Abstract: A process of heat treating an Al—Si—Cu—Mg—Fe—Zn—Mn—Sr-TMs alloy, where the TMs include Zr and V, includes heat treating the alloy to produce a microstructure having a matrix with Zr and V in solid solution after solidification. The solid solution Zr, in wt. %, is at least 0.16%, the solid solution V, in wt. %, is at least 0.20% after heat treatment, and Cu and Mg are dissolved into the matrix during the heat treatment and subsequently precipitated during the heat treatment. The composition of the alloy, in wt. %, includes Cu between 3.0-3.5%, Fe between 0-0.2%, Mg between 0.24-0.35%, Mn between 0-0.40%, Si between 6.5-8.0%, Sr between 0-0.025%, Ti between 0.05-0.2%, V between 0.20-0.35%, Zr between 0.2-0.4%, maximum 0.5% total of other alloying elements, and balance Al.

Abstract: A method of manufacturing a part includes melting, rapidly solidifying and consolidating pre-alloyed powders using an additive manufacturing process. The method provides a finished part with a microstructure with at least one non-equilibrium phase. The pre-alloyed powders can be powders of aluminum alloyed with iron and molybdenum, and the additive manufacturing process forms a near-net shaped part that can be finished with techniques such as machining, polishing and drilling, among others. The additive manufacturing process can be a laser melting technique such as selective laser melting or laser metal deposition and an average dendrite arm spacing of the rapidly solidified and consolidate pre-alloyed powders is less than 1.0 ?m. Finished parts formed from the aluminum alloy powders alloyed with iron and molybdenum exhibit enhanced strength at elevated temperatures such as an ultimate tensile strength greater than 400 MPa at 300° C. and greater than 350 MPa at 350° C.

Abstract: A method of manufacturing a part includes melting, rapidly solidifying and consolidating pre-alloyed powders using an additive manufacturing process. The method provides a finished part with a microstructure with at least one non-equilibrium phase. The pre-alloyed powders can be powders of aluminum alloyed with iron and molybdenum, and the additive manufacturing process forms a near-net shaped part that can be finished with techniques such as machining, polishing and drilling, among others. The additive manufacturing process can be a laser melting technique such as selective laser melting or laser metal deposition and an average dendrite arm spacing of the rapidly solidified and consolidate pre-alloyed powders is less than 1.0 ?m. Finished parts formed from the aluminum alloy powders alloyed with iron and molybdenum exhibit enhanced strength at elevated temperatures such as an ultimate tensile strength greater than 400 MPa at 300° C. and greater than 350 MPa at 350° C.

Abstract: A process of heat treating an Al—Si—Cu—Mg—Fe—Zn—Mn—Sr-TMs alloy, where the TMs include Zr and V, includes heat treating the alloy to produce a microstructure having a matrix with Zr and V in solid solution after solidification. The solid solution Zr, in wt. %, is at least 0.16%, the solid solution V, in wt. %, is at least 0.20% after heat treatment, and Cu and Mg are dissolved into the matrix during the heat treatment and subsequently precipitated during the heat treatment. The composition of the alloy, in wt. %, includes Cu between 3.0-3.5%, Fe between 0-0.2%, Mg between 0.24-0.35%, Mn between 0-0.40%, Si between 6.5-8.0%, Sr between 0-0.025%, Ti between 0.05-0.2%, V between 0.20-0.35%, Zr between 0.2-0.4%, maximum 0.5% total of other alloying elements, and balance Al.

Abstract: A high fatigue strength aluminum alloy comprises in weight percent copper 3.0-3.5%, iron 0-1.3%, magnesium 0.24-0.35%, manganese 0-0.8%, silicon 6.5-12.0%, strontium 0-0.025%, titanium 0.05-0.2%, vanadium 0.20-0.35%, zinc 0-3.0%, zirconium 0.2-0.4%, a maximum of 0.5% other elements and balance aluminum plus impurities. The alloy defines a microstructure having an aluminum matrix with the Zr and the V in solid solution after solidification. The matrix has solid solution Zr of at least 0.16% after heat treatment and solid solution V of at least 0.20% after heat treatment, and both Cu and Mg are dissolved into the aluminum matrix during the heat treatment and subsequently precipitated during the heat treatment. A process for heat treating an Al—Si—Cu—Mg—Fe—Zn—Mn—Sr-TMs alloy comprises heat treating the alloy to produce a microstructure having a matrix with Zr and V in solid solution after solidification.

Abstract: A method of treating a high pressure die cast (HPDC) material to improve rivetability is provided. The method includes exposing the HPDC material to a temperature between 300° C. and 450° C. for a time period between 10 minutes and 5 hours in a heat treatment step. In this method, the heat treatment results in eutectic silicon spheroidization of the HPDC material such that the HPDC material does not crack after rivet installation. The method further includes the step of exposing the HPDC material to a subsequent heat treatment step at about 180° C. for about 30 minutes after quenching. Moreover, the quenching may be a forced air quench for a period of 6° C./s.

Abstract: A high fatigue strength aluminum alloy comprises in weight percent copper 3.0-3.5%, iron 0-1.3%, magnesium 0.24-0.35%, manganese 0-0.8%, silicon 6.5-12.0%, strontium 0-0.025%, titanium 0.05-0.2%, vanadium 0.20-0.35%, zinc 0-3.0%, zirconium 0.2-0.4%, a maximum of 0.5% other elements and balance aluminum plus impurities. The alloy defines a microstructure having an aluminum matrix with the Zr and the V in solid solution after solidification. The matrix has solid solution Zr of at least 0.16% after heat treatment and solid solution V of at least 0.20% after heat treatment, and both Cu and Mg are dissolved into the aluminum matrix during the heat treatment and subsequently precipitated during the heat treatment. A process for heat treating an Al—Si—Cu—Mg—Fe—Zn—Mn—Sr-TMs alloy comprises heat treating the alloy to produce a microstructure having a matrix with Zr and V in solid solution after solidification.

Abstract: An exemplary casting assembly for an engine block includes, among other things, an insert and at least one magnet configured to retain the insert in a predefined position within an engine block mold cavity. An exemplary engine block casting method includes, among other things, positioning at least one insert in a mold cavity, retaining the insert in position with at least one magnet, introducing material into the mold cavity to form an engine block, and solidifying the material to secure the insert within the engine block.

Abstract: A high pressure casting die is disclosed. The high pressure casting die may include a die half that defines a recessed area and a build plate that may nest within the recessed area of the die half. The high pressure die casting may further include an additive section that is disposed on the build plate. The additive section may include a plurality of metallic powder layers, the thermal conductivity or the thermal expansion coefficient of the build plate and the additive section may be within 10% of each other.

Abstract: An exemplary casting assembly for an engine block includes, among other things, an insert and at least one magnet configured to retain the insert in a predefined position within an engine block mold cavity. An exemplary engine block casting method includes, among other things, positioning at least one insert in a mold cavity, retaining the insert in position with at least one magnet, introducing material into the mold cavity to form an engine block, and solidifying the material to secure the insert within the engine block.

Abstract: The present invention in one or more embodiments provides a vehicle roof structure which includes a cast node including a pillar portion for receiving a pillar and a roof-rail portion for receiving a roof rail, the roof-rail portion having first and second ends, which may have a closed first cross-section and a closed second cross-section, respectively. The closed first cross-section may be different from the closed second cross-section such that the first and second ends are to receive two individual roof rails of different dimensions. The closed first cross-section may be larger in opening dimension than the closed second cross-section, when the first end is positioned closer to a front of the vehicle than the second end.

Abstract: The present invention in one or more embodiments provides a vehicle roof structure which includes a cast node including a pillar portion for receiving a pillar and a roof-rail portion for receiving a roof rail, the roof-rail portion having first and second ends, which may have a closed first cross-section and a closed second cross-section, respectively. The closed first cross-section may be different from the closed second cross-section such that the first and second ends are to receive two individual roof rails of different dimensions. The closed first cross-section may be larger in opening dimension than the closed second cross-section, when the first end is positioned closer to a front of the vehicle than the second end.

Abstract: A vehicle roof module includes a front extruded cross member, a first pair of nodes each received in an end region of the front cross member, a first and a second extruded side rail with each end region receiving one of the first pair of nodes, a second pair of nodes each received in another end region of the first and second rails, a rear extruded cross member with each end region receiving one of the second pair of nodes, and a panel mounted to the front cross member, rear cross member, and first and second side rail. Each end region of each side rail defines an interior hollow portion and has at least one nodule extending from the side rail into the hollow portion to maintain a bond gap between the side rail and the node received into the side rail end region for receiving adhesive.

Abstract: A vehicle roof module includes a front extruded cross member, a first pair of nodes each received in an end region of the front cross member, a first and a second extruded side rail with each end region receiving one of the first pair of nodes, a second pair of nodes each received in another end region of the first and second rails, a rear extruded cross member with each end region receiving one of the second pair of nodes, and a panel mounted to the front cross member, rear cross member, and first and second side rail. Each end region of each side rail defines an interior hollow portion and has at least one nodule extending from the side rail into the hollow portion to maintain a bond gap between the side rail and the node received into the side rail end region for receiving adhesive.

Abstract: A method for quantitatively predicting and consequently minimizing the amount of critical phases such as eutectic Al2Cu formed during solidification of Al—Si—Cu alloys used in a vehicle engine component comprises developing a micromodel to simulate microstructure evolution in cast Al—Si or Al—Cu alloys. The micromodel is calibrated using experimental thermal analysis cooling curves and an optimization process. Microstructure evolution and cooling curves are simulated for a casting using the calibrated micromodel. Precipitation of critical phases such as Al2Cu in the casting is predicted as a function of solidification conditions. The model allows casting process variables to be varied with predictable results so that the casting process can be controlled via the micromodel.