Abstract: A method of welding a component made from a ferrous alloy to a component made from an aluminum alloy includes machining and cleaning a fay surface on the ferrous alloy component, machining and cleaning a fay surface on the aluminum alloy component, depositing a layer of copper alloy material onto the fay surface of the ferrous alloy component, forming a weld groove on at least one of the layer of copper alloy material deposited on the fay surface of the ferrous alloy component and the fay surface of the aluminum alloy component, and laser welding the layer of copper alloy deposited on the fay surface of the ferrous alloy component and the fay surface of the aluminum alloy component to one another.

Abstract: A method of joining parts, where at least one of the parts has a faying surface defining grooves therein. One of the parts is formed of a majority of titanium, and the other part is formed of a majority of iron. The method includes providing a set of opposed welding electrodes disposed on a side of each part and applying pressure to and heating the parts via the set of electrodes to form a joint between the parts. A bonded assembly includes a first part formed of a majority of titanium and a second part formed of a steel alloy. The first and second parts having a bond that includes a portion of the first part directly in contact with and attached to a portion of the second part. The parts may be a titanium-containing differential carrier case bonded to a steel gear.

Abstract: Systems and methods are provided for controlling additive manufacturing material deposition using a magnetic field. A system may include a build surface; a material depositor through which a magnetically responsive material is deposited on the build surface; an energy source; and a magnet set. The magnet set applies the magnetic field to the build surface and/or to the material depositor. The magnetic field is configured to attract the magnetically responsive material while the energy source melts the magnetically responsive material.

Abstract: A ladle, process, and system for casting an aluminum-based alloy includes a casting ladle. The casting ladle includes a cup and the cup defines an opening. The ladle also includes an ultrasonic transducer including an end immersed in the cup, wherein the cup exhibits a first depth and the ultrasonic transducer is immersed in the cup at a second depth in a range of 5 percent to 100 percent of the first depth. An aluminum-based alloy melt is introduced into an opening of a casting ladle, an ultrasonic transducer immersed in the aluminum-based alloy melt is activated, and the aluminum-based alloy melt is transferred onto a casting surface.

Abstract: A method of joining first and second parts formed of dissimilar materials is provided. The first part defines a first part contacting surface having a frustoconical shape. The first and second parts are brought into contact with one another, with one of the first and second parts being rotated while the other remains stationary, so as to generate frictional heat between the contacting surfaces of the parts, the generated frictional heat producing softened adjacent regions in the first and second parts. A force is applied to the first and second parts to plastically deform the softened adjacent regions and to forge together the first and second parts to form a solid-state joint. A composite torsional damper hub assembly includes a steel stem and a damper hub welded to the stem at an interface. The damper hub is formed of aluminum or an aluminum alloy, and the interface is generally frustoconical.

Abstract: A composite metal flexplate is disclosed that includes an aluminum center plate and a steel ring gear joined to the aluminum center plate by a solid-state joint. The solid-state joint that joins together the aluminum center plate and the steel ring gear may be formed by friction welding. During the friction welding process, a surface of an annular body of the steel ring gear is preheated, followed by bringing the preheated surface of the annular body into contact with a surface of a periphery of a circular body of the aluminum center plate. The two contacting surfaces are then caused to experience relative rotational contacting movement, which generates frictional heat therebetween and softens adjacent regions of the steel ring gear and the aluminum center plate. Once this occurs, an applied force is administered to compress and forge the contacting surfaces together, thereby establishing the solid-state joint.

Abstract: Angled, single laser weld and a method of forming an angled, single laser weld including arranging a first and second faying surfaces of a first and second component adjacently to form an interface between the components; irradiating at least one of the first and second components at the interface with a laser, wherein the first faying surface defines a plane formed at an angle alpha in the range of +1-5 degrees to 60 degrees from an axis A perpendicular to the first front surface and the second faying surface matches the first faying surface; and forming a junction at the interface with an hourglass shaped weld.

Abstract: Articles and methods involving fluidic devices are generally provided. In some embodiments, a fluidic device comprises a first layer comprising first and second regions that are disconnected from each other in the first layer and a second layer comprising a channel in fluidic communication with the first and second regions. The device may also comprise a third layer comprising a channel in fluidic communication with the first and second regions. One or more portions of a channel and/or one or more reagents may comprise reagent. In some embodiments, a method comprises flowing two or more fluid samples towards each other through a channel. The fluids may meet at an interface and/or may react at an interface.

Abstract: A method of joining parts, where at least one of the parts has a faying surface defining grooves therein. One of the parts is formed of a majority of titanium, and the other part is formed of a majority of iron. The method includes providing a set of opposed welding electrodes disposed on a side of each part and applying pressure to and heating the parts via the set of electrodes to form a joint between the parts. A bonded assembly includes a first part formed of a majority of titanium and a second part formed of a steel alloy. The first and second parts having a bond that includes a portion of the first part directly in contact with and attached to a portion of the second part. The parts may be a titanium-containing differential carrier case bonded to a steel gear.

Abstract: A nodular iron alloy and automotive components, such as a crankshaft, are provided. The nodular iron alloy may include iron, about 2.2-3.2 wt % carbon, about 1.7-2.3 wt % silicon, about 0.2-0.6 wt % manganese, a maximum of 0.03 wt % phosphorus, a maximum of 0.02 wt % sulfur, about 0.2-0.6 wt % copper, about 0.1-0.4 wt % chromium, about 0.4-0.8 wt % nickel, about 0.15-0.45 wt % molybdenum, about 0.2-1.0 wt % cobalt, about 0.02-0.06 wt % magnesium, and a maximum of 0.002 wt % rare earth element(s). The nodular iron alloy may have a Young's modulus in the range of 175-195 GPa and an as-cast ultimate tensile strength in the range of 750-950 MPa. This alloy possesses favorable strength, stiffness and noise/vibration/harshness qualities, making it suitable in crankshaft applications. A method of forming the nodular iron alloy includes feeding a magnesium-based material into a molten iron alloy through a continuous system at a constant amount.

Abstract: A method for manufacturing a crankshaft for an internal combustion engine with a plurality of journals having a hardened case with a first microstructure. The crankshaft is comprised of a steel comprising between about 0.3 wt % and 0.77 wt % Carbon. The first microstructure of the hardened case of the journals comprises between about 15% and 30% ferrite and a balance of martensite and the resultant subsurface residual stress between 310 MPa and 620 MPa.

Abstract: A method for manufacturing a crankshaft for an internal combustion engine with a plurality of journals having a hardened case with a first microstructure. The crankshaft is comprised of a steel comprising between about 0.3 wt % and 0.77 wt % Carbon. The first microstructure of the hardened case of the journals comprises between about 15% and 30% ferrite and a balance of martensite and the resultant subsurface residual stress between 310 MPa and 620 MPa.

Abstract: A method for heat treating a crankshaft for a vehicle propulsion system, or other work piece, includes heating at least a portion of the crankshaft to a gradual temperature profile. The temperature profile has gradually lower temperatures from the surface to the core of the crankshaft. The temperature profile includes a midpoint temperature at a midpoint between the surface and an innermost part of the core, the midpoint temperature being at least 50% of the surface temperature as measured in the Celsius scale. The surface temperature is within a transformation range of the crankshaft material. The method further includes quenching the surface of the crankshaft journal. The material of the crankshaft is preferably a carbon steel alloy having a DI less than 1.7 and having greater than 0.3 wt % carbon.

Abstract: An engine block, an automotive structure, and a method of coating an inner surface of an engine cylinder bore of an engine cylinder are provided. The method includes providing an inner bore substrate defining an inner surface of the engine cylinder bore, the inner bore substrate being formed of a first material. The method further includes disposing a thermal spray coating onto the inner surface of the engine cylinder bore. The thermal spray coating is formed of a second material that is different than the first material. The method also includes melting at least a portion of the thermal spray coating with a laser after performing the step of disposing the thermal spray coating onto the inner surface of the engine cylinder bore. The automotive structure and the engine block have a substrate covered by a thermal spray coating and laser remelted sections anchoring the coating to the substrate.

Abstract: A nodular iron alloy and automotive components, such as differential and drive axle components, are provided. The nodular iron alloy may include iron, about 3.1-3.3 wt % carbon, about 2.7-4.3 wt % silicon, about 0.15-0.40 wt % manganese, about 0-0.10 wt % magnesium, about 0-0.2 wt % nickel, about 0-0.4 wt % copper, about 0-0.30 wt % chromium, about 0-0.03 wt % phosphorus, and about 0-0.02 wt % sulfur. The nodular iron alloy may have an ultimate tensile strength of at least 620 MPa as-cast. This alloy possesses favorable weldability to weld with steel components without substantial preheating or post heat treatment for a strong and tough weldment, and it has good machinability to facility comprehensive machining operations.

Abstract: A steel alloy and automotive components, such as crankshafts, produced therefrom are provided. The steel alloy includes iron, about 0.34 to about 0.40 weight percent carbon, about 0.8 to about 1.2 weight percent manganese, about 0.40 to about 0.60 weight percent silicon, about 0.04 to about 0.07 weight percent sulfur, about 0.9 to about 1.2 weight percent chromium, about 0.20 to about 0.35 weight percent molybdenum, about 0.08 to about 0.15 weight percent vanadium, and about 0.02 to about 0.06 weight percent aluminum. The steel alloy may also include up to 0.03 weight percent phosphorus, up to 0.25 weight percent nickel, up to 0.20 weight percent copper, up to 0.03 weight percent titanium, up to 0.03 weight percent nitrogen, and up to 0.002 weight percent boron.

Abstract: A method for manufacturing a crankshaft for an internal combustion engine with a plurality of journals having a hardened case with a first microstructure. The crankshaft is comprised of a steel comprising between about 0.3 wt % and 0.77 wt % Carbon. The first microstructure of the hardened case of the journals comprises between about 15% and 30% ferrite and a balance of martensite and the resultant subsurface residual stress between 310 MPa and 620 MPa.

Abstract: A composite metal flexplate is disclosed that includes an aluminum center plate and a steel ring gear joined to the aluminum center plate by a solid-state joint. The solid-state joint that joins together the aluminum center plate and the steel ring gear may be formed by friction welding. During the friction welding process, a surface of an annular body of the steel ring gear is preheated, followed by bringing the preheated surface of the annular body into contact with a surface of a periphery of a circular body of the aluminum center plate. The two contacting surfaces are then caused to experience relative rotational contacting movement, which generates frictional heat therebetween and softens adjacent regions of the steel ring gear and the aluminum center plate. Once this occurs, an applied force is administered to compress and forge the contacting surfaces together, thereby establishing the solid-state joint.

Abstract: A bearing shell for an automotive propulsion system is provided, along with a crankshaft assembly and an engine having a bearing shell. The bearing shell comprises an inner layer having an inner layer thickness. The inner layer defines a bearing surface on an inner side. The bearing surface of the inner layer is configured to support and contact an oil film. The bearing shell also has an outer layer disposed around the inner layer and radially outward of the inner layer. The outer layer has an outer layer thickness that is greater than the inner layer thickness, the outer layer thickness being at least one millimeter. The outer layer is formed of an outer layer material comprising an aluminum alloy and/or a metal matrix composite material. The inner layer is formed of an inner layer material, wherein the outer layer material is stronger than the inner layer material.