Abstract: Systems and methods resolve stresses in additive manufacturing. A stress resolution profile including frequency and amplitude parameters of an ultrasonic input are determined based on physical properties of the product. Successive layers of a material are added and energy is applied to incorporate the material of each layer into the product. An ultrasonic input is applied with the determined parameters to resolve stress as the product is built up. The ultrasonic input is varied as a depth of the material incorporated into the product increases.

Abstract: Prior to manufacturing a product by additive manufacturing, a stress relief profile including frequency and amplitude parameters of an ultrasonic input is determined based on physical properties of the product, including resonant frequencies of the product and a material from which the product is manufactured. Successive layers of a material are added and energy is applied to incorporate the material of each layer into the product. A processor accesses stress relief profile parameters for each layer, determines whether a layer requires stress relief and determines a frequency and a power level for the stress relief at the layer. An ultrasonic input is applied with the determined parameters to relieve stress as the product is built up.

Abstract: A sputtering target comprising a forged aluminum material having an average grain size between about 15 and 55 microns. The aluminum material has at least one of the following: a homogeneous texture with minimal texture banding as measured by banding factor B below about 0.01; a texture gradient H of less than 0.2; or either weak (200) texture or near random texture characterized by maximum intensity of inverse pole figure less than 3 times random in multiple directions.

Abstract: Systems and methods resolve stresses in additive manufacturing. A stress resolution profile including frequency and amplitude parameters of an ultrasonic input are determined based on physical properties of the product. Successive layers of a material are added and energy is applied to incorporate the material of each layer into the product. An ultrasonic input is applied with the determined parameters to resolve stress as the product is built up. The ultrasonic input is varied as a depth of the material incorporated into the product increases.

Abstract: A computer-implemented method for predicting material properties in an Additive Manufacturing (AM) process is provided.

Abstract: A computer-implemented method for predicting material properties in an Additive Manufacturing (AM) process is provided.

Abstract: A computer-implemented method for predicting material properties in an Additive Manufacturing (AM) process is provided.

Abstract: A sputtering target comprising a forged aluminum material having an average grain size between about 15 and 55 microns. The aluminum material has at least one of the following: a homogeneous texture with minimal texture banding as measured by banding factor B below about 0.01; a texture gradient H of less than 0.2; or either weak (200) texture or near random texture characterized by maximum intensity of inverse pole figure less than 3 times random in multiple directions.

Abstract: A reference standard for calibrating an ultrasonic scanning apparatus comprising a first portion comprising a first material, a first face, and a second face opposite the first face. The reference standard also has a second portion comprising a second material, a first face, and a second face opposite the first face. The second face of the second portion is adjacent the first face of the first portion and forms an interface. The reference standard also includes a reference material extending axially through the first face of the first portion and the second face of the second portion. The first portion and second portion are configured to enclose the reference material such that the calibration standard is void free at an interface between the first material and the reference material and at an interface between the second material and the reference material.

Abstract: A method of purifying and casting a material comprising placing a material to be purified within a crucible, the crucible located within a purification chamber; providing thermal energy to the material to maintain the material in a molten state; providing a purification gas into the molten material to purify the material until a first measured condition is attained; passing the material in a fluid state from the purification chamber having a first atmosphere to a casting chamber having a second atmosphere, the purification chamber in fluid communication with the casting chamber such that the material passes from the purification chamber to the casting chamber without exposure to a third atmosphere; placing the material into a mold within the casting chamber; cooling the material within the mold to form a cast material.

Abstract: Unitary closure panels for automotive vehicles may be formed to have regions of different materials by a spray casting process. Separate sprays of different materials, for example two different metal alloys, are applied to touching regions of a spray application surface. The separate sprays may be applied sequentially or simultaneously to the forming surface to coat the respective regions so that the regions are contiguous or overlapping and a unitary body is formed. The spray formed body may be compressed and trimmed between facing surfaces to form a vehicle closure panel of specified outline, curvature, thickness, and porosity.

Abstract: A casting chamber configured to form a casting from molten material includes an outer mold, a plurality of inner core elements, and a surface portion of a thermal chill device. The thermal chill device includes first and second interchangeable elements with the surface portion of the thermal chill device including one of a first surface portion of the first interchangeable element and a second surface portion of the second interchangeable element. The first surface portion of the first interchangeable element includes an insulating material and the second surface portion of the second interchangeable element comprising a metallic material.

Abstract: A casting chamber configured to form a casting from molten material includes an outer mold, a plurality of inner core elements, and a surface portion of a thermal chill device. The thermal chill device includes first and second interchangeable elements with the surface portion of the thermal chill device including one of a first surface portion of the first interchangeable element and a second surface portion of the second interchangeable element. The first surface portion of the first interchangeable element includes an insulating material and the second surface portion of the second interchangeable element comprising a metallic material.

Abstract: One embodiment includes an insert including a body portion; a plurality of tabs extending from the body portion, wherein the tabs are tapered; and wherein the insert is constructed and arranged to provide damping.

Abstract: A method of improving the corrosion resistance of magnesium alloy castings containing more than about 2 per cent by weight of aluminum is described. The method comprises: first selecting a casting process suitable for developing at least on the surface of the casting a microstructure comprising aluminum-depleted magnesium grains surrounded by an aluminum-rich layer and preferably incorporating at least some of an intermetallic compound based on the composition Mg17Al12; and second, heat treating at least the outer layer of the casting to promote additional intermetallic compound precipitation as required.

Abstract: A system and method for dynamically mapping the position and speed of objects around a vehicle for collision avoidance purposes. The method determines the velocity of the vehicle in at least two orthogonal directions along with the position of the vehicle. From this information, a distance function map of the vehicle is created in a predefined area that includes a distance value at concentric locations from the vehicle. The distance function map is combined with distance function maps from all of the objects in the predefined area to determine whether a potential collision exists between the particular vehicle and any of the other objects.

Abstract: One embodiment includes an insert including a body portion; a plurality of tabs extending from the body portion, wherein the tabs are tapered; and wherein the insert is constructed and arranged to provide damping.

Abstract: An exemplary embodiment discloses a thermoformed composite powder metallurgy based material including a matrix of sintered metal particles including at least one of a metal and metal alloy; and carbon fibers within said matrix having an orientation and shape derived from a precursor fibrous matte.

Abstract: Residual stress is reduced in light metal alloy articles, e.g. aluminum alloy articles, formed as castings against a sand casting mold body by incorporating a wax composition of suitable softening or melting temperature with the sand particles of the mold or core body. The hot cast metal heats adjoining surfaces of the mold body. As the cooling metal forms a solid shell, the surrounding sand particle and wax mixture are heated sufficiently to melt or soften the wax incorporated on or between sand particles. This softens portions of the rigid mold body that could otherwise restrain shrinking surfaces of the casting and produce unwanted stressed regions that are retained in the casting and must be removed by subsequent processing.

Abstract: Unitary closure panels for automotive vehicles may be formed to have regions of different materials by a spray casting process. Separate sprays of different materials, for example two different metal alloys, are applied to touching regions of a spray application surface. The separate sprays may be applied sequentially or simultaneously to the forming surface to coat the respective regions so that the regions are contiguous or overlapping and a unitary body is formed. The spray formed body may be compressed and trimmed between facing surfaces to form a vehicle closure panel of specified outline, curvature, thickness, and porosity.