Shaft Weld Replacement with a Ceramic Locking Assembly Joint

35 Shaft Weld Replacement with a Ceramic Locking Assembly Joint--Goss Engineers, Inc., 3525 South Tamarac Drive, Suite 325, Denver, CO 80237-1433; (303) 721-8783 Mr. John L. Goss, Principal Investigator Ms. Gabrielle M. Goss, Business Official DOE Grant No. DE-FG03-97ER82388 Amount: $74,986 Joining is a critical, enabling technology in many industrial sectors that have problems of concern to the Department of Energy. The reliability of joints, especially welded joints, is often the limiting factor in the performance of systems in automobiles, power generators, and electronics. In the process industry, it is common to have mounting conditions where a shaft is mounted to a mill head and oftentimes a common cause of shaft failure is this very welding of the mill head to the shaft. This project will develop an innovative and highly efficient joint technology for the replacement of welded joints in shafts to mill heads. This concept involves the novel use of machinable ceramics and locking assembly joints that will eliminate current welding methods and maintain the structural integrity of the mill head and the shaft while providing improved heat-insulating characteristics. The new joint technology can be manufactured economically using current manufacturing capabilities. In Phase I, stress analysis and heat transfer computer models (finite element analysis) will be used to examine and optimize several shaft to head attachments. Additionally, computer models will be used to optimize future ceramic-metal shaft to mill head joining technology. In Phase II, the best methods for connecting shafts to heads with both ceramic and metal locking assembles will be determined. Prototype mill heads will be developed and tested to ascertain the operating characteristics of the new designs. A final design and prototype of a machinable ceramic locking assembly joint will also be developed and tested during Phase II. Commercial Applications and Other Benefits as described by the awardee: These advanced concepts and approaches will improve joining technology for shafts in both military and civilian markets. Applications include the power industry, turbine blades, gas turbines, aerospace, manufacturing, electrical, rubber, food processing, process machinery and heating and cooling systems.