Abstract: A method for forming a tube coupling includes forming a metallurgical joint between a copper tube and an aluminum tube and annealing the copper tube and the aluminum tube after forming the metallurgical joint. The metallurgical joint has a eutectic region and an intermetallic region after annealing the copper tube and the aluminum tube. The method may assist with improving a performance of the metallurgical joint. A related tube coupling and evaporator are also provided.

Abstract: A method for manufacturing a component including a bi-metallic sheet includes performing a manufacturing process that heats the bi-metallic sheet and physically constraining the bi-metallic sheet from deformation during the cooling of the bi-metallic sheet. Optionally, the method additionally includes physically constraining the bi-metallic sheet from deformation during the manufacturing process that heats the bi-metallic sheet. A constraining apparatus is also disclosed and includes a first constraining component having a first thermally conductive contact surface adapted to abut a first surface of a metal sheet, a second constraining component having a second contact surface adapted to abut a second surface of the metal sheet, and an engaging device operative to fix the first constraining component and the second constraining component in position relative to one another. The metal sheet is constrained between the first contact surface and the second contact surface during heating and/or cooling.

Abstract: Micrometer scale components comprise a component body comprising an alloy of a first solder metal and a second solder metal, the alloy having a higher liquidus temperature than the second solder metal; and a base region of the structure body wetted to a substrate, wherein the component body has a molded surface profile.

Abstract: A method for manufacturing micrometer scale components comprises depositing a first metal on a substrate, depositing a second metal in a mold, and alloying the first and second metals together to form the component.

Abstract: Seam protected encapsulated arrays of solid ceramic elements are disclosed. Vulnerable seams between solid ceramic elements arranged adjacent to each other in encapsulated arrays of solid ceramic elements are protected by a seam protector arranged in-line with the vulnerable seams and fixed to the encapsulated array. A stiffener may be arranged in-line with the vulnerable seams and fixed to the encapsulated array opposite to the seam protector. The solid ceramic elements may be encapsulated in a barrier material to prevent the base metal from reacting with the ceramic material units during casting, and/or provide crush/compression protection during cooling.

Abstract: Encapsulated arrays with tiles covered with a barrier layer are disclosed. Tiles formed of silicon carbide, and wrapped with a barrier layer, are encapsulated with a base metal formed of a steel alloy. During a casting process, to fabricate the encapsulated arrays, the barrier layer prevents the steel alloy and/or the silicon carbide from compromising each other.

Abstract: A brake disc arrangement is provided. The brake disc arrangement includes a mounting section, a brake plate section and a transitional interface positioned between the mounting section and the brake plate section and configured to attach the brake plate section to the mounting section. The transitional interface includes at least one extension extending radically from an outer circumference of the mounting section, the at least one extension having a cross-sectional configuration shaped as an I-Beam or other shape having at least two spaced apart projections on opposite side of the extension such that a vent gap is formed between the projections.

Abstract: Methods of forming bi-metallic castings are provided. In one method, a metal preform of a desired base shape is provided defining a substrate surface. A natural oxide layer is removed from the substrate surface, yielding a cleaned metal preform. The method includes forming a thin metallic film on at least a portion of the substrate surface of the cleaned metal preform, and metallurgically bonding the portion of the metal preform having the metallic film with an overcast metal to form a bi-metallic casting. The metallic film promotes a metallurgical bond between the metal preform and the overcast metal. In one aspect, the metal preform may comprise aluminum (Al) and the metallic film may comprise zinc (Zn).

Abstract: A method including positioning an insert in a vertical mold including a first mold portion and a second mold portion; and casting a material including a metal around at least a portion of the insert.

Abstract: A durable ceramic and metallic coating has been applied to ceramic tiles to protect the tiles while undergoing a molten metal casting operation. The plasma sprayed coating consists of a ceramic top coat layer of aluminum oxide, zirconium oxide, or other oxides with or without a metallic bond coat layer and with or without a functionally gradient coating. This coating protects the underlying ceramic tile, which is composed of boron carbide, silicon carbide, alumina (Al2O3) or other type of hard ceramic, from reacting chemically with the molten metal. The molten metal is cast around the ceramic tiles to create a lattice of ceramic tiles that are used for protection from projectiles and shrapnel.

Abstract: A stainless steel-and-amorphous alloy composite includes a stainless steel part and an amorphous alloy part. The stainless steel part has nano-pores defined in a surface thereof. The amorphous alloy part is integrally bonded to the surface having the nano-pores. A method for manufacturing the composite is also described.

Abstract: A product including a damping substrate and a layer over a portion thereof, the layer including graphite, and a body portion positioned so that the layer is interposed between the body portion and the damping substrate.

Abstract: A disc brake rotor has a support hub and coaxial braking band. The support hub has a plurality of radial seats and the braking band has a plurality of connecting elements which transfer torque between the band and the hub. The connecting elements are integral and made as one piece with the braking band and extend from the braking band in order to engage the corresponding radial seats. The connecting elements are surrounded by walls which are integral and made as one piece with the support hub such as to be fastened in the axial direction and in the tangential direction, but capable of sliding in the radial direction.

Abstract: An aluminum-and-amorphous alloy composite includes an aluminum part and an amorphous alloy part. The aluminum part has an aluminum oxide film formed on a surface thereof. The aluminum oxide film defines nano-pores. The amorphous alloy part is integrally bonded to the surface of the aluminum part having the aluminum oxide film. A method for manufacturing the composite is also described.

Abstract: A method for making an arrangement consisting of a cast part and a cast-in component composed of a metallic material. The cast-in component is composed of a metallic material that has a galvanically applied nickel layer. The layer is applied by positioning the cast-in component in an electrolyte bath and applying the coating on at least part of the surface of the component. The cast-in component is then positioned in a casting mold and a cast part is casted around the cast-in part.

Abstract: Discontinuous diamond particulate containing metal matrix composites of high thermal conductivity and methods for producing these composites are provided. The manufacturing method includes producing a thin reaction formed and diffusion bonded functionally graded interactive SiC surface layer on diamond particles. The interactive surface converted SiC coated diamond particles are then disposed into a mold and between the particles and permitted to rapidly solidify under pressure. The surface conversion interactive SiC coating on the diamond particles achieves minimal interface thermal resistance with the metal matrix which translates into good mechanical strength and stiffness of the composites and facilitates near theoretical thermal conductivity levels to be attained in the composite. Secondary working of the diamond metal composite can be performed for producing thin sheet product.

Abstract: A metal/ceramic bonding substrate includes: a ceramic substrate; a metal plate bonded directly to one side of the ceramic substrate; a metal base plate bonded directly to the other side of the ceramic substrate; and a reinforcing member having a higher strength than that of the metal base plate, the reinforcing member being arranged so as to extend from one of both end faces of the metal base plate to the other end face thereof without interrupting that the metal base plate extends between a bonded surface of the metal base plate to the ceramic substrate and the opposite surface thereof.

Abstract: Provided in one embodiment is a method of making use of foams as a processing aid or to improve the properties of bulk-solidifying amorphous alloy materials. Other embodiments include the bulk-solidifying amorphous alloy/foam composite materials made in accordance with the methods.

Abstract: A piston for in-cylinder fuel-injection type internal combustion engine includes a piston body, a low thermal conductor, and a piston head. The low thermal conductor is disposed on the top of the piston body. The low thermal conductor includes a low thermally-conductive substrate, and a coating layer. The low thermally-conductive substrate has opposite surfaces. The coating layer includes alumina fine particles (Al2O3). The coating layer is adhered on at least a part one of the opposite surfaces of the low thermally-conductive substrate that makes a cast-buried or enveloped surface to be cast buried or enveloped in the piston head.

Abstract: An automotive product having a plurality of components coated with a refractory interface coating and method for making the same are provided. The automotive product may include at least a first component and a second component configured to interconnect and engage one another. The first component may be composed of a first high-density material. The second component may be formed of a second lower-density material. A refractory interface coating may be applied at the interconnection between the first and second components to provide an enhanced surface finish to limit friction, prevent metallurgical bonding between the first material and second material, provide a barrier against galvanic corrosion, and provide a thermal barrier between the first component and second component to guard against thermal deformation or change in dimension of the second component.

Abstract: Encapsulated arrays with tiles covered with a barrier layer are disclosed. Tiles formed of silicon carbide, and wrapped with a barrier layer, are encapsulated with a base metal formed of a steel alloy. During a casting process, to fabricate the encapsulated arrays, the barrier layer prevents the steel alloy and/or the silicon carbide from compromising each other.

Abstract: An automotive disk brake assembly installed in an automobile having a wheel. The assembly includes a floating caliper supporting an inner and outer brake pad and a brake rotor having a disk, and a hat, and wherein the hat is bolted to the wheel. A hydraulic cylinder is adapted to push the inner brake pads into the disk surface, causing the floating caliper to move bringing the outer brake pad into contact with the disk. Finally, the rotor is made such that a complete 100 kilometer per hour, 0.9 gross vehicle weight braking causes the disk to expand in thickness by at least 0.15 mm and to cool to shrink in thickness, relative to its expanded thickness, by at least 0.1 mm within 60 seconds of the cessation of braking, in an ambient temperature of less than 30° C.

Abstract: An automotive disk brake assembly installed in an automobile having a wheel. The assembly includes a floating caliper supporting inner and outer brake pads and a brake rotor having a disk, a hat, wherein the hat is bolted to the wheel. A hydraulic cylinder pushes the inner brake pads into the disk surface, thereby causing the floating caliper to move so as to bring the outer brake pad into contact with the disk surfaces. Finally, the rotor is made of a material having a thickness and a coefficient of thermal expansion and conductivity, such that a complete 100 kilometer per hour, 0.9 gross vehicle weight braking causes the disk to expand in thickness by at least 0.10 mm and to cool to shrink in thickness, from its expanded thickness, by at least 0.05 mm within 60 seconds of cessation of braking, in an ambient temperature of less than 30° C.

Abstract: Embodiments provide methods, apparatuses and systems for depositing a thermal insulator coating onto a desired surface of a mold cavity or insert or preform. Embodiments also provide casting methods using a thermal insulator coating.

Abstract: A method comprising providing an insert having a portion capable of being oxidized and electrochemically anodizing the portion capable of being oxidized to provide a layer comprising an oxidized material thereon.

Abstract: A vibration-damped precision cast aluminum alloy automotive member for a vehicle powertrain and a method of its manufacture are disclosed. The vibration-damped precision cast aluminum alloy automotive member includes an internally disposed aluminum or aluminum alloy insert. An exterior surface of the insert, which includes an exposed oxide film, establishes a non-bonded interface with an interior surface of the automotive powertrain member. This non-bonded interface damps vibration propagation through the automotive powertrain member by experiencing frictional contacting movement when the automotive powertrain member is vibrationally excited.

Abstract: A light-weight, sound-damped, composite brake rotor for a vehicle braking system includes a rotor hat and an annular rotor cheek supported by, and cast around, the rotor hat. The rotor hat includes an axially-protruding central hub and an integral flange that extends radially from and circumferentially around the central hub. The rotor cheek includes a top ledge and a bottom ledge that overly a top annular surface and a bottom annular surface, respectively, of the integral flange. An annular interfacial boundary present between an underside of the top and/or bottom ledges and their respective adjacent annular surfaces of the integral flange includes a vibration damping interface. The brake rotor derives its vibration-deadening and sound-damping effects from the vibration damping interface through the occurrence of relative frictional contacting movement.

Abstract: An aluminum-and-amorphous alloy composite includes an aluminum part and an amorphous alloy part. The aluminum part has an aluminum oxide film formed on a surface thereof. The aluminum oxide film defines nano-pores. The amorphous alloy part is integrally bonded to the surface of the aluminum part having the aluminum oxide film. A method for manufacturing the composite is also described.

Abstract: An apparatus and method for manufacturing a downhole tool that reduces failures occurring along a bondline between a cemented matrix coupled around a blank. The cemented matrix material is formed from a powder and a binder material. The blank includes an internal blank component and a coating coupled around at least a portion of the surface of the internal blank component. The internal blank component includes a top portion and a bottom portion. The internal blank component is substantially cylindrically shaped and defines a channel extending through the top portion and the bottom portion. The coating is a metal in some exemplary embodiments. The coating reduces the migration of the binder material into the blank thereby allowing the control of intermetallic compounds thickness within the bondline.

Abstract: Method of making a composite casting involves providing a reinforcement insert with a ceramic coating, positioning the coated insert in a mold, and casting the molten metallic material into the mold where the metallic material is solidified. The composite casting produced includes the reinforcement insert disposed in a solidified metallic matrix with a ceramic coating between the reinforcement insert and the matrix.

Abstract: The present invention relates to a method and apparatus for producing rotatable sputtering targets by means of continuous casting. Target material is deposited around a cylindrical target holder (14) by means of a movable mould (30) surrounding the target holder. The mould (30) is fed with molten metal while it is translated along the target holder to progressively form the layer of molten metal on the outer surface of the target holder.

Abstract: A part having foam tape integrated into a base component. The base component of the part is a body side molding which is attached to a vehicle using an adhesive. More specifically, the part includes a foam layer integrally formed with the body side molding such that a first side of the foam layer is formed with the body side molding, and an adhesive layer attached to a second side of the foam layer. A release film material is selectively attached to the adhesive layer such that the adhesive layer is disposed between the release film material and the foam layer. The release film material is able to be removed from the adhesive layer, and the body side molding is attached to a vehicle using the adhesive layer. The body side molding is used to protect the vehicle, as well as provide an improvement in the appearance of the vehicle.

Abstract: Exemplary embodiments provide a progressive cavity pump or motor including a stator having a longitudinal bore and a rotor rotatably disposed within the longitudinal bore of the stator. The rotor includes a rotor core and a resilient outer layer formed of a resilient material bonded onto the outer surface of the rotor core. The resilient outer layer sealably connects the helical configurations on the outer surfaces of the rotor and the stator as the rotor rotates within the longitudinal bore of the stator.

Abstract: Discontinuous diamond particulate containing metal matrix composites of high thermal conductivity and methods for producing these composites are provided. The manufacturing method includes producing a thin reaction formed and diffusion bonded functionally graded interactive SiC surface layer on diamond particles. The interactive surface converted SiC coated diamond particles are then disposed into a mold and between the particles and permitted to rapidly solidify under pressure. The surface conversion interactive SiC coating on the diamond particles achieves minimal interface thermal resistance with the metal matrix which translates into good mechanical strength and stiffness of the composites and facilitates near theoretical thermal conductivity levels to be attained in the composite. Secondary working of the diamond metal composite can be performed for producing thin sheet product.

Abstract: Multi-component vane segment and method for forming the same. Assembly includes: positioning a pre-formed airfoil component (12) and a preformed shroud heat resistant material (18) in a mold, wherein the airfoil component (12) and the shroud heat resistant material (18) each comprises an interlocking feature (24); preheating the mold; introducing molten structural material (46) into the mold; and solidifying the molten structural material such that it interlocks the pre-formed airfoil component (12) with respect to the preformed shroud heat resistant material (18) and is effective to provide structural support for the shroud heat resistant material (18). Surfaces between the airfoil component (12) and the structural material (46), between the airfoil component (12) and the shroud heat resistant material (18), and between the shroud heat resistant material (18) and the structural material (46) are free of metallurgical bonds.

Abstract: A method for assembling anodes used in electro winning processes, that increases corrosion resistance, comprising pre-coating the copper bus bar by being cast plated at the adequate temperature, introducing said copper bar into an adequate mold and, by injection or a similar method the copper bar is peripherally coated with a lead-antimony alloy, moving the copper bar to the assembly table, and filling the slot with a lead-bismuth alloy, applying, once the lead-bismuth alloy poured into the slot has solidified, reinforcement solder,

Abstract: A cast metal part has a veneer made of cosmetic metal applied thereto so that the cast metal part has a cosmetic surface. A method for producing a cast metal part with a cosmetic surface comprises applying a veneer of cosmetic metal to a surface of the cast metal part. The cast metal part can be a die cast part, such as die cast aluminum or zinc. The veneer can be thin gauge highly cosmetic aluminum. The veneer of cosmetic metal can be applied to the surface of the cast metal part by placing the veneer into a casting mold used for forming the cast metal part, and casting molten metal onto the veneer in the casting mold. The veneer of cosmetic metal can also be applied to the surface of the cast metal part by solid-state welding, e.g., diffusion bonding, the veneer and the cast metal part together.

Abstract: A flux for application on and for reduction of oxide layers on a metal surface. The flux includes potassium fluoride, sodium fluoride, remaining moieties of water and gelatin. The can also include a reactant comprising moieties of at least one of the compositions of zirconium fluoride, lithium fluoride, sodium fluoride, potassium cryolite and potassium aluminum fluoride (KaAlF4), moieties of salts on the basis of at least one of the elements zirconium, lithium, potassium, sodium, bismuth boron and titanium and gelatin. The flux can be used in a method to reduce oxide layers on a metal surface by applying the flux onto the metal surface.

Abstract: Disclosed is a method for manufacturing a multilayered duplex material article. The method comprises providing a first layer from a non-cast material and a second layer from a cast material wherein the second layer is made from a material with a lower melting point than the first layer. In one embodiment the first layer is a wrought alloy and the second layer is cast onto the first layer.

Abstract: A bipolar plate (1) in combination with a sealant (50, 70) for a PEM fuel cell, wherein the bipolar plate (1) has an anode side with first flow channels (20) for transport of a proton-donating fuel or a cathode side with second flow channels (12) for transport of proton-accepting fluid, or both, wherein a sealant (50, 70) is provided parallel with the bipolar plate (1) for sealing the bipolar plate against an adjacent electrolytic membrane (40). The sealant (50, 70) has fluid channels (54a, 54b, 74a, 74b) across the sealant (50, 70) for transport of proton-donating fuel or proton-accepting fluid, respectively, across the sealant and along the bipolar plate.

Abstract: The present invention is related to a novel sterling silver compound for use in vermeil jewelry and other articles of manufacture. The compound includes an alloy composed of at least 92.5% by weight of silver, up to 7.5% by weight of gold, and the remainder in copper. The invention further relates to an article of jewelry including at least 92.5% by weight of silver, up to 7.5% by weight of gold, and the remainder in copper. The invention also relates to a method for making an article. The method includes providing a vessel and adding 3.75% by weight of gold, 94.0% by weight of silver, and 2.25% by weight of copper to the vessel. The method also includes melting the metals and mixing them until a homogenous mixture is formed. The method further includes pouring the homogenous mixture into a mold to form a semi-finished article and plating the semi-finished article with 18K rose gold.

Abstract: A product including a damping substrate and a layer over a portion thereof, the layer including graphite, and a body portion positioned so that the layer is interposed between the body portion and the damping substrate.

Abstract: A mold for creating metal ingots, a hottop sideboard and a system and method of manufacturing metal ingots utilizing the same. A hottop sideboard utilizes a layer of a rigid refractory material integrally connected to a layer a flexible refractory material that is compressed between the rigid layer and the sidewalls of the mold during use. The mold for creating metal ingots comprises: a main body having a floor and sidewalls that form a cavity for receiving a molten metal; a plurality of sideboards connected to the sidewalls and forming a perimeter about the cavity in a spaced relation from the floor, the sideboards comprising a first layer of a rigid refractory material and a second layer of a flexible refractory material, the first layer and the second layer being connected to one another; and the sideboards are secured to the sidewalls so that the second layer is compressed between the first layer and the sidewall.

Abstract: A liner outer surface is coated by a sprayed layer or a heterogeneous metal layer including a base metal phase and dispersed metal phases. During casting, liquid metal enters the sprayed layer from the dispersed metal phases and solidifies in a virtual vegetation root state. The surface of the cylinder block is thus rigidly fixed to the surface of the cylinder liner. In this case, a strong bonding force is produced between the cylinder block and the cylinder liner and high thermal conductivity is obtained compared to the prior art in which the liquid metal merely contacts a surface layer.

Abstract: A method including positioning an insert in a vertical mold including a first mold portion and a second mold portion; and casting a material including a metal around at least a portion of the insert.

Abstract: A stabilizer bar with a lateral retention collar is provided. The lateral retention collar is cast onto the stabilizer bar and can be made from a zinc-aluminum alloy. In addition, the lateral retention collar is cast onto the stabilizer bar using a die casting machine. The lateral retention collar has an axial sleeve with a flange that extends radially therefrom. In some instances, the flange has a width in the axial direction, with the width being between 5 and 50% of an overall axial width of the lateral retention collar. In addition, the flange has a radial thickness that is between 5 and 100% greater than the radial thickness of the sleeve. Casting of the lateral retention collar onto the stabilizer bar can provide a push-off load of greater than 5,000 pounds.

Abstract: This invention relates to foundry binder systems, which will cure in the presence of sulfur dioxide and a free radical initiator, comprising (a) an epoxy resin; (b) an acrylate; (c) an alkyl ester of a fatty acid, wherein the alkyl group of the ester is an aliphatic hydrocarbon having from 4 to 8 carbon atoms, preferably butyl tallate; and (d) an effective amount of a free radical initiator. The foundry binder systems are used for making foundry mixes. The foundry mixes are used to make foundry shapes (such as cores and molds) which are used to make metal castings, particularly ferrous castings.

Abstract: This invention relates to foundry binder systems, which cure in the presence of sulfur dioxide and an oxidizing agent, comprising (a) an epoxy resin; (b) an alkyl silicate; (c) an ester of a fatty acid, (d) an effective amount of a oxidizing agent, and (e) no ethylenically unsaturated monomer or polymer. The foundry binder systems are used for making foundry mixes. The foundry mixes are used to make foundry shapes (such as cores and molds) which are used to make metal castings, particularly ferrous castings.

Abstract: The invention relates to a method for producing a ring support (1) with a sheet metal cooling channel welded thereon (5), which is transfused later with an aluminium melt for producing a piston. The aim of the invention is to improve the production of openings (4) for supplying and removing oil. Said openings are produced even before the transfusion of the cooled ring support. When the alfin pretreament of the cooling ring supports occurs, said cooling channel is filled with melt and emptied again during removal front the alfin bath.

Abstract: Molds are fabricated having a substrate of high density, high strength ultrafine grained isotropic graphite, and having a mold cavity coated with a refractory metal such as W or Re or a refractory metal carbide such as TaC or HfC. The molds may be made by making the substrate (main body) of high density, high strength ultrafine grained isotropic graphite, by, for example, isostatic or vibrational molding, machining the substrate to form the mold cavity, and coating the mold cavity with titanium carbide via either chemical deposition or plasma assisted chemical vapor deposition, magnetron sputtering or sputtering. The molds may be used to make various metallic alloys such as nickel, cobalt and iron based superalloys, stainless steel alloys, titanium alloys and titanium aluminide alloys into engineering components by melting the alloys in a vacuum or under a low partial pressure of inert gas and subsequently casting the melt in the graphite molds under vacuum or low partial pressure of inert gas.