Abstract: The method allows fabricating a bottle mold having dissimilar metal inserts embedded in regions where the bottle mold is most subject to attack by hot glass, and has a glass contact surface with refined grain size. To fabricate the bottle mold, rough castings are made by pouring cast-iron into a composite mold having dissimilar metal insert blanks fixably positioned therein. The dissimilar metal insert blanks become embedded in the cast-iron matrix to form rough dissimilar metal inserts in the rough casting. The composite mold has regions formed by metal chills that are partially embedded in a sand mix. The chills and the exposed surfaces of the rough dissimilar metal inserts define a cavity surface of the rough casting, which is subsequently machined to provide the glass contact surface of the bottle mold. The chills refine the grain size of the cast iron at the glass contact surface.

Abstract: A method is provided for manufacturing a cylinder for an internal combustion engine, which makes it possible not only to manufacture the cylinder by a high-pressure die casting method at low cost and in high precision, but also to prevent relative misalignment among the scavenging port, suction port and exhaust port of the cylinder. This method is characterized by the steps of: preparing a cylinder liner made of an aluminum alloy pipe and provided with the scavenging port, and a bore-core die as well as cores for scavenging ducts both being uncollapsible and configured so as not to intrude into the scavenging ports; setting the cylinder liner in place in the bore-core die; and casting, by means of metal mold casting method, an aluminum alloy onto the outer peripheral surface of the cylinder liner to thereby mold a main body of the cylinder.

Abstract: An apparatus for injection-molding products, comprising an injection mold (2) divisible into at least two parts (6, 8) such that consequently at least one mold cavity (14) is cleared, wherein on at least one part of the injection mold guiding means (22) are provided for a transfer device (4) for providing an insert in the mold cavity and/or for taking a product from the mold cavity.

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 and infiltrating the porous structure with a molten 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 metal casting fabrication method is provided. In accordance with the method, first a metal plate is disposed in the cavity of molding dies. This metal plate includes a first surface formed with a heat insulating layer, and a second surface opposite to the first surface. With the metal plate placed in the cavity, the heat insulating layer is held in contact with the dies, while the opposite or second surface is partially exposed to the cavity. The injected molten metal properly fills the cavity from end to end since its heat is not conducted unduly to the dies via the metal plate.

Abstract: A process of manufacturing an automobile component comprises molding a high strength first element of steel at a temperature about 1550° C.; removing dirt from a surface of the first element of steel and increasing a roughness of surface thereof by sand polishing; placing the first element of steel in a mold; casting a low tensile strength second element of iron on the first element of steel in the mold at a temperature about 1200° C.; cooling the mold; initially polishing a surface of the half-finished component; and diffusing a melted copper into gaps between the first element of steel and the second element of iron at a temperature ranged from about 1080° C. to about 1200° C. to produce the finished component.

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 infiltrating a porous metal skeleton an infiltrant composition is used similar to that of the powder skeleton, but with the addition of a melting point depressant. The infiltrant quickly fills the skeleton. As the melting point depressant diffuses into the base powder, the liquid may undergo diffusional solidification and the material eventually homogenizes. Maintaining the infiltrant at a liquidus composition for the infiltration temperature typically ensures that the bulk composition or properties will remain uniform throughout the part, particularly in the direction of infiltration. Success of such an infiltration is enhanced by effective means of maintaining the molten infiltrant at a liquidus composition. It is also beneficial, in some cases, for the time scale of the infiltration to be much faster than the time scale of the diffusion of the melting point depressant and the subsequent solidification and homogenization.

Abstract: A method of operating a twin wheel conform metal extrusion device or a cladding extrusion device for producing a composite of an extruded metal shell bonded to a metal foam core. A metal feedstock is extruded through an extrusion die defining a cavity housing a hollow extrusion mandrel to produce a metal shell. Liquid foam of a second metal is simultaneously delivered through the hollow mandrel bore such that the foam exiting the axial bore is metallurgically bonded to the metal extruded through the cavity.

Abstract: The present invention is directed to new processes in which electromagnetic levitation forces are used to infiltrate a porous matrix with a solid infiltrant. In such processes, controlled heating of these components, melting the infiltrant while both components are subjected to levitation forces, and containerless transportation and subsequent contact of both components results in the infiltration of the porous matrix. Such containerless processing provides for infiltrated porous matrices which are free of contaminants generally introduced by the containers used in traditional methods of infiltration.

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: Methods and materials for preparing investment molds useful in pressure infiltration casting of near net-shape metal or metal matrix composite (MMC) components. One embodiment of the invention includes disposing a slurry of an appropriately sized refractory material and a vehicle around a preform or fugitive pattern, removing the bulk of the vehicle, then curing/drying the refractory material to create an investment mold of the invention. Subsequently, pressure infiltration casting with a molten infiltrant using the investment mold permits infiltration of the mold cavity and/or preform without infiltration of the investment mold. As a result, the investment mold readily is removed to provide the near net-shape metal or MMC component. In other embodiments of the invention, a non-fugitive pattern is used, typically with a modified refractory cement of the invention.

Abstract: A system and method for centrifugal casting of composites, especially metal-matrix composites. According to the system and method, a porous preform is infiltrated with matrix material using a centrifugal force to pressurize the matrix material against the preform. The pressure head of the matrix material is maintained at an approximately constant level throughout infiltration.

Abstract: A method is provided of in-situ casting well equipment wherein a metal is used which expands upon solidification, the method comprising the steps of: placing a body of said metal in a cavity in the well; bringing said body at a temperature above the melting point of the metal; cooling down said body to below the melting point of the metal, thereby solidifying the metal of said body in the cavity.

Abstract: A heat-dissipating device and its manufacturing process are provided for significantly increasing the number and size of blades so as to enhance the heat-dissipating performance. The heat-dissipating device has a plurality of blades arranged around the hub of the heat-dissipating device and there is an overlapped region formed between every two adjacent blades. A single mold is used to manufacture such a heat-dissipating device so that not only can the manufacturing cost be reduced but it can significantly increase the number and size of blades so as to increase the heat-dissipating efficiency.

Abstract: To provide a manufacturing apparatus that is capable of manufacturing metal-ceramic composite members in various shapes with high productivity, and a mold member and a manufacturing method therefor. An apparatus for manufacturing a metal-ceramic composite member was made, the apparatus including: a plurality of process regions, namely, an atmosphere replacing/heating part 11, a molten metal push-out part 21, and a cooling part 31; and a guide 48 for allowing a mold to pass through these plural process regions, molds 60 having ceramic members 86 placed therein are successively inserted into a mold inlet 43 provided in this guide 48 to pass through the guide 48 practically in a shielded state from the atmosphere, a molten metal 53 is poured thereto in the molten-metal push-out part 21, and the molten metal 53 is cooled and solidified in the cooling part 31 to join a metal and a ceramic, thereby manufacturing the metal-ceramic composite member.

Abstract: A method and apparatus for positioning components of a brake system, which includes a push rod, a ball end coupled to the push rod, and a force transfer member placed between the push rod and the ball end. The force transfer member has both a flowable property and a solidifying property, whereby the force transfer member is flowable when being placed between the push rod and ball end and, after a passage of time, the force transfer member solidifies.

Abstract: A method for producing a metal matrix composite having improved properties includes the step of forming a sintered ceramic preform including a network of uniformly distributed ceramic particles having a particle size of 1 micron or less and being bonded together at their points of contact by sintering. After sintering to form a preform, the preform is placed in a mold and infiltrated with molten metal. The molten metal is then solidified to form a shaped body. This shaped body is then subjected to sufficient strain to eliminate at least 50% and preferably 80% of the bonds in the network. The shaped body is then subjected to a metal forming step such as wrought or semisolid forming.

Abstract: A fiber reinforced porous preform is positioned within a die cavity defined by upper and lower die members, and the lower die member defines at least one gate opening in the center portion of a water cooled shot sleeve which receives a vertically moveable shot piston. The area of the gate opening is small relative to the area of the shot sleeve, and the lower die member defines an annular recess above the inner surface of the shot sleeve for entrapping a shell of pre-solidified metal. Air vent slots extend outwardly between the shot sleeve and lower die member and are closed by the shell of pre-solidified metal. In one embodiment, the shot sleeve and shot piston are non-circular or oval in cross-section; and the lower die member has a plurality of longitudinally space gate openings.

Abstract: A plate-shaped composite material has a first member and a second member. The first member is an expanded metal formed of a metal plate. The coefficient of linear expansion of the metal plate is less than or equal to 8×10−6/degrees Celsius. The first member suppresses thermal expansion of the composite material. The coefficient of thermal conductivity of the second member is greater than or equal to 200 W/(m×K). The second member maintains the coefficient of thermal conductivity of the composite material. This structure provides a reliable coefficient of thermal conductivity and high strength. The structure is suitable for a cooling substrate on which electronic elements such as semiconductors are mounted.

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

Abstract: The invention relates to a reinforced structural element comprising a metallic matrix and a reinforcement comprising inorganic fibers, the reinforcement at least partially penetrating through the structural element. The reinforcement is designed in the form of a fabric in at least two dimensions. The structural element with a wall thickness of between 0.2 mm and 5 mm takes the form of a metal sheet or semifinished product.

Abstract: An exhaust manifold is provided having substantially ceramic inner and insulation layers. The manifold preferably has a metal outer structural layer to impart strength to the manifold. The ceramic layers are made of ceramic fibers with the interstitial spaces between the fibers being filled with ceramic filler material. The preferred ceramic fibers are aluminosilicate fibers. The preferred ceramic filler material is alumina, silica, glass-ceramic or other metal oxide. A method of making an exhaust manifold having a substantially ceramic inner and insulation layer is also provided.

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 and infiltrating the porous structure with a molten 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 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: The present invention is generally directed towards a carrier of a motor vehicle. The carrier is formed of a first portion and the second portion. The first portion is made of aluminum having ceramic particles reinforcing the aluminum matrix. The second portion is made of unreinforced aluminum metal or metal alloy. Preferably the second portion is present in form of discrete pockets in the first portion and is adapted to be machined or welded.

Abstract: The present invention provides improved heated manifolds, heaters and nozzles for injection molding, having a high strength metal skeleton infiltrated with a second phase metal having higher thermal conductivity. Also disclosed is method of forming a manifold, heater or nozzle preform and infiltrating the preform with a highly thermally conductive material. The invention also provides a method of simultaneously infiltrating and brazing injection molding components of similar or dissimilar materials together.

Abstract: In order to impregnate a porous workpiece with a liquid impregnating agent, the pre-manufactured workpiece is arranged in an injection mould or diecasting mould and the liquid impregnating agent is introduced into the mould with the aid of a commercially available injection moulding or diecast moulding apparatus. To limit the need for post impregnation cleaning and/or shaping, the mould cavity is configured to closely fit the shape of the pre-manufactured workpiece. The impregnating agent may be a natural or synthetic lubricant, a plastic or, more commonly, a molten metal or metal alloy.

Abstract: A holder comprising an insert for reinforcing a metal matrix composite article and methods of making the same. In another aspect, the present invention provides metal matrix composite articles reinforced with an insert(s) and methods of making the same. Useful metal matrix composite articles comprising the inserts include brake calipers.

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: To prevent, in a cooled ring carrier (1) for pistons, durinh Alfin bonding, the formation of oxides induced by air that escapes due to porous ring carrier material and, as a consequence, an impairment of the ring carrier bond. To this end, the cooled ring carrier, once the ring carrier part and the sheet metal part (3) have been linked, is subjected to negative pressure in a vacuum tank.

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 method for manufacturing a crankshaft supporter having a bearing holding section that holds a bearing for supporting a crankshaft, and that is cast in aluminum alloy with a preform cast inside, the preform having a through hole extending therethrough. Provided are a core pin to process the through hole, and a pin hole shaped in the preform to accommodate the core pin. The core pin includes a pin insert section having an outer diameter less than inner diameter of the preform pin hole, and a head section having an outer diameter greater than the inner diameter of the preform pin hole. The pin hole insert section is inserted into the pin hole to contact the head section with an outer surface of the preform for securement inside a mold for casting. The core pin is removed during subsequent cutting of a larger diameter hole through the cast bearing holding section.

Abstract: A process for connecting at least two components, particularly body components of motor vehicles, wherein the first component has an undercut on a side facing the second component. In the area of the undercut, a connection piece is cast to the first component. The connection piece is designed such that, during its solidification, the connection piece is firmly connected with the first component by the contraction of a last-solidifying core area of the connection piece. Then the second component is mounted on the connection piece.

Abstract: A method for producing a composite structure in which a foamed metal core (1) is surrounded with a metal body (3). The method includes the following steps: a) producing a foamed metal core (1) with an essentially closed surface; b) introducing the foamed metal core (1) into a pressure die-casting mold; c) filling the pressure die-casting mold at a first casting pressure (p1); d) reducing the first casting pressure (p1) before the pressure die-casting mold has been filled; e) filling the pressure die-casting mold entirely, the first casting pressure (p1) being reduced to zero or almost zero; and f) applying a second casting pressure (p2) and maintaining the second casting pressure for a predetermined holding period.

Abstract: The present invention involves a method of making an integrated mold product with a molding tool. The method includes introducing polymeric material in the molding tool and molding the polymeric material to define an outer layer in the mold. The outer layer has a channel formed thereon. The method further includes introducing molten metal in the channel of the outer layer when the outer layer is at about the same temperature as the molding tool and cooling the molten metal in the channel to define a metal insert in the channel of the outer layer for electrical and thermal conductivity, structural support, and electromagnetic shielding.

Abstract: A method for producing an aluminum nitride/aluminum base composite material comprising the steps of; (A) charging aluminum nitride powder into a container provided in a molten metal pressure apparatus, (B) applying pressure to the aluminum nitride powder in the container, (C) pouring a molten aluminum base material into the container, and, (D) applying pressure to the molten aluminum base material in the container to fill the aluminum base material in space between the aluminum nitride powder particles.

Abstract: The specification and drawings describe and show an embodiment of and method of forming a liquid flow through heat exchanger structure cast in a metal matrix composite. The composite comprises a preform reinforcement material infiltrated with molten metal. The composite reinforcement material is injection molded around the heat exchanger structure allowing for intimate contact between the composite and structure. The composite formed has a specific coefficient of thermal expansion to match an active heat-generating device mounted thereon. The present invention allows for enhanced thermal and mechanical properties by eliminating voids or gaps at the composite to heat exchanger structure interface, these voids or gaps being present in prior art fabrication methods or induced by usage due to thermal cycling of prior art composites.

Abstract: An intermediate material is formed by coating at least a half of the surface of a function selecting material having at least one of physical property values that are different from those of a casting metal material forming a cast product with a coating metal material and the casting metal material is cast together with the intermediate material to form a composite body in casting the product.

Abstract: A bar code identification stencil for uniquely identifying a plurality of articles. The stencil includes a carrier strip, which carries an identification code or symbology. The identification code or symbology is formed of a plurality of spaced apart data cells, or data cells, which are used to form a machine readable bar code. The stencil will be made of materials compatible to the manufacturing processes, which make the articles to be marked, and compatible to the materials out of which the articles to be marked are made. The stencil is scalable in size and shape, as are the data cells, or data cells, scalable in size and shape—all as required by the specifications of the data symbology to be directly marked on the part, or article. The bar code is unique for each of the plurality of articles to be identified.

Abstract: An impermeable ceramic mold is disposed within a steel die and used in a process for pressure casting of elevated melting temperature alloys and pressure infiltration casting of elevated melting temperature alloys having wear resistant particles, included therewith. The ceramic mold provides an insulation layer between the molten metal and the steel die, and prevents welding between the molten metal and the die. The alloy steel die encloses the ceramic mold and provides the strength needed to resist the pressures generated during pressure infiltration casting.

Abstract: A core member has a core member side journal portion and a core member bolt hole on both sides of the core member side journal portion and is provided in a separation state from a surface of a casting mold through a cast-off pin including a step portion in a vertical direction in the casting mold. A radius of curvature of the core member side journal portion of the core member is made greater than a radius of curvature of the cap side journal portion of the bearing cap in such a manner that a clearance between the cap side journal portion and the core member side journal portion is larger than a clearance between the core member bolt hole and the cast-off pin. A pouring gate is provided on a side surface of the casting mold to inject a base material along the bonding portion of the bearing cap.

Abstract: The microstructure of a metal matrix composite comprising copper and reinforcement material is improved when the metal matrix composite comprises at least about 0.02% by weight of at least one of silver and gold. In one embodiment, the process for making a metal matrix composite comprises compacting powder particles of a reinforcement material to form a green compact, sintering the green compact to produce a porous skeletal body and infiltrating the porous skeletal body with an infiltrant comprising copper and at least about 0.1% of at least one of silver and gold, based on the weight of infiltrant. In another embodiment, the process comprises forming a mixture of particles of reinforcement material, copper and at least about 0.02% by weight of at least one of silver and gold, compacting the mixture to form a green compact, and sintering the green compact to form a near net shape metal matrix composite.

Abstract: A die provided for fixing a porous ceramic insert for producing a light metal component which is reinforced by the insert. For this purpose, the insert is positioned in the die in such a way that any force which occurs for the purpose of fixing the insert is compensated for by a collinear force, which minimizes the bending moments exerted on the insert. Furthermore, shielding elements are used to protect the insert from a casting metal flowing into the die. Furthermore, the invention describes a process in which the velocity of a casting plunger which moves the casting metal into the die is regulated in such a way that the insert is not damaged by the kinetic energy of the casting metal. This is achieved by filling the die at a low velocity until the metal has flowed around the insert. Then, the casting plunger is accelerated, thus ensuring optimum filling of the die with the casting metal.

Abstract: A turbine blade or turbine vane includes a metallic nonfoam region, and a ceramic foam region joined to the metallic region. The ceramic foam region is an open-cell solid ceramic foam made of ceramic cell walls having an intracellular volume therebetween. The ceramic is preferably alumina. The intracellular volume may be empty porosity, or an intracellular metal such as an intracellular nickel-base superalloy.

Abstract: A method and apparatus for molding wind chimes reduces the likelihood that a glass insert will fracture when they are placed in a mold and the mold is charged with molten metal. The casting temperature of the molten metal is adjusted to compensate for the surface area of the glass insert that is contacted by the molten metal. The glass insert are annealed prior to molding. A flexible mold is utilized. The tolerances of the glass insert are carefully controlled. The molded wind chime is carefully cooled.

Abstract: At least one aspect of the present invention relates to an improved method of incorporating fluid lines in a spray-formed article. The method comprises forming a first component having a backing surface followed by placing a fluid defining flexible conduit adjacent the backing surface. Next, metal droplets are sprayed over the backing surface to from a metallic adhesion layer. The metal droplets used to form the adhesion layer are sprayed in a sufficient amount that the adhesion layer at least partially encapsulates the flexible conduit whereby the conduit is fastened to the backing surface by the metallic adhesion layer. Also provided by the present invention is an article made in accordance with a method of the invention.

Abstract: A method and apparatus for molding wind chimes reduces the likelihood that a glass insert will fracture when they are placed in a mold and the mold is charged with molten metal. The casting temperature of the molten metal is adjusted to compensate for the surface area of the glass insert that is contacted by the molten metal. The glass insert are annealed prior to molding. A flexible mold is utilized. The tolerances of the glass insert are carefully controlled. The molded wind chime is carefully cooled.

Abstract: The invention relates to a method of fabricating a pyrometallurgical reactor cooling element with flow channels. In order to enhance heat transfer capability, the wall surface area of the flow channel, which is traditionally round in cross-section, is increased without increasing the diameter or length of the channel.

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.