Abstract: A piston for a reciprocating piston engine includes a piston body including a piston form and a superalloy overlay cladding and metallurgically bonded with a portion of the piston form. The superalloy overlay includes a first weld layer disposed on the piston form which includes a first plurality of adjoining weld beads. The superalloy overlay further includes a second weld layer disposed on the first weld layer which includes a second plurality of adjoining weld beads.

Abstract: A system for an engine comprises a component manufactured via additive manufacturing. The component includes a first material with a first contraction rate. An insert is disposed in the component and comprises a second material with a second contraction rate that is lower than the first contraction rate. When the component and the insert are exposed to a temperature suitable for sintering, the component contracts around the insert, thereby coupling the insert and the component.

Abstract: A turbocharger shaft includes a connection portion at a connection with a wheel of the turbocharger. The shaft includes a stainless steel cladding at least along one or more grooves of the connection portion to reduce the risk of cold cracking and bending fatigue.

Abstract: A system includes a controller, a pretreating machine, and an additive manufacturing machine. The pretreating machine is coupled to the controller. The pretreating machine includes a pretreater structured to form an interface layer on a component. The additive manufacturing machine is coupled to the controller. The additive manufacturing machine includes a material feed and a forming beam. The material feed is configured to selectively provide a first amount of material on the interface layer. The forming beam is configured to substantially melt the first amount of material, thereby forming a first layer of a first material deposit on the interface layer.

Abstract: A system includes a controller, a pretreating machine, and an additive manufacturing machine. The pretreating machine is coupled to the controller. The pretreating machine includes a pretreater structured to form an interface layer on a component. The additive manufacturing machine is coupled to the controller. The additive manufacturing machine includes a material feed and a forming beam. The material feed is configured to selectively provide a first amount of material on the interface layer. The forming beam is configured to substantially melt the first amount of material, thereby forming a first layer of a first material deposit on the interface layer.

Abstract: A system includes a controller, a pretreating mahine, and an additive manufacturing machine. The pretreating machine is coupled to the controller. The pretreating machine includes a pretreater structured to form an interface layer on a component. The additive manufacturing machine is coupled to the controller. The additive manufacturing machine includes a material feed and a forming beam. The material feed is configured to selectively provide a first amount of material on the interface layer. The forming beam is configured to substantially melt the first amount of material, thereby forming a first layer of a first material deposit on the interface layer.

Abstract: A turbocharger shaft includes a connection portion at a connection with a wheel of the turbocharger. The shaft includes a stainless steel cladding at least along one or more grooves of the connection portion to reduce the risk of cold cracking and bending fatigue.

Abstract: A catalytic device and method for forming a catalytic device are described. The devices and methods described can be used for emissions systems in heavy duty diesel engines. In particular, a method of spin forming a catalytic device generally includes disposing a mat about an outer surface of a catalyst substrate and inserting the catalyst substrate and mat inside a shell. The mat is between the shell and the catalyst substrate. The shell, catalyst substrate, and mat can be spin formed into at least a generally elliptical shape but generally other than a circle shape.

Abstract: A catalytic device and method for forming a catalytic device are described. The devices and methods described can be used for emissions systems in heavy duty diesel engines. In particular, a method of spin forming a catalytic device generally includes disposing a mat about an outer surface of a catalyst substrate and inserting the catalyst substrate and mat inside a shell. The mat is between the shell and the catalyst substrate. The shell, catalyst substrate, and mat can be spin formed into at least a generally elliptical shape but generally other than a circle shape.

Abstract: A catalytic device and method for forming a catalytic device are described. The devices and methods described can be used for emissions systems in heavy duty diesel engines. In particular, a method of spin forming a catalytic device generally includes disposing a mat about an outer surface of a catalyst substrate and inserting the catalyst substrate and mat inside a shell. The mat is between the shell and the catalyst substrate. The shell, catalyst substrate, and mat can be spin formed into at least a generally elliptical shape but generally other than a circle shape.

Abstract: A system and method for removing gases from an engine coolant system. In one embodiment, the system includes a fluid system that is operable to collects gas, and a gas collection system coupled to the fluid system. The system also includes a venturi pump system coupled to the fluid system and to the collection system, where the venturi pump system is operable to extract the gas from the fluid system via the collection system.

Abstract: A system and method for removing gases from an engine coolant system. In one embodiment, the system includes a fluid system that is operable to collects gas, and a gas collection system coupled to the fluid system. The system also includes a venturi pump system coupled to the fluid system and to the collection system, where the venturi pump system is operable to extract the gas from the fluid system via the collection system.

Abstract: A catalytic device and method for forming a catalytic device are described. The devices and methods described can be used for emissions systems in heavy duty diesel engines. In particular, a method of spin forming a catalytic device generally includes disposing a mat about an outer surface of a catalyst substrate and inserting the catalyst substrate and mat inside a shell. The mat is between the shell and the catalyst substrate. The shell, catalyst substrate, and mat can be spin formed into at least a generally elliptical shape but generally other than a circle shape.

Abstract: A fluid pumping apparatus, system, and method are disclosed in which an apparatus according to one embodiment of the invention comprises a housing, an inlet through which the fluid enters the housing, an outlet through which the fluid leaves the housing, a valve comprising a valve member and a valve seat, the valve being positioned between the inlet and the outlet such that the fluid from the inlet must flow through the valve to reach the outlet, and a magnet mechanism, configured to exert a continuous magnetic force. The magnet mechanism is positioned to continuously urge the valve member into a first position. System and method embodiments are also disclosed.

Abstract: An injector is provided which includes a nozzle valve element, a control volume, and an injection control valve for controlling fuel flow from the control volume so as to control nozzle valve movement. Importantly, the injector includes a nozzle valve lift detecting device for detecting nozzle valve lift and providing a nozzle valve element lift feedback signal. In addition, an injection control valve member movement detecting device may be provided for detecting movement of the injection control valve member into open and/or closed positions and generating a control valve member position feedback signal. One or both of the feedback signals may be used for adjusting the timing and/or rate of opening of the injection control valve thereby controlling the timing and/or rate of opening of the nozzle valve element to control the timing and/or rate of fuel injection of subsequent injection events.

Abstract: An EMI/RFI shield for seams and cracks in surfaces of shielded structures disclosed. At least one conductive screen is applied in electrical contact with the surfaces and a conductive coating is applied over the screen to physically bond the screen to the surfaces and to maintain electrical conduction.

Abstract: A method of joining shielding materials used for minimizing passage of electromagnetic and radio frequency energy through the walls of an enclosure, comprising the steps of securing a metallic backing plate to one wall of the enclosure, positioning an end portion of a first sheet of shielding material to the backing plate, then positioning an end portion of second sheet of shielding material atop the end portion of the first sheet of shielding material, and then applying a vibrating tool to the overlapped end portions of the first and second sheets of shielding material to metallurgically bond the facing surfaces of the overlapped shielding materials. A joint structure resulting from practice of the method is also disclosed.