Abstract: A runner mold portion includes a first internal cavity. A component mold portion is disposed in a first direction relative to the runner mold portion, where a direction of gravity is opposite the first direction, the component mold portion including a second internal cavity with an inner shape having an outer shape of a component of a vehicle, the second internal cavity fluidly connected to the first internal cavity of the runner mold portion. A pump is configured to pump a predetermined amount of the liquid metal into the first internal cavity of the runner mold portion and into the second internal cavity of the component mold portion. An actuator is configured to, after the pump has pumped the predetermined amount of the liquid metal into the first and second internal cavities, actuate a piston based on increasing a pressure within the first and second internal cavities.

Abstract: An electrical connection for a vehicle and methods of forming an electrical connection for a vehicle. The electrical connection includes a first electrical component including a first joining area. The electrical connection also includes a conductor including a second joining area. The conductor is joined at the second joining area to the first joining area of the first electrical component. In addition, the electrical connection includes a fusion zone formed in the first electrical component in the first joining area. The conductor includes a copper-graphene multilayer composite formed on the surface of the conductor, the composite including at least one of the following composite structures: a) alternating layers of graphene and copper deposited on the substrate, b) graphene particles dispersed in a copper matrix, and c) alternating layers of graphene and copper deposited on a copper foil, wherein the copper foil is wrapped around the substrate.

Abstract: Systems, methods, and devices for forming and implementing a graphene-copper composite powder are disclosed. The graphene-copper composite powder may be formed by providing an inert environment, introducing a first mist to the inert environment, introducing a second mist to the inert environment, and mixing the first mist and the second mist within the inert environment to thereby produce a graphene-copper composite powder. The first mist being atomized copper with a negative charge, and the second mist including graphene flakes with a positive charge. The graphene-copper composite powder may be used to form components via additive manufacturing or traditional powder metallurgy processes.

Abstract: A flexible grinder device and method for cleaning an as-cast inner hole surface using the flexible grinder device is provided. The flexible grinder device includes a hydraulic motor powered by a fluid; a control module in communication with the hydraulic motor; a flexible pressure vessel coupled to the hydraulic motor; and an abrasive layer coupled to an outer surface of the flexible pressure vessel. The flexible pressure vessel is configured to contain the fluid, and the fluid is configured to be pressurized. The flexible pressure vessel is rotatable by the hydraulic motor, and the flexible pressure vessel is conformable with an as-cast inner hole surface.

Abstract: A method of calculating residual stress in weld joints including establishing a finite element geometric model of an assembly comprising of a first metal alloy joined to a second metal alloy with a weld fillet and calculating the residual stress of the assembly by performing a finite element analysis (FEA) on the finite element geometric model over a predetermined heating and cooling temperature range effective to form the weld fillet by laser welding. The first metal alloy and the second metal alloy are dissimilar metals. The finite element analysis includes incorporating phase transformation and phase-specific properties of each of the first metal alloy and the second metal alloy, respectively, over the predetermined temperature range. The FEA may be executed by a solver and the phase transformation and phase-specific properties of the alloys may be incorporated into the solver by a user material subroutine (UMAT).

Abstract: A method of making a conductor includes folding/stacking/rolling an ultra-conducting copper foil into a multiple layer folded/stacked/rolled ultra-conducting copper foil. Cladding the multiple layer folded/stacked/rolled ultra-conducting coper foil with one of copper and aluminum into a cladded folded/stacked/rolled ultra-conducting copper foil and plastically deforming the cladded folded/stacked/rolled ultra-conducting copper foil into one of a cladded ultra-conducting copper wire, bar, and cable.

Abstract: A composite conductor for a vehicle, a propulsion system for a vehicle, and a method of forming a composite busbar for a vehicle. The composite conductor includes a surface, and a first copper tape laminated to the surface. The composite conductor is electrically conductive exhibiting an electrical conductivity of 1.0×10{circumflex over (7)} Siemens per meter (S/m) or greater. The first copper tape includes a layer of carbon nanotubes sandwiched between a first copper layer and a second copper layer. The composite busbar may be connected to a plurality of windings in the stator of an electric motor.

Abstract: A fastener includes a head disposed at a proximal end of a longitudinal axis and having a first horizontal axis extending therethrough that is perpendicular to the longitudinal axis. The head has a first surface and a bearing surface spaced apart from the first surface across the first horizontal axis. The fastener includes a threaded portion spaced apart from the head along the longitudinal axis and a shank abutting the head at a fillet and disposed between the head and the threaded portion along the longitudinal axis. The fillet has a second horizontal axis extending therethrough that is substantially parallel to the first horizontal axis and intersects the longitudinal axis. The bearing surface and second horizontal axis define a first angle therebetween such that the bearing surface is oblique with respect to the second horizontal axis and longitudinal axis. A fastener system and method of forming the fastener are described.

Abstract: A system for manufacturing an ultra-conductive winding for an electric motor of a vehicle comprising a substrate extending along a longitudinal axis, an ultra-conductive composite (UCC) foil material having a thickness of 5-30 micrometers and overlapping a portion of the substrate, a substrate support selectively engageable with a portion of the substrate or the UCC material, and a finishing mechanism including a joining mechanism and a cutting mechanism configured to move along or parallel to the longitudinal axis.

Abstract: A die casting system includes a die having a casting chamber, an ingate in fluid communication with the casting chamber, and a pressurization device. A molten metal is introduced from the ingate into the casting chamber along a flow direction. The ingate has a first surface movable in a direction perpendicular to the flow direction of the molten metal. The pressurization device is configured to bias the first surface to cause the ingate to have a first cross-sectional area in a plane perpendicular to the flow direction based on a first pressure of the molten metal in the ingate and to have a second cross-sectional area in the plane perpendicular to the flow direction based on a second pressure of the molten metal in the ingate. The second pressure is greater than the first pressure.

Abstract: A busbar for high conductivity distribution of electrical power within a power module of an electric vehicle (EV). The busbar may include a plurality of multilayer composites having copper-graphene laminations. One or more of the multilayer composite may include a first copper-graphene lamination having a plurality of graphene layers disposed between a plurality of copper layers, a second copper-graphene lamination having a plurality of graphene layers disposed between a plurality of copper layers, and a carrier substrate disposed relative to the first and second copper-graphene laminations.

Abstract: A computer-implemented method, when executed on data processing hardware, causes the data processing hardware to perform operations. The operations include i) via application of a machine learning algorithm to a micrograph representative of a metallic material, detecting clusters of dendrite arms in the metallic material and generating an image frame based on the micrograph and representative of the clusters of dendrite arms, ii) detecting, via application of a watershed algorithm to the image frame, individual dendrite arms within the clusters of dendrite arms, iii) applying at least one filter to the image frame, iv) identifying at least one cluster of dendrite arms in the image frame that satisfies the at least one filter, and v) generating, for the at least one cluster of dendrite arms, a cluster profile including at least an average dendrite arm spacing (DAS) value for the at least one cluster of dendrite arms.

Abstract: An induction rotor assembly is provided. The induction rotor assembly includes a laminated stack, a plurality of foils, a plurality of conductor bars, a first end ring, and a second end ring. The laminated stack includes a body with an outer circumferential surface with a plurality of grooves extending from the first end to the second end. Each one of the plurality of foils is disposed within one of the grooves. Each of the foils is disposed between each of the conductor bars and each of the grooves. Each of the plurality of conductor bars includes a first conductor end and a second conductor end. The first end ring mates with a surface of each first conductor end. The second end ring mates with a surface of each second conductor end, and the plurality of conductor bars extends between the first end ring and the second end ring.

Abstract: Provided is a kit for rapid detection of avian leukosis virus subgroup J (ALV-J) based on a CRISPR/Cas13a system. The method is based on the combination of the CRISPR/Cas13a system and recombinase aided amplification (RAA) for ALV-J detection. An oligonucleotide probe is designed as a substrate for CRISPR/Cas13a trans-cleavage and produces a detectable signal. The method can substantially improve detection sensitivity by amplifying a detection signal twice by RAA and T7 transcription. The detection method further exhibits excellent specificity, allowing for clear differentiate from other avian viruses. It does not require expensive experimental equipment and special laboratory environment, and it is rapid and efficient. The method is of great significance for biological research and on-site detection of ALV-J.

Abstract: A composite wire bundle for a stator winding, a stator including a composite wire bundle, and a method of forming a composite wire bundle. The composite wire bundle includes a plurality of copper wires, wherein each of the plurality of copper wires include a first surface. The composite wire bundle also includes a copper-graphene multilayer composite applied to the first surface of each of the plurality of copper wires, wherein the copper-graphene multilayer composite includes a second surface. Further, the composite wire bundle includes a fluoropolymer matrix formed around the second surfaces and a jacket encapsulating the fluoropolymer matrix.

Abstract: A brake rotor includes a body, at least one thermal barrier, and a substrate. The body includes at least one braking surface and a plurality of venting channels. The at least one thermal barrier is disposed on the at least one braking surface. The at least one thermal barrier includes a first ceramic layer having a first density and a first porosity, and a second ceramic layer having a second density and a second porosity. The second density is less than the first density, and the second porosity is greater than the first porosity. The second ceramic layer is selectively engaged with the at least one braking surface of the body. The substrate is selectively coupled to first ceramic layer of the at least one thermal barrier in a first state of the body. The brake rotor is free of the substrate in a second state of the body.

Abstract: An electric machine including a stator and a rotor. The rotor is configured to rotate within the stator and includes: a core; a first end ring at a first end of the core and a second end ring at a second end of the core; conductors extending across the core that electrically connect the first end ring and the second end ring; and a first reinforcing ring that is cast within the first end ring and a second reinforcing ring that is cast within the second end ring.

Abstract: A method for controlling a pump motor associated with a component molding system includes applying a selected activation energy to the pump motor, driving, with the pump motor, a casting medium from a source to a mold through a casting medium delivery system, delivering the casting medium into a mold cavity, detecting one or more casting medium delivery parameters in the casting medium delivery system, detecting one or more casting medium mold parameters in the mold cavity, sending a first plurality of signals representing the casting medium delivery parameters to a controller, sending a second plurality of signals representing the casting medium mold parameters to the controller, processing the first plurality of signals and the second plurality of signals to determine pump motor control parameters, and adjusting the selected activation energy to the pump motor based on the pump motor control parameters.

Abstract: An electronics module housing is provided. The electronics module housing includes a high-pressure die cast integrated power electronics (IPE) housing component having at least one coating-free mating surface. The integrated power electronics housing component is formed from an aluminum alloy including silicon between 6.5 wt. % and 7.5 wt. %, copper between 0.05 wt. % and 0.30 wt. %, magnesium between 0.1 wt. % and 0.6 wt. %, iron between 0.20 wt. % and 1.50 wt. %, chromium more than 0 wt. % and less than 0.30 wt. %, and manganese more than 0 wt. % and than 0.15 wt. %.

Abstract: A spreader configured to be implemented in a die of a die casting system is disclosed. The spreader includes: a substrate; a hardening layer and an oxide layer. The hardening layer includes: a nitride and carbide layer disposed on the substrate and increasing hardness; and a white layer disposed on the nitride and carbide layer. The oxide layer includes: an inner transition layer disposed on the white layer and increasing resistance to oxidation; and an outer iron oxide layer disposed on the inner transition layer and increasing resistance to soldering during die casting of a part in the die casting system.