Abstract: A method of manufacturing a highly insulating three-dimensional (3D) structure is provided. The method includes depositing a first layer of hollow microspheres onto a base. The hollow microspheres have a metallic coating formed thereon. A laser beam is scanned over the hollow microspheres so as to sinter the metallic coating of the hollow microspheres at predetermined locations. At least one layer of the hollow microspheres is deposited onto the first layer. Scanning by the laser beam is repeated for each successive layer until a predetermined 3D structure is constructed. The 3D structure includes a composite thermal barrier coating (TBC), which may be applied to a surface of components within an internal combustion engine, and the like. The composite TBC is bonded to the components of the engine to provide low thermal conductivity and low heat capacity insulation that is sealed against combustion gasses.

Abstract: A composite thermal barrier coating (TBC) may be applied to a surface of components within an internal combustion engine. The composite TBC provides low thermal conductivity and low heat capacity insulation that is sealed against combustion gasses. The composite TBC includes three layers, bonded to one another, i.e., a first (bonding) layer, a second (insulating) layer, and a third (sealing) layer. The insulating layer is disposed between the bonding layer and the sealing layer. The bonding layer is bonded to the component and to the insulating layer. The insulating layer includes hollow microspheres that are sintered together to form insulation that provides a low effective thermal conductivity and low effective heat capacity. The sealing layer is a thin film that is configured to resist the high temperatures, present within the engine. The sealing layer is impermeable to gasses and presents a smooth surface.

Abstract: An aluminum alloy that can be cast into structural components wherein at least some of the raw materials used to produce the alloy are sourced from secondary production sources. In addition to aluminum as the primary constituent, such an alloy includes 5 to 14% silicon, 0 to 1.5% copper, 0.2 to 0.55% magnesium, 0.2 to 1.2% iron, 0.1 to 0.6% manganese, 0 to 0.5% nickel, 0 to 0.8% zinc, 0 to 0.2% of other trace elements selected from the group consisting essentially of titanium, zirconium, vanadium, molybdenum and cobalt. In a preferred form, most of the aluminum is from a secondary production source. Methods of analyzing a secondary production aluminum alloy to determine its constituent makeup is also disclosed, as is a method of adjusting the constituent makeup of such an alloy in situations where the alloy is out of tolerance when measured against its primary source counterpart.

Abstract: A degassing and grain refinement system for a cast aluminum-based component and a method of achieving both hydrogen gas presence reduction and grain size reduction in a cast aluminum-based component. Ultrasonic vibrations are imparted to both the liquid metal travel path from its source to the mold to achieve the reduction in hydrogen gas in the molten metal, as well as to one or more locations within the mold to achieve relatively small and equiaxed grains in the component upon solidification.

Abstract: A method of manufacturing a highly insulating three-dimensional (3D) structure is provided. The method includes depositing a first layer of hollow microspheres onto a base. The hollow microspheres have a metallic coating formed thereon. A laser beam is scanned over the hollow microspheres so as to sinter the metallic coating of the hollow microspheres at predetermined locations. At least one layer of the hollow microspheres is deposited onto the first layer. Scanning by the laser beam is repeated for each successive layer until a predetermined 3D structure is constructed. The 3D structure includes a composite thermal barrier coating (TBC), which may be applied to a surface of components within an internal combustion engine, and the like. The composite TBC is bonded to the components of the engine to provide low thermal conductivity and low heat capacity insulation that is sealed against combustion gasses.

Abstract: A device and method for transferring filtered molten metal to a die casting mold. The device and method include a casting filtration system that includes a funnel and a continuously replaceable filter placed fluidly between a molten metal source and a casting mold. Both the funnel and filter are automatically moved into cooperation with a molten metal receptacle such as a shot sleeve prior to each casting operation, and then automatically moved out of the way so that pressurization of the filtered molten metal may take place in the receptacle. In addition, the filter may be formed on a continuous strand such that indexed movement of the strand will advance the used portion of the filter out of the way to make room for a new unused filter portion that will be ready for a subsequent repeated casting operation.

Abstract: A composite thermal barrier coating (TBC) may be applied to a surface of components within an internal combustion engine. The composite TBC provides low thermal conductivity and low heat capacity insulation that is sealed against combustion gasses. The composite TBC includes three layers, bonded to one another, i.e., a first (bonding) layer, a second (insulating) layer, and a third (sealing) layer. The insulating layer is disposed between the bonding layer and the sealing layer. The bonding layer is bonded to the component and to the insulating layer. The insulating layer includes hollow microspheres that are sintered together to form insulation that provides a low effective thermal conductivity and low effective heat capacity. The sealing layer is a thin film that is configured to resist the high temperatures, present within the engine. The sealing layer is impermeable to gasses and presents a smooth surface.

Abstract: Copper-free aluminum alloys suitable for high pressure die casting and capable of age-hardening under elevated temperatures are provided. The allow includes about 9.5-13 wt % silicon, about 0.2 to 0.6 wt % Magnesium, about 0.1 to 2 wt % iron, about 0.1 to 2 wt % manganese, about 0.1 to 1 wt % nickel, about 0.5 to 3 wt % zinc, and 0 to 0.1 wt % strontium, with a balance of aluminum. Methods for making high pressure die castings and castings manufactured from the alloy are also provided.

Abstract: A method of transferring molten metal to a die casting mold is disclosed. The method includes providing a ladle with a dip well and a dispensing nozzle having a fluid metal filter formed therein as well as providing a receptacle fluidly between the ladle and the mold. Further the method includes delivering the molten metal from the ladle to the receptacle by positioning an exit face of the dispensing nozzle over the receptacle and rotating the ladle such that the exit face of the dispensing nozzle is repositioned proximal the bottom of the receptacle and conveying the molten metal that has been delivered to the receptacle into a mold cavity that is placed in fluid communication therewith.

Abstract: A degassing and grain refinement system for a cast aluminum-based component and a method of achieving both hydrogen gas presence reduction and grain size reduction in a cast aluminum-based component. Ultrasonic vibrations are imparted to both the liquid metal travel path from its source to the mold to achieve the reduction in hydrogen gas in the molten metal, as well as to one or more locations within the mold to achieve relatively small and equiaxed grains in the component upon solidification.

Abstract: A device and method for transferring filtered molten metal to a die casting mold. The device and method include a casting filtration system that includes a funnel and a continuously replaceable filter placed fluidly between a molten metal source and a casting mold. Both the funnel and filter are automatically moved into cooperation with a molten metal receptacle such as a shot sleeve prior to each casting operation, and then automatically moved out of the way so that pressurization of the filtered molten metal may take place in the receptacle. In addition, the filter may be formed on a continuous strand such that indexed movement of the strand will advance the used portion of the filter out of the way to make room for a new unused filter portion that will be ready for a subsequent repeated casting operation.

Abstract: An aluminum alloy that can be cast into structural components wherein at least some of the raw materials used to produce the alloy are sourced from secondary production sources. In addition to aluminum as the primary constituent, such an alloy includes 5 to 14% silicon, 0 to 1.5% copper, 0.2 to 0.55% magnesium, 0.2 to 1.2% iron, 0.1 to 0.6% manganese, 0 to 0.5% nickel, 0 to 0.8% zinc, 0 to 0.2% of other trace elements selected from the group consisting essentially of titanium, zirconium, vanadium, molybdenum and cobalt. In a preferred form, most of the aluminum is from a secondary production source. Methods of analyzing a secondary production aluminum alloy to determine its constituent makeup is also disclosed, as is a method of adjusting the constituent makeup of such an alloy in situations where the alloy is out of tolerance when measured against its primary source counterpart.

Abstract: A method of transferring molten metal to a die casting mold is disclosed. The method includes providing a ladle with a dip well and a dispensing nozzle having a fluid metal filter formed therein as well as providing a receptacle fluidly between the ladle and the mold. Further the method includes delivering the molten metal from the ladle to the receptacle by positioning an exit face of the dispensing nozzle over the receptacle and rotating the ladle such that the exit face of the dispensing nozzle is repositioned proximal the bottom of the receptacle and conveying the molten metal that has been delivered to the receptacle into a mold cavity that is placed in fluid communication therewith.

Abstract: Copper-free aluminum alloys suitable for high pressure die casting and capable of age-hardening under elevated temperatures are provided. The allow includes about 9.5-13 wt % silicon, about 0.2 to 0.6 wt % Magnesium, about 0.1 to 2 wt % iron, about 0.1 to 2 wt % manganese, about 0.1 to 1 wt % nickel, about 0.5 to 3 wt % zinc, and 0 to 0.1 wt % strontium, with a balance of aluminum. Methods for making high pressure die castings and castings manufactured from the alloy are also provided.

Abstract: A ladle for a molten metal includes a main body having a hollow interior and an opening for receiving the molten metal. The main body has a sidewall with a nozzle formed therein. The nozzle defines an axis of rotation for the main body. The nozzle contacts, seals and is in fluid communication with the mold. The nozzle is configured to deliver the molten metal to a mold when the main body is rotated from a first position to a second position.

Abstract: An exemplary method for forming a sand core includes forming a core insert; forming a sand core precursor around the core insert; and creating at least one passage within the sand core precursor by removing or otherwise transforming a portion of the core insert, wherein the at least one passage includes at least one exit point. The sand core may then be utilized in a casting mold assembly to form a cast part.

Abstract: A ladle for a molten metal includes a main body having a hollow interior and an opening for receiving the molten metal. The main body has a sidewall with a nozzle formed therein. The nozzle defines an axis of rotation for the main body. The nozzle contacts, seals and is in fluid communication with the mold. The nozzle is configured to deliver the molten metal to a mold when the main body is rotated from a first position to a second position.

Abstract: A ladle for a molten metal includes a main body having a hollow interior and an opening for receiving the molten metal. The main body has a sidewall with a nozzle formed therein. The nozzle defines an axis of rotation for the main body. The nozzle contacts, seals and is in fluid communication with the mold. The nozzle is configured to deliver the molten metal to a mold when the main body is rotated from a first position to a second position.

Abstract: An exemplary method for forming a sand core includes forming a core insert; forming a sand core precursor around the core insert; and creating at least one passage within the sand core precursor by removing or otherwise transforming a portion of the core insert, wherein the at least one passage includes at least one exit point. The sand core may then be utilized in a casting mold assembly to form a cast part.