Abstract: A modular casting mold for casting an automotive component includes a plurality of die portions defining a mold cavity corresponding to an automotive component, at least one of the plurality of die portions is an active die portion adapted to control the temperature of the modular casting mold throughout the casting process and including features for ejecting an automotive component cast within the modular casting mold, and the modular casting mold adapted to be attached to another modular casting mold for casting a single automotive component.

Abstract: A modular casting mold for casting an automotive component includes a plurality of die portions defining a mold cavity corresponding to an automotive component, at least one of the plurality of die portions is an active die portion adapted to control the temperature of the modular casting mold throughout the casting process and including features for ejecting an automotive component cast within the modular casting mold, and the modular casting mold adapted to be attached to another modular casting mold for casting a single automotive component.

Abstract: A cup plug insertion tool comprises a cylindrical base and a cylindrical collet extending from the base and including at least two longitudinal slots that divide the collet into at least two flexible segments adapted to flex radially inward under force, an annular groove formed adjacent the base, the annular groove adapted to allow the flexible segments to flex radially inward, further wherein, the force necessary to flex the flexible segments radially inward is tunable based on a width and depth of the annular groove, a first section defining a circumferential outer diameter and a circumferential inner diameter, a second section defining a circumferential outer diameter that is larger than the circumferential outer diameter of the first section, a tip positioned at the distal end of the collet, and a chamfer formed between the outer diameter of the first section and the tip.

Abstract: A cup plug insertion tool comprises a cylindrical base and a cylindrical collet extending from the base and including at least two longitudinal slots that divide the collet into at least two flexible segments adapted to flex radially inward under force, an annular groove formed adjacent the base, the annular groove adapted to allow the flexible segments to flex radially inward, further wherein, the force necessary to flex the flexible segments radially inward is tunable based on a width and depth of the annular groove, a first section defining a circumferential outer diameter and a circumferential inner diameter, a second section defining a circumferential outer diameter that is larger than the circumferential outer diameter of the first section, a tip positioned at the distal end of the collet, and a chamfer formed between the outer diameter of the first section and the tip.

Abstract: A method of manufacturing an aluminum alloy cylinder head includes providing a precision sand core and mold assembly, a liquid aluminum alloy delivery system, and a mold manipulator system. The precision sand core and mold assembly is disposed in the mold manipulator system and the liquid aluminum alloy delivery system includes an in-furnace ultrasonic actuator and a launder tube having at least an ultrasonic actuator. The liquid aluminum alloy delivery system is sealed to the precision sand core and mold assembly and provides liquid aluminum alloy into a gating system of the precision sand core and mold assembly. The precision sand core and mold assembly is rotated approximately 180°. The precision sand core and mold assembly is vibrated.

Abstract: A method of manufacturing an aluminum alloy cylinder head includes providing a precision sand core and mold assembly, a liquid aluminum alloy delivery system, and a mold manipulator system. The precision sand core and mold assembly is disposed in the mold manipulator system and the liquid aluminum alloy delivery system includes an in-furnace ultrasonic actuator and a launder tube having at least an ultrasonic actuator. The liquid aluminum alloy delivery system is sealed to the precision sand core and mold assembly and provides liquid aluminum alloy into a gating system of the precision sand core and mold assembly. The precision sand core and mold assembly is rotated approximately 180°. The precision sand core and mold assembly is vibrated.

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: A cylinder liner for an engine block that includes an inter-bore saw cut includes a first engine block bonding surface, and a second engine block bonding surface that has a lower level of bonding between the cylinder liner and an engine block than the first engine block bonding surface. The second engine block bonding surface extending from an axial end portion of the liner a distance greater than a depth of the saw cut in inter-bore section of the engine block.

Abstract: A cylinder liner for an engine block that includes an inter-bore saw cut includes a first engine block bonding surface, and a second engine block bonding surface that has a lower level of bonding between the cylinder liner and an engine block than the first engine block bonding surface. The second engine block bonding surface extending from an axial end portion of the liner a distance greater than a depth of the saw cut in inter-bore section of the engine block.