Abstract: A high pressure die casting (HPDC) system for casting ultra-large single-piece castings for vehicles. The HPDC system includes a clear feeding path from at least one ingate to a predetermined thicker section of a mold cavity, a last to solidify ingate having an equivalent or larger feeding modulus than the highest feeding modulus of the other ingates, and thermal management elements. The clear feeding path, last to solidify ingate, and thermal management elements ensure sufficient supplemental molten metal flow to the thicker portion of the mold cavity to accommodate for shrinkage of the thicker portion of an ultra large casting during the casting and solidification process.

Abstract: A design for repair casting having a repairable ultra-large single-piece casting and a replacement part. The ultra-large single-piece casting includes a main body portion, at least one predefined replaceable portion integrally cast with the main body portion, and a cut-guide delineating the predefined replaceable portion from the main body portion. The cut-guide includes a continuous channel defined on an exterior surface of the single-piece casting. The cut-guide further includes a rib extending from a channel wall on the main body portion. A damaged replaceable portion is excisable from the main-body portion by cutting through the single-piece casting along the cut-guide. The excised damaged replaceable portion may be replaced with the replacement part, which has substantially the same geometry, dimensions, and mechanical properties as an undamaged replaceable portion. The replacement part may be joined to the main body portion by mechanical means or by welding.

Abstract: A method of repairing an ultra-large single-piece cast component of a vehicle body. The method includes the steps of locating a damaged portion of the cast component, determining an extent of the damaged portion of the ultra-large cast component, defining a cut-line sectioning off the damaged portion from an undamaged portion of the ultra-large cast component, cutting along the cut-line to excise the damaged portion from the undamaged portion of the ultra-large cast component, and joining a replacement piece to the undamaged portion of the ultra-large cast component. The replacement piece is fabricated based on the original manufacturer’s geometry and dimensional data of the excised damaged portion. The undamaged portion of the ultra-large cast component remains on the vehicle body during the repair.

Abstract: Aluminum alloy components may include a composition including concentrations of, in wt. %, chromium of greater than or equal 0 to less than or equal 0.3, manganese of greater than or equal 0 to less than or equal 0.4, silicon of greater than or equal 6.5 to less than or equal 9.5, magnesium of greater than or equal 0 to less than or equal 0.35, iron of greater than or equal 0.2 to less than or equal 0.4, zinc of greater than or equal 0 to less than or equal 0.15, copper of greater than or equal 0 to less than or equal 0.5, titanium of greater than or equal 0 to less than or equal 0.2, strontium of greater than or equal 0 parts per million to less than or equal 200 parts per million, and a balance being aluminum.

Abstract: A valve seat formed within an aluminum engine component includes a valve seat surface machined within the aluminum engine component, a layer of copper alloy material laser clad onto the valve seat surface of the aluminum engine component, the layer of copper alloy material having a thickness of less than 2.0 millimeters, and a layer of copper alloy/tool steel carbide material laser clad onto the layer of copper alloy material, the layer of copper alloy/tool steel carbide material having an average thickness of less than 0.5 millimeters, wherein the layer of copper alloy/tool steel carbide material has an outer surface that is machined to a final valve seat profile.

Abstract: A cylinder head valve seat of an automobile vehicle includes a valve seat having a valve seat surface integrally joined to an engagement end. The engagement end includes multiple materials extending through a cross section of the engagement end. The multiple materials include: a first material having a first thermal conductivity; and a second material having a second thermal conductivity higher than the thermal conductivity of the first material, wherein the first material transitions into the second material.

Abstract: An aluminum alloy is disclosed that is suitable for casting and additive manufacturing processes. The aluminum alloy may be used in the casting and additive manufacturing of engine blocks and/or cylinder heads of modern internal combustion engines. The aluminum alloy exhibits improved ductility and fatigue properties suitable for elevated operating temperatures from about 250° C. to 350° C. The alloy includes about, by weight, 4-10% Copper (Cu), 0.1-1.0% Manganese (Mn), 0.2 to 5% Magnesium (Mg), 0.01-1.0% Cerium (Ce), 0.01-2% Nickel (Ni), 0.01-0.8% Chromium (Cr), 0.01-1.0% Zirconium (Zr); 0.01-1.0% Vanadium (V), 0.01-0.3% Cobalt (Co), 0.01-1.0% Titanium (Ti), 1-200 ppm Boron (B), 1-200 ppm Strontium (Sr), 0.5% max Iron (Fe), 0.1% max other trace elements, and balance of aluminum (Al).

Abstract: A valve seat formed within an aluminum engine component includes a valve seat surface machined within the aluminum engine component, a layer of copper alloy material laser clad onto the valve seat surface of the aluminum engine component, the layer of copper alloy material having a thickness of less than 2.0 millimeters, and a layer of copper alloy/tool steel carbide material laser clad onto the layer of copper alloy material, the layer of copper alloy/tool steel carbide material having an average thickness of less than 0.5 millimeters, wherein the layer of copper alloy/tool steel carbide material has an outer surface that is machined to a final valve seat profile.

Abstract: A cylinder head having a cast-in-place valve seat for an automobile vehicle includes a valve seat having an inner wall. At least one retaining feature integrally and homogeneously extends from the inner wall. The valve seat when positioned into a casting mold has the at least one retaining feature assisting in retaining the valve seat in the casting mold. A metal in a molten form is received in the casting mold. A cast component formed after cooling of the metal has the valve seat cast-in-place.

Abstract: A cylinder head valve seat of an automobile vehicle includes a valve seat having a valve seat surface integrally joined to an engagement end. The engagement end includes multiple materials extending through a cross section of the engagement end. The multiple materials include: a first material having a first thermal conductivity; and a second material having a second thermal conductivity higher than the thermal conductivity of the first material, wherein the first material transitions into the second material.

Abstract: A cylinder head having a cast-in-place valve seat for an automobile vehicle includes a valve seat having an inner wall. At least one retaining feature integrally and homogeneously extends from the inner wall. The valve seat when positioned into a casting mold has the at least one retaining feature assisting in retaining the valve seat in the casting mold. A metal in a molten form is received in the casting mold. A cast component formed after cooling of the metal has the valve seat cast-in-place.

Abstract: A system for casting an aluminum alloy includes a first chamber for containing a first melt at a first temperature, a second chamber for containing second melt at a second temperature that is lower than the first temperature, a mixing chamber in communication with the first chamber and the second chamber for simultaneously receiving and mixing the first melt from the first chamber with the second melt from the second chamber, and a mold chamber in communication with the mixing chamber and for receiving the mixed melt.

Abstract: A degassing and grain refinement system for a cast aluminum-based component and a method of achieving both hydrogen gas presence reduction and grain size reduction in a cast aluminum-based component. Ultrasonic vibrations are imparted to both the liquid metal travel path from its source to the mold to achieve the reduction in hydrogen gas in the molten metal, as well as to one or more locations within the mold to achieve relatively small and equiaxed grains in the component upon solidification.

Abstract: A degassing and grain refinement system for a cast aluminum-based component and a method of achieving both hydrogen gas presence reduction and grain size reduction in a cast aluminum-based component. Ultrasonic vibrations are imparted to both the liquid metal travel path from its source to the mold to achieve the reduction in hydrogen gas in the molten metal, as well as to one or more locations within the mold to achieve relatively small and equiaxed grains in the component upon solidification.

Abstract: A method to automatically quantify dendrite arm spacing in dendritic microstructures. Once a location of interest in a cast material specimen has been identified, the information contained in it is automatically analyzed to quantify dendrite cell size information that is subsequently converted into a quantified dendrite arm spacing through an empirical relationship or a theoretical relationship. In one form, the relationship between DCS and DAS is such that the DAS in dendritic structure of cast aluminum alloys may be automatically determined from the measurement of one or more of dendrite cell size and the actual volume fraction of the eutectic phases in the local casting microstructure. Non-equilibrium conditions may be accounted for in situations where a theoretical volume fraction of a eutectic phase of the alloy in equilibrium condition is appropriately modified.

Abstract: A method of computationally determining material property changes for a cast aluminum alloy component. Accuracy of the determination is achieved by taking into consideration material property changes over the projected service life of the component. In one form, the method includes accepting time-dependent temperature data and using that data in conjunction with one or more constitutive relationships to quantify the impact of various temperature regimes or conditions on the properties of heat-treatable components and alloys. Finite element nodal analyses may be used as part of the method to map the calculated material properties on a nodal basis, while a viscoplastic model may be used to determine precipitation hardening and softening effects as a way to simulate the time and temperature dependencies of the material. The combined approach may be used to determine the material properties over the expected service life of a cast component made from such material.

Abstract: A method to automatically quantify dendrite arm spacing in dendritic microstructures. Once a location of interest in a cast material specimen has been identified, the information contained in it is automatically analyzed to quantify dendrite cell size information that is subsequently converted into a quantified dendrite arm spacing through an empirical relationship or a theoretical relationship. In one form, the relationship between DCS and DAS is such that the DAS in dendritic structure of cast aluminum alloys may be automatically determined from the measurement of one or more of dendrite cell size and the actual volume fraction of the eutectic phases in the local casting microstructure. Non-equilibrium conditions may be accounted for in situations where a theoretical volume fraction of a eutectic phase of the alloy in equilibrium condition is appropriately modified.

Abstract: A cylinder head is formed by positioning a clad preform including a first and second layer in a casting die cavity with the second layer in communication with the die cavity and the first layer facing outwardly to define a combustion surface. Molten material provided to the die cavity is solidified to form a cast portion metallurgically bonded to the second layer. An aperture of the preform forms a port in fluid communication with a passage of the cast portion. A plurality of dome-shaped preforms may define the combustion chambers of a cylinder head formed by the method. The preform may define a cylinder head face. The first layer may be a steel-based layer, and the second layer and cast portion may be aluminum-based, such that the first layer and combustion surface has higher thermal fatigue strength relative to the cast portion.

Abstract: A cylinder head is formed by positioning a clad preform including a first and second layer in a casting die cavity with the second layer in communication with the die cavity and the first layer facing outwardly to define a combustion surface. Molten material provided to the die cavity is solidified to form a cast portion metallurgically bonded to the second layer. An aperture of the preform forms a port in fluid communication with a passage of the cast portion. A plurality of dome-shaped preforms may define the combustion chambers of a cylinder head formed by the method. The preform may define a cylinder head face. The first layer may be a steel-based layer, and the second layer and cast portion may be aluminum-based, such that the first layer and combustion surface has higher thermal fatigue strength relative to the cast portion.

Abstract: A valve seat insert including an annular body disposed about a central axis. The annular body includes a radially inward face that defines an orifice and a radially outward face that is opposite the radially inward face. Additionally, the annular body includes a top face, and a bottom face that is opposite the top face. The valve seat insert further includes a plurality of heat transfer protrusions that extend from the radially outward face of the annular body.