Abstract: A method and apparatus for packing wheel bearings with grease. A frame is provided for supporting an axle assembly comprising an axle shaft with a wheel mounted on a wheel bearing at each end. A horizontally mounted ram and cylinder is mounted adjacent each wheel. Each ram has a greasing head at its distal end and each head has a nose portion adapted to pivot relative to a body portion. Each nose portion has an open-mouthed greasing chamber. Each ram is advanced toward each wheel so that each open-mouthed greasing chamber is in communication with a wheel bearing. Pressurized grease is delivered to a greasing chamber and, therefor, to a bearing.

Abstract: A reinforced hydroform member having an outer structural member reinforced by a structural foam supported by the outer structural member. The structural foam extends along at least a portion of the length of the outer structural member. The structural foam is a heat-activated epoxy-based resin. As the foam is heated, it expands and adheres to adjacent surfaces. The preferred structural foam material is commercially available from L&L Products of Romeo, Michigan under the designation L5206, L5207, L5208, or L5209.

Abstract: A method of repairing a crack (14) in a component (12). The method includes preparing a surrounding surface (22) of the crack (14) for repair and welding a first portion (24) of the component (12) on a first side (26) of the crack (14) to a second portion (28) of the component (12) on a second side (30) of the crack (14) to form a fused crack area (50). The method may also include applying a patch (78) over the fused crack area (50) for additional strength.

Abstract: A method for repairing a leak in a pipe joint, the joint including a gasket. The method requires a passage to be formed through the wall of the first pipe. A space is then formed in the gasket communicating with the passage. After this, a sealant is injected through the passage into the space thus allowing the fluid to repair the leak.

Abstract: A process of brazing cracks and gaps in a single crystal article which takes places isothermally under the following conditions: the temperature of the isothermal solidification is between TLiqidus, Braze+5*(wt-%BBraze) and (Tsolidus, base material−70*(wt-%BBraze)), while (wt-%B*wt-%Cr) is between 15 and 40 and (Tsolv.&ggr;′, base material−TLiqidus, Braze) is above 140° C. This results in an homogeneous &ggr;/&ggr;′-microstructure of the isothermal solidified, brazed joint with mechanical properties similar to those of the base material.

Abstract: Disclosed are processes to recreate the as-manufactured or as-installed shape and finish to worn fuel pump bearings, wherein such processes entail either restoring or replacing the bearings, and further entail placing a resurfacing compound and a final top coating onto the top surface of the bearing.

Abstract: A method of making or reconstituting a steel tooling used in the processing of high temperature molten material includes machining an undercut surface in the tooling which provides an inset edge trapping receiving surface with an end marginal wall. The undercut is prepared for the reception of a barrier layer which fills the undercut and merges with the tooling surface bordering the undercut. Then a chemical barrier providing wear resisting coating surface which is thermally expansively and contractibly compatible with the tooling surface to avoid fracturing stresses due to differential rates of thermal expansion and contraction at elevated temperatures is fused to the receiving surface.

Abstract: A method for restoring thickness to load-bearing components of gas turbine engines, and for repairing a honeycomb structured gas turbine engine component. A surface of the component such as the backing surface of a honeycomb component after honeycomb removal is roughened and cleaned. A selected build-up material is deposited onto the substrate by high velocity oxy-fuel deposition or low pressure plasma spray. The component is heat treated to enhance the bond between the deposited material particles, and between the deposited material and the substrate by diffusion.

Abstract: A process of brazing cracks and gaps in a single crystal article which takes places isothermally under the following conditions: the temperature of the isothermal solidification is between TLiqidus, Braze+5*(wt-%BBraze) and (Tsolidus, base material−70*(wt-%BBraze)), while (wt-% B*wt-%Cr) is between 15 and 40 and (Tsolv.&ggr;′, base material−TLiqidus, Braze) is above 140° C. This results in an homogeneous &ggr;/&ggr;′-microstructure of the isothermal solidified, brazed joint with mechanical properties similar to those of the base material.

Abstract: A method is disclosed for reconditioning blades for turbo-machinery that have a material deficiency resulting from wear and tear, damage, or dimensions that are smaller than specified, in which material is removed, at least from parts of the blade, and is replaced with new material. The actual geometry of the blade is measured at certain specific points and is stored. The desired geometry, or the desired profile in its desired position, is determined via data processing technology. The desired geometry is compared with the actual geometry, and in cases of significant deviations in position, is adjusted to coincide with the actual geometry. The adjusted desired geometry is mathematically reduced by a defined amount of coating to be removed. The calculated net geometry is actually produced via the removal of material, at least over part of the blade, and new material is applied to the finished net geometry, until the desired profile is achieved.

Abstract: There is provided a method for repairing a leak in a pipe joint. At the joint of the two pipes there is a gasket. The method requires a passage to be formed through the wall of the first pipe. A space is then formed in the gasket communicating with the passage. After this, a sealant is injected through the passage into the space thus allowing the fluid to repair the leak.

Abstract: A method for repairing defects in a gas turbine component that comprises a substrate and an existing coating on the substrate. The article includes cooling holes having a predetermined air flow requirement and an outer shaped portion and an inner metering portion. The method comprises removing the existing coating and recoating the surface of the article with a nonoriginal coating. After the nonoriginal coating is applied onto the component, the cooling holes that meet a predetermined inspection criteria are reworked to remove the excess nonoriginal coating deposited in the outer shaped portion of the cooling holes. The reworking is done by receiving an electrode, having only a shaped portion with a preselected shape, in the outer shaped portion of the cooling holes thus restoring the cooling holes to the predetermined air flow requirement.

Abstract: A method for reconditioning an articulated connector while it is still mounted to the end structure of a rail car is disclosed. The connector is measured to find areas and amounts of wear on portions of the connector. The measurements are taken relative to a reference portion of the connector. Weld metal is then applied to the worn portion of the connector. The excess weld metal is manually or automatically machined away so that the connector falls within the required dimensions. A measurement of the weld area is again taken to ensure that the specified dimensions have been achieved. Apparatuses for measuring wear and specified dimensions and aiding in the method of reconditioning the connectors are also disclosed.

Abstract: A method for restoring thickness to load-bearing components of gas turbine engines, and for repairing a honeycomb structured gas turbine engine component. A surface of the component such as the backing surface of a honeycomb component after honeycomb removal is roughened and cleaned. A selected build-up material is deposited onto the substrate by high velocity oxy-fuel deposition or low pressure plasma spray. The component is heat treated to enhance the bond between the deposited material particles, and between the deposited material and the substrate by diffusion.

Abstract: A hole patching device including mechanism for covering an opening on an interior surface of a wall, the covering mechanism being formed of a generally rigid material and being at least two inches in diameter; mechanism for guiding the covering mechanism through the opening, which may include a slit cut from a center of the covering mechanism to an outer edge of the covering mechanism; mechanism for securing the covering mechanism to the interior surface of the wall to define a pocket; an insert for filling the pocket; and a hardenable material spread over the insert and pocket smoothable with the wall and a method of use.

Abstract: A side outer panel that is a body panel is separated into a body front side section (10), a body rear side section (11) and a side sill section (12). These separated repair parts are produced using local molds produced to correspond to each part. The local molds are produced only when the mold cost is lower than the lost material cost in the case where the divided repair parts are produced by directly cutting from the body panel.

Abstract: A method for repairing a turbine blade having a crack in a trailing edge portion of the blade includes the steps of cutting back a first surface of the turbine blade adjacent the blade trailing edge portion where the crack is located, and cutting back a second surface of the turbine blade adjacent the blade trailing edge portion where the crack is located. Each cut back step comprises cutting back the respective surface by a depth greater than the length of the crack and less than the trailing edge radius to remove the crack and form a cut back trailing edge portion. A compound radius is used to prevent a blunt transition into the trailing edge that would result in aerodynamic losses and to reduce the airfoil root stresses. The method also includes applying a thermal barrier coating to the turbine blade to increase service life. Prior to applying the coating, the tip portion of the turbine blade is modified to account for the change in the thermal characteristics of the turbine blade.

Abstract: A process is presented for recycling a toner cartridge, including a used magnetic roller and a used doctor blade. The process requires: (1) removal of the doctor blade and magnetic roller from the cartridge; (2) treatment of the doctor blade to restore the shape of said doctor blade; (3) coating of the doctor blade and magnetic roller with an antistatic and anti abrasive coating; and (4) placement of the doctor blade and magnetic roller back into the cartridge. Additional processes involving reuse of other toner cartridge components are also described.

Abstract: A method of making or reconstituting tooling to be used in the processing of high temperature molten material comprises machining an undercut in the tooling surface which terminates at a shoulder and provides an inset barrier receiving surface; a chemical barrier providing interface coating system to which a ceramic-based material will fuse, is fused over the undercut receiving surface. Then a thermally-insulative ceramic-based coating is fused to the interface system to fill the undercut and merge with the tooling surface.

Abstract: A method is provided for repairing an article having a fissure in a metallic overlay environmental resistant coating that includes the element Al, for example an overlay coating of the MCrAlY type. The method depletes more than about 90 wt. % of the Al from an exposed coating surface within the fissure and from a coating outer surface adjacent the fissure, to a depth of at least about 7 mils, without removal of the coating and while substantially maintaining the coating thickness. Thereafter, the fissure is repaired.

Abstract: A method for repairing a composite material having an internal void includes identifying the location of the internal void and forming a single channel extending from a surface of the composite material to the internal void. The method further includes pulling a vacuum in the internal void and inserting a repair material through the channel into the internal void.

Abstract: A carpet seam repair tool, and a method, for repairing a seam in installed carpet wherein a first carpet portion is separated from a second carpet portion along a seam rift and the seam overlies an adhesive tape. The repair tool includes a pair of legs joined by a pin at and end thereof for enabling coplanar movement of the legs about the pin. In use, the tool is inserted in the seam rift and a setscrew fixes the legs in a selected spaced relationship, thereby holding the carpet portions apart. The repair tool includes a wheel, rotatably attached at an end of each leg, opposite the pin. During a repair operation, the tool is drawn along the seam rift while the wheels hold the carpet portions away from the underlying tape. By holding the carpet portions away from each other, and by separating them from the tape, the repair tool enables convenient deposition of adhesive along the tape, while reducing the likelihood of getting the adhesive on the carpet portions.

Abstract: A method of refurbishing a damaged section of the outer rim bead of an automotive wheel. The method comprises the initial step of contouring the outer rim bead via a first grinding process to create a feathered transition between the damaged section and the remainder of the outer rim bead. Thereafter, the damaged section is profiled via a second grinding process to generally conform the shape of the damaged section to the remainder of the outer rim bead. Finally, the damaged section is painted. The refurbishment steps may be completed on-site without removing the wheel from the vehicle and without removing the tire from the wheel.

Abstract: A Silicon carbide-silicon matrix composite having improved oxidation resistance at high temperatures in dry or water-containing environments is provided. A method is given for sealing matrix cracks in situ in melt infiltrated silicon carbide-silicon matrix composites. The composite cracks are sealed by the addition of various additives, such as boron compounds, into the melt infiltrated silicon carbide-silicon matrix.

Abstract: A method of repairing metal surfaces, in particular hydraulic cylinder interior walls and pistons, which are damaged by scoring, denting, grooving, etc. A catalytically hardened synthetic resin, preferably an epoxy, is mixed with a selected metal powder to form a mixture which, when hardened has a coefficient of thermal expansion substantially equal to that of the metal surface. A hardener is mixed with the filled resin and the damaged areas are filled with the mixture. The resin is cured, then dressed so that the damaged areas conform to adjacent undamaged surfaces. The repair area (and other surface areas, if desired) is then electroplated with a hoard, tough, wear-resistant metal, preferably by brush plating. The plated areas are then polished and the repaired article is ready for use.

Abstract: The present invention relates to a device to assist in filling a hole in a sheet or plate of any material, with a filler compatible with the material, the device comprising a flexible plate adapted to be inserted through the hole in the sheet or plate; a detachable attachment member adapted to extend generally perpendicularly from a surface of the flexible plate and including a connection to locate at least one locking member thereto; the locking member being detachably attachable to the attachment member so as to apply a tensile load on the attachment member thereby causing the flexible plate to bear on and be held adjacent to the hole.

Abstract: A machine tool or die that is fabricated from thermally spray-formed steel is repaired on the factory floor by first cleaning the area to be repaired to removed all dirt and impurities. Next the surface is prepared by means of preheating the surface with propane torches at a rate not exceeding 50° Centigrade per hour to boil off the moisture in the tool. The weldment is formed by the TIG welding process and then finished by conventional machining, grinding and polishing.

Abstract: A process of the kind used for producing or repairing a turbine or compressor or fan blade by laser consolidation wherein a laser beam is moved relative to a metal surface and a stream of metal is supplied to the surface via a supply tube, so that said laser beam melts a thin layer of the metal substrate and also melts the metal being delivered to the substrate and thus forms a band of fused metal on said surface, the process being repeated until a desired blade is built up or repaired. The invention is characterized in that the laser beam is orientated at an acute angle to the surface. The supply tube may deliver the metal substantially along a path normal to the surface, with the laser beam being one of a plurality of laser beams each orientated at an acute angle to the surface and spaced around the supply means.

Abstract: Friction Pull Plug Welding is a solid state repair process for defects up to one inch in length, only requiring single sided tooling, or outside skin line (OSL), for preferred usage on flight hardware. The most prevalent defect associated with Friction Pull Plug Welding (FPPW) was a top side or inside skin line (ISL) lack of bonding. Bonding was not achieved at this location due to the reduction in both frictional heat and welding pressure between the plug and plate at the end of the weld. Thus, in order to eliminate the weld defects and increase the plug strength at the plug ‘top’ a small ‘hat’ section is added to the pull plug for added frictional heating and pressure.

Abstract: A method for reinforcing a selected portion of a structural part utilizes a flexible tube having a unexpanded, preferably thermally expandable resin sheath. The sheath may be limited to a selected region along the length of the flexible tube. The flexible tube is inserted through a curved passage and conforms to the geometry of the part to be reinforced. After the portion of the tube having the sheath reaches the desired location, the tube is secured in place. Upon heating, the resin expands to several times its original volume and fills the structural cavity only at that region.

Abstract: An improved cobalt-base braze alloy composition and method for diffusion brazing are provided for use in repairing superalloy articles, such as gas turbine engines, power generation turbines, refinery equipment, and heat exchangers. The improved cobalt-base braze alloy composition includes nickel; at least one element selected from the group of rhenium, palladium, platinum, ruthenium, and iridium; at least one element selected from the group of boron and silicon; and the remaining balance consists of cobalt. This composition may also include aluminum and/or one or more rare earth/lanthanide series elements, and the composition may be combined with one or more powdered base metal superalloy compositions to form an improved diffusion braze alloy mixture. In the improved method for repairing superalloy articles, the foregoing mixture is applied to a region of the superalloy article to be repaired.