Abstract: The corrosion resistance of formed and shaped sheet magnesium alloy articles may be improved by applying to the article a substantially crack- and pore-free ductile metal layer on at least selected surfaces and cut or sheared edges. An exemplary ductile metal may be aluminum or its alloys. Two methods of applying such a ductile metal layer are described. One method is suitable for extended areas of the magnesium alloy surface, and is applied prior to stamping the article while a second method, suitable for cut or sheared edges, is intended for application after the article is fully formed. The incorporation of both embodiments into conventional sheet metal stamping processes to form the corrosion resistant formed magnesium article is described.

Abstract: Porous, amorphous lithium storage materials and a method for making these materials are disclosed herein. In an example of the method, composite particles of a lithium storage material in an amorphous phase and a material that is immiscible with the lithium storage material are prepared. Phase separation is induced within the composite particles to precipitate out the amorphous phase lithium storage material and form phase separated composite particles. The immiscible material is chemically etched from the phase separated composite particles to form porous, amorphous lithium storage material particles.

Abstract: A cutting tool for machining metal workpieces using polycrystalline diamond cutting surfaces with interspersed guide surfaces and chip evacuation surfaces. When machining holes in cast aluminum alloy workpieces it is found that aluminum machining chips adhere to guide surfaces and chip evacuation surfaces and mar the machined surface. It is found that when the guide and chip evacuation surfaces are coated with a diamond-like carbon material, aluminum chips do not mar the machined surfaces.

Abstract: A process for fabricating sintered, substantially pore-free titanium aluminide articles with minor alloying element additions is disclosed. Such articles may find application as automobile engine valves and connecting rods and may be fabricated by rapidly sintering intimately mixed powders of substantially pure titanium and rapidly-cooled particles of aluminum alloyed with the minor alloying element(s).

Abstract: A method for manufacturing an inner door panel for a vehicle side door that employs a die casting process. The method includes providing a die cast mold having opposing mold halves that combine to define a die cavity configured to provide the inner door panel having an integrated impact beam. The mold cavity also includes channels that form a runner and gating system that causes the molten material to form an outer frame defining a central opening that allows the mold halves to be separated when the door panel has hardened within the mold.

Abstract: One embodiment includes providing a contiguous tubular member including at least one of a first material or a second material, so that the tubular member has a wall thickness that varies along the length of the tubular member; bending the tubular member; and hydroforming the tubular member into a part.

Abstract: Microencapsulated chemical(s), as water-soluble solid particles, are embedded in at least one the paint layers on the surface of a magnesium article used in an automobile. If the protective paint film is scratched or otherwise mechanically disturbed to expose the surface of the magnesium article the capsules will be ruptured. This will expose the encapsulated chemical(s) to ambient water enabling them to dissolve and form an aqueous solution capable of reacting with the exposed magnesium to form a protective passivating layer on the exposed magnesium to resist corrosion. In a second embodiment the encapsulated chemicals include a deliquescing compound for extraction of moisture from the atmosphere sufficient to induce dissolution of the passivating layer-forming chemical(s) and trigger the formation of the passivating layer in the absence of ambient water.

Abstract: A composite of silicon and tin is prepared as a negative electrode composition with increased lithium insertion capacity and durability for use with a metal current collector in cells of a lithium-ion battery or a lithium-sulfur battery. This negative electrode material is formed such that the silicon is present as a distinct amorphous phase in a matrix phase of crystalline tin. While the tin phase provides electron conductivity, both phases accommodate the insertion and extraction of lithium in the operation of the cell and both phases interact in minimizing mechanical damage to the material as the cell experiences repeated charge and discharge cycles. In general, roughly equal atomic proportions of the tin and silicon are used in forming the phase separated composite electrode material.

Abstract: A method of resistance spot welding a steel workpiece and an aluminum or aluminum alloy workpiece together includes several steps. One step involves inserting a cover between the aluminum or aluminum alloy workpiece and an adjacent welding electrode. In another step, the adjacent welding electrode is pressed against cover, and another opposed welding electrode is pressed against the steel workpiece at a weld site. In yet another step, electrical current is passed between the welding electrodes, passed through the cover, and passed through the workpieces in order to initiate and grow a molten weld pool within the aluminum or aluminum alloy workpiece.

Abstract: One embodiment includes a rechargeable charge storage device including a microcapsule disposed within said rechargeable charge storage device; and a thermal retardant chemical species contained within said microcapsule, wherein said microcapsule is adapted to release said chemical species upon being exposed to a triggering event either prior to or during an unstable rise in temperature of said charge storage device.

Abstract: A magnesium alloy panel for a vehicle includes a first region and a second region extending from the first region to an edge. The first region has a first microstructure having a first corrosion resistance. The second region has a second microstructure different than the first microstructure and has a second corrosion resistance greater than the first corrosion resistance. A system for mass producing magnesium alloy panels includes a forming apparatus and a laser cutting apparatus. The forming apparatus forms a panel having a first microstructure having a first corrosion resistance. The laser cutting apparatus cuts the panel to form the edge using a laser, and forms the second microstructure while forming the edge. The second microstructure is different than the first microstructure and has a second corrosion resistance greater than the first corrosion resistance. A method for mass producing magnesium alloy panels is also provided.

Abstract: A method of bonding a metal to a substrate involves forming an oxide layer on a surface of the substrate, and in a molten state, over-casting the metal on the substrate surface. The over-casting drives a reaction at an interface between the over-cast metal and the oxide layer to form another oxide. The other oxide binds the metal to the substrate surface upon solidification of the over-cast metal.

Abstract: Methods of forming bi-metallic castings are provided. In one method, a metal preform of a desired base shape is provided defining a substrate surface. A natural oxide layer is removed from the substrate surface, yielding a cleaned metal preform. The method includes forming a thin metallic film on at least a portion of the substrate surface of the cleaned metal preform, and metallurgically bonding the portion of the metal preform having the metallic film with an overcast metal to form a bi-metallic casting. The metallic film promotes a metallurgical bond between the metal preform and the overcast metal. In one aspect, the metal preform may comprise aluminum (Al) and the metallic film may comprise zinc (Zn).

Abstract: Porous, amorphous lithium storage materials and a method for making these materials are disclosed herein. In an example of the method, composite particles of a lithium storage material in an amorphous phase and a material that is immiscible with the lithium storage material are prepared. Phase separation is induced within the composite particles to precipitate out the amorphous phase lithium storage material and form phase separated composite particles. The immiscible material is chemically etched from the phase separated composite particles to form porous, amorphous lithium storage material particles.

Abstract: An oil filter and oil-additive dispensing device comprising an oil filter and oil additive replenishment system further comprising: a full-flow oil filter; a by-pass oil filter; an oil additive dispensing system; and an on-vehicle controller to dispense additive as required, track additive consumption and signal the need for a replacement system is described. Also a method of using such oil filter and oil-additive dispensing device to extend the useful life of lubricating oil in a vehicle engine is described.

Abstract: A tire includes a pair of sidewalls in spaced apart relation and extending substantially radially from a respective inner circumferential portion to a respective outer circumferential portion, a tread extending between and connecting outer circumferential portions of the sidewalls, at least a portion of a tire cavity defined by the tread and sidewalls, and a bead portion on the inner circumferential portion of each radially extending sidewall, the bead portion providing an engagement surface for engaging a wheel on which the tire is to be mounted, and a noise reducing foam disposed in at least a portion of the tire cavity.

Abstract: A virtual-sunroof system for providing a virtual sunroof at an interior of a vehicle for viewing by a passenger of the vehicle. The system includes a virtual-sunroof imaging device configured and arranged at the vehicle to collect image information from an environment above the vehicle and create digital image data using the image information. The system also includes a virtual-sunroof projection device configured and arranged in the vehicle to be in communication with the virtual-sunroof imaging device for providing a virtual sunroof display. The virtual sunroof display provided (a) is viewable above a head of the passenger, (b) is formed using the image data, (c) represents accurately at the interior of the vehicle a rendition of the environment above the vehicle, and (d) has a size, shape, and location corresponding generally to a size, shape, and location that an actual conventional-type sunroof would have in the vehicle.

Abstract: A capsule-in-capsule system comprising at least two segregated chemical reactants is described. An inner capsule contains one reactant and is itself contained, with a second chemical reactant, in an outer capsule. The inner capsule and its contents is fabricated first; then it is incorporated into the second reactant; and the combination of the second reactant and inner capsule is encapsulated in the outer capsule. The reactants may be hydrophobic or hydrophilic and present as fluids, solids or combinations of solid(s) and fluids(s). When subjected to suitably high pressure, the capsule wall materials will fracture or rupture, releasing and preferably mixing all encapsulates to enable their prompt reaction. The utility of the invention is illustrated by its application to development of a corrosion inhibiting passive film on magnesium auto body material and to the adhesive bonding of members where precise positioning is desired.

Abstract: A composite of silicon and tin is prepared as a negative electrode composition with increased lithium insertion capacity and durability for use with a metal current collector in cells of a lithium-ion battery or a lithium-sulfur battery. This negative electrode material is formed such that the silicon is present as a distinct amorphous phase in a matrix phase of crystalline tin. While the tin phase provides electron conductivity, both phases accommodate the insertion and extraction of lithium in the operation of the cell and both phases interact in minimizing mechanical damage to the material as the cell experiences repeated charge and discharge cycles. In general, roughly equal atomic proportions of the tin and silicon are used in forming the phase separated composite electrode material.

Abstract: A hemming station is configured for hemming a panel assembly including an outer panel having a hem flange defined by a hem edge. The hemming station includes a roller configured to fold the hem flange, a heating device configured to heat the hem edge, and a control unit. The control unit is configured to control the roller and the heating device such that the roller folds the hem flange when the temperature of the hem edge is in a predetermined temperature range.