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Advancing rocket propulsion through Additive Manufacturing, novel surface finishing technologies and public-private partnerships

Whilst Additive Manufacturing is undoubtedly having a huge impact on the design and manufacture of rocket propulsion systems, most notably combustion chambers and nozzles, the Achilles’ heel of all AM process is currently as-built surface finish.

Advancing-rocket-propulsion-through-Additive-Manufacturing

Technical Papers

Gear Repair for Helicopters and Wind Turbines via Isotropic Superfinishing

The wind turbine, aerospace, and helicopter gear industries recognize the importance of surface finish and surface texture for maximizing component and system performance.

Gear Repair for Helicopters and Wind Turbines via Isotropic Superfinishing

Videos

ISF Surface Versus Machined Surface

Why ISF® Surfaces are superior to machined surfaced: As the load of the mating surface is increased, the lubrication film becomes thinner, and the asperities of the machine surface contact each other resulting in plastic deformation, metal debris and scuffing, not so with REM Surface Engineering’s ISF® Surface.

Technical Papers

Gear Corrosion During the Manufacturing Process

No matter how well gears are designed and manufactured, gear corrosion can occur that may easily result in catastrophic failure. Since corrosion is sporadic and a rare event and often difficult to observe in the root fillet region or in finely pitched gears with normal visual inspection, it may easily go undetected.

Technical Papers

High Speed, Automatable Superfinishing of Rear-Axle Hypoid Gears

The benefits gained by superfinishing rear-axle hypoid gearsets are now well documented. Friction, wear and operating temperature are significantly reduced. The main impediment to commercially implementing this process, however, is that it increases manufacturing cost in terms of process speed, work in process and labor.

Technical Papers

The Effect of Superfinishing on Gear Micropitting, Part II

It should be noted from the outset that the data presented in Part I and Part II of this paper was generated by independent laboratories. Superfinishing of the gears was the authors’ sole contribution to these studies.

Technical Papers

A Novel Approach to the Refurbishment of Wind Turbine Gears

Multi-megawatt wind turbine gearboxes operate under demanding environmental conditions including considerable variation in temperature, wind speed, and air quality.

Videos

The Rapid ISF® Process

REM Surface Engineering’s automotive process, Rapid ISF® (Isotropic Superfinishing), is able to produce a planar surface of Ra .1 µm or less in 4 minutes. The Rapid ISF Process increases fuel efficiency and power density and is compatible with a just-in-time environments.

Videos

REM ISF (Isotropic Superfinish) Process Overview

REM Surface Engineering’s ISF Process Overview. A basic understanding of superfinishing for metal components.

White Papers

Materials Matter: Gear Corrosion in the Manufacturing Process

No matter how well gears are designed and manufactured, gear corrosion can occur during the manufacturing process, which may, in turn, result in catastrophic failure.

White Papers

Materials Matter: Comparing Surface Roughness Parameters

Effective gear design must account for a range of potential failure modes. As discussed in previous Materials Matter columns, gear failure modes can be fatigue-based and progressive (such as micropitting) or sudden (such as scuffing).

White Papers

Materials Matter: Lambda Ratio

The lambda ratio was originally developed to quantify the quality of lubricant operating regimes relative to bearing performance.

White Papers

Materials Matter: Micropitting

Micropitting is a gear failure mode that typically occurs when higher contact stresses are applied to hardened gear teeth. Unlike most other failure modes, micropitting does not always proceed to component failure if left unaddressed.

White Papers

Materials Matter: Scuffing

Gear meshing is one of the most complex areas of study in tribology. Meshing consists of both sliding and rolling motion and can be affected by a number of other operating parameters.

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