pattern which minimizes conductor length and minimizes energy losses.

Abstract: The presence, size and location of a crack in a shaft is determined by comparing actual measured natural frequencies of the operating shaft system with the results of an analytical model. From a multi-station analytical model of an uncracked operating shaft system, natural frequencies and associated mode shapes are derived. A suspected axial location of a crack is defined, and a natural frequency of interest is selected which has an associated mode shape exhibiting significant localized bending at the suspected axial location of the crack and at a site of response measurement. The analytical model is modified to include a representation of an asymmetric crack at the suspected crack location. A predicted split and downward shift of a lateral natural frequency of interest as a function of crack depth and/or a predicted downward shift of a torsional natural frequency of interest as a function of crack depth is calculated from the modified model.