Abstract: An embodiment of a tool assembly includes a spring-loaded shaft assembly disposed along a first axis, a hub, and a roller disk. The hub is connected to a distal end of the spring-loaded shaft assembly. The hub has an upper hub portion adjacent to the distal end of the spring-loaded shaft assembly aligned with the first axis, and a lower hub portion extending along a second axis. The second axis forms an angle relative to the first axis. The roller disk is joined to the lower portion of the hub, and has a working surface about its perimeter. The roller disk is rotatable about the second axis parallel to the second portion of the hub. The working surface includes a profile along its width such that an effective radius of the roller disk varies along a width thereof.

Abstract: An embodiment of a tool assembly includes a hub connected to a distal end of a spring-loaded shaft assembly disposed along a first axis. An upper hub portion is adjacent to the distal end of the spring-loaded shaft assembly aligned with the first axis, and a lower hub portion extends along a second axis, forming a nonzero angle relative to the first axis. A roller disk is joined to the lower portion of the hub, and is rotatable about the second axis parallel to the second portion of the hub. A load cell is disposed along the first axis between a proximal end of the shaft and the roller disk, and is adapted to measure a downward force applied along the shaft assembly.

Abstract: An embodiment of a tool assembly includes a robotic assembly, a tool mount, and a non-axisymmetric deep rolling tool. The robotic assembly includes a plurality of linear arms connected in series between a base end and a working end. Adjacent ones of the plurality of arms are connected via a corresponding plurality of multi-axis joints such that the working end is articulated by movement of one or more of the plurality of arms relative to one or more of the plurality of multi-axis joints. The tool mount is connected to one of the linear arms or one of the multi-axis joints at the working end of the robotic assembly. The non-axisymmetric deep rolling tool is connected to the tool mount, and includes a spring-loaded shaft assembly disposed along a first axis. A hub has an upper hub portion adjacent to the distal end of the spring-loaded shaft assembly aligned with the first axis, and a lower hub portion extending along a second axis, forming a nonzero angle relative to the first axis.

Abstract: A manufacturing process includes collecting metal chips produced by a subtractive manufacturing processes and sorting the metal chips. The process further includes heating the metal chips to form a melt, removing impurities from the melt, deoxidizing the melt and atomizing the melt to form metal powder. The powder is then used to form a metal part by additive manufacturing or powder metallurgy processes.

Abstract: One embodiment includes a method for enhancing bond strength between a powder deposit and a substrate. Powder is deposited on the substrate. Powder is shot peened with peening media that is harder than both the powder and the substrate to produce bond strength between the powder and the substrate that is at least twice bond strength between the powder and the substrate without shot peening.

Abstract: A method of producing a heat exchanger includes designing the heat exchanger to include a wall with a target thickness. A model is created relating process parameters to geometry of a single track melt pool and relating the single track melt pool geometry to a heat exchanger wall thickness. At least one variable process parameter is defined. The model, heat exchanger wall target thickness, and variable process parameters are used to identify a set of process parameters to produce the heat exchanger wall target thickness. The melt pool geometry is predicted based on the model and process parameters. The heat exchanger wall target thickness is predicted based on the melt pool geometry. The process parameters that will produce the heat exchanger wall target thickness are identified. The additive manufacturing process is controlled based upon the identified set of process parameters to create the heat exchanger wall target thickness.

Abstract: A method for deep roll peening a workpiece includes deep roll peening a workpiece by moving the workpiece along a feed path through multiple groups of opposed rollers that are arranged in series. Each group of opposed rollers includes a rim that defines a workpiece engagement surface that exerts a deep roll peening force on the workpiece. A deep roll peening system includes multiple groups of opposed rollers. Each of the opposed rollers is rotatably mounted and has a rim that defines a workpiece engagement surface. The workpiece engagement surfaces are spaced apart from each other by a gap. The groups are arranged in series such that the gaps define a feed path for receiving a workpiece into serial contact with the workpiece engagement surfaces.

Abstract: A brake assembly and a method for manufacturing a brake assembly are provided. The brake assembly includes a brake pad affixed to a substrate. The brake pad extends from the substrate to a brake pad friction surface, and includes abradable cellular metal foam with the hardened ceramic particles.

Abstract: A pressure vessel assembly includes a plurality of lobes, each lobe having at least one vertically arranged interior wall, the lobes positioned in a side by side arrangement such that a first interior wall of a first lobe is positioned adjacent a second interior wall of a second lobe, the first interior wall having a first wall top and bottom side, the second interior wall having a second wall top and bottom side, the first wall top side joined to the second wall top side and the first wall bottom side joined to the second wall bottom side. Also included are first and second end wall surfaces of each of the plurality of lobes. Further included is a plurality of end caps, each of the end caps joined to the end wall surfaces of the lobes, each of the end caps joined to at least one adjacent end cap.

Abstract: A method of manufacturing an elevator safety spring is provided. The method includes determining a plurality of dimensional parameters of the elevator safety spring. The method also includes selecting a plurality of dimensions within the dimensional parameters. The method further includes manufacturing the elevator safety spring based on the selected parameters, the elevator safety spring having an I-beam cross-section.

Abstract: An example peening tool includes at least one first roller having a peening surface disposed about and along a first core. At least a portion of the at least one first roller is configured to contact a component to be peened along a length. The length extends along at least a portion of the first core. The at least one first roller is configured to provide line contact on the component along the length. A profile of the at least one first roller is determined based on a profile of the component. The peening tool includes a backer disposed in register with the first plurality of rollers such that the first plurality of rollers moves with the backer during peening. The at least one first roller and the backer are configured to be arranged on opposing surfaces of the component. Peening models may predict peening parameters and controller settings.

Abstract: An electrical device includes an electromagnetic component configured to generate a magnetic flux. The electromagnetic component includes a soft magnetically-conductive material configured to pass magnetic flux therethrough along a flux path. The soft magnetically-conductive material includes at least one grain oriented portion having metal grains that are oriented parallel with respect to the magnetic flux.

Abstract: An adjacent safety configuration for an elevator includes a second pair of safeties displaced from a first pair of safeties by at least 0.1 seconds of travel time at a rated speed of the elevator. An adjacent safety configuration for an elevator including a second pair of safeties displaced from the first pair of safeties to provide a predetermined time period before the second pair of safeties pass over a point on a guide rail previously passed over by the first pair of safeties to permit the guide rail surface to decrease by a predetermined temperature. A method of spacing an adjacent safety configuration for an elevator system including de-rating a pair of trailing safeties with respect to a pair of leading safeties as a function of a rated speed of the elevator and a spacing between the pair of trailing safeties and the pair of leading safeties.

Abstract: An illustrative example container includes a plurality of internal support members having a surface contour that at least approximates a minimum surface. The plurality of internal support members collectively provide structural support for carrying loads on the container. The plurality of internal support members collectively establish a plurality of cavities for at least temporarily containing fluid. An outer shell is connected with at least some of the internal support members. The outer shell includes a plurality of curved surfaces. The outer shell encloses the cavities.

Abstract: An apparatus to cut and surface process a workpiece includes a cutting tool to cut the workpiece; a peening tool to peen surfaces of the cut workpiece; and a controller to control the cutting tool, the peening tool and the workpiece to move simultaneously.

Abstract: A system is provided for additively manufacturing a part. This additive manufacturing system includes a base, a solidification device and a detection device. The base is adapted to support material; e.g., powder material. The solidification device is adapted to solidify at least a portion of the supported material to form at least a portion of the part. The detection device is adapted to detect emissions produced by the solidification of at least a portion of the material.

Abstract: A pressure vessel configured to store a pressurized fluid is provided including a plurality of lobes. Each lobe includes at least one vertically arranged interior wall. The plurality of lobes are positioned in a side by side configuration such that a first interior wall of a first lobe is positioned adjacent a second interior wall of a second adjacent lobe. The first interior wall and the second interior wall are configured to contact one another at a first point of tangency. A first tangent intersects the first lobe at the first point of tangency and a second tangent intersects the second lobe at the first point of tangency. The first tangent and the second tangent are separated by about 120 degrees.

Abstract: One embodiment includes a method for enhancing bond strength between a powder deposit and a substrate. Powder is deposited on the substrate. Powder is shot peened with peening media that is harder than both the powder and the substrate to produce bond strength between the powder and the substrate that is at least twice bond strength between the powder and the and peening material substrate without shot peening.

Abstract: A method of making a component comprises producing a layer of sheet material including an aperture over a movable support. An insulating material is deposited in a first portion of the aperture to form an insulating coating with one or more pockets. A conductive material is deposited in the one or more pockets. Heat and pressure are applied to the layer and the movable support is lowered by a thickness of the layer. The steps are repeated to form a laminated stack defining the component. In some embodiments, the laminated stack of sheet materials forms an induction machine.

Abstract: One embodiment includes a powder spheroidizing method. The method includes loading a powder into a fluidized bed assembly, fluidizing at least some of the powder in the fluidized bed assembly using an inert gas, and heating the powder while fluidized in the fluidized bed assembly.