Abstract: A system, process, and component are disclosed. The system and process involve an induction heater arranged and disposed to heat a component to form a heated surface and a nozzle arrangement positioned to apply a fluid to the heated surface to form a processed surface of a component. The processed surface includes compressive residual stress resulting in increased resistance to fatigue, including fretting fatigue, for the component.

Abstract: A method of monitoring laser shock peening of a material includes forming an ablative layer on the material, directing the laser beam at the ablative layer to produce an acoustic wave in the material, converting the acoustic wave in the material to thermal energy external to the material and measuring the thermal energy.

Abstract: A magnetic particle inspection (MPI) apparatus is disclosed that includes a chordal field coil pair and a radial field coil pair. The chordal field coil pair includes first and second chordal field coils configured to produce a chordally oriented magnetic flux about a test article.

Abstract: A forging method including extruding a billet to form a ring shaped hollow workpiece; reducing a cross section of the workpiece; and forging the workpiece in a closed die having a first split die including a plurality of first die segments and a second split die including a plurality of second die segments by sequentially advancing pairs of opposing die segments from the first split die and second split die towards each other.

Abstract: A system, process, and component are disclosed. The system and process involve an induction heater arranged and disposed to heat a component to form a heated surface and a nozzle arrangement positioned to apply a fluid to the heated surface to form a processed surface of a component. The processed surface includes compressive residual stress resulting in increased resistance to fatigue, including fretting fatigue, for the component.

Abstract: A system for laser shock peening includes a laser positioned to direct a laser pulse at a first side of a work piece and a coupler on a second side of the work piece. The system further includes a Doppler shift detector positioned to measure a velocity of the coupler. A method for laser shock peening includes depositing an amount of energy from a laser pulse into a first side of a work piece and transmitting a pulse having a first frequency at a second side of the work piece. The method further includes receiving a reflected pulse having a second frequency from the second side of the work piece and determining the velocity of the work piece based on the difference between the first frequency and the second frequency.

Abstract: A method for near net shape forging a titanium component includes heating a titanium billet to a temperature in the alpha-beta temperature range and extruding the titanium billet into a first die having a temperature approximately 500° F. below the temperature of the titanium billet. A system for near net shape forging a titanium component includes a titanium billet having a temperature in the alpha-beta temperature range and a punch in contact with the titanium billet. A first die proximate to the titanium billet for receiving the titanium billet has a temperature approximately 500° F. below the temperature of the titanium billet.

Abstract: A method of monitoring laser shock peening of a material includes forming an ablative layer on the material, directing the laser beam at the ablative layer to produce an acoustic wave in the material, converting the acoustic wave in the material to thermal energy external to the material and measuring the thermal energy.

Abstract: A system for laser shock peening includes a laser positioned to direct a laser pulse at a first side of a work piece and a coupler on a second side of the work piece. The system further includes a Doppler shift detector positioned to measure a velocity of the coupler. A method for laser shock peening includes depositing an amount of energy from a laser pulse into a first side of a work piece and transmitting a pulse having a first frequency at a second side of the work piece. The method further includes receiving a reflected pulse having a second frequency from the second side of the work piece and determining the velocity of the work piece based on the difference between the first frequency and the second frequency.

Abstract: A method for stiffening a wind turbine tower employing fingerplate assemblies on flangeless joints between adjacent tubular tower sections. The method includes limiting the intercan gap between adjacent end surfaces of the tower sections at the flangeless joints and selecting a number of fingerplates to fasten each flangeless joints to limit distortion. Establishing dimensions for the fingerplates may further minimize localized tower distortion. Selecting a material for the fingerplate with a lower Young's modulus than a material for the tubular section also results in reduced localized tower distortion. Attaching a coverplate to a top tubular section limits tip displacement for the tower.

Abstract: A magnetic particle inspection (MPI) apparatus is disclosed that includes a chordal field coil pair and a radial field coil pair. The chordal field coil pair includes first and second chordal field coils configured to produce a chordally oriented magnetic flux about a test article.

Abstract: A forging method including extruding a billet to form a ring shaped hollow workpiece; reducing a cross section of the workpiece; and forging the workpiece in a closed die having a first split die including a plurality of first die segments and a second split die including a plurality of second die segments by sequentially advancing pairs of opposing die segments from the first split die and second split die towards each other.

Abstract: A method of forging a workpiece includes (a) incrementally advancing the workpiece in a closed die forge, the closed die forge including a stationary, flat die and a first split die including a plurality of first die segments, each die segment being incrementally advanced in sequence to contact the incrementally advancing workpiece; (b) replacing the stationary, flat die with a second split die including a plurality of second die segments; and (c) forging the workpiece forged in (a) between the first split die and the second split die, wherein the first die segments are stationary and at least some of the plurality of second die segments are incrementally advanced in sequence.

Abstract: An extrusion die for radial extrusion of a rotor shaft for a wind turbine generator has a body and a mandrel received in the body. The mandrel and body cooperatively define a tubular interior chamber. A punch is received in the tubular interior chamber and is moveable with respect to body and mandrel. A radial extrusion insert has a radial interior chamber in communication with the tubular interior chamber. The radial extrusion insert includes an arcuate edge disposed in a transition area between the tubular interior chamber and the radial interior chamber.

Abstract: A method for stiffening a wind turbine tower employing fingerplate assemblies on flangeless joints between adjacent tubular tower sections. The method includes limiting the intercan gap between adjacent end surfaces of the tower sections at the flangeless joints and selecting a number of fingerplates to fasten each flangeless joints to limit distortion. Establishing dimensions for the fingerplates may further minimize localized tower distortion. Selecting a material for the fingerplate with a lower Young's modulus than a material for the tubular section also results in reduced localized tower distortion. Attaching a coverplate to a top tubular section limits tip displacement for the tower.

Abstract: A method of forging a workpiece includes (a) incrementally advancing the workpiece in a closed die forge, the closed die forge comprising a stationary, flat die and a first split die comprising a plurality of first die segments, each die segment being incrementally advanced in sequence to contact the incrementally advancing workpiece; (b) replacing the stationary, flat die with a second split die comprising a plurality of second die segments; and (c) forging the workpiece forged in (a) between the first split die and the second split die, wherein the first die segments are stationary and at least some of the plurality of second die segments are incrementally advanced in sequence. Another forging method includes extruding a billet to form a ring shaped hollow workpiece; reducing a cross section of the workpiece; and forging the workpiece in a closed die comprising a first split die comprising a plurality of first die segments and a second split die comprising a plurality of second die segments.