Abstract: Disclosed herein is a composite core die comprising a reusable core die; and a disposable core die; wherein the disposable core die is in physical communication with the reusable core die; and further wherein surfaces of communication between the disposable core die and the reusable core die serve as barriers to prevent the leakage of a slurry that is disposed in the composite core die.

Abstract: Disclosed herein is a method comprising disposing a casting composition within a sacrificial die; wherein internal features of the sacrificial die provide a replica of a desired casting; wherein the casting composition has a viscosity of about 1 to about 1,000 Pascal-seconds at room temperature when tested at a shear rate of up to 70 seconds?1; reacting the casting composition to form a gel matrix; removing the sacrificial die; extracting a solvent from the gel matrix to form a dried gel; and firing the dried gel to form a ceramic core. Disclosed herein too is a casting composition comprising a monomer and/or a polymer; and a metal and/or ceramic powder; wherein the casting composition has a viscosity of about 1 to about 1,000 Pascal-seconds at room temperature when tested at a shear rate of up to 70 seconds?1 and a flow index of less than 0.6.

Abstract: A method of curing a coating on a metal conductor comprising: (a) connecting the metal conductor in series with a power transformer; and (b) passing a current through the metal conductor so as to achieve a temperature sufficient to cure the coating.

Abstract: Disclosed herein is a spray coating process for a robotic spray gun assembly comprising importing a discretized model of an object geometry to be coated; importing a numerically characterized spray pattern file; importing a robot motion file comprising a plurality of motion positions, dwell times and orientations defining a spray direction of the robotic spray gun; reading each motion position within the motion file; determining which portions of the object geometry are visible at each motion position; computing a void volume fraction at each visible portion of the object geometry based on the core compression, the incident angle of the robotic spray gun and the ricocheting of the spray for each motion position; and calculating total coating thickness on portions of the object geometry for the complete motion step.

Abstract: An insulated stator bar and method of applying an outer insulation to a bare stator bar to form the insulated stator bar. The outer insulation surrounds a perimeter of the bare bar and extends along a longitudinal length of the bar. The outer insulation comprises at least one extruded member, e.g., a single extruded member, two individual extruded members, etc., containing an electrical insulation material. The at least one extruded member comprises an opposing pair of edges parallel to the longitudinal length of the bar. The edges are attached together so that the perimeter of the bar is entirely enclosed by the at least one extruded member.

Abstract: A simulation system for generating a predicted performance for fabricated parts comprises a rheological degradation database for storing rheological degradation data for associated materials, a mechanical degradation database for storing mechanical degradation data for associated materials and a computer coupled to the rheological degradation database and the mechanical degradation database for computing part performance predictions for a respective material with a predetermined geometry under predetermined processing conditions, partially based on the rheological degradation data and the mechanical degradation data.

Abstract: A slot armor component for use in a rotor of a dynamo-electric machine comprises a plurality of profile co-extruded polymer layers. The composite cross-section of the profile co-extruded layers may include a first leg portion and a second leg portion disposed at an angle to the first leg portion. The plurality of co-extruded polymer layers may include a glass-filled polymer layer arranged between two unfilled polymer layers such as a glass-filled Ultem layer having a glass-fill concentration equal to or less than 30% arranged between two unfilled Ultem layers or a glass-filled polyetheretherketone (PEEK) layer having a glass-fill concentration equal to or less than 30% arranged between two unfilled PEEK layers.

Abstract: An insulated stator bar and method of applying an outer insulation to a bare stator bar to form the insulated stator bar. The outer insulation surrounds a perimeter of the bare bar and extends along a longitudinal length of the bar. The outer insulation comprises at least one extruded member, e.g., a single extruded member, two individual extruded members, etc., containing an electrical insulation material. The at least one extruded member comprises an opposing pair of edges parallel to the longitudinal length of the bar. The edges are attached together so that the perimeter of the bar is entirely enclosed by the at least one extruded member.

Abstract: A synthetic model of a component is created from a 3-D numerical model thereof. A core is then cast inside the synthetic model. The synthetic model may then be removed from the cast core, and then the cast core is used for casting an authentic component therearound. The core is removed from inside the authentic component, which authentic component precisely matches the original synthetic model therefor.

Abstract: An insulated stator bar and method of applying an outer insulation to a bare stator bar to form the insulated stator bar. The outer insulation surrounds a perimeter of the bare bar and extends along a longitudinal length of the bar. The outer insulation comprises at least one extruded member, e.g., a single extruded member, two individual extruded members, etc., containing an electrical insulation material. The at least one extruded member comprises an opposing pair of edges parallel to the longitudinal length of the bar. The edges are attached together so that the perimeter of the bar is entirely enclosed by the at least one extruded member.

Abstract: A method for enabling design of a profile extrusion capping die includes, obtaining a size and configuration of a land formable by the capping die, obtaining material properties of a capping resin, obtaining operating conditions for processing the capping resin, and determining, from the size and configuration of the land, the material properties, the operating conditions, at least one of a velocity distribution and a pressure distribution of the capping resin adjacent to an outlet of the land. Desirably, the method also includes obtaining a size and configuration of a runner formable by the profile extrusion capping die, and determining at least one of the velocity distribution and the pressure distribution of the capping resin in the land and the runner. Advantageously, the method is implemented on a system or computer using a finite element mesh of the land and the runner and graphically displaying the velocity distribution and the pressure distribution.

Abstract: A slot armor component for use in a rotor of a dynamo-electric machine comprises a plurality of profile co-extruded polymer layers. The composite cross-section of the profile co-extruded layers may include a first leg portion and a second leg portion disposed at an angle to the first leg portion. The plurality of co-extruded polymer layers may include a glass-filled polymer layer arranged between two unfilled polymer layers such as a glass-filled Ultem layer having a glass-fill concentration equal to or less than 30% arranged between two unfilled Ultem layers or a glass-filled polyetheretherketone (PEEK) layer having a glass-fill concentration equal to or less than 30% arranged between two unfilled PEEK layers.

Abstract: A method for making an article by an investment casting process is presented, along with a method for making casting cores, the casting cores made by this method, and dies for making such cores. The method for making a component comprises providing a single-piece sacrificial die, the die comprising at least one internal cavity; introducing a ceramic slurry into the at least one cavity of the die, the slurry comprising a ceramic and a carrier fluid; curing the slurry to form a ceramic casting core; removing the sacrificial die by exposing the die to an environment adapted to destroy the die while leaving the ceramic casting core intact; and performing an investment casting process using the ceramic casting core as part of a mold-core assembly to form the component.

Abstract: A slot armor component for use in a rotor of a dynamo-electric machine comprises a profile extruded material having a first leg portion and a second leg portion disposed at an angle to the first leg portion, the second leg portion being shorter and thicker than the first leg portion. The material may be glass-filled polyetheretherketone (PEEK) such as a less than or equal to 30% (â30%) glass-filled polyetheretherketone (PEEK). Alternatively, the material may be unfilled polyetheretherketone (PEEK), glass-filled Ultem such as less than or equal to 30% (â30%) glass-filled Ultem, or unfilled Ultem.

Abstract: A slot armor component for use in a rotor of a dynamo-electric machine comprises a plurality of profile co-extruded polymer layers. The composite cross-section of the profile co-extruded layers may include a first leg portion and a second leg portion disposed at an angle to the first leg portion. The plurality of co-extruded polymer layers may include a glass-filled polymer layer arranged between two unfilled polymer layers such as a glass-filled Ultem layer having a glass-fill concentration equal to or less than 30% arranged between two unfilled Ultem layers or a glass-filled polyetheretherketone (PEEK) layer having a glass-fill concentration equal to or less than 30% arranged between two unfilled PEEK layers.

Abstract: An electrode for rejuvenating a cooling passage within an airfoil, the electrode including a tip, an end, a conductive core extending between the tip and the end, and an insulating coating disposed on the conductive core. The insulating coating exposes a number of conductive strips of the conductive core extending between the tip and the end. The insulating coating forms a number of insulating portions and further exposes a number of spacer portions of the conductive core longitudinally positioned between the insulating portions. The insulating portions substantially span a distance between the tip and the end and are positioned between the conductive strips.

Abstract: A method for controlling distortion of a turbine case (“case”) includes measuring a temperature distribution for the case that includes thermal gradients. The method further includes modeling thermal stresses on the case induced by the thermal gradients, calculating an out of roundness index (“index”) resulting from the thermal stresses, and comparing the index with at least one distortion limit to determine whether the case has a satisfactory or an unsatisfactory index. The temperature distribution is controlled for an unsatisfactory index to produce the satisfactory index. A system for controlling distortion of the turbine case includes a thermal measurement system, for measuring the temperature distribution, and a computer configured for modeling the thermal stresses, calculating and comparing the index with the distortion limit, and controlling the temperature distribution for an unsatisfactory index to produce the satisfactory index.

Abstract: An electrode for rejuvenating a cooling passage within an airfoil, the electrode including a tip, an end, a conductive core extending between the tip and the end, and an insulating coating disposed on the conductive core. The insulating coating exposes a number of conductive strips of the conductive core extending between the tip and the end. The insulating coating forms a number of insulating portions and further exposes a number of spacer portions of the conductive core longitudinally positioned between the insulating portions. The insulating portions substantially span a distance between the tip and the end and are positioned between the conductive strips.

Abstract: A method for controlling distortion of a turbine case (“case”) includes measuring a temperature distribution for the case that includes thermal gradients. The method further includes modeling thermal stresses on the case induced by the thermal gradients, calculating an out of roundness index (“index”) resulting from the thermal stresses, and comparing the index with at least one distortion limit to determine whether the case has a satisfactory or an unsatisfactory index. The temperature distribution is controlled for an unsatisfactory index to produce the satisfactory index. A system for controlling distortion of the turbine case includes a thermal measurement system, for measuring the temperature distribution, and a computer configured for modeling the thermal stresses, calculating and comparing the index with the distortion limit, and controlling the temperature distribution for an unsatisfactory index to produce the satisfactory index.

Abstract: A curved turbulator configuration is in a radial cooling passage of an airfoil, where the radial cooling passage is defined by at least a leading wall and a trailing wall, and the airfoil includes a tip and a root. The curved turbulator configuration includes a number of spaced curved turbulator pairs positioned along a center-line on an inner surface of the leading wall and a number of spaced complementary curved turbulator pairs positioned along a center-line on an inner surface of the trailing wall. An electrode for forming the curved turbulator configuration in the radial cooling passage includes a leading face having a curved turbulator pattern, a trailing face having a complementary curved turbulator pattern, a conductive core, and an insulating coating disposed thereon that is partly removed.