Abstract: An assembly of like two rib cores enclosing a splitter core are used to carry two or four sound damping inserts for sand mold casting of a pair of vented and damped brake rotors. Sand mold bodies are configured to define outboard surfaces of hub and rotor surfaces of the cast brake rotors. The three-piece core assembly is shaped to define the complex inner surfaces in casting of vented rotor bodies carrying one or two annular sound damping inserts.

Abstract: One embodiment includes a product including a metallic foam portion which may serve to reduce the weight of the product and/or vent the product and/or provide damping.

Abstract: One embodiment of the invention includes a method including providing an insert, wherein at least a portion of the insert is attracted to a magnet; providing a mold including a first mold portion, a second mold portion, and a magnet having at least a portion thereof in or adjacent to at least one of the first mold portion or the second mold portion; positioning the insert in one of the mold portions such that the at least one magnet at least assists in holding the insert in place; and closing the mold and casting a molten material into the mold and around or adjacent to at least a portion of the insert and solidifying the material.

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: 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: A part including a body including a metal, and a frictional damping means, the frictional damping means comprising frictional surfaces in local contact but not bonded together, or the frictional damping means including a layer including at least one of particles, flakes, or fibers, the layer having a thickness ranging from about 1 ?m to about 500 ?m.

Abstract: A method including positioning an insert in a vertical mold including a first mold portion and a second mold portion; and casting a material including a metal around at least a portion of the insert.

Abstract: One embodiment includes a damped product including a first portion, a second portion, a first cavity formed in one of the first portion or the second portion, and a frictional damping insert at least partially received in the first cavity so that the first portion and the second portion completely enclose the frictional damping insert and so that vibration of the product is damped by the insert.

Abstract: A multi-piece sound dampened brake rotor comprises a relatively light weight hub with a hub flange and a heavier rotor body with a sound damping insert and a rotor body flange. The hub and rotor body are attached at their flanges. The flanges may be mechanically attached such as with bolts. Or the hub and rotor may be attached by casting the hub of a lower melting metal alloy against the rotor body and rotor body flange. The rotor body may have vanes for air cooling and a sound damping insert may be incased in either or both body portions sandwiching the vanes.

Abstract: Various embodiments of the invention include products and parts including a frictional damping means and methods of making and using the same.

Abstract: The invention provides a method for manufacturing a coulomb damped disc brake rotor, including the steps of: (A) providing a mold having the general shape of the coulomb damped disc brake rotor; (B) placing a coulomb damper insert having a generally annular body and at least one tab extending generally radially from the generally annular body, wherein the at least one tab operates to locate the coulomb damper insert within the mold, and wherein the at least one tab at least partially defines an orifice with its major axis generally coincident with the periphery of the coulomb damped disc brake rotor; and (C) causing casting material to enter the mold to substantially encapsulate the coulomb damper insert with the casting material to form a rotor cheek of the coulomb damped disc brake rotor. A coulomb damper insert and coulomb damped disc brake rotor are also disclosed.

Abstract: Improved lubricant system useful in metal forming processes. The lubricant formulations contain boron nitride lubricant with graphite additions. These formulations enhance lubricity while maintaining good adherence at elevated temperatures.

Abstract: The invention provides a method for manufacturing an automotive component member, including the steps of: (A) positioning at least one insert into a mold, wherein the insert defines a plurality of holes; and (B) casting a portion of the automotive component member in the mold to substantially encapsulate 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. The method may include the step of coating the insert to prevent bonding between the insert and the casting material. A damped automotive component member having an insert cast therein is also disclosed.

Abstract: Small sheet metal reinforcement pieces are co-formed with a larger sheet metal part during a hot stretch forming against a heated forming tool surface. Locator holes are made in blanks for the reinforcing pieces so they can be precisely located on locator pins in the forming surface where the reinforcing pieces are ultimately to be attached to the formed sheet part. A preheated blank of the larger part is stretched against the trapped reinforcement blanks and both the part and reinforcing pieces are shaped against the hot tool. The part and reinforcing pieces are removed and cooled, and the closely fitting reinforcing pieces attached to the part at a suitable later time.

Abstract: The present invention includes high strength, high temperature and strain rate applications of a zinc-base alloy including about 83 to 94 weight percent zinc, about 4 to about 11 percent copper and about 2 to about 4 percent aluminum. The composition may also include minor components such as magnesium and impurities. The alloy is used to construct automotive components which are subject to an instantaneous load of between 40-500 MPa. The alloy is particularly suitable for constructing components which are subject to such loads under high temperatures. In fact, components constructed from the alloy become much stronger at higher temperatures under sudden stress.

Abstract: The present invention includes high strength, high temperature and strain rate applications of a zinc-base alloy including about 83 to 94 weight percent zinc, about 4 to about 11 percent copper and about 2 to about 4 percent aluminum. The composition may also include minor components such as magnesium and impurities. The alloy is used to construct automotive components which are subject to an instantaneous load of between 40-500 MPa. The alloy is particularly suitable for constructing components which are subject to such loads under high temperatures. In fact, components constructed from the alloy become much stronger at higher temperatures under sudden stress.