Abstract: A process for the manufacture of metal products includes the steps of providing a mold including a first portion made of an aggregate and a binder, delivering a molten metal into the mold, removing a first portion of the mold with a fluid and solidifying at least one targeted portion of the molten metal which will form the metal product with the fluid. A flow of fluid to the mold is stopped for a period of time. Subsequently, a remaining portion of the molten metal is solidified to form the metal product. The at least one targeted portion of the metal product has better mechanical properties than does a remaining portion of the metal product. A unitary, one-piece aluminum alloy component with differing mechanical properties is also disclosed.

Abstract: A process for the manufacture of metal products includes the steps of providing a mold including a first portion made of an aggregate and a binder, delivering a molten metal into the mold, removing a first portion of the mold with a fluid and solidifying at least one targeted portion of the molten metal which will form the metal product with the fluid. A flow of fluid to the mold is stopped for a period of time. Subsequently, a remaining portion of the molten metal is solidified to form the metal product. The at least one targeted portion of the metal product has better mechanical properties than does a remaining portion of the metal product. A unitary, one-piece aluminum alloy component with differing mechanical properties is also disclosed.

Abstract: A process for the manufacture of metal products includes the steps of providing a mold including a first portion made of an aggregate and a binder, delivering a molten metal into the mold, removing a first portion of the mold with a fluid and solidifying at least one targeted portion of the molten metal which will form the metal product with the fluid. A flow of fluid to the mold is stopped for a period of time. Subsequently, a remaining portion of the molten metal is solidified to form the metal product. The at least one targeted portion of the metal product has better mechanical properties than does a remaining portion of the metal product. A unitary, one-piece aluminum alloy component with differing mechanical properties is also disclosed.

Abstract: A process for the manufacture of metal products includes the steps of providing a mold including a first portion made of an aggregate and a binder, delivering a molten metal into the mold, removing a first portion of the mold with a fluid and solidifying at least one targeted portion of the molten metal which will form the metal product with the fluid. A flow of fluid to the mold is stopped for a period of time. Subsequently, a remaining portion of the molten metal is solidified to form the metal product. The at least one targeted portion of the metal product has better mechanical properties than does a remaining portion of the metal product. A unitary, one-piece aluminum alloy component with differing mechanical properties is also disclosed.

Abstract: An exhaust system for use with an engine is disclosed. The exhaust system may have a passageway, a flow control device situated to feed reductant into the passageway, and a particulate collection device located in fluid communication with the passageway downstream of the flow control device. The particulate collection device may be catalyzed to promote NOX reduction in a presence of the reductant. The exhaust system may also have a reduction device located in fluid communication with the passageway downstream of the flow control device. The reduction device may be catalyzed to promote NOX reduction in a presence of the reductant, and the particulate collection device and the reduction device may receive reductant from only the flow control device.

Abstract: A method forms a die-cast metal part having a globular microstructure. The method includes the steps of introducing a metal charge into a chamber in a molten state above the liquidus temperature, and holding the metal charge in the chamber without stirring or agitation until it attains a solid fraction state with a non-homogenous, substantially dendritic microstructure. The metal charge is forced from the chamber through an orifice such that passage through the orifice imparts sheer that breaks the substantially dendritic microstructure to a substantially globular non-dendritic microstructure. The metal charge with the substantially globular non-dendritic microstructure is forced into a cavity having the shape of the die-cast part.

Abstract: A method and apparatus for the lost pattern casting of metals is disclosed. In the method, a pattern is formed from a material and a mold is formed around at least a portion of the pattern. The mold includes a particulate material and a binder. The pattern is removed from the mold and molten metal is delivered into the mold. The mold is contacted with the solvent and the molten metal is cooled such that it at least partially solidifies to form a casting. The step of cooling includes contacting a shell of solidifying metal around the molten metal with the solvent. An apparatus is also disclosed.

Abstract: A piston includes a ring groove. The ring groove has a top face and a bottom face, and one of the top face and the bottom face is composed of a first material having a preestablished rate of thermal conductivity, the other of the top face and bottom face is composed of a second material having a preestablished rate of thermal conductivity being less than the rate of thermal conductivity of the first material.

Abstract: A piston includes a ring groove. The ring groove has a top face and a bottom face, and one of the top face and the bottom face is composed of a first material having a preestablished rate of thermal conductivity, the other of the top face and bottom face is composed of a second material having a preestablished rate of thermal conductivity being less than the rate of thermal conductivity of the first material.

Abstract: A screed assembly has a screed plate that is formed of a material having a thermal conductivity of less than about 25 W/mK, and a thermal barrier material having a thermal conductivity of less than about 0.5 W/mK that substantially covers an upper surface of the screed plate. The low thermal conductance properties of the screed plate obviate the need for auxiliary heating systems to preheat or maintain the screed plate in thermal equilibrium with a paving material.

Abstract: A flowable slurry comprising powder matrix particles and reinforcing particles is pumped, under pressure, through an atomizing nozzle to form discrete droplets containing reinforcing particles coated with the powder matrix particles The discrete droplets are suspended in an elevated temperature environment for a sufficient time to evaporate the water from the droplets and form nonreacted reinforced powder particles. The reinforced powder particles are nonagglomerated and are suitable for immediate use as powder for thermal spray coatings or for dry processed compacted structural components.

Abstract: A coating for a metallic substrate has a metallic bond coat, a metallic seal coat and a centrally disposed layer of ceramic material. Transition layers comprising a controllably positioned mixture of metallic and ceramic materials are interposed, respectively, between the bond coat and the central layer of ceramic material, and between the seal coat and the central layer of ceramic material. The coating provides a desirable thermal barrier for internal engine components. Further, the coating is graded to avoid harmful internal thermal stress between dissimilar materials in the coating, and has a sealed external surface that is resistant to corrosion, erosion, hot gas infiltration, and wear during operation in an internal combustion engine.

Abstract: A method for painting an engine by the electrocoating process includes coating preselected components of the engine with an electrically nonconductive ceramic material prior to assembly, and pressurizing the engine prior to immersion in an electrically charged paint bath.The method is particularly useful for avoiding paint deposition on preselected components, such as the hot exhaust elements, of an engine. A thermal insulating and corrosion resistant coating for the preselected components is thus provided, and undesirable paint burnoff during subsequent engine operation is avoided.

Abstract: A paint fixture, for supporting a workpiece during the electrostatic application of a spray paint, has an electrically conductive metallic body. The body has a first surface portion that is covered by the workpiece during the electrostatic paint spray application process, and a second surface portion that is covered by a heat resitant, electrically nonconductive material.