Abstract: A structural assembly includes a fastener and an additively manufactured component. The additively manufactured component includes a base, a void defined in the base, and a support disposed across the void. The fastener is secured to the base within the void, and the support is captured within a distal end portion of the fastener.

Abstract: Gear devices and methods for operating gear devices are provided. In one example, a gear device is provided that comprises structures designed to attenuate targeted vibrations occurring during rotation of the gear device. The structures includes radially aligned struts extending between an inner carrier and an outer carrier, a plurality of openings arranged between the struts, and/or resonators extending between sequential struts.

Abstract: A system is provided for attaching a layer of a metal to other layers in a material stack-up using a metal mechanical fastener that does not allow for direct contact between the fastener and the metal layer, thereby neutralizing any galvanic reaction between the metal sheet and the fastener and avoiding corrosion. The metal layer may be any of several metals, including magnesium. The fastener is a rivet, a screw or a bolt. The disclosed inventive concept uses an insulating layer to insulate the magnesium layer. In one embodiment, a layer of a thin metal is formed over the insulating layer. Where the fastener is a rivet and the metal is magnesium, the insulating layer and thin metal provide a barrier between the magnesium layer and the rivet prongs following rivet insertion, thus isolating the rivet. The system enables a greater application of fastener joining, particularly with magnesium and mixed material joining.

Abstract: A system for attaching material stack-up layers of at least two layers together using mechanical fasteners is disclosed. The material stack-up comprises at least an upper layer and a lower layer. The lower layer has a relatively constant thickness equal to or greater than 4.0 mm or may have alternating thick and thin areas in which the thickness of the thick area is equal to or greater than 4.0 mm. A mechanical fastener attaches the upper layer and the lower layer and is inserted at least partially into the lower layer. The fastener is inserted into the thick area of the embodiment having alternating thick and thin areas. The lower layer may be any of a variety of materials, including magnesium or any other brittle material. The lower layer may also be a casting, such as a magnesium casting. The mechanical fastener may be any of fasteners, screws or bolts.

Abstract: Gear devices and methods for operating gear devices are provided. In one example, a gear device is provided that comprises structures designed to attenuate targeted vibrations occurring during rotation of the gear device. The structures includes radially aligned struts extending between an inner carrier and an outer carrier, a plurality of openings arranged between the struts, and/or resonators extending between sequential struts.

Abstract: An engine component includes stratified metal layers. The stratified metal layers form walls of a cylinder head having internal cavities defining a cooling jacket configured to direct coolant within and through the walls. The stratified metal layers also form a lattice disposed within and spanning between opposing surfaces of the cooling jacket configured to promote heat transfer between the stratified metal layers and coolant.

Abstract: An engine component includes stratified layers that form an integral cylinder head and an internally cooled valve guide located in a cylinder head guide boss. The integral cylinder head further includes a coolant passage within a body of the valve guide that is in fluid communication with a cylinder head cooling jacket.

Abstract: An engine component includes stratified metal layers. The stratified metal layers form walls of a cylinder head having internal cavities defining a cooling jacket configured to direct coolant within and through the walls. The stratified metal layers also form a lattice disposed within and spanning between opposing surfaces of the cooling jacket configured to promote heat transfer between the stratified metal layers and coolant.

Abstract: An assembly and a method of joining a first part with a second part at an attachment area that includes a localized area on the first part. The localized area is cleaned and activated by a plasma jet. An organosilicon composition is applied by plasma-enhanced chemical vapor deposition to the localized area. An adhesive is applied to the localized area and the second part is mechanically fastened to the first part in the localized area.

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 assembly and a method of joining a first part with a second part at an attachment area that includes a localized area on the first part. The localized area is cleaned and activated by a plasma jet. An organosilicon composition is applied by plasma-enhanced chemical vapor deposition to the localized area. An adhesive is applied to the localized area and the second part is mechanically fastened to the first part in the localized area.

Abstract: An assembly and a method of joining a first part with a second part at an attachment area that includes a localized area on the first part. The localized area is cleaned and activated by a plasma jet. An organosilicon composition is applied by plasma-enhanced chemical vapor deposition to the localized area. An adhesive is applied to the localized area and the second part is mechanically fastened to the first part in the localized area.

Abstract: A system for attaching material stack-up layers of at least two layers together using mechanical fasteners is disclosed. The material stack-up comprises at least an upper layer and a lower layer. The lower layer has a relatively constant thickness equal to or greater than 4.0 mm or may have alternating thick and thin areas in which the thickness of the thick area is equal to or greater than 4.0 mm. A mechanical fastener attaches the upper layer and the lower layer and is inserted at least partially into the lower layer. The fastener is inserted into the thick area of the embodiment having alternating thick and thin areas. The lower layer may be any of a variety of materials, including magnesium or any other brittle material. The lower layer may also be a casting, such as a magnesium casting. The mechanical fastener may be any of fasteners, screws or bolts.

Abstract: A system is provided for attaching a layer of a metal to other layers in a material stack-up using a metal mechanical fastener that does not allow for direct contact between the fastener and the metal layer, thereby neutralizing any galvanic reaction between the metal sheet and the fastener and avoiding corrosion. The metal layer may be any of several metals, including magnesium. The fastener is a rivet, a screw or a bolt. The disclosed inventive concept uses an insulating layer to insulate the magnesium layer. In one embodiment, a layer of a thin metal is formed over the insulating layer. Where the fastener is a rivet and the metal is magnesium, the insulating layer and thin metal provide a barrier between the magnesium layer and the rivet prongs following rivet insertion, thus isolating the rivet. The system enables a greater application of fastener joining, particularly with magnesium and mixed material joining.

Abstract: A friction stir spot welding tool and a self-piercing riveting tool are disclosed for joining parts. The parts are clamped between a head and anvil support of the friction stir spot welding tool or the self-piercing riveting tool. A plurality of clamping and heating modules are attached to an attachment fixture on the head and the anvil support that heats the area around the pin of the friction stir spot welding tool or self-piercing riveting tool prior to and during the joining operation.

Abstract: An assembly and a method of joining a first part with a second part at an attachment area that includes a localized area on the first part. The localized area is cleaned and activated by a plasma jet. An organosilicon composition is applied by plasma-enhanced chemical vapor deposition to the localized area. An adhesive is applied to the localized area and the second part is mechanically fastened to the first part in the localized area.

Abstract: A friction stir spot welding tool and a self-piercing riveting tool are disclosed for joining parts. The parts are clamped between a head and anvil support of the friction stir spot welding tool or the self-piercing riveting tool. A plurality of clamping and heating modules are attached to an attachment fixture on the head and the anvil support that heats the area around the pin of the friction stir spot welding tool or self-piercing riveting tool prior to and during the joining operation.

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.