Abstract: One embodiment includes a product including a metallic foam portion which may serve to reduce the weight of the product and/or vent the product and/or provide damping.

Abstract: Methods and apparatus for creating an overall assembly formed from a transparent member and a metal member are disclosed. According to one aspect of the present invention, a method includes positioning a transparent member in a mold configured for insertion molding, and providing a liquid metal into the mold. The method also includes hardening the liquid metal in the mold. Hardening the liquid metal includes binding the metal to the transparent member to create the integral assembly.

Abstract: A method of pressure forming a metal matrix composite (MMC), comprises: placing a fibre preform (not shown) into a die cavity (14) defined by a split die (12); introducing molten metal into the die cavity (14) through a sprue (16) to envelope the fibre preform; sealing the sprue (16); applying pressure direct to molten metal in the die cavity (14) with a mechanical compaction piston (18) to encourage infiltration of the fibre preform during solidification.

Abstract: A composite of a metal matrix with one or more incorporated secondary phases is referred to as a metal matrix composite (MMC). Secondary phase refers to all the particles or fibers which have a different composition than the metal matrix, and which are incorporated therein. As incorporation phases, elements and compounds are possible which, as a result of their material characteristics, are suited for improving individual properties of the metal matrix. Besides an improvement in individual properties of the pure metal matrix as a result of the incorporated secondary phase, certain properties of the metal are also degraded, in particular by particles having a size of 1 to 50 ?m. For example, the elongation at break decreases, the strength may decrease, or the tribology may become less favorable.

Abstract: A mold assembly device for use in sand casting of engine cylinder blocks is disclosed, the mold assembly device includes a magnet for securing a cast-in-place cylinder bore liner during assembly of a mold package, wherein the magnet militates against undesirable movement of the bore liner during assembly of the mold package.

Abstract: An assembly including a polymeric member and a unitary metal casting wherein the metal casting relatively moveably captures the polymeric member on the metal casting. The assembly can be adapted for use as a crank arm in a transmission shift mechanism. In some embodiments of the assembly, the polymeric member includes an opening defining a rotational axis of said polymeric member. The metal casting extends into the opening and includes at least one enlarged diameter portion with the polymeric member being rotationally disposed on the metal casting and axially captured on the metal casting by the at least one enlarged diameter portion of the metal casting. A method of manufacture is also disclosed.

Abstract: Magnesium or magnesium alloy components having galvanic corrosion protection isolators secured in place by metallurgical bonding during casting of the magnesium or magnesium alloy component. The isolators are formed of materials that are characterized by an absolute potential difference that is between that of magnesium and a contacting metallic component.

Abstract: A method of producing an abrasive tool, comprising the steps of preparing a blank of an abrasive tool including abrasing grains in a bond; placing the thusly formed blank in a container; covering the thusly formed blank in the container with at least a protective material; applying a glass material in the container so as to close the container and to form a lock which prevents penetration of an outside atmosphere through the lock into an interior of the container and at the same time allows escape of gases and contaminant from the interior of the container outside; placing the container into a heating device and providing in the heating device a temperature allowing melting of the glass material and creating the lock and also providing sintering of the blanks in the interior of the container; removing the container from the heating device after the sintering; breaking the lock and removing the sintered blanks which form the abrasive tools from the container.

Abstract: Described are wrought forms of copper alloys for infiltrating powder metal parts, the method for preparing the copper alloys and their wrought forms, the method for their infiltration into a powder metal part, and the infiltrated metal part infiltrated with the novel alloys having a generally uniform distribution of copper throughout and exhibiting high transverse rupture strength, tensile strength and yield strength. Infiltrated metal parts prepared by infiltrating powder metal parts with reduced amounts of the novel infiltrant typically weigh less and have superior strengths compared to similarly prepared infiltrated metal parts prepared with standard methods and conventional infiltration.

Abstract: A method for fabricating a reinforced matrix composite comprising the step of providing a composite preform having a fibrous structure and applying matrix material onto the preform in locations along the preform. A barrier material is applied to at least a portion of the coated preform to direct the flow of matrix material into the preform. The composite preform is heated to a temperature sufficient to render the matrix material viscous and insufficient to cure the matrix material. The pressure to the interior of the composite preform is reduced, while the pressure to the barrier material is increased. The temperature is maintained to flow the matrix material into the composite preform and to force gases from the fibrous structure. The composite preform is then cured and cooled to form a reinforced matrix composite having a low void content and a substantially uniform matrix distribution.

Abstract: A ceramic foam having pores in the range of 20 to 800 microns and 10 to 30 % of theoretical density is placed in a preheated mould and molten metal or plastics is drawn in to form a bicomposite structure.

Abstract: A method for manufacturing cast components, in which method the cast mold and/or macroscopic inserts to be placed either totally or partly inside thereof are left totally or partly as a part of the final component to be used, after the casting the piece is further treated with temperature and/or pressure in order to improve the compactness of both the cast materials and the materials acting as inserts and to improve the bond between the cast material and the solid material attached thereto, and the portion of the solid or partly solid material (inserts) to be placed into the cast mold and remaining in the final component, inclusive the portion of the mold eventually remaining in the final component, of the weight of the total component is more than 3 percent by weight.

Abstract: After a molten metal of aluminum or an aluminum alloy having a temperature, which is higher than the liquidus line temperature of aluminum or the aluminum alloy by 5 to 200° C., is injected into a mold, when the mold is cooled to solidify the molten metal, the molten metal injected into the mold is pressurized at a pressure of 1.0 to 100 kPa from a high-temperature side to a low-temperature side, and the mean cooling rate is set to be 5 to 100° C./minute while the mold is cooled from the liquidus line temperature to 450° C., the temperature gradient formed in the mold being set to be in the range of from 1° C./cm to 50° C./cm.

Abstract: A cold plate unit includes a coolant system and a fluid system in heat exchange relationship, and a metallic unit. The coolant system has inlet and outlet manifolds and a plurality of coolant lines each including a plurality of loops. The fluid system includes at least one fluid line preferably also including a plurality of loops, and preferably is interleaved with the coolant lines. The metallic unit incorporates the coolant and fluid systems. An apparatus for cooling at least one fluid includes a cold plate and a dispenser unit. The cold plate unit includes a coil basket having a fluid system and a coolant system. The fluid system includes a plurality of fluid lines each comprising a plurality of loops. The coolant system includes coolant inlet and outlet lines, at least one inlet manifold, at least one outlet manifold and a plurality of coolant line segments each comprising a plurality of loops.

Abstract: The invention concerns a method for casting a part made of metal alloy such as an aluminum alloy comprising the following steps: forming a core (N, PNC) having at least one shaft (PC) designed to form in the part a cylinder and at least one cavity (P) designed to form in the part a support and/or retaining zone for a working member, and at least a cooling unit (RE) proximate to the cavity; positioning the core in a metal mould cavity, and feeding the mould lined with its liquid alloy core by gravity. The invention is particularly useful for casting internal engine cylinder blocks with aluminum cylinders with improved geometrical and mechanical properties of the crankshaft bearing zones.

Abstract: A cylinder liner (2) for a cylinder block has a contouring (6) at one end. The contouring (6) serves to support the liner (2) on a sleeve (4) inside a die-casting tool. When the liner (2) is cast in, recesses (10) of the liner (2) are filled by the material of the cylinder crankcase whereby preventing the liner (2) from seating toward an oil chamber (14). The invention also relates to a method for producing a cylinder liner of the aforementioned type.

Abstract: A thermoforming apparatus having a mold with an internal vacuum chamber and a quench for cooling a thermoplastic sheet while it remains on the mold. Because the quench cools the sheet, conventional cooling lines are eliminated from the mold. A preferred process of using the thermoforming apparatus includes drawing a heated sheet over the mold, creating a partial vacuum in the vacuum chamber of the mold to maintain the sheet on the mold and quenching the sheet on the mold in a quenching tank. A preferred process of manufacturing a mold with an interior vacuum chamber includes forming an impression of the mold in a casting media, suspending a vacuum line or vacuum cabinet within the impression and pouring molten material around the vacuum line or vacuum cabinet to form the mold at least partially surrounding the vacuum line or vacuum cabinet. Vacuum holes are drilled through the mold from the mold face to the vacuum chamber.

Abstract: A method of manufacturing a flux ring for an electric motor which has a ring with an anchoring mechanism. The ring is placed inside of a die. A first isotropic magnetic material is added into the die such that the anchoring mechanism secures the first isotropic magnetic material onto the ring. A second anisotropic magnetic material is added into the die adjacent the first isotropic magnetic material. The anchoring mechanism secures the second anisotropic magnetic material onto the ring.

Abstract: There is provided a method of cast molding a cylinder for an internal combustion engine by making use of an insert core, which makes it possible to rationally form the chamfered portions at the rim portion, on the cylinder bore side, of the scavenging ports, the suction port and the exhaust port with high precision and high freedom in dimension and configuration without fluctuation in size and configuration of the chamfered portion.

Abstract: A method is provided of in-situ casting well equipment wherein a metal is used which expands upon solidification. A body of such metal is placed in a cavity in a well. Before or after placing the metal in the cavity in the well, the body is brought at a temperature above the melting point of the metal. The metal of the body in the cavity is solidified by cooling it down to below the melting point of the metal.

Abstract: Process of making a lightweight part comprising an inner core including a metal foam, a dense core surface layer that is metallically joined to the inner core, and an outer wall comprising an essentially pore-free cast metal layer that is at least one of positively engaged with the dense core surface layer and surrounding the inner core and metallically joined to the dense core surface layer and surrounding the inner core, wherein the process includes creating a core part by forming the dense core surface layer, forming the inner core of a metal foam, and metallically joining together the inner core and the dense core surface layer and creating a finished part by positioning the core part in a casting mold, feeding a melt material into the casting mold, and allowing the melt material to solidify so as to form the outer wall. This abstract is neither intended to define the invention disclosed in this specification nor intended to limit the scope of the invention in any way.

Abstract: A process for the production of a braking band having ventilation ducts comprises the steps of a) moulding a core of metallic material, b) inserting the core in a mould, in a central position, c) filling the mould with at least two layers of material which are to form the braking band, in a manner such that the core is “sandwiched” between the at least two layers, d) performing a first heating of the mould to a temperature such as to bring about hardening of the at least two layers until the at least two layers adopt a three-dimensional structure, e) subjecting the semi-finished product produced in step d) to a second heating to a temperature such as to bring about fusion of the metallic material of the core, and f) collecting the molten core.

Abstract: In a method of manufacturing a cylinder head having a partition plate for an intake port, there is prepared a partition plate having an intake-side distal end and a cylinder-side distal end. The partition plate is located in a core to form the intake port and molten metal is supplied to a periphery of the partition plate. After solidifying the molten metal, the core is removed. At least the intake-side distal end of the partition plate is located in an expansion-permit space that permits thermal expansion of the partition plate caused by heat of molten metal.

Abstract: The invention relates to a method for producing a brake disk (B) that comprises a supporting part (2) and a friction ring (R). The inventive method involves the following working steps: manufacturing, especially by casting, the supporting part (2) with at least one radially protruding projection (10) situated on the periphery of the supporting part; forming a cast core (14), which is made of core sand and which surrounds the projection (10) over a foot section (10a) that is assigned to the supporting part (2), onto the supporting part (2) while sealing a free end section (10b) of the projection (10) so that this end section (10b) is not made wet by the sand of the cast core (14); casting the friction ring (R) onto the supporting part (2), which is provided with the cast core (14), while casting around the free end section (10b) of the projection (10).

Abstract: A method of making a casting having a cast portion and a cap nut includes forming a hole with a stepped shape in the cap nut to have a large-diameter hole on an opening side and a threaded small-diameter hole on a bottom side, inserting a fixing member into the large-diameter hole, supporting the fixing member in a sand mold, pouring a casting material into the sand mold so that the cap nut is enveloped in the cast portion and that a first surface of the cap nut adjacent to the hole is exposed outside without being covered with a second surface of the cast portion, and removing the fixing member from the cap nut after the casting is taken out of the sand mold.

Abstract: A method for manufacturing a clad component in which a cladding workpiece having a section comprising a first metal onto which a number of metal beads are rigidly bonded is inserted into a mold. A molten second metal is poured into the mold, where it flows about and covers the beads and is then permitted to cool. This process forms an article made of the second metal, which is mechanically interlocked to the beads, clad by the first metal. Typically the first metal is a high-melting point strong metal, such as steel, and the second metal is a lower-melting point, weaker, but lighter metal, such as aluminum.

Abstract: The invention relates to a method for forming a green article for subsequent sintering or infiltration. This method includes providing a mold having an internal cavity that outlines the shape of the article, introducing metal or ceramic particles into the mold in an amount sufficient to provide the article in a desired size, adding a solution comprising an organic fluxing agent onto the particles with the solution carrying the organic fluxing agent into interstices between the particles, and freezing the solution to form a solid green article. The invention also relates to an apparatus and method for manufacturing dimensionally stable articles.

Abstract: The invention relates to a molten material processing device having an elongated thermal element like a heating element, a thermocouple, a sensor, a heatpipe and a cooling pipe which is characterised in that said elongated thermal element (2) is located in a recess (3) provided in a surface (6) of the molten material processing device (1), the recess (3), comprising a first portion (4) and a second portion (5), has a cross-section which is larger than a cross-section of the thermal element (2), so as to provide a clear space (7) between the thermal element (2) and the surface (6) of the processing device (1), the clear space (7) which is limited by the first portion (4) and the thermal element (2) is filled by a thermally sprayed material (8) and the second portion (5), which is adapted to the cross-section of the thermal element (2), partially surrounds and directly contacts same.

Abstract: A cast-bonding process includes a magnesium coating step and a magnesium nitride-forming step. The magnesium-coating step is carried out by supplying gasified magnesium into a mold in which a cast-in insert formed from an aluminum alloy, or an aluminum-based composite material is set, so that magnesium may coat the insert. The magnesium nitride-forming step is carried out by supplying nitrogen gas into the mold so that the coating magnesium and nitrogen gas may react to form magnesium nitride. Then, a molten aluminum alloy is poured into the mold for cast-bonding the insert.

Abstract: A method for the manufacture of a three-dimensional object includes the steps of forming a mixture that contains a binder and a least one of aluminum or a first aluminum-base alloy into a green composite, removing the binder from said green composite, forming a porous perform structure, reacting the aluminum or first aluminum base alloy with nitrogen to form a rigid and continuous skeleton and infiltrating the porous structure with molten aluminum or second aluminum base alloy to form the three-dimensional object with near theoretical density. The green composite may be formed by an additive process such as computer aided rapid prototyping, for example, selective laser sintering. The method facilitates the rapid manufacture of aluminum components by an inexpensive technique that provides high dimensional stability and high density.

Abstract: A partition plate for an intake port of a cylinder head to be manufactured by cast molding is preliminarily set prior to the cast molding in a sand core applied to form the intake port and then cast in by the cast molding to partition the intake port into a plurality of ports. The partition plate is provided with an intake-side distal end, a cylinder-side distal end, a pair of side edges continuous with the intake-side distal end and the cylinder-sided distal end and to be cast in by molten metal during the cast molding. Each of the pair of side edges having end faces facing in a thickness direction and a side end face continuous with the end faces. The partition plate is further provided with a promoter section provided on at least one of the side end face and the end faces of each of the pair of side edges to promote solidification of the molten metal.

Abstract: A golf putter includes a shalt and a head secured to the shalt. The head includes a forward portion that defines a face, and the head includes a rear portion positioned rearward of the face. The rear portion may have the configuration of a ring structure. Whereas the forward portion is formed of a first material, the rear portion may be formed of a different material with greater density. In manufacturing the head, the rear portion may be formed and then placed within a mold having the shape of the entire head. Molten first material is then introduced into the mold to form the forward portion.

Abstract: A method of modifying a surface of a casting involves providing a casting mould; placing a perforated mask with the mould to define a masked area of the mould; spray-coating the masked area of the mould with a coating material selected for forming a surface layer on the casting; introducing a liquid casting material to the mould; and, solidifying the liquid casting material to form a surface modified casting. The present method reduces the tendency for the coating material to spall from the mould and permits the formation of thicker coating layers on the mould. Thicker and better quality surface layers may be formed on 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: A method for the manufacture of a three-dimensional object includes the steps of forming a mixture that contains a binder and a least one of aluminum or a first aluminum-base alloy into a green composite, removing the binder from said green composite, forming a porous preform structure, reacting the aluminum or first aluminum base alloy with nitrogen to form a rigid skeleton and infiltrating the porous structure with molten aluminum or second aluminum base alloy to form the three-dimensional object with near theoretical density. The green composite may be formed by an additive process such as computer aided rapid prototyping, for example selective laser sintering. The method facilitates the rapid manufacture of aluminum components by an inexpensive technique that provides high dimensional stability and high density.

Abstract: A plasticizing barrel for a plastics processing machine includes a body having a hollow cylindrical configuration and defining an axis; and a coating formed on an inner wall surface of the body and including at least one groove extending in axial direction of the body. The coating, e.g., a wear-resisting protective layer, may be produced through centrifugal casting, whereby the grooves are formed by projections of a negative mold inserted in the hollow-cylindrical body.

Abstract: An air brake actuator assembly includes a pre-formed air chamber component and a cast brake housing. A portion of the cast brake housing is cast around a portion of the air chamber component. This securely attaches the air chamber component to the cast brake housing without requiring additional fastening structures.

Abstract: The method relates to metallurgical recycling of waste products, preferably titanium alloys chips scrap. Accordingly after crushing and cleaning, the chip scrap is subjected to vacuum-thermal degassing (VTD); the chip scrap is pressed into briquettes; the briquettes are placed into a mould allowing sufficient remaining space for the addition of molten metal alloy; the mould is pre-heated before filling with the molten metal alloy; the mould remaining space is filled with molten metal alloy. After cooling, the electrode is removed from the mould. The method provides a means for 100% use of chip scrap in producing consumable electrodes having increased mechanical strength and reduced interstitial impurities content leading to improved secondary cast alloys.

Abstract: A process for the production of thin walled parts of steel, wherein there are layers that are at least partly differently treatable relating to their strength and hardness qualities. This process can include creating a composite material from a plurality of different layers by connecting at least one core layer and at least one surface layer together. At least one layer of the core or surface layer is cast adjacent to another layer to form a composite material having an alloy gradient that is flat at each interface between any of the core layer or the surface layer. Next, the process can include deforming the composite material along a length of these layers. Finally the process can include heat treating the layers to transform the strength and hardness qualities of at least one of these layers.

Abstract: A sink compound laminate molding process having a copper material in thickness of 0.1-0.8 mm placed at the bottom of the molding cavity with the bottom of the copper laminate fully bound to the bottom of the molding cavity, the copper being heated up to 300-600° C., and molten aluminum being filled into the molding cavity using a gravity casing process to create diffusion bonding to the interface between the copper and aluminum materials, molten aluminum being cooled and cured to avail an integrated compound laminate in a given profile of heterogeneous copper and aluminum.

Abstract: A stent having marker tabs formed from a micro-alloyed combination of materials provides for more precise placement and post-procedural visualization in a vessel, by increasing the radiopacity of the stent under X-ray fluoroscopy. A unique micro-alloying process is utilized to form the tabs, comprising a first alloy and a second alloy, wherein one of these alloys is radiopaque. This substantially eliminates the possibility of galvanic action between the tab and the stent. This process is also applicable to other medical devices.

Abstract: A damped blade is provided that includes a blade structural member defining at least one coolant channel and a liner formed of a shape memory alloy extending at least partially along the at least one coolant channel defined by the blade structural member. The shape memory alloy that forms the liner is maintained generally at its transition temperature by means of coolant circulated through the coolant channel. The shape memory alloy that forms the liner will resist the onset of vibrations within the blade, thereby effectively damping blade vibrations. A method of fabricating a damped blade is also provided.

Abstract: A product having a metal-fabric joint includes forming a fabric anchoring component by casting a low melting point yet high compressive strength material into a cavity in a metal component. The product includes (a) a metal housing including an interior entrance, at least first and second opposed interior walls, and an interior end opposite the interior entrance, the at least first and second opposed interior walls and the interior end defining an interior cavity; (b) a fabric; (c) a fabric anchor assembly; and (d) a castable material disposed in the interior cavity so as to envelop the fabric and the fabric anchor assembly. A method of fabricating the product includes the steps of (a) anchoring the fabric with the fabric anchor assembly; (b) inserting the anchored fabric in the interior cavity; (c) providing the interior cavity with the castable material so as to envelop the anchored fabric; and (d) solidifying the castable material to a cast material so as to form the product.

Abstract: A brake drum includes a ring-shaped drum body (13), and a friction member (16) secured to the inner circumferential surface (18) of the drum body. Because the drum body is formed of a lightweight Al alloy and the friction member is formed of an Al-base composite material, the brake drum can be reduced in weight as a whole. Further, because the friction member, having projecting portions (17a) formed on its outer periphery (17), is cast-enveloped by molten metal of the Al alloy, the friction member and the drum body can be firmly fastened together. Thus, even when a great braking force is applied to the drum brake, the friction member can be prevented from being undesirably detached from the drum body.

Abstract: The invention relates to a process for producing metal/metal foam composite components, wherein a flat or shaped metal part is introduced into the cavity of a die, the cavity being at least partially delimited by the metal part, and then a mixture comprising a metal melt and a blowing agent which is solid at room temperature is introduced into the cavity, where it is foamed.

Abstract: A carbon nano material and a resin binder are plasticized and injection molded to form a preliminarily molded member. The preliminarily molded member is degreased by a heat treatment and made to a preliminarily molded porous member composed of the carbon nano material. The preliminarily molded porous member is inserted into a cavity of a product mold. A molten low melting point metal is injected into and fills the cavity. The preliminarily molded porous member is impregnated with the low melting point metal by injection pressure, thereby a composite metal product composed of the low melting point metal material integrally composited with the carbon nano material is molded. With the above arrangement, the characteristics of the carbon nano material are applied to the composite metal product to improve the functions thereof.

Abstract: The filtration cartridge comprises a filtration element and a heat-resistant extension band having a first and a second longitudinal edge. The first edge of the extension band is attached along an edge of the filtration element. In a first embodiment, a metallic cast end member is formed by immersing the second edge of the extension band into molten metal. The molten metal is then allowed to solidify with the second edge of the extension band embedded therein. In a second embodiment, the extension band is squeezed on a porous inner core and an end plate is welded on the end of the inner core. Providing filtration cartridges with a metallic end member allows increasing their resistance to mechanical shocks and increasing their maximum operating temperatures.

Abstract: The invention relates to a process for producing shaped metal parts, in particular reduced-weight shaped parts made from metallic materials. In this process, a metal body with a surface which is closed on all sides and a hollow structure in the interior is placed into a die as a core and is then surrounded with a metal melt by casting. The surface region of the metal body has a mean density which is higher than the interior of the metal body by a factor of 1.5 to 20.

Abstract: A method for the manufacture of a three-dimensional object includes the steps of forming a mixture that contains a binder, a wetting agent, and a least one of aluminum or a first aluminum-base alloy into a green composite, removing the binder from said green composite forming a porous preform structure and infiltrating the porous preform structure with a molten second aluminum base alloy to form the three-dimensional object with near theoretical density. The wetting agent assists in wetting during infiltration. The green composite may be formed by an additive process such as computer aided rapid prototyping, for example selective laser sintering. The method facilitates the rapid manufacture of aluminum components by an inexpensive technique that provides high dimensional stability and high density.

Abstract: A core box assembly for casting a crankshaft. The core box assembly comprises axially aligned cores that define different axial portions of a cavity that receives molten metal to cast the crankshaft. Oil gallery cores are placed in the core box assembly to form as-cast oil galleries in the crankshaft. Heavy metal inserts are held by sand cores disposed in the portions of the cavity that form the counterweights of the crankshaft.