Abstract: A battery cell pack has a plurality of battery cells that are assembled into a prismatic frame, with deformable separators interposed to accommodate elastic and plastic deformation caused by cyclic and acyclic expansion and contraction thereof during charging and discharging over the life of the battery cell pack. The battery cells are arranged in a horizontal stack within the prismatic frame, and the deformable separators are interposed between subsets of the battery cells. The deformable separators exert compressive force on the subsets of the battery cells along a longitudinal axis that is defined by the horizontal stack. The compressive force exerted by the deformable separators is at least a minimum force over a service life of the battery cell pack.

Abstract: A rotor for an electric machine includes strengthened structural elements effected through surface alloying and heating via an induction heating fixture. A rotor includes laminations formed to have internal cavities and structural members adjacent the cavities. A number of the laminations are stacked to form a lamination stack. An alloying material is applied to the lamination stack at the structural members. The lamination stack is placed in a fixture so that an inductor extends along the structural members and cooling elements extend through the cavities. A current is applied to the inductor to heat the structural members, alloying the alloying material into the structural members.

Abstract: A cooling system includes a housing configured to enclose an electric vehicle component immersed in cooling fluid and to define a first volume. A variable volume member defines a second volume that varies in response to a first signal. A combined volume is defined by the first volume and the second volume. Heat causes the cooling fluid to transition between a liquid state and a vapor state in the combined volume. A pressure sensor is configured to sense a pressure in the combined volume. A condenser is configured to cause the cooling fluid to transition from the vapor state back to the liquid state. A controller includes a volume adjustment module configured to generate the first signal to vary the second volume of the variable volume member to adjust the combined volume in response to the pressure and a first temperature of the electric vehicle component.

Abstract: A battery electrode, and a method for fabricating the battery electrode are described. The battery electrode includes a current collector having a woven mesh planar sheet that is composed of metallic strands. The metallic strands define a multiplicity of interstitial spaces, and the woven mesh planar sheet includes a first surface and a second surface. An active material including lithium is embedded in the interstitial spaces of a first portion of the woven mesh planar sheet, and an electrical connection tab arranged on a second portion of the woven mesh planar sheet.

Abstract: A method to make a stator lamination of an axial flux motor for an automobile vehicle includes: constructing a stator having multiple stator stack members, including: providing a stator lamination with individual ones of the stator stack members; forming the stator lamination from a single lamination sheet of steel defining a sinuous-shaped assembly having multiple bends; compressing the stator lamination; and machining the stator lamination to create a first edge by removing a first portion of the multiple bends and to create a second edge opposite to the first edge by removing a second portion of the multiple bends.

Abstract: An electrode structure for a battery includes a middle layer made of an electrically conductive perforated mesh having a top surface, a bottom surface, a plurality of interconnected electrically conductive segments and a plurality of perforations among adjacent ones of the interconnected segments. A top layer of an electrode material is disposed on the top surface, and a bottom layer of the electrode material is disposed on the bottom surface, such that the top and bottom layers are disposed in physical contact with each other through the perforations in the middle layer. A method of manufacturing the electrode structure includes providing the layer of perforated mesh, applying the top and bottom layers of electrode material to the top and bottom surfaces, and curing the top and bottom layers of electrode material using one or more of heat, electromagnetic radiation and convection to produce a layer of cured electrode structure.

Abstract: An alloy composition is provided. The alloy composition includes silicon (Si) at a concentration of greater than or equal to about 0.55 wt. % to less than or equal to about 0.75 wt. %, magnesium (Mg) at a concentration of greater than or equal to about 0.55 wt. % to less than or equal to about 0.75 wt. %, chromium (Cr) at a concentration of greater than or equal to about 0.15 wt. % to less than or equal to about 0.3 wt. %, and a balance of the alloy composition being aluminum (Al). The alloy composition has an intermetallic phase content of less than or equal to about 3 wt. %. Methods of preparing the alloy composition and of processing the alloy composition are also provided.

Abstract: A system and method of increasing a cooling rate of a metal sand casting during solidification. The system includes a 3-D printed manufactured sand mold defining a mold cavity, a coolant inlet port extending into the manufactured sand mold, a myriad of coolant passageways surrounding a portion of the mold cavity, and a coolant outlet port in fluid communication with the coolant passageways. The system further includes a coolant vapor extraction system having a collection manifold in fluid connection with the outlet port of the sand mold. A molten metal is poured into the mold cavity and a liquid coolant is introduced into the sand mold. The liquid coolant changes state into a gas phase as it permeates through the sand mold, thereby increasing the cooling rate of the casting. The liquid coolant may be that of a liquid nitrogen.

Abstract: A method for laminating a lithium metal anode is provided. The method includes procuring a current collector, including a portion of the current collector to be covered with a lithium foil lamination, and procuring a plurality of lithium foil portions. The plurality of lithium foil portions each include a length configured for matching one of a length of the portion of the current collector to be covered with the lithium foil lamination or a width of the portion of the current collector to be covered with the lithium foil lamination. The method further includes disposing the plurality of lithium foil portions upon the portion of the current collector to be covered with the lithium foil lamination, wherein the plurality of lithium foil portions is arranged side-by-side, and applying heat and pressure to join the plurality of lithium foil portions to the current collector.

Abstract: The present disclosure describes a method of manufacturing a vehicle body structure component. The method includes extruding a tube to include at least one reinforced region extending along a length of the tube. The tube has a first thickness in the at least one reinforced region and a second thickness in other regions of the tube. The first thickness is greater than the second thickness. The method further includes cutting a blank from the tube such that the blank includes at least a portion of the at least one reinforced region and forming the blank into a desired shape of the component.

Abstract: The present disclosure provides a method of preparing a metal sheet. The method includes extruding a component along an extrusion axis. The component has a wall at least partially defining an interior region. The component includes a metal. The method further includes unfurling the wall to form a sheet precursor. The sheet precursor has a first thickness and a first transverse dimension. The method further includes rolling the sheet precursor along a rolling axis to form the metal sheet. The metal sheet has a second thickness perpendicular to the rolling axis. The second thickness is less than the first thickness. The second transverse dimension is parallel to the rolling axis. The second transverse dimension is greater than the first transverse dimension. In certain aspects, the metal includes lithium and the metal sheet is a lithium metal electrode.

Abstract: A cover for integrated power electronics (IPE), the cover including a first sheet, a second sheet bonded to the first sheet by at least one joining point in a perimeter region, a cavity defined between the bonded first sheet and second sheet, wherein the perimeter region seals the cavity, and a filler material disposed within the cavity.

Abstract: A crankshaft for an internal combustion engine is provided. The crankshaft comprises at least four main journals aligned on a crankshaft axis of rotation defining a centerline. The crankshaft further comprises at least three pin journals. Each pin journal is disposed about a respective pin journal axis and positioned between the main journals. Each of the pin journals is joined to a pair of crank arms. Each pair of crank arms is joined to a respective main journal. Each of the main journals, pin journals, and crank arms is made of a first metallic material. Each crank arm has an over-molded counterweight metallurgically bonded thereto. Each counterweight is disposed opposite a respective pin journal relative to the centerline for balance and stability. Each counterweight is made of a second metallic material. The crankshaft has a weight ratio of the second metallic material to the first metallic material of between 0.20 to 0.50.

Abstract: A hydraulic gerotor pump for an automatic transmission may comprise a housing and a gear set rotatably disposed within the housing. The gear set may comprise an inner gear and an outer gear having radially opposed intermeshing teeth that together define a plurality of circumferentially disposed variable volume pumping chambers therebetween. The housing may be made of a first aluminum-based material, and the inner gear and the outer gear of the gear set may be made of a second aluminum-based material. The linear coefficient of thermal expansion of the first aluminum-based material may be substantially the same as that of the second aluminum-based material.

Abstract: A cast steel alloy for an engine of a vehicle is provided. The cast steel alloy comprises 0.29 to 0.65 weight percent (wt %) carbon, 0.40 to 0.80 wt % silicon, 0.6 to 1.5 wt % manganese, up to 0.03 wt % phosphorus, 0.04 to 0.07 wt % sulfur, 0.8 to 1.4 wt % chromium, 0.2 to 0.6 wt % nickel, 0.15 to 0.55 wt % molybdenum, 0.25 to 2.0 wt % copper, up to 0.03 wt % titanium, 0.07 to 0.17 wt % vanadium, 0.02 to 0.06 wt % aluminum, up to 0.03 wt % nitrogen (N), and 0.01 to 0.06 wt % of at least one of cerium (Ce) and lanthanum. The cast steel alloy has unexpected and unconventional results such as reduced ferrite and enhanced strengths.

Abstract: A method of manufacturing a threaded hole in a workpiece includes providing the workpiece having a region with a hole. The method also includes cutting a threading for the hole. Furthermore, the method includes, independent of cutting the threading, densifying the region proximate the hole to reduce material porosity in the region.

Abstract: A structural assembly includes a frame and a plurality of panels. The frame includes a wall that at least partially defines an interior region. The plurality of panels is disposed at least partially in the interior region and is coupled to the frame. The plurality of panels includes a first panel and a second panel. The first panel includes a first surface and a second surface opposite the first surface. The first surface defines a first plurality of depressions and the second surface defines a first plurality of protrusions complementary to the first plurality of depressions. The second panel includes a third surface and a fourth surface opposite the third surface. The third surface defines a second plurality of depressions. The fourth surface defines a second plurality of protrusions complementary to the first plurality of depressions. The first panel is coupled to the second panel.

Abstract: The present disclosure provides a negative electrode for an electrochemical cell that cycles lithium ions. The negative electrode may include a negative electroactive material and a lithiation additive. The negative electroactive material may have a first cell voltage window. The lithiation additive may have a second cell voltage window. The second cell voltage window may be less than the first cell voltage window. When the electrochemical cell is operated in the second cell voltage window, the lithiation additive may lithiated the cell.

Abstract: In an embodiment, a method of forming a cooling plate, comprises laser welding a plurality of weld lines to physically connect a first substrate and a second substrate wherein the plurality of weld lines forms an inflatable track; and inflating the inflatable track with an inflation fluid to form a cooling channel in the cooling plate. In another embodiment, the cooling plate can comprise a first substrate and a second substrate and a plurality of weld lines can form a fluid tight seal for a cooling channel located therebetween.

Abstract: A brake rotor includes a friction portion, a hat portion axially extending from the friction portion and including a top face that is axially displaced from the friction portion and a side wall that extends from the friction portion to the top face, and a nose portion which extends axially from the top face of the hat portion away from the friction portion.