Caterpillar Inc.

Thomas E Clements

Kenneth W Burris

Gary D Keil

Robert E Sharp

Daniel Joseph Sordelet

David Anthony Cusac

Daniel Patrick Vertenten

Hyung K Yoon

Leonid Chuzhoy

John B Walenta

Anthony F Cieszkiewicz

Charles F Berndt

Steven M Cross

Timothy M Hoefft

A process of remanufacturing a component such as an attachment flange used in turbochargers is provided and includes using a steam oxidation process to form an adhesion layer on top of a sealing surface of the component. The adhesion layer is an oxidation layer that a thermal metal spray coating can be applied on top of in order to prevent spalling that can occur at high heat. Once the process is completed, the component can be inspected to ensure that it meets or exceeds the manufacturer's original specifications.

Steam oxidation of thermal spray substrate

A method of forming an oxide layer on a powder metal part includes subjecting the powder metal part to a steam oxidation process. An oxide layer is formed on the powder metal part. The oxide layer has a thickness greater than 7 microns.

Steam oxidation of powder metal parts

An article and method for forming an article having a hard-finished surface including a predetermined density of carbides to improve pitting and wear resistance and to significantly increase the overall life of the article. This method comprises selecting a carburizing grade material to form an article, carburizing the article to form a microstructure on at least one portion of the article having a predetermined density of carbides dispersed in the microstructure to a predetermined depth, quenching the article to form a hardened matrix dispersed with carbides and hard finishing the article to form the surface, the surface having at least approximately 20% by volume fraction carbides dispersed in the hardened matrix.

Carbide method and article for hard finishing resulting in improved wear resistance

A method and apparatus for characterizing a quench for producing desired hardness characteristics on a steel part. The characterization preferably includes a series of heat transfer coefficients versus temperature for the quench determined from information representative of known quenches and distinguishing part characteristics such as geometry, size and composition. The quench characterization determined using the present method and apparatus can be utilized in hardness prediction software programs, and for determining a suitable quench for producing the desired hardness characteristics on the part.

Method and apparatus for characterizing a quench

A process for improving fatigue resistance of a case hardened component having a case thickness 't', subjected to one or more of rolling, sliding, abrasion, bending and pitting includes determining the magnitude of fatigue strength at surface and at a plurality of pre-selected points along thickness 't' of a component. The applied fatigue stresses acting upon the component at the surface and at the plurality of pre-selected points along thickness 't' are also determined. Then, a compressive residual stress profile is tailored from the surface to thickness 't' of the component. The compressive residual stresses at the surface and at the plurality of the pre-selected points along thickness 't' respectively have a magnitude sufficient to attain a net resultant stress which is at least 25% lower than the fatigue strength at the surface and the corresponding plurality of pre-selected points.

Process for improving fatigue resistance of a component by tailoring

Method of manufacturing a crankshaft

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Peoria, IL, United States of America

Thomas E Clements