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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

White Papers

Materials Matter: Nitriding’s “White Layer” and Isotropic Superfinishing

Developed in the early 20th century, nitriding has evolved into a standard process across many industrial applications. Often considered the simplest technique for case hardening, the process is commonplace in aircraft manufacturing, bearings, automotive components, turbine generation systems, and various industrial machineries.

White Papers

Repairing Wind Turbine Gears and Assemblies with Isotropic Superfinishing

As the wind turbine industry matures, the importance of operations and management (O&M) costs grows. In the early years of large kilowatt and small megawatt class wind turbines, pre-mature gearbox failure due to gear fatigue was very common and was a significant issue for wind turbine gearbox manufacturers, wind turbine OEM’s and owner-operators.

Technical Papers

Future Advanced Rotorcraft Drive System (FARDS) Full Scale Gearbox Demonstration

The Future Advanced Rotorcraft Drive System (FARDS) program focused on improving the performance and affordability of current aircraft drive systems.

White Papers

Oil-Out Endurance Under the Lens

Oil-out conditions, or conditions in which an aircraft is operating without any oil in its gearbox or transmission, are devastating for an aircraft’s hardware.

White Papers

Materials Matter: Additive Manufacturing: Challenges, Possibilities, and the Gear Industry

Additive Manufacturing (AM) is a technology that has the potential to fundamentally alter manufacturing, specifically metal manufacturing. The ability to design complex shapes, which could not otherwise be manufactured, coupled with a significant reduction in scrap metal, has obvious benefits.

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.

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