Abstract: A method of forming a coated article is disclosed. The method involves heating a magnesium alloy component, positioning the component in a mold such that a gap exists between component outer surfaces and mold inner surfaces, and heating a magnesium-containing alloy material above its melting temperature, which is lower than that of the component. The material is formed from magnesium alloyed with i) the component element, but at a higher concentration, ii) at least one element that is different than the component element, or iii) the component element and at least one other element. The method further includes introducing the material into the gap, thereby covering at least the outer surfaces of the component, and cooling the material to form a substantially evenly distributed solidified coating on the outer surfaces of the component. The coating has a higher wear and/or corrosion resistance than that of the magnesium alloy component.

Abstract: A system and method for predicting fatigue life in metal alloys for very high cycle fatigue applications. The system and method are especially useful for cast metal alloys, such as cast aluminum alloys, where a fatigue endurance limit is either non-existent or hard to discern. Fatigue properties, such as fatigue strength in the very high cycle fatigue region, are based on a modified random fatigue limit model, where the very high cycle fatigue strength and infinite life fatigue strength are refined to take into consideration the sizes of the discontinuities and microstructure constituents since the fatigue life scatter depends upon the presence of discontinuities and microstructure constituents. The sizes of the discontinuities and microstructure constituents that can initiate fatigue cracks can be determined with extreme value statistics, then input to the modified random fatigue limit model.

Abstract: Some die cast aluminum alloy articles have internal cylindrical surfaces such as the round internal cylinder surfaces of a cylinder block for an internal combustion engine. During casting solidification molten aluminum alloys shrink against the metallic permanent mold tools used to mold and define such internal surfaces, and tend to stick to the tool surfaces making it difficult to remove the casting. The tendency of some aluminum casting alloys to solder to the tool can further intensify sticking. In this invention, an aluminum alloy sleeve is placed on and over the tool surface before casting and the sleeve isolates the tool from the molten aluminum. The sleeve becomes bonded to the casting and facilitates removal of the casting from the tool. The sleeve may be (and preferably is) fully machined from the internal casting surface. The sleeve may be of the same composition as the casting, in which case handling and recycling of machining chips would be facilitated.

Abstract: A major engine casting, such as an engine block or a cylinder head, fabricated of either magnesium or aluminum alloy, has a cast-in-place metal tube or form embedded within it. The tube or form enables circulation of liquid while substantially physically isolating the casting alloy from the circulating liquid and thereby restricting or eliminating corrosive interaction between them.

Abstract: A method of forming a coated article is disclosed. The method involves heating a magnesium alloy component, positioning the component in a mold such that a gap exists between component outer surfaces and mold inner surfaces, and heating a magnesium-containing alloy material above its melting temperature, which is lower than that of the component. The material is formed from magnesium alloyed with i) the component element, but at a higher concentration, ii) at least one element that is different than the component element, or iii) the component element and at least one other element. The method further includes introducing the material into the gap, thereby covering at least the outer surfaces of the component, and cooling the material to form a substantially evenly distributed solidified coating on the outer surfaces of the component. The coating has a higher wear and/or corrosion resistance than that of the magnesium alloy component.

Abstract: A system and method for predicting fatigue life in metal alloys for very high cycle fatigue applications. The system and method are especially useful for cast metal alloys, such as cast aluminum alloys, where a fatigue endurance limit is either non-existent or hard to discern. Fatigue properties, such as fatigue strength in the very high cycle fatigue region, are based on a modified random fatigue limit model, where the very high cycle fatigue strength and infinite life fatigue strength are refined to take into consideration the sizes of the discontinuities and microstructure constituents since the fatigue life scatter depends upon the presence of discontinuities and microstructure constituents. The sizes of the discontinuities and microstructure constituents that can initiate fatigue cracks can be determined with extreme value statistics, then input to the modified random fatigue limit model.

Abstract: Some die cast aluminum alloy articles have internal cylindrical surfaces such as the round internal cylinder surfaces of a cylinder block for an internal combustion engine. During casting solidification molten aluminum alloys shrink against the metallic permanent mold tools used to mold and define such internal surfaces, and tend to stick to the tool surfaces making it difficult to remove the casting. The tendency of some aluminum casting alloys to solder to the tool can further intensify sticking. In this invention, an aluminum alloy sleeve is placed on and over the tool surface before casting and the sleeve isolates the tool from the molten aluminum. The sleeve becomes bonded to the casting and facilitates removal of the casting from the tool. The sleeve may be (and preferably is) fully machined from the internal casting surface. The sleeve may be of the same composition as the casting, in which case handling and recycling of machining chips would be facilitated.

Abstract: Die casting of some magnesium alloys may yield castings that are susceptible to corrosion when exposed to salt water or other aggressive oxidizing environments. Such corrosion may result from the existence of different microstructures in a cross-section of the die casting (e.g. between the surface of the part and the center) that produce galvanic couples that are susceptible to such corrosive attack. However, a die temperature may be determined for casting of the part such that a more uniform cross-sectional microstructure is produced in which minimal or negligible galvanic potentials are produced.

Abstract: A releasable fastener system comprises a loop portion and a hook portion. The loop portion includes a support and a loop material disposed on one side thereof. The hook portion generally includes a support and a plurality of closely spaced upstanding hook elements extending from one side thereof, wherein the plurality of hook elements comprises or incorporates a shape memory alloy fiber. When the hook portion and loop portion are pressed together they interlock to form a releasable engagement. The resulting joint created by the engagement is relatively resistant to shear and pull forces and weak in peel strength forces. Introducing a thermal activation signal to the plurality of hook elements causes a change in shape orientation, flexural modulus property, or a combination thereof that effectively reduces the shear and/or pull off forces in the releasable engagement.

Abstract: A releasable fastener system comprises a loop portion and a hook portion. The loop portion includes a support and a loop material disposed on one side thereof. The hook portion generally includes a support and a plurality of closely spaced upstanding hook elements extending from one side thereof, wherein the plurality of hook elements comprises or incorporates a shape memory alloy fiber. When the hook portion and loop portion are pressed together they interlock to form a releasable engagement. The resulting joint created by the engagement is relatively resistant to shear and pull forces and weak in peel strength forces. Introducing a thermal activation signal to the plurality of hook elements causes a change in shape orientation, flexural modulus property, or a combination thereof that effectively reduces the shear and/or pull off forces in the releasable engagement.

Abstract: A preform for impregnation of a metal or ceramic matrix material comprising a multiplicity of reinforcement particles bonded together so as to define a three-dimensional, open-cell reticulum comprising a plurality of randomly oriented thread-like portions interconnected one to the next via a plurality of nodes. A reinforced composite made from such preform and method of making the preform is disclosed/claimed wherein the reinforcement particles are mixed with prepolymers used to produce a fugitive binder for the particles comprising a foamed polymer, and the particles align themselves with the polymer portions of the resulting foam.

Abstract: This invention relates to a lead-free ceramic insulator, such as that utilized in headlamp switching assemblies. The composition utilized to make the lead-free ceramic insulator includes low melting glasses which form low-viscosity liquids at low temperatures. The glasses generally contain alkali and/or alkaline earth oxides and boron oxide. Aluminum oxide may be added to compensate for the alkali and alkaline earth containing glasses which are sensitive to corrosion by water. The compositions have a low sintering temperature.

Abstract: Disclosed are electrorheological fluids having spherical, or near-spherical, fullerene-type particles and a nonconducting or dielectric fluid.

Abstract: A preform for impregnation of a metal or ceramic matrix material comprising a multiplicity of reinforcement particles bonded together so as to define a three-dimensional, open-cell reticulum comprising a plurality of randomly oriented thread-like portions interconnected one to the next via a plurality of nodes. A reinforced composite made from such preform and method of making the preform is disclosed/claimed wherein the reinforcement particles are mixed with prepolymers used to produce a fugitive binder for the particles comprising a foamed polymer, and the particles align themselves with the polymer portions of the resulting foam.

Abstract: Disclosed are electrorheological fluids having ceramic particles of high ion conductivity and a nonconducting or dielectric fluid. The high ion conductive particle may be a material having the formula A.sub.1+x Zr.sub.2 Si.sub.x P.sub.3-x O.sub.12, where A is a monovalent ion, such as a material comprising at least one selected from the group consisting of Li, Na, K, Ag and Cu; and x ranges from 0 to 3. The liquid phase may include a silicone fluid or mineral oil. In the case of a mineral oil, the oil may also include an amine-terminated polyester to improve stability of the fluid.

Abstract: Disclosed are electrorheological fluids having ceramic particles of high ion conductivity and a nonconducting or dielectric fluid. The high ion conductive particle may be a beta-alumina material, such as a material having the formula AM.sub.5-11 O.sub.8-17, where A is a monovalent ion, such as a material comprising at least one selected from the group consisting of Li, Na, K, Rb, Ag and Te; and M is a trivalent ion, such as a material comprising at least one selected from the group consisting of Al, Fe and Ga. The liquid phase may include a silicone fluid or mineral oil. In the case of a mineral oil, the oil may also include an amine-terminated polyester to improve stability of the fluid.

Abstract: Disclosed are electrorheological fluids having ceramic particles of high ion conductivity and a nonconducting or dielectric fluid. The high ion conductive particle may be a beta-alumina material, such as a material having the formula AM.sub.5-11 O.sub.8-17, where A is a monovalent ion, such as a material comprising at least one selected from the group consisting of Li, Na, K, Rb, Ag and Te; and M is a trivalent ion, such as a material comprising at least one selected from the group consisting of Al, Fe and Ga. The liquid phase may include a silicone fluid or mineral oil. In the case of a mineral oil, the oil may also include an amine-terminated polyester to improve stability of the fluid.

Abstract: Disclosed are electrorheological fluids having ceramic particles of high ion conductivity and a nonconducting or dielectric fluid. The high ion conductive particle may be a material having the formula Na.sub.3 PO.sub.4. The liquid phase may include a silicone fluid or mineral oil. In the case of a mineral oil, the oil may also include an amine-terminated polyester to improve stability of the fluid.

Abstract: Disclosed are electrorheological fluids having zeolite particles and a nonconducting or dielectric fluid. The liquid phase includes an amine-terminated polyester to improve stability of the fluid.

Abstract: Disclosed are electrorheological fluids having ceramic particles of high ion conductivity and a nonconducting or dielectric fluid. The high ion conductive particle may be a material having the formula A.sub.x (L.sub.x/2 Sn.sub.1-(x/2))O.sub.4, where A is a monovalent ion, such as a material comprising at least one selected from the group consisting of Na and K; and x ranges from 0 to 1; and L is a divalent ion, such as a material comprising at least one selected from the group consisting of Mg, Ca and Zn. The liquid phase may include a silicone fluid or mineral oil. In the case of a mineral oil, the oil may also include an amine-terminated polyester to improve stability of the fluid.