Abstract: A component includes a structural member and an outer wall covering the structural member with a gap between the outer wall and the structural member. The outer wall includes an array of holes, each of the array of holes extending from an exterior surface of the outer wall to an interior surface of the outer wall. The outer wall includes an array of recesses on the interior surface of the outer wall, each hole in the array of holes terminating within one of the array of recesses of the outer wall.

Abstract: A component includes a structural member and an outer wall covering the structural member with a gap between the outer wall and the structural member. The outer wall includes an array of holes each of the array of holes extending from an exterior surface of the outer wall to an interior surface of the outer wall. The outer wall includes an array of recesses on the interior surface of the outer wall, each hole in the array of holes terminating within one of the array of recesses of the outer wall.

Abstract: A method of manufacturing a steering wheel, comprising: forming a rim portion separately with a decorative outer coating via a first forming process; forming a hub separately from the rim portion via a second forming process, the hub having at least a pair of spoke portions; and securing the rim portion to the pair of spoke portions, wherein the decorative outer coating is applied to the rim portion prior to the rim portion being secured to the pair of spoke portions.

Abstract: An aluminum-based casting alloy having improved corrosion resistance and casting characteristics for sand and permanent mold casting processes. The aluminum-based casting alloy contains from about 4.0 to about 7.0 percent silicon by weight, at least 87 percent aluminum by weight, from about 0.25 percent to about 0.5 percent manganese by weight, a maximum of 0.08 percent copper by weight, and from about 0.2 percent to about 0.8 percent iron by weight.

Abstract: An electrical connector capable of being sealingly connected to a housing structure by using a friction stir welding technique includes a polymeric electrical connector harness, at least one electrical conductor extending through the electrical connector harness, and a welding strip sealingly connected around a perimeter of the electrical connector harness to facilitate welding of the electrical connector to a housing structure, such as a sealed metal housing, to sealingly close an opening defined in the housing structure. The electrical connector can be used in a process that creates a hermetic seal between the connector and the housing structure, eliminates the need for mechanical fasteners and/or adhesives, and/or reduces capital equipment and energy costs.

Abstract: A heatsink for conducting heat away from an electric module in thermal contact with the heatsink includes at least a first heatsink member joined to at least a second heatsink member by a weld joint to define a heatsink having an internal plenum. By replacing conventional adhesive and fastening means used for sealing heatsink members together with a welded joint, a more durable and reliable sealed plenum is obtained. In a preferred aspect, the weld joint is created using a friction stir welding technique.

Abstract: A method of manufacturing a steering wheel, comprising: forming a rim portion separately with a decorative outer coating via a first forming process; forming a hub separately from the rim portion via a second forming process, the hub having at least a pair of spoke portions; and securing the rim portion to the pair of spoke portions, wherein the decorative outer coating is applied to the rim portion prior to the rim portion being secured to the pair of spoke portions.

Abstract: An assembly for a sealed electronic component includes at least one electronic device mounted on a substrate, and a metal enclosure comprising first and second housing components that are welded together to define a sealed enclosure. The resulting assembly provides a reliable seal that eliminates the need for mechanical fasteners, adhesives, and equipment for applying and curing adhesives.

Abstract: An electrical connector capable of being sealingly connected to a housing structure by using a friction stir welding technique includes a polymeric electrical connector harness, at least one electrical conductor extending through the electrical connector harness, and a welding strip sealingly connected around a perimeter of the electrical connector harness to facilitate welding of the electrical connector to a housing structure, such as a sealed metal housing, to sealingly close an opening defined in the housing structure. The electrical connector can be used in a process that creates a hermetic seal between the connector and the housing structure, eliminates the need for mechanical fasteners and/or adhesives, and/or reduces capital equipment and energy costs.

Abstract: An aluminum-based die casting alloy exhibiting improved corrosion resistance and good die-castability contains from about 4.5 to about 12 percent silicon by weight, at least 87 percent aluminum by weight, from about 0.25 percent to about 0.6 percent manganese by weight, and a maximum of 0.2 percent copper by weight. The alloys preferably contain iron in an amount sufficient to improve hot tear resistance and to decrease the tendency for die sticking or soldering during die casting.

Abstract: A process of cleaning a component following a forming operation that has left a residue on the component surface. The process comprises a thermal treatment during which the surface of the component is subjected to a controlled open flame, preferably in the presence of a limited amount of excess oxygen. Residues can be removed by the open flame to the extent that adhesion of a coating to the component surface can be greatly enhanced. Surface residue levels prior to the thermal treatment can be reduced by the use of lubricants prepared by diluting with de-ionized water or reverse osmosis water, thereby further increasing the likelihood of a residue-free surface having optimal adhesion properties. Under some circumstances, residue levels can be sufficiently reduced with the use of lubricants diluted with de-ionized or reverse osmosis water such that the thermal treatment can be omitted.

Abstract: An aluminum-based die casting alloy exhibiting improved corrosion resistance and good die-castability contains from about 4.5 to about 12 percent silicon by weight, at least 87 percent aluminum by weight, from about 0.25 percent to about 0.6 percent manganese by weight, and a maximum of 0.2 percent copper by weight. The alloys preferably contain iron in an amount sufficient to improve hot tear resistance and to decrease the tendency for die sticking or soldering during die casting.

Abstract: An aluminum-based die casting alloy exhibiting improved corrosion resistance and good die-castability contains from about 4.5 to about 12 percent silicon by weight, at least 87 percent aluminum by weight, and a maximum of 0.2 percent copper by weight. The alloys preferably contain iron in an amount sufficient to improve hot tear resistance and to decrease the tendency for die sticking or soldering during die casting.

Abstract: A parallel guide mechanism includes a peripheral housing and a central mass, for accepting a mechanical input from a user, located within the peripheral housing. The central mass moves responsive to the mechanical input. A first beam and a second beam horizontally separated by a gap and substantially located in a first plane extend from a first vertical surface of the central mass and connect the central mass to a first inner vertical surface of the peripheral housing. A third beam located in a second plane is vertically spaced apart from the first and second beams and is horizontally positioned in the first gap between the first and second beams and extends from the first vertical surface of the central mass and connects the central mass to the first inner vertical surface of the peripheral housing.

Abstract: A rapid prototyping process is provided by which prototype components can be fabricated that are suitable for conceptual evaluations. The rapid prototyping process of this invention is more efficient than comparable prior art processes, in that the previous requirement to completely process a prototype article within a single process chamber is eliminated, such that different process steps can be conducted simultaneously on different articles within a single process system. The process entails the steps of forming a prototype within a process chamber that generates the prototype through successively depositing and sintering individual layers of a powder material that fuses together so as to form the prototype. The prototype is then removed from the process chamber and cooled within a separate cooling chamber through which a nonoxidizing cooling medium flows.

Abstract: A gas turbine component that includes a very thin wall. The gas turbine component being of a single-piece, single-cast structure. In one form of the gas turbine component it is formed of a superalloy composition and is capable of withstanding gases impinging upon the walls at temperatures greater than 4000.degree. F.

Abstract: A method of making a fused polycarbonate pattern for casting alloy structures, particularly gas-turbine blades, or components. A plurality of powder layers are fused together by a laser beam in a layer-by-layer fashion to produce the pattern. A pattern/casting mold is made and the pattern is burned out in a flash flame oven at a temperature ranging from about 1600.degree. F. to about 2100.degree. F. Preferably the burn-out step is conducted in the presence of an air stream so that the polycarbonate pattern is burned out ash free.

Abstract: Disclosed is a single-cast, thin wall structure capable of withstanding impinging gases at temperatures of 4300.degree. F. and higher, and method of making the same. Using a bleed line of the instant invention allows for a decreasing metal pressure with respect to time which prevents any damage to the thin outer mold wall.

Abstract: Disclosed is a method of making a fused pattern/core combination for a gas-turbine blade or component. A plurality of powder layers are fused together by a laser beam in a layer-by-layer fashion to produce the pattern/core combination. The core may have thin sections having a thickness of about 0.06 of an inch.