Abstract: A piston assembly including a piston body pivotally connected to a connecting rod by a wrist pin. The wrist pin includes a sealed cavity therein partially filled with a heat transfer medium. The heat transfer medium may be composed of a fusible alloy. The sealed cavity may be comprised of discrete compartments. The wrist pin may be integrated with the connecting rod and share a conjoined sealed cavity therewith so that heat transfer medium can draw heat effectively away from the piston body.

Abstract: A piston assembly including a piston body pivotally connected to a connecting rod by a wrist pin. The wrist pin includes a sealed cavity therein partially filled with a heat transfer medium. The heat transfer medium may be composed of a fusible alloy. The sealed cavity may be comprised of discrete compartments. The wrist pin may be integrated with the connecting rod and share a conjoined sealed cavity therewith so that heat transfer medium can draw heat effectively away from the piston body.

Abstract: This invention introduces a new category of engineered surfaces and corresponding production processes for better wear resistance and lower friction loss. The structured surfaces can be applied on many automobile components with frictional surfaces. The composite structure settles the usual conflicts between surface functions and stresses. Two sets of multiple-step processes are introduced to achieve high production efficiency and low cost. Unlike traditional surface technologies that generate single and uniform layers on the whole part surface, the new technology processes the part surface selectively for more effective surfaces with versatile functions.

Abstract: This invention introduces a new category of engineered surfaces and corresponding production processes for better wear resistance and lower friction loss. The structured surfaces can be applied on many automobile components with frictional surfaces. The composite structure settles the usual conflicts between surface functions and stresses. Two sets of multiple-step processes are introduced to achieve high production efficiency and low cost. Unlike traditional surface technologies that generate single and uniform layers on the whole part surface, the new technology processes the part surface selectively for more effective surfaces with versatile functions.

Abstract: An exothermic cord, foil, or ribbon is produced by first cold drawing individual round wires of the constituent materials under a cover gas. The cold drawing operation yields a clean surface that is free of oxidation and other contaminants. Next, the constituent wires are brought together and twisted, cold drawn, swaged, and/or friction welded to create a unitary cord exhibiting intimate contact between the constituent materials. The unitary cord may then be used directly or further shaped to a desired form and/or thickness. By controlling the size ratio between the cross-sections of the constituents, a degree of control can be exercised over the exothermic reaction characteristics. The unitary cord, once formed, can be coated with braze and/or flux materials to aid in a subsequent joining operation. Multiple cords can be woven together to form a cloth structure.

Abstract: An electrochemical machining (ECM) system for machining a workpiece includes a plurality of ECM stations. A first ECM station machines a first region of the workpiece. A second ECM station machines a second region of the workpiece separate from the first region. Additional ECM stations may also be utilized. Each ECM station includes a stationary electrode for delivering electric current for eroding material from the workpiece. Each ECM station also includes an ultrasonic transducer for determining a width of electrolyte between the stationary electrode and the workpiece. Machining of the workpiece in each ECM station is completed when the width of electrolyte reaches a predetermined width.

Abstract: An apparatus and method of electrochemical machining utilizes a computer controlled static array of electrically insulated cathode sections to selectively and individually energize the electrodes for the purpose of shaping the surface of a part. The tightly clustered array of electrodes can be formed by individual wires as an example. The waste reaction products may be managed so as to improve machining accuracy. The electrodes can be composed of materials capable of generating an oxide layer or that resist electrolytic dissolution to combat the problem of crossover erosion in closely spaced conditions. An alternative approach to remedy crossover erosion is to extend the reach of insulation into the gap space between tool and part.

Abstract: A magnetically levitated high-speed spindle assembly (20) is provided for forming non-circular holes (22) in workpieces (24) or non-circular surfaces on pins. The non-circular holes (22) can be formed with dimensionally varying axial trajectories at high speeds and with great accuracy. This is accomplished by supporting a rotating spindle (26) between first (58) and second (60) magnetic bearing clusters and independently controlling these bearing clusters (58, 60) to move a shaping tool (32) at the end of the spindle (26) in a predetermined orbital path (B). A multiple input-multiple output control strategy is used to control spindle (26) movements in the X and Y axes. The tilt angle between the cutting edge (34) of the shaping tool (32) and the orbital path (B) is maintained perpendicular under this multiple input-multiple output control of the magnetic bearing clusters (58, 60) to further improve shaping precision and spindle (26) stability during high-speed operations.