Abstract: An ultrasonic welding apparatus and method for detaching or effecting release of an ultrasonic welding tool stuck or attached to a weldment. The method includes the step of utilizing a mechanism mounted adjacent to the ultrasonic welding tool to hold the weldment in position during welding and/or while the ultrasonic welding tool is withdrawn and, if necessary, using the mechanism to detach the weldment from the ultrasonic welding tool. The method contemplates providing a twist, rotary or axial motion to one of the ultrasonic welding tool or weldment to effect release of the ultrasonic welding tool. The apparatus may include a clamp member having a distinct clamping area or pad located adjacent to the sonotrode or anvil of the ultrasonic welding tool. The clamp mechanism provides vibration control, noise mitigation, and a more uniform boundary condition during welding and facilitates part release upon the completion of the welding process.

Abstract: An ultrasonic welding apparatus and method for detaching or effecting release of an ultrasonic welding tool stuck or attached to a weldment. The method includes the step of utilizing a mechanism mounted adjacent to the ultrasonic welding tool to hold the weldment in position during welding and/or while the ultrasonic welding tool is withdrawn and, if necessary, using the mechanism to detach the weldment from the ultrasonic welding tool. The method contemplates providing a twist, rotary or axial motion to one of the ultrasonic welding tool or weldment to effect release of the ultrasonic welding tool. The apparatus may include a clamp member having a distinct clamping area or pad located adjacent to the sonotrode or anvil of the ultrasonic welding tool. The clamp mechanism provides vibration control, noise mitigation, and a more uniform boundary condition during welding and facilitates part release upon the completion of the welding process.

Abstract: A method and apparatus for joining multiple layers of materials using an ultrasonic welding apparatus. The ultrasonic welding apparatus utilizes a sonotrode to perform a weld between at least the top and intermediate layer of the multi-layer member. Then, either the multi-layer member or the ultrasonic welding apparatus is rotated such that the bottom layer is positioned adjacent the sonotrode wherein the sonotrode forms a weld between at least the bottom layer and intermediate layer of the multi-layer member. The apparatus includes an ultrasonic welding gun having a C-shape frame including a base portion and a head portion. An ultrasonic welding device, including a sonotrode, is secured to the head portion and an anvil secured to the base portion. The ultrasonic welding gun is connected to a robot operative to position the ultrasonic welding gun to perform the welding operation.

Abstract: A method and apparatus for joining multiple layers of materials using an ultrasonic welding apparatus. The ultrasonic welding apparatus utilizes a sonotrode to perform a weld between at least the top and intermediate layer of the multi-layer member. Then, either the multi-layer member or the ultrasonic welding apparatus is rotated such that the bottom layer is positioned adjacent the sonotrode wherein the sonotrode forms a weld between at least the bottom layer and intermediate layer of the multi-layer member. The apparatus includes an ultrasonic welding gun having a C-shape frame including a base portion and a head portion. An ultrasonic welding device, including a sonotrode, is secured to the head portion and an anvil secured to the base portion. The ultrasonic welding gun is connected to a robot operative to position the ultrasonic welding gun to perform the welding operation.

Abstract: An apparatus for ultrasonically welding workpieces that reduces sonotrode adhesion during the ultrasonic welding process. The sonotrode tip has a specific surface configuration, including a curvilinear shaped outer surface combined with a plurality of grooves and lands. Due to the curvilinear surface, the depth of the grooves gradually decreases near the outer edge or periphery of a contact surface of the sonotrode tip. Further, such a groove and land combination also provides a sharp edge or corner that reduces sliding of the tip on the workpiece and correspondingly reduces sticking. In addition, various types of coatings or inserts may also be used to reduce sticking of the sonotrode tip to the workpiece.

Abstract: A method of solid free form fabrication of an object includes the steps of providing a substrate, forming a plurality of molten droplets, and spraying the molten droplets upward against the substrate to form a net shape object.

Abstract: An electrochemical method of modifying the surface hardness of a non-allotropic metal member 10, comprising: (a) forming the member to near net-shape with at least one surface 12 to be hardened; (b) subjecting the surface 12 to rapid melting and resolidification by incidence of an electrical discharge between an electrode 16 and the surface 12 closely spaced thereto, the spacing containing an electrolyte with plasma forming capability, the surface 12 being hardened by crystallographic change of the globules resulting from substitutional alloying; and (c) cropping the surface grains 29 of the surface to increase load bearing capacity while retaining liquid retention capacity.

Abstract: A method of electric arc spraying metal upon an article. The method comprises providing an article to be sprayed, providing a supply of fusible metal feedstock, providing a metal feedstock feeding device, and providing a substrate of conductive heat resistant material. The substrate has a centrally disposed orifice extending therethrough. A source of electrical current is provided having a first electrode electrically coupled with an end of the metal feedstock, and a second electrode electrically coupled with the plate of conductive material. The source of current is activated to establish an electric arc between the metal feedstock and the plate of conductive material. The electrical arc creates a droplet spray of metal from the metal feedstock. The droplet spray is directed through the orifice in the substrate towards the article. The power supply is periodically pulsed between a first current and a second current.

Abstract: A method for producing a composite mandrel (20) for use in creating a precise set of surface features inside a hot isostatic pressed (HIP) billet for producing a desired tool uses a composite nickel shell (16) and ceramic interior (18). A free form fabrication (FFF) or wax positive pattern (10) of the desired tool is made first, then a layer of nickel is deposited on the surface of the FFF positive pattern to produce a nickel shell (16) which is a negative of the desired tool. The final step in creating the composite mandrel (20) is filling the nickel shell (16) with ceramic material (18) to increase the rigidity of the nickel shell thereby forming a mandrel for use in an HIP process to make the desired tool.

Abstract: A swash plate type compressor having a cylinder block with cylinder bores disposed parallel to the axis of the cylinder block. A rotary shaft rotatably mounted within the cylinder block carries an aluminum swash plate. The swash plate is fixed to the rotary shaft and has two facial surfaces and an end surface. The facial surfaces have a coating of between 0.0005 inches to 0.002 inches of a heat curable, cross-linked polyfluoro elastomer bonded directly to the aluminum, a lubricious additive and a load bearing additive. A piston reciprocally fitted within the cylinder bore contains shoes which slideably intervene between the piston and the swash plate facial surfaces and reciprocate the pistons by rotation of the swash plate. The coating on the swash plate permits the use of slow silicon alloy aluminum without the need of metal plating or high finish polishing.