Abstract: A method is provided for producing a measuring transducer in order to transform at least one physical variable into at least one electric variable. A plurality of planar, insulating and conductive layers are respectively structured according to predefineable models which are adapted to each other and which are assembled in order to form a multi-layered arrangement.

Abstract: The disclosure relates to a differential pressure transducer unit comprising an over-load protection system which is used to measure low differential pressure in liquids and gases under high static pressure load which can be connected to flanges on the working pressure lines. The differential pressure transducer unit consists of a planar multi-layered arrangement comprising layers which are conductive, insulating and which are insulated from each other, whereby the insulating and conductive layers comprises recesses which at least partially cover each other, wherein the measuring mechanism and the measuring value processing means are accommodated. At least one of the layers is a functional component of the over-load protection system.

Abstract: The disclosure relates to a differential pressure transducer unit comprising an over-load protection system which is used to measure low differential pressure in liquids and gases under high static pressure load which can be connected to flanges on the working pressure lines. The differential pressure transducer unit consists of a planar multi-layered arrangement comprising layers which are conductive, insulating and which are insulated from each other, whereby the insulating and conductive layers comprises recesses which at least partially cover each other, wherein the measuring mechanism and the measuring value processing means are accommodated. At least one of the layers is a functional component of the over-load protection system.

Abstract: The present invention provides a miniature gas turbine engine for power generation. The engine has a highly integrated unitary rotor shaft where turbine, compressor and shaft are made in one piece in one fabrication process. The turbine and compressor are positioned back to back on the shaft in an overhung configuration, allowing the front bearings to be located in the cold zone of the engine. Preferably, the Mold SDM fabrication technique is utilized to make the unitary rotor shaft in one monolithic part out of ceramics such as silicon nitride, eliminating the need for post process assembly while strengthening the integrity, reliability, and performance of the unitary rotor shaft. Integrated with a permanent magnet in the unitary rotor shaft, the miniature gas turbine engine can generate electric power of 1 kW or less. Additionally, the axial length of the miniature gas turbine engine is about 100 mm or less.

Abstract: The present invention provides a miniature gas turbine engine for power generation. The engine has a highly integrated unitary rotor shaft where turbine, compressor and shaft are made in one piece in one fabrication process. The turbine and compressor are positioned back to back on the shaft in an overhung configuration, allowing the front bearings to be located in the cold zone of the engine. Preferably, the Mold SDM fabrication technique is utilized to make the unitary rotor shaft in one monolithic part out of ceramics such as silicon nitride, eliminating the need for post process assembly while strengthening the integrity, reliability, and performance of the unitary rotor shaft. Integrated with a permanent magnet in the unitary rotor shaft, the miniature gas turbine engine can generate electric power of 1 kW or less. Additionally, the axial length of the miniature gas turbine engine is about 100 mm or less.

Abstract: This invention relates to a method of embedding electric components or optical components, such as sensors, in a high-temperature metal and the embedded products produced by the method. In the preferred embodiment the components are embedded on a substrate of the high-temperature metal by being placed on a first insulating layer. A second electrically insulating layer, a low thermal conductivity layer, a high thermal conductivity layer, and a primer layer are then deposited in order. The high thermal conductivity layer is in good thermal contact with the substrate. The high-temperature metal is deposited, preferably as molten drops, on the primer layer and the heat from the drops is conducted by high thermal conductivity layer to the substrate while the components are protected by the low thermal conductivity layer.

Abstract: A method for forming a three-dimensional object by applying segments of complementary material and deposition material so as to form layers of material. Selected segments of material are then shaped after one or more segment is formed. In this manner, layers of material form a block containing the object made of deposition material and surrounded by complementary material. Then, the complementary material which serves as a support structure during forming is removed. Preferably, the complementary material has a lower melting temperature than the deposition material and is removed by heating the block. The deposition material and complementary material are preferably applied by thermal spray deposition but may be applied by weld deposition, liquid slurry, gravity drop or any manual means such as a hand sifter. It is also preferred but not necessary to use masks when applying the material.

Abstract: A system and method for manufacturing an article that is formed by the incremental buildup of layers on a work surface contains a material deposition station to deposit the layers. In addition, a plurality of processing stations are employed. Each processing station performs a separate function such that when the functions are performed in series, a layer of the article is produced and is prepared for the deposition of the next layer. An article transfer apparatus repetitively moves the work surface and any layers formed thereon selectively among the deposition station and the processing stations. The article transfer apparatus continues to move between the processing stations until each layer is processed and a completely manufactured article is produced.

Abstract: A collector electrode and adjacent electric weld torch are placed at a selected distance from a work surface or substrate. An electric welding current is generated so that a welding current arc forms between the collector electrode and the weld torch. A feed metal is then fed into the welding current arc and is melted into molten metal adjacent to the collector electrode. The molten metal is then deposited onto a work surface. The collector electrode and weld torch are positioned so that the welding current arc between the weld torch and the collector electrodes does not penetrate the work surface or the already-deposited metal.

Abstract: A smart structure or an electronic package is formed by thermal spraying utilizing a plurality of masks positioned and removed over a work surface in accordance with a predetermined sequence. The masks correspond to cross sections normal to a centerline through the structure. Masks are placed above a work surface and sprayed with either at least one primary material to form at least one electronic component and a complementary material. In this manner, layers of material form a block of deposition material and complementary material. Then, the complementary material which serves as a support structure during forming may be removed.

Abstract: In a method and apparatus for forming a three-dimensional object, successive layers of metal are welded together to build the object. After each layer is formed a complementary material is placed adjacent the layer. In this manner, layers of material form a block of welded metal and complementary material. Then, all or a portion of the complementary material which serves as a support structure during forming can be removed. The welded layers are milled to a final shape either after each layer is formed or after all layers have been made. Existing CNG machines can be easily modified to practice the method.

Abstract: A method for forming a three-dimensional article by thermal spraying utilizes a plurality of masks having a support layer with a removable liner thereon and a cut-away portion. The masks correspond to cross-sections normal to a centerline through the object. A set of masks defines all cross-sections through the object. A first mask is placed above a work surface and sprayed with a deposition material forming a first layer portion of the deposition material within the cut-out and second layer portion on the liner. The liner and second layer portion of deposition material thereon are removed. A second mask is placed over the remaining support portion of the first mask and sprayed with deposition material therein. Then the liner portion of the second mask and deposition material therein are removed. This process is repeated until the three dimensional article is formed. Then the mask support portions surrounding the article are removed from the article.