Abstract: Systems and methods are provided for cleaning surfaces of a workpiece. The system includes a housing defining an enclosure, a holding structure within the enclosure that is configured to support a workpiece, a first powder removal device that is configured to propel a first media toward the holding structure such that the first media contacts the workpiece while the workpiece is supported by the holding structure, a first sensing device that is configured to detect surface characteristics of the workpiece while the workpiece is supported by the holding structure, and a controller configured to, by a processor: detect a powder material on a surface of the workpiece based on the surface characteristics, and selectively operate the first powder removal device to remove the powder material from the surface with the first media while the workpiece is supported by the holding structure.

Abstract: Systems and methods are provided for producing powders. The system includes a housing having an enclosure, a crucible configured to produce a melt of a first material, a droplet device configured to receive the melt of the first material from the crucible and produce a flow of droplets of the melt of the first material within the enclosure of the housing, wherein the droplets solidify within the enclosure, and a distribution device configured to propel a second material into the flow of droplets of the first material within the enclosure such that the second material is mixed with the droplets of the first material to produce the powder that includes the first material, the second material, and/or a reaction product thereof.

Abstract: A design for repair casting having a repairable ultra-large single-piece casting and a replacement part. The ultra-large single-piece casting includes a main body portion, at least one predefined replaceable portion integrally cast with the main body portion, and a cut-guide delineating the predefined replaceable portion from the main body portion. The cut-guide includes a continuous channel defined on an exterior surface of the single-piece casting. The cut-guide further includes a rib extending from a channel wall on the main body portion. A damaged replaceable portion is excisable from the main-body portion by cutting through the single-piece casting along the cut-guide. The excised damaged replaceable portion may be replaced with the replacement part, which has substantially the same geometry, dimensions, and mechanical properties as an undamaged replaceable portion. The replacement part may be joined to the main body portion by mechanical means or by welding.

Abstract: A method of repairing an ultra-large single-piece cast component of a vehicle body. The method includes the steps of locating a damaged portion of the cast component, determining an extent of the damaged portion of the ultra-large cast component, defining a cut-line sectioning off the damaged portion from an undamaged portion of the ultra-large cast component, cutting along the cut-line to excise the damaged portion from the undamaged portion of the ultra-large cast component, and joining a replacement piece to the undamaged portion of the ultra-large cast component. The replacement piece is fabricated based on the original manufacturer’s geometry and dimensional data of the excised damaged portion. The undamaged portion of the ultra-large cast component remains on the vehicle body during the repair.

Abstract: A high heat-absorption casting core for manufacturing a cast component includes a core body. The core body has at least a portion thereof defined by metal powder. The metal powder is configured to absorb heat energy from the cast component during cooling of the component and solidification thereof. The core body may be additionally defined by a sand fraction in contact with the metal powder fraction. A system and a method for manufacturing a cast component using the high heat-absorption casting core are also envisioned.

Abstract: A hybrid part includes a base structure and a plurality of layers of additive manufacturing material disposed on and attached to the base structure. The base structure may includes a plurality of sheets of base material, and/or a base formed by any non-additive manufacturing method. A method of forming a hybrid part includes providing a base structure that includes either or both of: a) a plurality of sheets of base material, and b) a base formed by a non-additive method. The method further includes disposing a plurality of layers of additive manufacturing material, layer by layer, onto the base structure.

Abstract: A method of forming an additive manufactured component comprises depositing a first layer of build material on a build platform within an additive manufacturing machine, depositing reinforcement fibers into the first layer of build material, orienting the reinforcement fibers within the first layer of build material, lowering the build platform, depositing a second layer of build material on top of the first layer of build material, depositing reinforcement fibers into the second layer of build material, and orienting the reinforcement fibers within the second layer of build material.

Abstract: A tubular structure comprises a first end and a second end, a cylindrical outer structure, and at least one inner cavity defined by the cylindrical outer structure and the first and second ends. The first and second ends each include a recess and a cap press fit within the recess. The caps provide a connection point for the ends of the tubular structure. Each end includes a vent in fluid communication with the inner cavity during manufacturing of the tubular structure, prior to insertion of the caps. An isotropic internal support structure extends longitudinally between the ends within the cylindrical outer structure and defines an oil flow channel extending through the tubular structure, each cap includes a cap orifice aligned with the oil flow channel, and the cylindrical outer structure, the first and second ends, and the internal support structure are continuously and unitarily formed.

Abstract: A high heat-absorption casting core for manufacturing a cast component includes a core body. The core body has at least a portion thereof defined by metal powder. The metal powder is configured to absorb heat energy from the cast component during cooling of the component and solidification thereof. The core body may be additionally defined by a sand fraction in contact with the metal powder fraction. A system and a method for manufacturing a cast component using the high heat-absorption casting core are also envisioned.

Abstract: An additive manufacturing method comprises: positioning a sheet of composite material; curing a predetermined portion of the sheet; cutting the sheet about the perimeter of the predetermined portion to create a preceding processed sheet; adding a successive sheet of composite material atop and in contact with the preceding processed sheet; curing a predetermined portion of the successive sheet such that the predetermined portions of the successive sheet and the preceding processed sheet are bonded together; and cutting the successive sheet about the perimeter of its predetermined portion to create a subsequent processed sheet. The steps of adding, curing and cutting a successive sheet may be repeated for a plurality of cycles to produce a three-dimensional composite product.

Abstract: A method of operating an anti-lock braking system includes that real-time brake corner temperature data, real-time brake corner pressure data real-time brake corner torque data, and deceleration parameters of the vehicle are detected. The method also includes that an apparent friction at the brake corner is determined in response to at least the real-time brake corner temperature data, the real-time brake corner pressure data, the real-time brake corner torque data, and the deceleration parameters of the vehicle.

Abstract: A method of forming an additive manufactured component comprises depositing a first layer of build material on a build platform within an additive manufacturing machine, depositing reinforcement fibers into the first layer of build material, orienting the reinforcement fibers within the first layer of build material, lowering the build platform, depositing a second layer of build material on top of the first layer of build material, depositing reinforcement fibers into the second layer of build material, and orienting the reinforcement fibers within the second layer of build material.

Abstract: A hybrid part includes a base structure and a plurality of layers of additive manufacturing material disposed on and attached to the base structure. The base structure may includes a plurality of sheets of base material, and/or a base formed by any non-additive manufacturing method. A method of forming a hybrid part includes providing a base structure that includes either or both of: a) a plurality of sheets of base material, and b) a base formed by a non-additive method. The method further includes disposing a plurality of layers of additive manufacturing material, layer by layer, onto the base structure.

Abstract: A method of monitoring a brake corner of a vehicle including that real-time brake corner temperature data of the brake corner is detected, real-time brake corner pressure data of the brake corner is detected, and real-time brake corner torque data of the brake corner is detected. The method further includes that a brake drag or a brake pulsation is determined in response to the braking energy of the brake corner, whether the brake pedal of the vehicle is applied, and at least one of the real-time brake corner pressure data of the brake corner and the real-time brake corner torque data of the brake corner.

Abstract: A tubular structure comprises a first end and a second end, a cylindrical outer structure, and at least one inner cavity defined by the cylindrical outer structure and the first and second ends. The first and second ends each include a recess and a cap press fit within the recess. The caps provide a connection point for the ends of the tubular structure. Each end includes a vent in fluid communication with the inner cavity during manufacturing of the tubular structure, prior to insertion of the caps. An isotropic internal support structure extends longitudinally between the ends within the cylindrical outer structure and defines an oil flow channel extending through the tubular structure, each cap includes a cap orifice aligned with the oil flow channel, and the cylindrical outer structure, the first and second ends, and the internal support structure are continuously and unitarily formed.

Abstract: An additive manufacturing method comprises: positioning a sheet of composite material; curing a predetermined portion of the sheet; cutting the sheet about the perimeter of the predetermined portion to create a preceding processed sheet; adding a successive sheet of composite material atop and in contact with the preceding processed sheet; curing a predetermined portion of the successive sheet such that the predetermined portions of the successive sheet and the preceding processed sheet are bonded together; and cutting the successive sheet about the perimeter of its predetermined portion to create a subsequent processed sheet. The steps of adding, curing and cutting a successive sheet may be repeated for a plurality of cycles to produce a three-dimensional composite product.

Abstract: A method of operating an anti-lock braking system includes that real-time brake corner temperature data, real-time brake corner pressure data real-time brake corner torque data, and deceleration parameters of the vehicle are detected. The method also includes that an apparent friction at the brake corner is determined in response to at least the real-time brake corner temperature data, the real-time brake corner pressure data, the real-time brake corner torque data, and the deceleration parameters of the vehicle.

Abstract: A method of monitoring a brake corner of a vehicle including that real-time brake corner temperature data of the brake corner is detected, real-time brake corner pressure data of the brake corner is detected, and real-time brake corner torque data of the brake corner is detected. The method further includes that a brake drag or a brake pulsation is determined in response to the braking energy of the brake corner, whether the brake pedal of the vehicle is applied, and at least one of the real-time brake corner pressure data of the brake corner and the real-time brake corner torque data of the brake corner.

Abstract: An exemplary method of performing a brake pad wear check includes providing a brake assembly, including a brake pad and a brake rotor, providing a controller electronically connected to the brake assembly, the controller configured to calculate an expected wear of the brake pad, determine a brake pad wear threshold, compare the expected wear of the brake pad to the brake pad wear threshold, and if a first condition is satisfied, perform the brake pad wear check.

Abstract: An electromechanical brake system capable of conducting a brake pad wear check includes a structure defining a chamber, a member that rotates with a wheel, a motor mounted to the structure, a reciprocating piston, a brake pad, and a controller. The piston is driven by the motor between a variable actuated position and a retracted position. The brake pad is movably supported by the structure, operatively coupled to the piston, and adapted for braking contact with the member when the piston is in the actuated position, and spaced from the member when the piston is in the retracted position. The controller controls reciprocation of the piston between the actuated and retracted positions via energization of the motor, performs a brake pad wear check by calculating a change in a parameter associated with a change in distance between positions, and compares the change in parameter to a threshold value.