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 tool assembly which is particularly suitable for friction stir welding applications. The tool assembly includes a holder having an axis and one end adapted to be rotatably driven by a rotary drive mechanism about the holder axis. A tool having an axis is also provided and includes a tool tip at one end. A fastener detachably and coaxially secures the holder and tool together. This fastener includes a first part secured to the second end of the holder and a second part secured to the second end of the tool.

Abstract: A method for correcting surface and near surface defects in metal components in which the component is first inspected to identify both the site and size of a component defect. Thereafter, it is determined if the defect is correctable by friction stir processing and, if so, the defect is corrected by performing friction stir processing on the component at the site of the defect. Optionally, one of several different sized friction stir processing tools is selected as a function of the size of the defect.

Abstract: A fuel pump for a direct injection internal combustion engine having a body with a valve seat. The valve includes a valve head and the valve is movably mounted to the body between an open position and a closed position. In its open position, the valve head is spaced from the valve seat white in its closed position, the valve head abuts against the valve seat and closes the valve. An electric coil upon energization moves the valve to an open position and, conversely, upon deenergization allows the valve to move to a closed position. A control circuit controls the energization of the coil to reduce the pump noise during operation of the engine, especially at low speeds.

Abstract: A friction stir spot welding tool having a rotatably driven shank. A shoulder adjacent to one end of the shank is generally circular in shape having a concave profile while a pin having a generally triangular cross-sectional shape protrudes axially outwardly from the shoulder. To perform the spot welding operation, the shank is rotatably driven and the shoulder is plunged into the workpiece such that the pin penetrates past the workpiece interface to a predetermined depth to perform the spot weld. The proposed triangular pin tool is found to significantly increase the weld strength when compared to conventional pin shaped tools due to the following: (1) it inhibits the formation of the vertical hook in the stir zone (the upward rise of the hook is arrested when the pin plunges into the workpieces interface), and (2) due to the asymmetric rotational pattern of the triangular pin it enhances the mixing of the material around the tool pin and oxide layer is dispersed (made discontinuous) in the stir zone.

Abstract: A fuel pump for a direct injection internal combustion engine having a body with a valve seat. The valve includes a valve head and the valve is movably mounted to the body between an open position and a closed position. In its open position, the valve head is spaced from the valve seat white in its closed position, the valve head abuts against the valve seat and closes the valve. An electric coil upon energization moves the valve to an open position and, conversely, upon deenergization allows the valve to move to a closed position. A control circuit controls the energization of the coil to reduce the pump noise during operation of the engine, especially at low speeds.

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 tool assembly which is particularly suitable for friction stir welding applications. The tool assembly includes a holder having an axis and one end adapted to be rotatably driven by a rotary drive mechanism about the holder axis. A tool having an axis is also provided and includes a tool tip at one end. A fastener detachably and coaxially secures the holder and tool together. This fastener includes a first part secured to the second end of the holder and a second part secured to the second end of the tool.

Abstract: A housing for an electrical circuit having a metal base with an open top and a metal lid which overlies the open top of the base and forms an interior chamber adapted to contain an electronic circuit. The outer periphery of the lid is attached to the base by friction stir welding to thereby form a hermetically sealed chamber dimensioned to contain an electronic circuit. An electronic port is electrically connected to the electronic circuit and accessible exteriorly of the housing.

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 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.

Abstract: A method for correcting surface and near surface defects in metal components in which the component is first inspected to identify both the site and size of a component defect. Thereafter, it is determined if the defect is correctable by friction stir processing and, if so, the defect is corrected by performing friction stir processing on the component at the site of the defect. Optionally, one of several different sized friction stir processing tools is selected as a function of the size of the defect.

Abstract: A tool assembly which is particularly suitable for friction stir welding applications. The tool assembly includes a holder having an axis and one end adapted to be rotatably driven by a rotary drive mechanism about the holder axis. A tool having an axis is also provided and includes a tool tip at one end. A fastener detachably and coaxially secures the holder and tool together. This fastener includes a first part secured to the second end of the holder and a second part secured to the second end of the tool.

Abstract: A housing for an electrical circuit having a metal base with an open top and a metal lid which overlies the open top of the base and forms an interior chamber adapted to contain an electronic circuit. The outer periphery of the lid is attached to the base by friction stir welding to thereby form a hermetically sealed chamber dimensioned to contain an electronic circuit. An electronic port is electrically connected to the electronic circuit and accessible exteriorly of the housing.