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 metal forming apparatus characterized by rapid cooling includes a forming tool having a first portion defining a forming surface and a second portion defining a cavity for a working gas. A plurality of fins are in conductive heat transfer relationship with the forming tool. The metal forming apparatus enables a high thermal efficiency mode of operation when the effect of the fins is negated for use during metal forming operation, and a rapid cooling mode for use in preparing for tool maintenance. A corresponding method is also provided.

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 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: 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 quick plastic forming (QPF) tool is provided in which a thermal gap is created that reduces or eliminates some of the conductive heat loss paths when the QPF tool is in an open position during part removal or sheet loading. By reducing conductive heat loss, a more precise temperature control for the QPF tool from manufacturing cycle to manufacturing cycle may be realized. The QPF tool may also have a thermal gap when the tool is placed in a semi-open position during idle times. The QPF tool may also include components for creating the thermal gap when the QPF tool is moved to the open position and control the lateral movement of the part forming section of the QPF tool as the part is moved between the open position and the closed position.

Abstract: A quick plastic forming (QPF) tool is provided in which a thermal gap is created that reduces or eliminates some of the conductive heat loss paths when the QPF tool is in an open position during part removal or sheet loading. By reducing conductive heat loss, a more precise temperature control for the QPF tool from manufacturing cycle to manufacturing cycle may be realized. The QPF tool may also have a thermal gap when the tool is placed in a semi-open position during idle times. The QPF tool may also include components for creating the thermal gap when the QPF tool is moved to the open position and control the lateral movement of the part forming section of the QPF tool as the part is moved between the open position and the closed position.

Abstract: Metal forming apparatuses provide enhanced thermal efficiency by reducing thermal conduction from a forming tool to a shield. In one embodiment, a shield extends between a tool and a mounting plate, and is in conductive heat transfer relationship with the tool via a plurality of protuberances. In another embodiment, a shield extends between a tool and a mounting plate, and thermally insulating material separates the tool and the shield.

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

Abstract: Metal forming apparatuses provide enhanced thermal efficiency by reducing thermal conduction from a forming tool to a shield. In one embodiment, a shield extends between a tool and a mounting plate, and is in conductive heat transfer relationship with the tool via a plurality of protuberances. In another embodiment, a shield extends between a tool and a mounting plate, and thermally insulating material separates the tool and the shield.

Abstract: A metal forming apparatus characterized by rapid cooling includes a forming tool having a first portion defining a forming surface and a second portion defining a cavity for a working gas. A plurality of fins are in conductive heat transfer relationship with the forming tool. The metal forming apparatus enables a high thermal efficiency mode of operation when the effect of the fins is negated for use during metal forming operation, and a rapid cooling mode for use in preparing for tool maintenance. A corresponding method is also provided.

Abstract: Method of preforming and forming a sheet metal article from a preheated blank of sheet metal uses opposing dies including a punch having a punch surface defining a final configuration for the article and a cavity die having a cavity surface defining a preform configuration. The blank is placed between the dies and has a first side surface facing the cavity die and a second side surface facing the punch. A vacuum is applied to the first side of the blank to draw and shape the blank into the cavity die to a preform configuration conforming to the cavity surface. The punch and the cavity die are then closed toward one another and gas pressure is then applied to the first side surface of the blank to press the second side surface against the punch surface to the finish configuration.

Abstract: A press and tooling apparatus for forming a preheated blank includes a heated upper tool and an opposing heated lower tool mounted within the press for relative closing movement to press the preheated blank there between. A binder ring assembly surrounds the lower tool and is mounted on the press for movement relative to the lower tool so at to bind the preheated blank to the upper tool in air tight sealing relationship in readiness for closure of the tools and application of pressurized gas to force the blank into contact with the upper tools. The binder ring assembly includes an upper ring that is heated so as to prevent the cooling of the preheated blank, and a lower ring that supports the upper ring and is fixedly connected to the upper ring by spaced apart connectors so as to minimize the heat transfer path from the heated upper ring to the lower ring.

Abstract: A cleaning apparatus for removing metallic buildup from forming surfaces of metal forming dies while the dies are in a press and operating at elevated temperatures. The cleaning apparatus includes a programmable positioner having a robotic arm with an end effector carrying a brush assembly. The brush assembly includes a rotary drive motor rotatably carrying a metallic wire brush. The brush has a plurality of radially extending plain carbon steel bristles having tips adapted for removing metallic buildup from the forming surfaces of dies. The positioner operates to move the rotatable wire brush in a predetermined path that engages the brush with the forming surfaces of the dies for sweeping and cleaning metallic buildup from the forming surfaces.

Abstract: Work hardened sheets of formable metal are annealed by thermal conduction and heated to a forming temperature. In a preferred embodiment, the sheet is placed on a flat surface of a heated lower platen to partially heat and soften the sheet and an opposing heated upper platen is brought close enough to the sheet to contribute heat but not to constrain the sheet as it expands. The platens are then both brought close to the sheet to heat it to its forming temperature largely by thermal conduction.

Abstract: A hot forming tool is heated with multiple electrical resistance cartridge heaters. The heaters are located in the body of the tool so as to maintain the entire forming surface within a predetermined temperature range. Numerical thermal and optimization analyses direct the placement of the heaters so that when each heating element is simultaneously powered on for an identical fraction of the time, an acceptable temperature distribution will be produced within the tool at the tool operating temperature.

Abstract: A method of making positive lead-acid storage battery paste by initially mixing polyacetal resin particles with the leady ingredients and subsequently removing the particles during electrochemical formation of the paste to leave a plurality of electrolyte retaining macropores distributed throughout the paste to improve the reserve capacity of the battery.

Abstract: A method of making a negative lead-acid storage battery plate wherein a gossamer mat of elongated, carbon/graphite fibers is bonded to a thin paper sheet which is thereafter applied to the face of the plate such that the carbon/graphite fibers lie contiguous the active material of the plate and serve to distribute the "formation" current more uniformly across the face of the unformed plate and into the regions of the unformed active material most remote from the conductive grid wires.

Abstract: A pump is disclosed which utilizes battery gas for circulating a body of liquid electrolyte in an electrochemical cell. The pump comprises an electrolyte conduit immersed in the electrolyte body and having an electrolyte inlet adjacent the bottom of the electrolyte body, an electrolyte outlet closely below the surface of the body, and a gas inlet below the outlet. The pump also comprises a hood for collecting battery gas rising in the electrolyte body and a passage for conveying collected gas from the hood to the conduit gas inlet. Gas bubbles released into the conduit at the gas inlet rise and carry electrolyte to the outlet, thereby circulating the electrolyte.