Material Salvage of Cast Iron Engine Blocks
The
Structural & Material Analysis Team conducted a project to salvage cracked cast iron
engine blocks. They identified the engine blocks' material aging process and then used
Design of Experiments techniques to identify the best welding procedure.
Finally, they simulated specimen and sub-scale component testing to validate the weld process. The
result of the project is a cost-effective welding technique to successfully restore the
engine blocks instead of discarding them.
SES Conversion
Working with the U.S. Office of Naval Research, NC3R developed the processes and technologies
to assess the feasibility of converting an inactive Surface Effect Ship (SES) to an experimental
vessel utilizing an advanced hull form called SLICE. The project required in-depth analysis of
the SES to determine its original specifications, current condition, possibility for upgrades, etc.
With the information gathered through the reverse engineering of the SES,
the
Sustainable Design
Team compiled a vast database that details the physical and economic characteristics of
all primary components within the ship system. NC3R determined that converting and upgrading a
SES to utilize SLICE technology will cost less than one-fourth of the price of an equivalent, new ship.
CV Joint Remanufacturability Study
The
Structural & Material Analysis
Team conducted an independent study on the hardness depth of both
new and used Constant Velocity joints from different manufacturers to determine the hardness of the
joints. To ensure proper functionality in a remanufactured joint, the remanufacturer needs to know
how deeply the original hardness penetrates the joint components and the amount of hardness remaining
after the depressions are ground out. The team determined the hardness
of various CV joints and how the joint can be expected to perform with age, wear and grinding.
As a part of this study, NC3R's
Intelligent Testing & Diagnostic
Team completed the second modification
of a test fixture that allows for observation of a CV joint in various stages of dynamic
operation. With this technology, CV joints from different manufacturers can be quantitatively compared.
Cleaning Process Assessment for a Turbocharger Remanufacturer
The
Clean Technologies Team conducted an assessment of cleaning processes at a turbocharger
remanufacturer where parts cleaning had historically been a major bottleneck in production. The
assessment focused on making performance and environmental improvements using state-of-the-art,
non-hazardous cleaning technologies.The Team assessed the company's cleaning performance and tested
the feasibility of using alternative cleaning technologies.
Following NC3R's recommendations, the company improved cleaning performance, increased throughput, reduced waste generation, doubled
capacity, and improved working conditions.
Development of Custom Cleaning Systems
Through feasibility testing of a variety of cleaning chemistries and equipment,
the
Clean Technologies
Team developed a custom process to clean a rigid packaging material. The process
allows the packaging to be reused, eliminating the disposal of a significant solid waste stream
and reducing emissions.
Demonstration of Non-hazardous Abrasive Technologies
The
Clean Technologies Team educates industry
on innovative, environmentally preferable cleaning
technologies through workshops and demonstrations. For example, CO2 pellet and baking soda cleaning
technologies are demonstrated at NC3R to interested companies.
Operational Assistance for an Office Furniture Remanufacturer
The
Operational Assistance Team assessed the production
operations and refurbishing techniques of an office furniture remanufacturer with the goal of improving process flow and capacity planning strategy. As a result of the Team's recommendations, the remanufacturer
improved efficiency and saw a reduction in production costs.
Facility Planning for a Fuel Systems Remanufacturer
The
Operational Assistance Team conducted a facility-planning project
for a carburetor and fuel
injection remanufacturer. The remanufacturer wanted to increase capacity and efficiency of their
production process by moving to a larger facility. The Operational Assistance Team developed a plan
that included better material handling methods, a much more efficient production layout, lower travel
distance, an improved work environment and higher capacity. With implementation of the Team's plan,
the company was able to add additional remanufacturing personnel.
Precision Machining Cost Assessment for a Construction Equipment Manufacturer
This direct assistance project was an analysis of the feasibility and cost of remanufacturing a line
of construction equipment. A thorough investigation into the design and life cycle of the equipment
yielded information on the disassembly and documentation of parts, failure modes and effects and wear.
The
Operational Assistance Team identified opportunities for
possible individual part cost reductions,
allowing the customer to embark on a long-term machine tool replacement plan.
