Abstract: One embodiment includes a method including providing a first portion of a product, the first portion of the product having a body and a flange extending therefrom; and casting a material around at least a portion of the flange to enclose the same and to provide a second portion of the product and wherein the at least the portion of the flange is constructed and arranged to provide frictional damping of the product.

Abstract: The invention provides a method for manufacturing a friction damped disc brake rotor, including the steps of: (A) providing a ceramic coating on an insert, wherein the insert has a body with tabs extending therefrom to hold the insert in a desired position within a mold; (B) washing the ceramic coating off of the tabs; (C) positioning the insert into the mold; and (D) casting a rotor cheek of the disc brake rotor in the mold around the insert such that a portion of each tab is bonded with the rotor cheek, and such that the coating is substantially non-bonded with the rotor cheek so that the coating provides a proper interfacial boundary between the body and the cheek for damping, and the at least partial bonding of each tab with the rotor cheek prevents corrosion-causing exterior elements from reaching the interfacial boundary when the friction damped disc brake rotor is in use.

Abstract: A method for improving corrosion resistance in FNC cast iron substrates without the need for additional coating or painting. The exemplary methods remove a portion of the FNC coating applied to a cast iron substrate, preferably through polishing, to expose the epsilon phase portion of the compound area. The epsilon phase portion is thought to provide improved corrosion protection as compared to non-polished FNC cast iron substrates. One exemplary product that may be provided with improved corrosion protection according to the above method is a brake rotor having a FNC treatment.

Abstract: A component with a first number of natural modes of vibration. An insert may be coupled to the component. The insert may have a second number of natural modes of vibration which is a different number than the first number of natural modes of vibration of the component. The insert helps damp vibrations in the component when the component is vibrated.

Abstract: One exemplary embodiment includes a damped product. The damped product is composed of a sintered powder metallurgy material and has a first portion and a second portion. The first portion has a density that is greater in value that a density of the second portion. The different densities damp vibrations in the product when the product is vibrated.

Abstract: A method including providing a first portion including one of an annular portion or a hub portion; rotating a second portion including the other of the hub portion or the annular portion; and pressing the second portion against the first portion such that friction between the hub portion and the annular portion causes a weld joint to be created; and wherein the annular portion may or may not include a frictional damping means, which may include an insert.

Abstract: One exemplary embodiment of a brake rotor includes a cheek member, an intermediate portion, and a hub member. The intermediate portion may be located between the cheek and hub members, and may extend from either the cheek member or the hub member. The intermediate portion may have an exposed section with multiple openings located in the exposed section. The intermediate portion may also have multiple blades extending from inner surfaces of all or some of the openings. The blades cause airflow to pass through the openings to cool the intermediate portion.

Abstract: The invention provides a method for manufacturing a friction damped disc brake rotor, including the steps of: (A) positioning at least one insert into a mold, wherein the insert has a body with tabs extending therefrom to hold the insert in a desired position within the mold; and (B) casting a rotor cheek of the disc brake rotor in the mold around the insert such that a portion of each tab is bonded with the rotor cheek and the body is substantially non-bonded with the rotor cheek so that the body provides a proper interfacial boundary with the cheek for damping while the bonding of the tabs with the rotor cheek prevents corrosion-causing exterior elements from reaching the interfacial boundary.

Abstract: One embodiment of a product includes an insert for disposition in or on a component. The insert may have at least one contact surface that can experience relative frictional movement against an adjacent interior surface of the component. The at least one contact surface of the insert may comprise a nominal plane and surface features arranged in a nonstochastic pattern. The insert may also be constructed and arranged for disposition in or on the component to dampen sound when the component is vibrated.

Abstract: The invention provides a method for manufacturing a powertrain component enclosure member, including the steps of: (A) positioning at least one insert into a mold, wherein the insert is provided with a coating to prevent bonding between the insert and the casting material; and (B) casting a wall of the powertrain component enclosure member in the mold around the insert such that a major portion of the insert is substantially non-bonded with the casting material to provide a proper interfacial boundary with the casting material for damping.

Abstract: A ferrous metal tool is provided for the forming of light metal sheet workpieces at elevated temperatures, with the forming surface of the tool prepared to minimize friction and adhesion when engaged in deformation of the hot sheet metal. The forming surface of a steel tool is nitrocarburized to form a compound layer and diffusion layer on the surface. The compound layer initially comprises an outer gamma-phase material and an underlying epsilon phase material. Gamma-phase material is removed to expose underlying epsilon phase material, and low friction particles are embedded in the modified nitrocarburized compound layer of the forming tool.

Abstract: A product including a damping substrate and a layer over a portion thereof, the layer including graphite, and a body portion positioned so that the layer is interposed between the body portion and the damping substrate.

Abstract: A component that carries a filler material. The filler material can convert from a solid state and into a molten state when the filler material is heated. Relative movement between the component and the filler material helps dampen vibrations and other oscillations in the component if and when the component is vibrated or otherwise oscillated.

Abstract: An insert has a body which defines a cavity with a filler held in the cavity. Relative movement between the body and the filler helps dampen vibrations in a component when the insert is carried in the component and when the component is vibrated.

Abstract: A component defines at least one chamber that is confined by the component. The chamber has an inner surface. A filler material is disposed inside the chamber. Relative movement between the inner surface and the filler material helps dampen vibrations and other oscillations if and when the component is vibrated.

Abstract: The apparatus of the present invention provides a brake rotor assembly. The brake rotor assembly includes a generally annular rotor having a frictional surface and a radially inner rotor flange defining a plurality of rotor teeth. The brake rotor assembly also includes a hub section integrally formed onto the rotor. The hub section has a peripheral hub flange configured to engage the plurality of rotor teeth and thereby prevent rotation of the hub section relative to the rotor. The rotor is preferably composed of a first material such as steel or cast iron, and the hub section is preferably composed of a second material such as aluminum or magnesium that is lighter by volume than the first material. Accordingly, the overall weight of the rotor assembly is less than that of a comparable rotor assembly composed entirely of steel or cast iron.

Abstract: A ferrous metal tool is provided for the forming of light metal sheet workpieces at elevated temperatures, with the forming surface of the tool prepared to minimize friction and adhesion when engaged in deformation of the hot sheet metal. The forming surface of a steel tool is nitrocarburized to form a compound layer and diffusion layer on the surface. The compound layer initially comprises an outer gamma-phase material and an underlying epsilon phase material. Gamma-phase material is removed to expose underlying epsilon phase material, and low friction particles are embedded in the modified nitrocarburized compound layer of the forming tool.

Abstract: One embodiment of the invention includes a frictional damping insert including a body constructed and arranged to be incorporated into a product and to form at least a portion of a frictional damping means, the body including lines of weakness constructed and arranged to segment the body into separate sections upon exposure to a molten material.

Abstract: One embodiment of the invention includes a product including an annular portion including a frictional surface and a first flange portion extending from the frictional surface, wherein the first flange portion comprises a first face, a second face, and a third face; and a hub portion and a second flange portion extending from the hub portion, wherein the second flange portion engages the first face, the second face, and the third face of the first flange portion.

Abstract: A method of joining or repairing metal surface structures. Joinder and/or repair of metal or metal-polymer laminate panels may be carried out using so-called “cold metal transfer” gas metal arc welding techniques. Moreover, suitable zinc-copper-aluminum alloys may improve weldability, durability and strength. The reduced thermal input permits effective weld formation at the metal sheet layers without giving rise to temperature gradient sufficient to significantly damage the interior elements.