Abstract: A rechargeable lithium-ion battery assembly configured to provide power to a forklift vehicle, the battery assembly including a plurality of battery modules integrated into the assembly, where each integrated battery module includes a plurality of battery cells within a module casing, with the cells being grouped and interconnected in both series and parallel to provide in combination an overall predetermined electrical potential between a positive terminal and a negative terminal for each module, and where each module uses two conductors within a printed circuit board assembly (PCBA) as busbars, with the PCBA being disposed adjacent to a first end of each battery cell in the module and being electrically coupled by wire bonds with each battery cell, and the PCBA also having a processor (a battery management system, or BMS) for management control of the integrated module.

Abstract: Disclosed embodiments involve a rechargeable lithium-ion battery module assembly for use as an auxiliary power unit (APU), particularly in commercial trucks. Battery module assembly is recharged through the semi-trailer truck's alternator during engine operation. Battery module assembly has active voltage control capabilities to reduce charge time. Each battery array has two collector plate printed circuit board assemblies (PCBA) and two banks of lithium iron phosphate (LFP) battery cells. Individual battery cells are wire bonded to the collector plate PCBs, one of such PCBs incorporates a battery management system to monitor the electrical parameters and state of charge of the battery cells in the system. Battery cells are thermally coupled to an aluminum enclosure with a thermal gap filling material. Using different chemistries for the APU and the starting battery of the commercial truck, and methods of sequential charge and discharge cycles of each, without any other discrete device.

Abstract: Many embodiments involve rechargeable battery assemblies that are forklift-battery-sized but that comprise multiple built in battery modules. A housing typically contains battery modules installed within the assembly as the assembly is typically symmetrical in configuration. Each battery module has an integrated battery supervisor system (BSS). A Battery Operating System Supervisor (BOSS) module processor serves as a battery management system for all the battery modules. The BOSS module grants permissions to battery modules to enable them to connect and disconnect from busbars at the appropriate times to prevent electrical issues.

Abstract: A turbomachine includes a shroud and a rotor, which includes first and second blades. A first blade tip and a second blade tip respectively include a base and a first layer. The second blade tip also includes an abrasive second layer layered over the respective first layer. The first layer has a lower material hardness than the shroud. The second layer has a lower thermal stability than the shroud and the first layer. The rotor performs a grind operation and, subsequently, a post-grind operation. The second layer, in the grind operation, contacts and removes material from the shroud, and wears away, thereby revealing the first layer of the second blade tip for the post-grind operation. The first layer of the first blade tip is spaced apart with at least some radial clearance from the shroud in the grind and post-grind operations.

Abstract: Many embodiments involve rechargeable battery assemblies that are forklift-battery-sized but that comprise multiple built in battery modules. A housing typically contains battery modules installed within the assembly as the assembly is typically symmetrical in configuration. Each battery module has an integrated battery supervisor system (BSS). A Battery Operating System Supervisor (BOSS) module processor serves as a battery management system for all the battery modules. The BOSS module grants permissions to battery modules to enable them to connect and disconnect from busbars at the appropriate times to prevent electrical issues.

Abstract: Many embodiments involve rechargeable battery assemblies that are forklift-battery-sized but that comprise multiple removable battery modules. The removable battery modules are individually rechargeable and are interchangeable with each other. A housing contains six battery modules installed vertically on the front side of the assembly, with their electrical and data connections occurring within the housing on the rear side. Assemblies will be two sided so that the system has two racks with six modules per rack. The handles of each module are collapsible and on the top edges of the overall assembly so that they are readily accessible during removal. Each battery module has an integrated battery supervisor system (BSS). A Battery Operating System Supervisor (BOSS) module processor serves as a battery management system for the all the battery modules. The BOSS module grants permissions to battery modules to enable them to connect and disconnect from busbars at the appropriate times to prevent electrical issues.

Abstract: A turbomachine includes a shroud and a rotor, which includes first and second blades. A first blade tip and a second blade tip respectively include a base and a first layer. The second blade tip also includes an abrasive second layer layered over the respective first layer. The first layer has a lower material hardness than the shroud. The second layer has a lower thermal stability than the shroud and the first layer. The rotor performs a grind operation and, subsequently, a post-grind operation. The second layer, in the grind operation, contacts and removes material from the shroud, and wears away, thereby revealing the first layer of the second blade tip for the post-grind operation. The first layer of the first blade tip is spaced apart with at least some radial clearance from the shroud in the grind and post-grind operations.

Abstract: Cladding material is applied by laser to a net-shape. A method of cladding a host component includes installing the component in a fixture. A shroud component is located against the host component adjacent a select location for the cladding. Cladding is applied to the host component to the select location and adjacent to shroud component so that the shroud component defines an edge of the cladding as applied. The edge of the cladding as defined by the shroud component defines a desired cladding profile requiring no/approximately no post-cladding processing to remove over-cladded material.

Abstract: A method of producing an abrasive tip for a turbine blade includes producing or obtaining a metal powder that is mixed with an abrasive ceramic powder and producing or obtaining a metallic mold that is in the shape of an airfoil. The metallic mold includes a hollow interior portion. The method further includes sealing the metal and ceramic powder mixture within the hollow interior portion of the metallic mold under vacuum and subjecting the sealed mold to a hot isostatic pressing process. The hot isostatic pressing process compacts and binds the metal and ceramic powder mixture together into a solid article in the shape of the airfoil. Still further, the method includes slicing the solid article into a plurality of airfoil-shaped slices and bonding one slice of the plurality of airfoil-shaped slices to a tip portion of a turbine blade.

Abstract: A method of producing an abrasive tip for a turbine blade includes producing or obtaining a metal powder that is mixed with an abrasive ceramic powder and producing or obtaining a metallic mold that is in the shape of an airfoil. The metallic mold includes a hollow interior portion. The method further includes sealing the metal and ceramic powder mixture within the hollow interior portion of the metallic mold under vacuum and subjecting the sealed mold to a hot isostatic pressing process. The hot isostatic pressing process compacts and binds the metal and ceramic powder mixture together into a solid article in the shape of the airfoil. Still further, the method includes slicing the solid article into a plurality of airfoil-shaped slices and bonding one slice of the plurality of airfoil-shaped slices to a tip portion of a turbine blade.

Abstract: Cladding material is applied by laser to a net-shape. A method of cladding a host component includes installing the component in a fixture. A shroud component is located against the host component adjacent a select location for the cladding. Cladding is applied to the host component to the select location and adjacent to shroud component so that the shroud component defines an edge of the cladding as applied. The edge of the cladding as defined by the shroud component defines a desired cladding profile requiring no/approximately no post-cladding processing to remove over-cladded material.

Abstract: Many embodiments involve rechargeable battery assemblies that are forklift-battery-sized but that comprise multiple removable battery modules. The removable battery modules are individually rechargeable and are interchangeable with each other. A housing contains six battery modules installed vertically on the front side of the assembly, with their electrical and data connections occurring within the housing on the rear side. Assemblies will be two sided so that the system has two racks with six modules per rack. The handles of each module are collapsible and on the top edges of the overall assembly so that they are readily accessible during removal. Each battery module has an integrated battery supervisor system (BSS). A Battery Operating System Supervisor (BOSS) module processor serves as a battery management system for the all the battery modules. The BOSS module grants permissions to battery modules to enable them to connect and disconnect from busbars at the appropriate times to prevent electrical issues.

Abstract: Dual alloy bladed rotors are provided, as are methods for manufacturing dual alloy bladed rotors. In one embodiment, the method includes arranging bladed pieces in a ring formation such that contiguous bladed pieces contact along shank-to-shank bonding interfaces. The ring formation is positioned around a hub disk, which is contacted by the bladed pieces along a shank-to-hub bonding interface. A metallic sealing material is deposited between contiguous bladed pieces utilizing, for example, a laser welding process to produce an annular seal around the ring formation. A hermetic cavity is then formed, which is circumferentially bounded by the annular seal and which encloses the shank-to-shank and shank-to-hub bonding interface. Afterwards, a Hot Isostatic Pressing process is performed during which the ring formation and the hub disk are exposed to elevated pressures external to the hermetic cavity sufficient to diffusion bond the shank-to-shank and shank-to-hub bonding interface.

Abstract: Dual alloy bladed rotors are provided, as are methods for manufacturing dual alloy bladed rotors. In one embodiment, the method includes arranging bladed pieces in a ring formation such that contiguous bladed pieces contact along shank-to-shank bonding interfaces. The ring formation is positioned around a hub disk, which is contacted by the bladed pieces along a shank-to-hub bonding interface. A metallic sealing material is deposited between contiguous bladed pieces utilizing, for example, a laser welding process to produce an annular seal around the ring formation. A hermetic cavity is then formed, which is circumferentially bounded by the annular seal and which encloses the shank-to-shank and shank-to-hub bonding interface. Afterwards, a Hot Isostatic Pressing process is performed during which the ring formation and the hub disk are exposed to elevated pressures external to the hermetic cavity sufficient to diffusion bond the shank-to-shank and shank-to-hub bonding interface.