Abstract: A parking pawl assembly having a housing, a parking pawl having a pin bore, a support sleeve fitted in the pin bore, and a pivot pin inserted through the support sleeve. The pivot pin is attached to the housing, thus pivotally attaching the parking pawl to the housing. The parking pawl includes a first end and a second end spaced from the first end. The first end defines the pin bore having an interior bore surface. The support sleeve includes an exterior surface fitted to the interior bore surface of the parking pawl. The exterior surface of the support sleeve may include outer diameter rolled threads or other locking features. The interior bore surface of the parking pawl may include inner diameter rolled threads operable to receive the outer diameter rolled threads of the support sleeve.

Abstract: A hybrid chill with enhanced heat transfer for casting of a sand cast aluminum engine block of a vehicle is provided. The hybrid chill comprises a base comprising an outer wall having a first side and a second side. Each of the first and second sides extends from a first longitudinal end to an opposite second longitudinal end. The outer wall is closed to define a hollow portion. The base further comprises a heat transfer fluid in a liquid phase disposed in the hollow portion. The heat transfer fluid has a boiling point of between 320° C. and 400° C. at 1 bar for enhanced heat transfer during casting. The chill further comprises a plurality of crankcase members. Each member is disposed on the first side. Each member is spaced apart from a respective adjacent member defining an open recess.

Abstract: An engine for a vehicle. The engine includes a cast engine block having a hybrid insert disposed in a fastener bore having rolled internal threads. The hybrid insert includes an internal surface having cut inner diameter (ID) threads and an external surface having rolled outer diameter (OD) threads. The rolled OD threads of the hybrid insert are received in the rolled internal threads of the fastener bore. The hybrid threaded insert may include a bi-metal in which the ID threads are formed of one metal alloy and the OD threads are formed of another metal alloy. Alternatively, the external surface of the hybrid insert may define locking features and the engine block is cast onto these locking features, thereby locking the hybrid insert to the engine block.

Abstract: A magnesium (Mg) alloy housing for a drive unit of an electric vehicle (EV) having a drive shaft connected to an electric motor is provided. The Mg alloy housing comprises a body comprising Mg alloy. The body is arranged to house the drive unit of the EV. The housing further comprises a cylindrical hub disposed on the body. The hub has a bore formed therethrough and arranged to couple the drive shaft of the electric motor to the drive unit. The hub comprises a Mg portion having an inner surface. The hub further comprises an aluminum (Al) insert having an outerface. The Al insert is arranged to be disposed on the Mg portion such that the inner surface is aligned with the outerface defining a weld interface. The Al insert comprises iron (Fe) and Manganese (Mn) and having a Fe/Mn weight ratio of between 1:20 and 1:30.

Abstract: A hybrid core for manufacturing a cast component, the hybrid core including a sand core portion having an exterior shape configured to define an interior feature of the cast component. The hybrid core also includes a metal chill element embedded within the sand core portion. The metal chill element is configured to locally absorb heat energy from the cast component during cooling of the cast component and solidification thereof. The metal chill element is constructed and arranged within the sand core portion to be removed during shake out from the cast component subsequent to the solidification thereof. A system and a method for manufacturing a cast component using such a hybrid core are also envisioned.

Abstract: A hybrid threading tap includes a reamer portion and a thread cutting portion having a plurality of cutting teeth. The thread cutting portion is arranged with the reamer portion along the longitudinal axis. The reamer portion is configured to be advanced within a hole of a workpiece to plastically deform and expand the hole to an expanded hole and provide the expanded hole with a zone of residual compressive stress. The plurality of cutting teeth is configured to cut a threading into the expanded hole within the zone.

Abstract: A method of manufacturing a threaded hole in a workpiece includes providing the workpiece having a region with a hole. The method also includes cutting a threading for the hole. Furthermore, the method includes, independent of cutting the threading, densifying the region proximate the hole to reduce material porosity in the region.

Abstract: A hybrid threading tool defines a longitudinal axis and includes a cutting portion with a plurality of cutting teeth. The plurality of cutting teeth are configured to cut a first threading into a workpiece. The hybrid threading tool also defines a forming portion that is attached to the cutting portion and that is arranged therewith along the longitudinal axis. The forming portion includes a plurality of forming teeth configured to plastically deform the first threading into a second threading for the workpiece.

Abstract: A hybrid threading tap includes a reamer portion and a thread cutting portion having a plurality of cutting teeth. The thread cutting portion is arranged with the reamer portion along the longitudinal axis. The reamer portion is configured to be advanced within a hole of a workpiece to plastically deform and expand the hole to an expanded hole and provide the expanded hole with a zone of residual compressive stress. The plurality of cutting teeth is configured to cut a threading into the expanded hole within the zone.

Abstract: A mold package for forming a cast device such as an engine block is described. The mold package includes a profiled chill and a mold core assembly that is disposed on the profiled chill. The mold core assembly defines a plurality of bulkheads of the engine block. The profiled chill includes a first chill portion having a second chill portion and a plurality of third chill portions arranged thereon, wherein the second chill portion is a semicylindrical element. The third chill portions are arranged to be adjacent to the plurality of bulkheads of the engine block.

Abstract: A method of manufacturing a threaded hole in a workpiece includes providing the workpiece having a region with a hole. The method also includes cutting a threading for the hole. Furthermore, the method includes, independent of cutting the threading, densifying the region proximate the hole to reduce material porosity in the region.

Abstract: A hybrid threading tool defines a longitudinal axis and includes a cutting portion with a plurality of cutting teeth. The plurality of cutting teeth are configured to cut a first threading into a workpiece. The hybrid threading tool also defines a forming portion that is attached to the cutting portion and that is arranged therewith along the longitudinal axis. The forming portion includes a plurality of forming teeth configured to plastically deform the first threading into a second threading for the workpiece.

Abstract: A hybrid core for manufacturing a cast component, the hybrid core including a sand core portion having an exterior shape configured to define an interior feature of the cast component. The hybrid core also includes a metal chill element embedded within the sand core portion. The metal chill element is configured to locally absorb heat energy from the cast component during cooling of the cast component and solidification thereof. The metal chill element is constructed and arranged within the sand core portion to be removed during shake out from the cast component subsequent to the solidification thereof. A system and a method for manufacturing a cast component using such a hybrid core are also envisioned.

Abstract: An apparatus for a motor vehicle engine block made of aluminum includes an insert having a first surface and a second surface spaced apart from the first surface, the first surface being substantially flat, and a plurality of projections extending from the second surface, the plurality of projections being inserted into a portion of the engine block to secure the insert to the portion of the engine block. The first surface of the insert is configured to mate with another component, other than the engine block, made of steel or cast iron to avoid fatigue fretting of the aluminum engine block.

Abstract: An apparatus for a motor vehicle engine block made of aluminum includes an insert having a first surface and a second surface spaced apart from the first surface, the first surface being substantially flat, and a plurality of projections extending from the second surface, the plurality of projections being inserted into a portion of the engine block to secure the insert to the portion of the engine block. The first surface of the insert is configured to mate with another component, other than the engine block, made of steel or cast iron to avoid fatigue fretting of the aluminum engine block.

Abstract: A cylinder block for use in an internal combustion engine includes a first and second cylinder bores, a first and second cylinder bore liners, and a Siamese insert. The first and second cylinder bores are disposed adjacent to each other. The first and second cylinder bores each comprise a first cylinder bore wall and a second cylinder bore wall, respectively, and a shared cylinder bore wall. The first cylinder bore liner is disposed on a first inner surface of the first cylinder bore wall and the second cylinder bore liner is disposed on a second inner surface of the second cylinder bore wall. The Siamese insert is disposed in a top portion of the shared cylinder bore wall.

Abstract: A cylinder block for use in an internal combustion engine includes a first and second cylinder bores, a first and second cylinder bore liners, and a Siamese insert. The first and second cylinder bores are disposed adjacent to each other. The first and second cylinder bores each comprise a first cylinder bore wall and a second cylinder bore wall, respectively, and a shared cylinder bore wall. The first cylinder bore liner is disposed on a first inner surface of the first cylinder bore wall and the second cylinder bore liner is disposed on a second inner surface of the second cylinder bore wall. The Siamese insert is disposed in a top portion of the shared cylinder bore wall.