Ford Global Technolgoies, LLC

Ford Motor Company Limited

John Edward Chancey

Larry Gerald Gargol

Lawrence Edward Ellis

Srikanth Chinthagunta Reddy

Christopher Kelly Palazzolo

Barry E Shepley

Deborah R Pank

Joseph Swithan Vanselous

Robert E DeJack

The present invention provides a plasma transferred wire arc torch assembly that includes a monolithic block assembly that combines into a single component several features that have previously been separate components. The monolithic block of the present invention combines the functions of a wire guide, an air baffle, and a nozzle. Integration of this components allows for a reduction in size of the plasma transferred wire arc torch assembly thereby making it possible to coat smaller diameter bores with metal.

Small bore PTWA thermal spraygun

The present invention provides a nonflammable ternary gas mixture to be used in a plasma machining operation. The ternary gas mixture of the present invention comprises from about 4% to about 6.2% hydrogen, 30% to 50% argon, and the balance nitrogen. In another embodiment of the present invention, a method of generating a high pressure plasma is provided. The method of this embodiment comprises introducing the ternary gas mixture of the present invention into a plasma torch apparatus, initiating a plasma in the plasma torch apparatus, and sustaining the plasma with a high voltage between a cathode and an anode.

Nonflammable ternary gas mix for high pressure plasmas

An aluminum pressure plate and flywheel, for a clutch in a vehicle drivetrain, have wear resistant surfaces applied at the clutch disc interface. The wear resistant surfaces are applied to the pressure plate and flywheel using a plasma transferred wire arc thermal spray process.

Clutch pressure plate and flywheel with friction wear surfaces

A cathode assembly for an electric arc spray apparatus. The cathode assembly utilizes a positive cathode retention design which provides for improved heat management characteristics, quick and easy cathode replacement and increased cathode life. The cathode assembly includes a cathode holder , a cathode including a first portion which resides within the cathode holder , a tip portion which extends from the cathode holder, and a shoulder portion which is formed on the outer surface of the cathode. The cathode assembly further includes a retention member or nut which removably attaches to the cathode holder and which engages the shoulder portion , effective to positively retain the cathode within the holder . The retention member also includes an aperture through which the cathode tip extends. The cathode retention member allows for a longer and larger cathode to be utilized and provides an increased amount of heat dissipating surfaces relative to prior designs, thereby increasing the life and improving the performance of the cathode.

Cathode assembly for an electric arc spray apparatus

A method and system for machining a cylinder head include loading a cylinder head into a first five axis computer numerically controlled (CNC) machine. A first fixture of the first CNC machine is then located against a top surface of the cylinder head such that the cylinder head is in a horizontal position. The first CNC machine then machines the cylinder head in the horizontal position. A second fixture of the first CNC machine is then located against a bottom surface of the cylinder head such that the cylinder head is in a vertical position. The first CNC machine then machines the cylinder head in the vertical position. The cylinder head is then moved into a second five axis CNC machine. A fixture of the second CNC machine is then located against a bottom surface of the cylinder head. The second CNC machine then machines the cylinder head.

Method and system for manufacturing a cylinder head

A method of preparing and coating cylindrical bore surfaces of an aluminum workpiece that comprises (a) inserting and rotationally reciprocally moving a plurality of honing elements against the bore surface with a pressure of at least 30 psi to effect a pattern of spiral overlapping abrasions on said surface, each element being constituted of multifaceted, irregular-shaped, abrasive particles (i.e., diamond or SiC) having a particle size of 30-1300 micrometers. The particles, when in contact with the surface, plow micro-sized, non-smooth and irregularly spaced grooves in the aluminum workpiece resulting in spiral peaks and valleys along the direction of movement of the particles, whereupon repeated reciprocation and rotation of the elements (i.e. 50-200 sfm) thereagainst results in overlapping grooves and cross-abrading of the prior peaks and valleys accompanied by a molding and folding over of certain of the peaks and valleys to create irregular, micro-sized tears, folds, and undercuts; and (b) thermally depositing wear resistant metallic particles onto the abraded surface to form a cohesive coating, said deposited particles migrating into the non-smooth grooves and into the irregular tears, folds, and undercuts during thermal deposition to increase the mechanical bond strength of the coating to the workpiece surface.

Growing community of inventors

Grosse Pointe Farms, MI, United States of America

John Edward Chancey