Abstract: A method of manufacturing a fuel injector having high-flow orifices in its tip includes removing a bulb from a fuel injector tip having at least one spray orifice with a first diameter, and friction welding a slug to the fuel injector tip, including forming a fused interface of material of the slug and material of the fuel injector tip. The method further includes modifying the slug subsequent to friction welding the slug to the fuel injector tip, including forming a new bulb from the slug having at least one spray orifice therein with a different diameter than that of the removed bulb. A remanufactured fuel injector, and fuel injector tip, includes an injector tip body having a first tip portion of a first material and a second tip portion of a material compatible for friction welding with the first material.

Abstract: An improved method for salvaging a spring element with a degraded force constant for return to a work environment. The spring element is subjected to a high temperature and extended duration annealing treatment alone or in combination with other treatments. The resultant salvaged spring is characterized by a more durable force constant relative to the original spring when it was new.

Abstract: A method of manufacturing a fuel injector having high-flow orifices in its tip includes removing a bulb from a fuel injector tip having at least one spray orifice with a first diameter, and friction welding a slug to the fuel injector tip, including forming a fused interface of material of the slug and material of the fuel injector tip. The method further includes modifying the slug subsequent to friction welding the slug to the fuel injector tip, including forming a new bulb from the slug having at least one spray orifice therein with a different diameter than that of the removed bulb. A remanufactured fuel injector, and fuel injector tip, includes an injector tip body having a first tip portion of a first material and a second tip portion of a material compatible for friction welding with the first material.

Abstract: A method of manufacturing a fuel injector having high-flow orifices in its tip includes removing a bulb from a fuel injector tip having at least one spray orifice with a first diameter, and friction welding a slug to the fuel injector tip, including forming a fused interface of material of the slug and material of the fuel injector tip. The method further includes modifying the slug subsequent to friction welding the slug to the fuel injector tip, including forming a new bulb from the slug having at least one spray orifice therein with a different diameter than that of the removed bulb. A remanufactured fuel injector, and fuel injector tip, includes an injector tip body having a first tip portion of a first material and a second tip portion of a material compatible for friction welding with the first material.

Abstract: An improved method for salvaging a spring element with a degraded force constant for return to a work environment. The spring element is subjected to a high temperature and extended duration annealing treatment alone or in combination with other treatments. The resultant salvaged spring is characterized by a more durable force constant relative to the original spring when it was new.

Abstract: A method of manufacturing a fuel injector having high-flow orifices in its tip includes removing a bulb from a fuel injector tip having at least one spray orifice with a first diameter, and friction welding a slug to the fuel injector tip, including forming a fused interface of material of the slug and material of the fuel injector tip. The method further includes modifying the slug subsequent to friction welding the slug to the fuel injector tip, including forming a new bulb from the slug having at least one spray orifice therein with a different diameter than that of the removed bulb. A remanufactured fuel injector, and fuel injector tip, includes an injector tip body having a first tip portion of a first material and a second tip portion of a material compatible for friction welding with the first material.

Abstract: A compression spring assembly is disclosed herein. The compression spring assembly may be used in a fuel injection device and may include a compression spring having first and second adjacent turns spaced apart by a distance. The compression spring assembly may further include a damping element arranged between the first and second turns and having first and second spaced apart support regions separated by an arched third support region. The first and second support regions may be configured to exert force on a surface of the first turn, and the third support region may be configured to exert force on a surface of the second turn to at least inhibit movement of the first turn toward the second turn during operation of the spring.

Abstract: A spring design method is disclosed. The method begins with inputting a first set of design parameters for a spring. The design parameters include a parameter that provides an estimate of non-linearity in the spring. The spring design method determines a spring design based on the first set of design parameters. A spring design and analysis method is disclosed. The method begins with creating a spring design. The spring design includes a parameter that provides an estimate of non-linearity in the spring design. The spring design and analysis method creates a spring animation file that enables stress levels in a spring design to be identified at the coil level. The spring design method next identifies the coil in the spring design having the lowest dynamic fatigue factor and determines whether the lowest dynamic fatigue factor is acceptable.