Abstract: A cooling insert for a die, such as a distributor for a high pressure die casting assembly, and a method of manufacturing the cooling insert, is provided. The cooling insert can be formed of H13 tool steel and is manufactured using an investment casting process, for example, a process which uses a printed investment casting shell. The cooling insert includes complex cooling channels to improve cooling and reduce the duration of the casting process.

Abstract: An insert for a steel shot sleeve of a high-pressure die casting assembly used to form aluminum vehicle components is provided. The insert is formed by additive manufacturing, for example laser sintering, and is located opposite a pouring hole of the shot sleeve. The insert includes multiple layers formed of metals and ceramic designed to reduce damage to the shot sleeve caused while casting the components. For example, a cylindrical body of the shot sleeve can be formed of steel, and the insert can include a base layer formed of the steel. The insert can include middle layers formed of a mixture of the steel; an alloy of chromium, iron, and molybdenum; and zirconium oxide. The insert can also include an inner layer formed of the zirconium oxide. The amount of ceramic increases and the amount of metal decreases in the direction moving toward the inner layer.

Abstract: A modular vehicle system includes a cabin module, front end module, and rear end module. The cabin module includes a floor structure of the vehicle and has a front end and a rear end, and a plurality of panels extending upwardly from the floor structure. The front end module is configured to include the front wheels of the vehicle. The rear end module is configured to include rear wheels of the vehicle. The front end module is configured to securely attach to the front end of the cabin module, and the rear end module is configured to securely attach to the rear end of the cabin module. Various types of modules can be constructed and assembled to define various types of vehicles. The floor structure of the cabin module may include an electric vehicle battery, and different cabin modules may have different battery types enabling different vehicle ranges.

Abstract: A system and method for inspecting an assembly including components joined by self-piercing rivets by a computerized tomography (CT) scan of the joint is provided. The system includes a source of x-rays, a mounting unit for an assembly including the joint which is subject to the x-rays, and an x-ray detector disposed opposite the source for detecting the x-rays. The x-rays are provided at a high energy level of at least 200 kV to generate images having a resolution of at least 200 micrometers (?m). A computer stitches the images together to form reconstructive images which show details of the joint. The assembly to be inspected is not destroyed or modified prior to the inspection process. The resolution of the images generated by the x-rays is high enough to determine the presence of cracks, if any, the interlock (SH), minimum thickness (Tmin), and overall structure of the unmodified assembly.

Abstract: An improved aluminum alloy for blending with a recycled aluminum alloy to form a material for high pressure vacuum die casting is provided. The improved aluminum alloy includes 10 to 12 wt. % silicon, 0.65 to 0.85 wt. % manganese, less than 0.05 wt. % iron, less than 0.05 wt. % magnesium, 0.2 to 0.4 wt. % strontium, less than 0.05 wt. % titanium, and less than 0.02 wt. % copper, based on the total weight of the improved aluminum alloy. The recycled aluminum alloy typically includes 0.60-1.0 wt. % silicon, ?0.35 wt. % iron, ?0.20 wt. % copper, 0.05-0.20 wt. % manganese, 0.40-0.8 wt. % magnesium, ?0.20 wt. % chromium, ?0.15 wt. % zinc, ?0.05 wt. % titanium, ?0.05 wt. % others (each), and ?0.15 wt. % others (total). The material meets the specifications for an Aural 5S alloy.

Abstract: A system for removing a heat check feature on an aluminum casting formed by a high pressure die casting process is provided. The system includes a laser source, a robotic arm, and a heat check sensor. The heat check sensor develops a surface profile of at least part of the casting and transmits heat check feature information to the laser source to project the beam of laser light thereon. The projection of the beam of laser light can be varied in time and power, which can depend on surface profile information obtained from the sensor. Once at least a portion of the heat check feature is removed, the casting is placed against another part such that the joint interface is primarily the portion where the heat checking has been removed. Self-piercing rivets are then driven into the casting and the part to permanently join them together.

Abstract: An insert for a steel shot sleeve of a high-pressure die casting assembly used to form aluminum vehicle components is provided. The insert is formed by additive manufacturing, for example laser sintering, and is located opposite a pouring hole of the shot sleeve. The insert includes multiple layers formed of metals and ceramic designed to reduce damage to the shot sleeve caused while casting the components. For example, a cylindrical body of the shot sleeve can be formed of steel, and the insert can include a base layer formed of the steel. The insert can include middle layers formed of a mixture of the steel; an alloy of chromium, iron, and molybdenum; and zirconium oxide. The insert can also include an inner layer formed of the zirconium oxide. The amount of ceramic increases and the amount of metal decreases in the direction moving toward the inner layer.

Abstract: A die casting furnace system includes a die casting holding furnace unit defining a cavity for holding a molten metal. A dosing unit is disposed within the cavity and defines a dosing area disposed in fluid communication with the cavity for receiving the molten material during a pressurization of the cavity. The cavity of said die casting holding furnace unit has a first storage capacity and the dosing area of said dosing unit has a second storage capacity being less than the first storage capacity. An ultrasonic unit is operably coupled with the finitely sized dosing area and is configured to introduce vibration into the received molten material for facilitating the removal of gases from the received molten material. The treatment of the finitely sized dosing area with the ultrasonic unit leads to improved metal cleanliness and accuracy that is not achievable with prior art systems.

Abstract: Disclosed herein is a bulk metallic glasses (BMG) comprising 0.0001 wt % to 0.7 wt % of Be, 0.0001 wt % to 0.2 wt % of Be, or 0.06 wt % to 0.08 wt % of Be. Be may have the effect of reducing a liquidus temperature of the BMG relative to melting temperatures of individual alloying elements of the BMG.

Abstract: An improved, castable, magnesium-based alloy having good creep resistance, good corrosion resistance, with improved tensile strength and elongation; methods for preparing the alloys; methods for preparing articles from the alloys; and articles, machines, and other devices comprising the same.

Abstract: A die castable magnesium based alloy comprising, by weight, between about 3 and 10% aluminum, between about 0.5 and 2.5% calcium, up to about 1.5% silicon, up to about 0.7% zinc, and the remainder being magnesium. The alloy has been found to exhibit more favorable castability and creep resistance than comparative magnesium based alloys.

Abstract: A die castable magnesium based alloy comprising, by weight, between about 3 and 10% aluminum, between about 0.5 and 2.5% calcium, up to about 1.5% silicon, up to about 0.7% zinc, and the remainder being magnesium. The alloy has been found to exhibit more favorable castability and creep resistance than comparative magnesium based alloys.