Abstract: A process for designing and manufacturing a cavitation erosion resistant component. The process includes selecting a base material for use in a cavitation erosion susceptible environment and conducting a uniaxial loading test on a sample of the selected material. Thereafter, atomic force microscopy (AFM) topography on a surface of the tested sample is conducted and used to provide a surface strain analysis. The process also includes crystal plasticity finite element modeling (CPFEM) of uniaxial loading and CPFEM nanoindentation of the selected material over a range of values for at least one microstructure parameter. A subrange of microstructure parameter values that correlate to CPFEM nanoindentation results that provide increased CE resistance is determined. Finally, a component having an average microstructure parameter value that falls within the subrange of microstructure parameter values is manufactured.

Abstract: A fuel delivery system for a direct injection internal combustion engine having two fuel rails and a plurality of fuel injectors attached to and fluidly connected with each fuel rail. A first fuel pump has its output connected with the first fuel rail while a second fuel pump has its output connected with the second fuel rail. A crossover pipe fluidly connects the outlets of both the first and second pumps. Both the first pump and the second pump each have an intake stroke and a pumping stroke. Furthermore, the intake stroke of the first pump coincides with the pumping stroke of the second pump and vice versa.

Abstract: A process for designing and manufacturing a cavitation erosion resistant component. The process includes selecting a base material for use in a cavitation erosion susceptible environment and conducting a uniaxial loading test on a sample of the selected material. Thereafter, atomic force microscopy (AFM) topography on a surface of the tested sample is conducted and used to provide a surface strain analysis. The process also includes crystal plasticity finite element modeling (CPFEM) of uniaxial loading and CPFEM nanoindentation of the selected material over a range of values for at least one microstructure parameter. A subrange of microstructure parameter values that correlate to CPFEM nanoindentation results that provide increased CE resistance is determined. Finally, a component having an average microstructure parameter value that falls within the subrange of microstructure parameter values is manufactured.

Abstract: A fuel delivery system for an internal combustion engine having a fuel pump with a high pressure outlet. A fuel rail defining an internal fuel chamber is fluidly connected to the fuel pump outlet. Additionally, at least two fuel injectors are fluidly connected to the fuel rail internal fuel chamber. At least one fluid check valve is fluidly positioned within the fuel rail in between two of the fuel injectors which reduces fuel pressure pulsations.

Abstract: A fuel delivery system for an internal combustion engine having a fuel pump with a high pressure outlet. A fuel rail defining an internal fuel chamber is fluidly connected to the fuel pump outlet. Additionally, at least two fuel injectors are fluidly connected to the fuel rail internal fuel chamber. At least one fluid check valve is fluidly positioned within the fuel rail in between two of the fuel injectors which reduces fuel pressure pulsations.

Abstract: A fuel pump having a housing which defines a pump chamber with an inlet and an outlet. A piston is reciprocally mounted in the pump chamber. An inlet valve is mounted fluidly in series between the pump chamber and the housing inlet which opens and closes the inlet in synchronism with the reciprocation of the piston. A rotary valve is mounted fluidly in series with the housing outlet and the rotary outlet valve is rotatably driven in synchronism with reciprocation of the piston. The rotary valve is configured so that it is fluidly open only at one or more predetermined angular positions of the rotary outlet valve. The open and close timings of the rotary inlet and outlet valves are completely controlled by a motor in order to control the fuel pressure, especially to avoid excessive fuel compression and resulting fuel pressure fluctuation.

Abstract: A fuel delivery system for a direct injection internal combustion engine having two fuel rails and a plurality of fuel injectors attached to and fluidly connected with each fuel rail. A first fuel pump has its output connected with the first fuel rail while a second fuel pump has its output connected with the second fuel rail. A crossover pipe fluidly connects the outlets of both the first and second pumps. Both the first pump and the second pump each have an intake stroke and a pumping stroke. Furthermore, the intake stroke of the first pump coincides with the pumping stroke of the second pump and vice versa.

Abstract: A fuel delivery system for a direct injection internal combustion engine having two fuel rails and a plurality of fuel injectors attached to and fluidly connected with each fuel rail. A first fuel pump has its output connected with the first fuel rail while a second fuel pump has its output connected with the second fuel rail. A crossover pipe fluidly connects the outlets of both the first and second pumps. Both the first pump and the second pump each have an intake stroke and a pumping stroke. Furthermore, the intake stroke of the first pump coincides with the pumping stroke of the second pump and vice versa.

Abstract: A high pressure fuel pump for use with a direct injection engine having a housing which defines a pump chamber. A port is formed in the housing which fluidly connects a fuel in the passageway with the pump chamber. An elongated valve is movably mounted within the housing between an open and a closed position. In its open position, the inlet passageway is fluidly connected with the pump chamber while, conversely, in the closed position the fuel valve blocks the fluid flow between the inlet passageway and the pump chamber. A circuit controls the deceleration of the valve to reduce pump noise.

Abstract: A high pressure fuel pipe construction for an internal combustion engine, such as a direct injection engine. A conduit for the fuel is open at each end and a ball having a throughbore is slidably positioned over one end of the conduit. A reinforcing sleeve is positioned inside the end of the conduit so that the sleeve extends entirely through the ball. The sleeve, ball and the end of the conduit are then brazed together to attach the ball and conduit together. A double chamfer is provided at one end of the ball throughbore to facilitate inspection of the brazing quality. Additionally, a loop is formed in the conduit and a dampener is attached to the loop.

Abstract: A fuel delivery system for a direct injection internal combustion engine having two fuel rails and a plurality of fuel injectors attached to and fluidly connected with each fuel rail. A first fuel pump has its output connected with the first fuel rail while a second fuel pump has its output connected with the second fuel rail. A crossover pipe fluidly connects the outlets of both the first and second pumps. Both the first pump and the second pump each have an intake stroke and a pumping stroke. Furthermore, the intake stroke of the first pump coincides with the pumping stroke of the second pump and vice versa.

Abstract: A noise reduction system for an automotive vehicle powered at least in part by an electric motor located separately from the passenger compartment. The system includes at least one sensor which produces an output signal having a frequency, amplitude and phase representative of noise generated by the electric motor. At least one speaker is positioned closely adjacent the electric motor. A speaker output controller receives the output from the sensor as an input signal and generates an output signal to the speaker so that the speaker produces an audible signal having substantially the same frequency and amplitude but inverted in phase relative to the output from the sensor.

Abstract: A high pressure fuel pipe construction for an internal combustion engine, such as a direct injection engine. A conduit for the fuel is open at each end and a ball having a throughbore is slidably positioned over one end of the conduit. A reinforcing sleeve is positioned inside the end of the conduit so that the sleeve extends entirely through the ball. The sleeve, ball and the end of the conduit are then brazed together to attach the ball and conduit together. A double chamfer is provided at one end of the ball throughbore to facilitate inspection of the brazing quality. Additionally, a loop is formed in the conduit and a dampener is attached to the loop.

Abstract: A high pressure fuel pipe construction for an internal combustion engine, such as a direct injection engine. A conduit for the fuel is open at each end and a ball having a throughbore is slidably positioned over one end of the conduit. A reinforcing sleeve is positioned inside the end of the conduit so that the sleeve extends entirely through the ball. The sleeve, ball and the end of the conduit are then brazed together to attach the ball and conduit together. A double chamfer is provided at one end of the ball throughbore to facilitate inspection of the brazing quality. Additionally, a loop is formed in the conduit and a dampener is attached to the loop.

Abstract: A high pressure fuel pump for use with a direct injection engine having a housing which defines a pump chamber. A port is formed in the housing which fluidly connects a fuel in the passageway with the pump chamber. An elongated valve is movably mounted within the housing between an open and a closed position. In its open position, the inlet passageway is fluidly connected with the pump chamber while, conversely, in the closed position the fuel valve blocks the fluid flow between the inlet passageway and the pump chamber. A circuit controls the deceleration of the valve to reduce pump noise.

Abstract: A fuel delivery system for a direct injection internal combustion engine which reduces mechanical stress on the fuel system components. The system includes a first and a second fuel rail mounted to the engine block for the internal combustion engine. A device is attached to the fuel rails which reduces movement of the fuel rails relative to the engine block and mechanical stress that would otherwise result from such movement.

Abstract: A method for fabricating multi-sheet structures in which a first sheet is arranged on a planar support and a blowing agent is placed on at least one selected portion of the first sheet. A second sheet is positioned over the first sheet so that the second sheet overlies the selected portion of the first sheet and the first and second sheets are then secured together by friction stir welding in a pattern which encloses the selected portion of the first sheet. Additional sheets may be secured together in a like fashion. Thereafter, the sheets are heated to a temperature sufficient to decompose the blowing agent.

Abstract: A method for monitoring the quality of a machining operation, such as a friction stir welding operation, in which a tool is rotatably driven by a motor during the machining operation. The energy consumption of the motor is determined from the initiation and to the completion of the machining operation. That energy consumption is then compared against a predetermined energy threshold. In the event that the energy consumed during the machining operation is less than the predetermined threshold, an error signal is generated.

Abstract: A fuel delivery system for a direct injection internal combustion engine which reduces mechanical stress on the fuel system components. The system includes a first and a second fuel rail mounted to the engine block for the internal combustion engine. A device is attached to the fuel rails which reduces movement of the fuel rails relative to the engine block and mechanical stress that would otherwise result from such movement.

Abstract: A method and apparatus for attenuating fuel pump noise in a direct injection internal combustion engine. In one proposal, the direct injection fuel nozzle is suspended from a fuel rail in a fashion that avoids direct metal-to-metal contact between the injector and the engine block. The direct injection nozzle may also be connected to the fuel rail by a pair of spaced-apart seals which equalize the longitudinal pressure on the nozzle during operation. Enlarged diameter fuel reservoirs and/or a restricted orifice may be provided fluidly in series between the fuel pump and the direct injection nozzle in order to attenuate noise resulting from fuel pump pulsation.