Abstract: A method of forming a cured film on an aluminum substrate includes depositing a film formed from a sol-gel coating composition onto the aluminum substrate without disposing a conversion coating composition onto the aluminum substrate. The method also includes, after depositing, curing the film. A coating system includes an aluminum substrate having a surface and a cured film disposed on and in contact with the surface. The cured film is formed from a sol-gel coating composition. The coating system is free from a layer formed from a conversion coating composition.

Abstract: A device for joining thermoplastic workpieces includes an ultrasonic welder including an ultrasonic transducer, a booster and a horn having a welding tip. A clamping mechanism attaches to the ultrasonic welder and includes an upper frame coupled to a boot. The welding tip of the horn of the ultrasonic welder projects into an aperture in the boot of the clamping mechanism. The clamping mechanism exerts a clamping force on the workpieces that differs from a welding force exerted on the workpieces by the ultrasonic welder when the ultrasonic welder is operating to join the thermoplastic workpieces.

Abstract: Methods for manufacturing structures are provided. The methods include manufacturing a shell structure by additive manufacturing methods and sectioning panels with predetermined shapes from the shell structure. The panels are subsequently coupled to shell structure. Devices for performing various steps of the methods are also provided.

Abstract: Methods and devices for manufacturing paneled structures are provided. The methods include manufacturing a frame structure by additive manufacturing methods and scanning a surface of the frame structure to determine whether there is more than a nominal surface deviation at a location where a panel will be disposed. When there is more than a nominal surface deviation, the methods also include generating a panel to be disposed at the location of the frame structure, wherein the panel has an engagement surface that is complimentary to the surface deviation.

Abstract: A method of forming additive energy directors according to various exemplary embodiments can include dispensing a molten material onto a substrate at a predetermined location. The method also includes solidifying the molten material to form at least one additive energy director onto the substrate.

Abstract: During an example coating method, a metallic substrate is provided. A foundation coat precursor is applied on the metallic substrate. The foundation coat precursor includes a matrix and a plurality of capsules present in the matrix. Each capsule includes a shell and a healing agent surrounded by the shell. A basecoat precursor is applied, and a clearcoat precursor is applied. The metallic substrate, the foundation coat precursor, the basecoat precursor, and the clearcoat precursor are heated i) after each respective application or ii) simultaneously, in order to cure the foundation coat, basecoat, and clearcoat precursors and respectively form a foundation coat, a basecoat, and a clearcoat. The foundation coat is ultraviolet (UV) stable and bonds the metallic substrate to the basecoat and the clearcoat.

Abstract: Methods and systems are provided for generating a mold. In one embodiment, a method includes: determining, by a processor, a fiber orientation for a plurality of points in a part; determining, by the processor, a distortion value based on the fiber orientations; and generating, by the processor, mold dimensions based on the distortion values.

Abstract: A method can be used for joining workpieces using a fastener. The fastener includes a first head and a shank extending from the first head along a fastener axis. The joining method includes the following steps: (a) rotating a fastener about a fastener axis; (b) moving the fastener toward the first and second workpieces while the fastener rotates about the fastener axis such that the fastener increases the temperature in the first and second workpieces in order to soften and pierce the first and second workpieces along the fastener axis; and (c) advancing the fastener through the first and second workpieces and toward an open cavity of a die after piercing the first and second workpieces while the fastener rotates about the fastener axis such that the shank is partially disposed inside the open cavity in order to form a second head.

Abstract: The present technology discloses methods for joining a first workpiece and a second workpiece through an interlocking weld, and products formed thereby. The first workpiece has a first surface and a second surface opposite the first surface, and the second workpiece has a first surface, a groove formed in the first surface, and a second surface opposite the first surface. The system is formed by applying energy to the system, at least partially melting material of the first workpiece, and causing the material to flow into the groove, and allowing or causing the material to cool, forming an interlocked-weld joint connecting the workpieces.

Abstract: A method for managing heat energy in a metal casting plant includes executing a local control optimization model to control mass of solid metal charges to each modular melting furnace. The local control optimization model is configured to achieve a commanded total mass of molten material and coincidentally minimize waste heat for each of the modular melting furnaces. The method for managing heat energy in the metal casting plant further includes executing a system control optimization model to manage operation of a heat energy recovery system. The system control optimization model is configured to manage the operation of the heat energy recovery system including transferring the waste heat from the modular melting furnaces to a plurality of heat demand centers while minimizing total loss of the waste heat in the metal casting plant.

Abstract: A hybrid stamping system for forming a work-piece includes a stamping press. The press includes first and second dies that have respective first and second die bases formed from a first material. The system also includes first and second inlays. Each inlay is formed from a second material and has opposing die and work-piece sides. The second material hardness is greater than the first material hardness. The die side of the first inlay is cast into the first base and the work-piece side of the first inlay is contoured to form one side of the work-piece. The die side of the second inlay is cast into the second base and the work-piece side of the second inlay is contoured to form another side of the work-piece. The first and second dies are mounted in the press opposite one another to form the work-piece between the first and second inlays.

Abstract: A method can be used for joining workpieces using a fastener. The fastener includes a first head and a shank extending from the first head along a fastener axis. The joining method includes the following steps: (a) rotating a fastener about a fastener axis; (b) moving the fastener toward the first and second workpieces while the fastener rotates about the fastener axis such that the fastener increases the temperature in the first and second workpieces in order to soften and pierce the first and second workpieces along the fastener axis; and (c) advancing the fastener through the first and second workpieces and toward an open cavity of a die after piercing the first and second workpieces while the fastener rotates about the fastener axis such that the shank is partially disposed inside the open cavity in order to form a second head.

Abstract: A device for joining thermoplastic workpieces includes an ultrasonic welder including an ultrasonic transducer, a booster and a horn having a welding tip. A clamping mechanism attaches to the ultrasonic welder and includes an upper frame coupled to a boot. The welding tip of the horn of the ultrasonic welder projects into an aperture in the boot of the clamping mechanism. The clamping mechanism exerts a clamping force on the workpieces that differs from a welding force exerted on the workpieces by the ultrasonic welder when the ultrasonic welder is operating to join the thermoplastic workpieces.

Abstract: A resistance spot welding system can join two polymeric workpieces and includes a power supply. The power supply has a positive terminal and a negative terminal. The resistance spot welding system further includes a welding electrode assembly electrically connected to the power supply. The welding electrode assembly includes a housing, a first electrically conductive pin and a second electrically conductive pin. The first and second electrically conductive pins both protrude from the housing. The first electrically conductive pin is electrically connected to the positive terminal of the power supply, and the second electrically conductive pin is electrically connected to the negative terminal of the power supply. The second electrically conductive material is electrically insulated from the first electrically conductive pin. The first and second electrically conductive pins are at least partly made of a material having a hardness ranging between 50 HRC and 70 HRC.

Abstract: A resistance spot welding method can be used to join polymeric and metallic workpieces together and includes the following steps: (a) placing an electrically conductive coating between a polymeric workpiece and a metallic workpiece, wherein the metallic workpiece has a textured surface facing the polymeric workpiece; (b) piercing the polymeric workpiece with first and second electrically conductive pins of a welding electrode assembly; (c) applying electrical energy to the first and second electrically conductive pins so that an electrical current flows through the first electrically conductive pin, the electrically conductive coating, and the second electrically conductive pin in order to at least partially melt the polymeric workpiece and the electrically conductive coating, thereby forming a weld pool; and (d) cooling the weld pool to form a solid weld nugget in order to establish a mechanical interface lock between the solid weld nugget and the textured surface.

Abstract: Provided is a system and a method for identifying inefficiency of energy utilization in a facility by using actual past consumption data. The method uses the past energy usage data, weather information, production information, and variables estimated using Stochastic Frontier equation to calculate energy inefficiency for a production facility.

Abstract: A method for managing heat energy in a metal casting plant includes executing a local control optimization model to control mass of solid metal charges to each modular melting furnace. The local control optimization model is configured to achieve a commanded total mass of molten material and coincidentally minimize waste heat for each of the modular melting furnaces. The method for managing heat energy in the metal casting plant further includes executing a system control optimization model to manage operation of a heat energy recovery system. The system control optimization model is configured to manage the operation of the heat energy recovery system including transferring the waste heat from the modular melting furnaces to a plurality of heat demand centers while minimizing total loss of the waste heat in the metal casting plant.

Abstract: A method for generating an electronic work order for plant maintenance includes detecting a fault of a machine in the plant, and communicating fault information to a system. The system has a server and a database for recording downtime of the machine. The method further includes generating the work order via the server in response to the fault, including recording, within in the work order, a plurality of values from the fault information. The work order is transmitted from the server to a computing device, and a confirmation signal is recorded by the computing device indicating completion of the repair. The method includes transmitting a completed work order from the computing device to the server and recording the completed work order in the database. A system is also disclosed for generating an electronic work order for maintenance in a plant. The system includes the database and server noted above.

Abstract: A damper for determining and regulating amount of airflow admitted into a heating, ventilation, and air conditioning (HVAC) duct of a building from the ambient includes a variable position gate. The gate is configured to generate a continuous access opening into the duct from the ambient. The damper also includes a mechanism configured to select a position for the gate between and inclusive of fully opened and fully closed and a first sensor configured to sense a velocity of the airflow admitted into the duct. The selected position of the gate determines an area of the continuous access opening and regulates the amount of airflow admitted into the duct. Additionally, when the continuous access opening is not fully closed, the airflow admitted into the duct by the gate is substantially uniform. An HVAC system employing the damper and a method for controlling a temperature inside the building are also disclosed.

Abstract: Disclosed herein are a system, method and apparatus for reporting, making alerts and predicting fault codes generated by machines in a line. Historical fault code data is received and filtered according to particular criteria to generate filtered fault code data. Classification of the filtered fault code data into physical groups and into logical groups is followed by sorting the groups to produce fault trend data. Processing the fault trend data with a plurality of analyzers generates output including reports, alerts, and predictions of future fault code occurrences.