Abstract: An integrated energy absorbing system of a vehicle with a front integrated energy absorbing casting and a back integrated energy absorbing casting. Each front and back casting is a single unified casting that makes up the integrated energy absorbing system. Ribbed sections such as “I” sections and “C” sections make up the castings and are formed from a variety of different techniques and/or formings such as cutout, waveform profile, tapering, flaring and/or rib spacing. Additional sections such as closed section castings may also be integrated in the integrated energy absorbing system.

Abstract: Composite parts (100) and methods of making the same are disclosed. A composite part may include an internal insert component (124) made of a first material. The internal insert component may be provided with surface features such as mechanical surface features or material surface features, on at least a portion of its surface. The composite part may further include an external part component (136) that is cast around at least a portion of the internal insert component, and is made of a second material different from the first material. The surface features of the internal insert component may help establish a bond within the composite part between the internal insert component and the external part component.

Abstract: Composite parts (10), methods of making the same (400), and tooling systems (200) for making the same are disclosed. According to one example, a high-pressure die casting process is used to manufacture a composite part (10) that is made from a composite metal material (12) with a metal matrix phase (20) and a particle phase (22) and includes an interior region (14) and an exterior region (16), where an average concentration of the particle phase (22) in the composite metal material (12) is higher in the exterior region (16) than in the interior region (14). An interior surface (206a, 206b) of a die mold (206) may be coated with a particle phase (22) (e.g., a ceramic-based material) and a molten metal matrix phase (20) (e.g., an aluminum-based material) may then be introduced into the die mold (206) such that a composite part (10) is formed with an exterior region (16) or outer layer that is particle-rich compared to an interior region (14).

Abstract: Composite parts and methods for making the same are disclosed. A composite part may include an internal insert component that is coated on at least a portion of its surface with certain types of particles, an external part component cast around the coated insert, and a particle-rich region that is formed between the two components, where the particle-rich region includes particles from the coated insert. A method for producing a composite part may include the steps of: positioning an internal insert component that is coated on at least a portion of its surface within a mold cavity of a casting die; casting a molten material of the external part component around the coated insert; and solidifying the molten material to form the external part component of the composite part.

Abstract: Composite parts (100) and methods of making the same are disclosed. A composite part may include an internal insert component (124) made of a first material. The internal insert component may be provided with surface features such as mechanical surface features or material surface features, on at least a portion of its surface. The composite part may further include an external part component (136) that is cast around at least a portion of the internal insert component, and is made of a second material different from the first material. The surface features of the internal insert component may help establish a bond within the composite part between the internal insert component and the external part component.

Abstract: A shaping tool includes a cooling system having one or more cooling passages configured for enhanced cooling. The cooling passages provide latent heat cooling of a heated material that is in contact with a shaping surface of the tool. Cooling fluid flows along the cooling passages in a two-phase flow regime in which a portion of the cooling fluid is liquid and a portion of the cooling fluid is vapor. A two-phase portion of the cooling passage can be shaped to follow a three-dimensional contour of the shaping surface. Opposing walls of the cooling passage can be provided by passage surfaces of separately formed pieces of the tool. The latent heat cooling provided by suitably configured cooling channels extracts more heat from the material being shaped in the tool than traditional cooling systems.

Abstract: A shaping tool includes a cooling system having one or more cooling passages configured for enhanced cooling. The cooling passages provide latent heat cooling of a heated material that is in contact with a shaping surface of the tool. Cooling fluid flows along the cooling passages in a two-phase flow regime in which a portion of the cooling fluid is liquid and a portion of the cooling fluid is vapor. A two-phase portion of the cooling passage can be shaped to follow a three-dimensional contour of the shaping surface. Opposing walls of the cooling passage can be provided by passage surfaces of separately formed pieces of the tool. The latent heat cooling provided by suitably configured cooling channels extracts more heat from the material being shaped in the tool than traditional cooling systems.

Abstract: A shaping tool includes a cooling system having one or more cooling passages configured for enhanced cooling. The cooling passages provide latent heat cooling of a heated material that is in contact with a shaping surface of the tool. Cooling fluid flows along the cooling passages in a two-phase flow regime in which a portion of the cooling fluid is liquid and a portion of the cooling fluid is vapor. A two-phase portion of the cooling passage can be shaped to follow a three-dimensional contour of the shaping surface. Opposing walls of the cooling passage can be provided by passage surfaces of separately formed pieces of the tool. The latent heat cooling provided by suitably configured cooling channels extracts more heat from the material being shaped in the tool than traditional cooling systems.