Abstract: A ball valve includes a valve body and a valve assembly. The valve body includes an elongated, generally tubular portion and a hydroformed stem seat. The stem seat extends generally radially from the tubular portion. The tubular portion and the stem seat are unitary. The valve assembly is coupled to the body at the stem seat.

Abstract: A fuel injector has a seat and at least one seat passage. The seat includes an outer tip surface through which the seat passage extends. A non-thermally conducting coating is provided on at least a portion of the outer tip surface and not on surfaces defining the seat passage. The coating is constructed and arranged to be heated by combustion gases so that the outer tip surface reaches a temperature greater than a temperature that the outer tip surface would reach if the coating was not provided so as to cause evaporation of fuel that contacts the outer tip surface, The seat passage is constructed and arranged to not be substantially heated by conduction from the outer tip surface and to be cooled by fuel passing there-through so as to prevent deposits of combustion from accumulating on surfaces defining the seat passage.

Abstract: According to one embodiment, a valve apparatus includes a movable member operating in conjunction with opening and closing of a valve, and a stationary member in sliding or abutting contact with the movable member. The valve apparatus includes a cladding portion that is integrally formed on a sliding-contact surface or an abutting contact surface of at least one of the movable member or the stationary member. The cladding portion is formed by inducing a pulsed discharge between an electrode, which is formed of a molded body consisting mainly of a metal, and a treatment target portion of the movable member or the stationary member, so as to weld and deposit a material of the electrode on a surface of the treatment target portion.

Abstract: A method for joining a first housing component to a second housing component by welding, the first housing component and the second housing component each being constituted as hollow bodies having a closed hollow cross section, a shape of the hollow cross section of the second component corresponding to a shape of the hollow cross section of the first component, including: making available the first housing component having a first inside dimension, making available the second housing component having an outside dimension, the outside dimension of the second housing component being smaller than the inside dimension of the first component, disposing the second housing component in the first housing component so that a peripheral gap is constituted between an inner wall of the first housing component and an outer wall of the second housing component, the region having a gap between the two housing components being a joining region, and welding the first housing component to the second housing component in the r

Abstract: The method for manufacturing a solid housing, in particular a valve housing for an electromagnetically operable valve, is characterized in that the following method steps are used: a) providing a sheet metal strip made of a magnetic or magnetizable material, b) introducing an additive into a middle area of the sheet metal strip and fusing there for forming a non-magnetizable structure, c) cutting the sheet metal strip into a sheet metal piece of desired width, d) deforming the sheet metal piece into a sleeve shape, e) mutual fastening of the cut edges now facing each other and running in the longitudinal direction of the sleeve for forming a sleeve blank, f) final machining of the sleeve blank until a desired geometry of the housing is achieved. The housing is suitable in particular for use in fuel injectors in fuel injector systems of mixture-compressing spark-ignition internal combustion engines.

Abstract: A method for manufacturing a solid housing, in particular a valve housing for an electromagnetically operable valve. The method includes providing at least three flat metal plates side by side, each having different magnetic properties directly adjacent to the others. The at least three plates are joined to the directly adjacent bordering edges to form a sheet metal section. The sheet metal section shaped into a sleeve shape. Furthermore, the bordering edges, which are now opposite one another, and run in the longitudinal direction of the sleeve to form a sleeve blank are joined together. The sleeve blank is machined until a desired geometric shape of the housing is achieved. The housing may be suitable in particular for use in fuel injectors in fuel injector systems of internal combustion engines operating by spark ignition of a compressed fuel-air mixture.

Abstract: Hot-isostatic-pressure (HIP) is used to bond a cemented carbide inlay (e.g., an inlay ring) on a metal substrate (e.g., a hull ring). For example, an inlay ring is made from a powdered metal inlay preform typically comprising at least one metal carbide and at least one nonvolatile cement. The inlay preform is compressed and sintered to make an inlay ring having a predetermined shape, the inlay ring having a modulus of elasticity substantially greater than that of a hull ring. An inlay ring and a hull ring are sealingly vacuum brazed together with at least one evacuated bonding area between them. HIP is applied to compress the hull ring against the inlay ring, thus fusing the hull ring and inlay ring in at least one evacuated bonding area. Following HIP, the inlay ring and hull ring form a fused assembly in which the inlay ring substantially retains its predetermined shape.

Abstract: A method for externally adjusting the axial length of a solenoid actuated fuel injector includes the step of externally forming a helical scribe mark in a housing component, thereby changing the axial length of the injector. By adjusting the length of the helical scribe mark and the depth of the scribe mark, and by measuring the stroke or the flow rate of the injector, the stroke or the flow rate of injector may be set precisely. The external adjustment of the length of the housing component may be made in cartridge form as well as in final assembly form of the fuel injector complementing the manufacturing process versatility.

Abstract: In a method for reducing “blow-out” of annular welds for attaching components in a fuel injector, a relief region is formed on radially-facing surfaces of the components. The relief region is adjacent to a press-fit region. The components are then pressed together, and a weld is made in the relief region. A sealed gap is thereby formed in the relief region between the weld and the press-fit region. The sealed gap provides for the expansion of trapped gases that could otherwise “blow out” the liquid weld bead.

Abstract: An inflow control assembly. The inflow control assembly can include an inner tubular member comprising a hole formed therethrough. A cover assembly can encircle the hole. The cover assembly can include a first outer member disposed about at least a portion of the inner tubular member. The first outer member can be secured to the inner tubular member. A second outer member can be disposed about at least a portion of the inner tubular member, and the second outer member can be secured to the inner tubular member. A screen portion can be disposed between the outer members and between the inner tubular member and the outer members. An annulus can be formed between the outer members and the inner tubular member, and the annulus can provide a flow path between the hole and the screen portion.

Abstract: Hot-isostatic-pressure (HIP) is used to make substantially nonporous cemented carbide inlays on metal substrates. A radiused shell preform typically comprising at least one metal carbide and at least one nonvolatile cement is shaped as a rigid frusto-conical shell having a substantially uniform thickness and a predetermined radius on every edge. HIP pressure is applied via a conforming adjustable sliding element to compress the preform against a conforming substrate. Surfaces of the conforming adjustable sliding element and conforming substrate, and/or the radiused shell preform, may in certain embodiments be coated substantially uniformly with at least one nonvolatile cement. Space around a radiused shell preform is evacuated without the need to totally enclose the radiused shell preform and its substrate in a can. Certain embodiments provide for leak testing of welded seals prior to application of HIP, and other embodiments make the use of welded seals unnecessary.

Abstract: A hot gas valve disc for a divert and attitude control disc switching element used in a propelled craft. The hot gas valve disc comprises a first layer comprising a first metal material having a first grain size and a first grain orientation, and at least one additional layer comprising a second metal material having a second grain size that differs from the first grain size, or a second grain orientation that differs from the first grain orientation. A method of manufacturing the hot gas valve disc comprises the steps of fabricating a first metal layer using a solid-free-form fabrication process, the first metal layer having a set of grain characteristics comprising grain size and grain structure, followed by heating the first layer and thereby changing at least one of the grain characteristics.

Abstract: The present invention provides methods of manufacturing a hot gas valve for a divert and attitude control system in a propelled craft. The methods include the steps of building a valve, or a plurality of separate valve components or segments using a solid free-form fabrication process, and assembling the plurality of separate valve components or segments if necessary to produce the hot gas valve. The solid free-form fabrication process comprises the steps of forming successive feedstock layers by depositing the feedstock material into a predetermined region, the feedstock layers representing successive cross-sectional component slices, and modifying the feedstock by directing an energy source to the predetermined region and thereby creating modified regions in the successive feedstock layers, the combined modified regions defining the hot gas valve or an at least partially-formed valve component or segment.

Abstract: In a pressure accumulator vessel of a high pressure fuel supply device, a chamfered section is formed in a connection between an accumulation chamber and a corresponding fuel passage. An inner plated part, which includes a plating layer, is formed along a wall surface of the accumulation chamber, a wall surface of the fuel passage and a wall surface of the chamfered section. The pressure accumulator vessel further includes connecting portions and sealing portions. The connecting portion is formed to join with a fuel pipe. The sealing portion is formed adjacent to the connecting portion to fluid-tightly engage with the fuel pipe. Each unplated part is formed along a wall surface of the corresponding connecting portion and a wall surface of the corresponding sealing portion.

Abstract: A method of fabricating a modular fuel injector permits the fabrication of the electrical group subassembly outside a clean room while a fuel group subassembly is fabricated inside a clean room. The method provides for manufacturing a sealed fuel injector unit via a predetermined number of different types of operations. Each type comprises a range of percentages of the predetermined number of operations.

Abstract: A ball valve includes a valve housing 10 and a ball 20. A pair of mirror-symmetrical housing halves 12, 14 are jointed together along a single weld line to enclose the ball having a through bore and a pair of recessed portions. The through bore 22 is in conformity with the weld line. Holes 42, 50 for respectively mounting a pair of stem assemblies are formed in portions of the valve housing opposed respectively to opposite ends of the through bore. The through bore of the ball is brought into alignment with openings 12A, 14A of the valve housing, and the recessed portions 26, 28 of the ball are brought into alignment with the holes, respectively. Next, the pair of stem portions 60, 68 are attached to both holes and fitted into both recessed portions, and the stems are welded circumferentially to peripheral edge portions of the holes, respectively.

Abstract: In a fuel injector, a valve unit consisting of a valve body and an injection plate is connected to a bottom end of a cylindrical housing. The valve unit is connected to the fuel injector after other components are assembled to the fuel injector. In the process of forming the valve unit, the valve body and the injection plate are coupled with each other, and then both are connected by welding. Then, the valve body having the injection plate welded thereto is inserted into a bottom end bore of the cylindrical housing, and then the valve body and the cylindrical housing are connected to each other by welding. A circular valve seat formed on the valve body is not deformed in the course of forming the valve unit and connecting the valve unit to the cylindrical housing.

Abstract: An improved method of sluice gate valve fabrication in which a cylindrical rod of an appropriate diameter is first cut and then the cylindrical rod is forged into a blank for a disk-shaped sluice gate body and pivot stems, with the pivot stems respectively formed at the upper and lower ends of the sluice gate body to provide for installing the pivot stems in the interior section of the sluice valve. The raw edges along the periphery of the blank are then removed by pressure punching to form a finished sluice gate body. The pivot stem at the lower end of the sluice valve body is machined into an abraded welding surface and then a shaft having the same diameter of the pivot stem is aligned with abraded welding surface and friction welded to it. As such, the pre-forged sluice gate and the friction welding of an existent shaft onto the pivot stem at the lower end of the sluice gate body minimizes forging mold volume and, furthermore, reduces the quantity of material required for sluice gate fabrication.

Abstract: A spray gun valve assembly is disclosed together with a method for manufacturing the same, wherein a spray gun valve plug (e.g., made of materials such as a tungsten carbide alloy) is secured to an end of an elongate valve stem (e.g., made of stainless steal) by resistance welding techniques. A holder component may act as an intermediate component between the plug and the valve stem, wherein the plug is resistance welded to the holder, and the holder is secured to the end of the valve stem. The method for securing the holder and the valve stem components can provide both a weld and a mechanical lock to secure these components together.

Abstract: A method of setting a distance between a first body and a second body in a fuel injector is disclosed. The method includes providing an intermediate body having a first end, a second end and a longitudinal axis, the first end being fixedly connected to the first body and the second end being fixedly connected to the second body. The intermediate body is compressed toward the longitudinal axis. The compression axially elongates the intermediate body, such that the first body is separated from the second body. An apparatus used to set the distance is also disclosed.

Abstract: A direct drive servo-valve wherein rotational motion of a drive motor rotor is converted into linear motion of a spool valve. The drive motor includes a shaft which has affixed to the end thereof a ball which engages the spool valve. The ball is affixed to the shaft by providing a bore internally of the shaft which is disposed eccentrically to the longitudinal axis of the shaft. The ball has a portion thereof ground of so as to provide an integral protrusion which is received within the bore in the end of the shaft. The ball is permanently affixed to the shaft by brazing the protrusion into the bore and a planar surface which surrounds the base of the protrusion to the end of the shaft against which it mates.

Abstract: A method of manufacturing and testing a standardized fuel injector configuration accommodates multiple fuel injector customers. Initially, a fuel injector is molded, the fuel injector having an inlet end and an outlet end. Passage of fuel through the fuel injector is controlled between the inlet end and the outlet end. The electrical terminal geometry to be molded with the electrically operated fuel injector is selected, and electrical current flow for the fuel injector is generated through the electrical terminals. The selected electrical terminal geometry is accessible for connection to any of a plurality of different connectors, which are independently molded. Test processes are conducted on the fuel injector and, subsequently, an independently molded post electrical plug is installed, encompassing the electrical terminals.

Abstract: Improved membrane valve for transferring fluids or gases in hermetic or semi-hermetic compressors, including a method and system for manufacturing a membrane valve and a membrane valve with applications for use in several motors, particularly in hermetic or semi-hermetic compressors which use, as a refrigeration fluid, an appropriate type of gas thus promoting the refrigeration physical affect. The above mentioned gas is to be transferred from one chamber to the other, according to a pre-determined frequency, when utilized in conjunction with a piston. A body and a membrane are produced from substantially thin metallic plates separately in accordance to an available process and subjected to rounding in order to eliminate live comers, and then juxtaposed thus composing the valve, with the above mentioned membrane on one side, fitted to the body which is fixed through a connection process and, on the other side, left free to oscillate, thus allowing the passage of a fluid such as a refrigeration gas.

Abstract: The present invention provides a carbon-carbon (C/C) composite valve structure useful for high temperature internal combustion engines comprising (a) a carbon-carbon (C/C) composite valve stem having a flared end and a non-flared end opposite the flared end; and (b) a carbon-carbon (C/C) composite valve head applied onto the flared end of the valve stem, wherein at least one of the carbon-carbon (C/C) composite valve stem and head is coated with a high temperature resistant coating.

Abstract: A method for forging a one-piece or two piece flange-type ball valve, including forging the left and right primary elements, the process including the direct forging of the water inlet seat and the ball valve seat for a one-piece flange-type ball valve, the forging of the water inlet seat, the ball valve seat, the position limiter seat and the water outlet seat. The fabrication of all the center through-holes and ball valve chamber are carried out in a single process without requiring the machining of the interior sections. Friction welding methods are used to weld the water inlet seat to the ball valve seat and the position limiter seat to the water outlet seat as if they were fabricated entirely by forging. The friction welding beads built-up along the mated welding surfaces inside the center through-hole and exterior are then removed to achieve a smooth finish and enable the valve to have a seamless appearance as though constructed of a single unit of material.