Abstract: An article exhibiting magnetic properties, a method for providing corrosion resistance to an article, and an electric machine element are disclosed. The article comprises a substrate comprising a first portion of a magnetic material, the magnetic material exhibiting magnetic properties. The article further comprises a transition layer comprising a second portion of the magnetic material and a first portion of a coating material. The transition layer is disposed on at least a portion of the substrate. The article further comprises an outer layer comprising a second portion of the coating material. The outer layer is disposed on at least a portion of the transition layer.

Abstract: A rupture resistant system is provided and comprises a tank comprising a top member, a combined body member, the combined body member forming a side and bottom of the tank, the combined body member comprising at least one curved non-linear surface to define a partially curved interior in at least a portion of the tank; and a component situated within the tank and susceptible to creating increasing pressure within the tank when under a fault condition. At least one of the top, sidewall, and bottom members is connected to another of the top, sidewall, and bottom members in a manner so as to cause an increase in inner volume of the tank under increased pressure conditions.

Abstract: An article exhibiting magnetic properties, a method for providing corrosion resistance to an article, and an electric machine element are disclosed. The article comprises a substrate comprising a first portion of a magnetic material, the magnetic material exhibiting magnetic properties. The article further comprises a transition layer comprising a second portion of the magnetic material and a first portion of a coating material. The transition layer is disposed on at least a portion of the substrate. The article further comprises an outer layer comprising a second portion of the coating material. The outer layer is disposed on at least a portion of the transition layer.

Abstract: A rupture resistant system is provided and comprises a tank comprising a top member, a combined body member, the combined body member forming a side and bottom of the tank, the combined body member comprising at least one curved non-linear surface to define a partially curved interior in at least a portion of the tank; and a component situated within the tank and susceptible to creating increasing pressure within the tank when under a fault condition. At least one of the top, sidewall, and bottom members is connected to another of the top, sidewall, and bottom members in a manner so as to cause an increase in inner volume of the tank under increased pressure conditions.

Abstract: An insulation system for an oil filled environment having a plurality of insulating units, each of the plurality of insulating units including a first layer of insulating material and a second layer of insulating material. At least one of the first and second layers includes a polymeric material. The insulating units are positioned with respect to each other such that the second layer of one insulating unit is adjacent to the first layer of another insulating unit.

Abstract: A brazed X-ray target includes a metallic cap and a graphite back including a nonlinear record groove attached thereto along a stepped surface. An upper corner joint of the stepped surface is distanced from a cap outer edge and a focal track where the maximum heat is generated during use of the target. The graphite back is extended outward toward the cap outer edge to increase a thermal storage of the graphite, and a recess is formed into the cap to maintain a selected moment of inertia of the target and thereby maintain the rotordynamics of a given X-ray tube.

Abstract: Hard tooling for consolidation of a workpiece there between is preserved for reuse by disposing between the tooling and a workpiece a plurality of distinct, superimposed sacrificial sheets, for example metal foils, to isolate the workpiece from the tooling. The sacrificial sheets are substantially non-adherent one to another; and a sheet in contact with a workpiece surface is substantially chemically non-reactive with such workpiece surface.

Abstract: An improved high performance x-ray system having a rotating anode therein which includes an improved coating for the x-ray tube rotor. The surface of the x-ray tube rotor is coated with a ductile, metal coating, preferably iron, having a thickness of about 0.2 to about 5.0 mils thick. The rotor coating has ductile properties with a strain to fail greater than 0.05% and thermal expansion properties which when placed on an x-ray tube rotor, provides at least about 40,000 x-ray scan-seconds prior to tube failure due to rotor spalling.

Abstract: An improved high performance x-ray system having a rotating anode therein which includes an improved coating for the x-ray tube rotor. The surface of the x-ray tube rotor is coated with a ductile coating wherein at least about 40,000 x-ray scan-seconds are accomplished prior to tube failure due to spalling. The coating may be a ductile alloy such as Rene' 80 having a thickness of about 0.2 to about 5.0 mils thick and may be even thicker. The rotor coating has ductile properties with a strain to fail greater than 0.05% and thermal expansion properties which when placed on an x-ray tube rotor, provides at least about 40,000 x-ray scan-seconds prior to tube failure due to rotor spalling.

Abstract: An improved two membered substantially crack-free water jet mixing tube of an abrasive water jet cutting device and a method of its preparation. The method comprises chemically vapor depositing diamond layer on a funnel shaped support member to form an inner member of the mixing tube, separating the inner member from the support member, depositing and then cooling an outer member on the outer side of the inner member to produce a compressive stress on the inner member that substantially prevents formation cracks on the inner member. The inner side of the inner member has a smooth bore having a microcrystalline structure and the outer member has a higher coefficient of thermal expansion than diamond. The invention is also directed to a water jet cutting device that incorporates the aforementioned improved substantially crack-free water jet mixing tube.

Abstract: A method for forming a ring structure having a high volume fraction of a filament reinforcement within a metal matrix is disclosed. The ring structure is formed by consolidating a set of nested rings each of which has a high volume fraction of the filamentary reinforcement therein. The nesting is done to provide a clearance between the rings of the nest of about 2 or 3 mils. The nested rings are enclosed within a HIPing can and the structure is HIPed at about 15 ksi and 1000.degree. C. for over an hour. A single superring structure results from the HIPing.

Abstract: A method for asymmetrically consolidating a ring structure having a filamentary reinforcement embedded in a plasma sprayed deposited matrix is taught. The method involves fabricating a filament reinforced plasma sprayed deposit matrix structure and asymmetrically consolidating the structure. The asymmetric consolidation is accomplished by placing a thicker and/or stronger can surface on the outer portions of the ring structure and a thinner and/or weaker can structure on the inner and side surfaces of the reinforced ring structure. The HIPing of the reinforced ring structure with the asymmetric can results in a preferential compaction of the ring from the inside toward the outside and avoids the buckling of and damage to the reinforcement filaments on the outer portions of the structure.

Abstract: A method for forming a ring structure having a high volume fraction of a filament reinforcement within a metal matrix is disclosed. The ring structure is formed by consolidating a set of nested rings each of which has a high volume fraction of the filamentary reinforcement therein. The nesting is done to provide a clearance between the rings of the nest of about 2 or 3 mils. The nested rings are enclosed within a HIPing can and the structure is HIPed at about 15 ksi and 1000.degree. C. for over an hour. A single superring structure results from the HIPing.

Abstract: A method for forming a reinforced metal structure having a filamentary reinforcement evenly distributed therein is taught. The structure is formed by the plasma spray deposit of matrix metal onto and about a filamentary reinforcement. A plurality of layers of filamentary reinforcement are embedded in the structure. Between each layer an abrasive grinding and smoothing operation is performed to render the surface of the spray deposited metal smooth and even and to permit the even spacing of filament reinforcement on the spray deposited surface. The abrasive grinding of the spray formed surface does not have deleterious effects on the property of the composite reinforced structure which is formed.

Abstract: A method of altering the composition of an alloy deposited by plasma-spray processing is disclosed. It has been found that the composition of a powder can be altered by selective vaporization of the more volatile components of the alloy. In order to do this, the gas mixture employed in the plasma processing is modified to a composition which imparts a higher superheat to the liquid particles undergoing plasma processing. In this way, an alloy which is out-of-specification can be brought within the specification as to its composition by reducing the more volatile components and accordingly increasing the concentration of the less volatile components.

Abstract: A low frequency RF plasma spray deposition method is provided, which is especially effective in reducing losses and improving particle heating. In one aspect of the invention, an RF plasma gun is operated in the frequency range below 1 MHz and an argon-helium mixture to which a third component, such as hydrogen, can also be admixed, is substituted for the standard argon-hydrogen mixture used at frequencies above 2 MHz. In another aspect of the invention, a RF plasma gun is operated in the frequency range of 400-500 kHz and specific start up and operating procedures and conditions are set forth for successful deposition of titanium and refractory metal alloys.

Abstract: A method of controlling the internal dimensions of a filament reinforced ring structure is taught. The method involves providing the ring structure with an internal dimension which is slightly smaller than the specification of the final dimension which is sought. The ring structure is mounted over a solid mandrel having a coefficient of thermal expansion which is greater than that of the ring structure. The solid mandrel is mounted within the ring structure and the combination is heated to a temperature at which the outer dimension of the mandrel is greater than that of the internal dimension of the ring structure. The result is to enlarge the internal dimensions of the ring structure to a value conforming very closely to a specification for the ring structure.

Abstract: A method for joining substrates of the active metals, such as niobium, tantalum, and titanium, and alloys of the active metals is disclosed. The substrates are joined in a deposit zone traversing areas to be joined on the substrates. The areas to be joined are formed to have deposit receiving surfaces that will form a diffusion bond with a spray deposit. An active metal or an alloy of an active metal compatible with the substrates to be joined is provided as a powder for plasma spraying. The substrates are disposed in a radio frequency low-pressure plasma-spray apparatus to receive a spray deposit on the deposit receiving surfaces in the zone. The deposit receiving surfaces are preheated and cleaned by passing the surfaces in heat coupling relation by the plasma, and placing the substrates at a negative DC potential relative to the plasma. A transferred arc from the radio frequency plasma-spray apparatus to the surfaces is generated that cleans the surfaces.

Abstract: A method for controlling the dimension of a reinforced metal matrix composite structure is taught. The structure is annular and the method is to render the structure non-round where the initial structure is essentially round. The cure of the essentially round condition is accomplished by forming a solid mandril very slightly smaller in dimensions than the final dimensions sought for the structure. The essentially round composite ring is forced onto the non-round mandril and heated to the relaxation temperature of the matrix. Because the mandril has a higher thermal coefficient of expansion than the matrix, the method is effective in forming an essentially round structure into a non-round configuration.

Abstract: A method for forming a shaft of filament reinforced matrix metal is provided. The hollow shaft structure is made up of a number of layers of monotape which are assembled together and then HIPed to form a consolidated composite tubular shaft structure. The monotapes employed in forming the individual layers are prepared by plasma spray deposition of matrix metal onto and around an aligned set of reinforcing filaments. Following the plasma spray deposition of the matrix metal, the upper portion of the metal is removed by grinding or machining to increase the density of the monotape by removing the lens dense upper layer. The monotapes are assembled into the hollow shaft configuration by wrapping onto a shaft shaped mandrel in successive layers wound at a pitch to the axis of the mandrel. Consolidation of the multilayer wound structure is accomplished by HIPing at at least 900.degree. C. and at least 15 ksi for a period of more than 1 hour.