Abstract: A method of manufacturing a cylinder block for an engine comprises providing a cylinder liner for the cylinder block and keeping the cylinder liner in a controlled atmosphere, removing the cylinder liner from the controlled atmosphere, removing moisture and gaseous contamination from the cylinder liner, and positioning the cylinder liner in a mold and over-casting a cylinder block in the mold.

Abstract: A method of forming an engine component includes providing a cylinder liner main body having a curved interior wall forming a cylinder bore extending along a bore axis and a curved exterior wall formed circumferentially about the curved interior wall. The method includes disposing a coating layer onto the interior wall and the exterior wall. A cylinder liner is provided that includes a main body and a coating layer disposed on an exterior wall and on an interior wall of the main body.

Abstract: A cooling system for a turbine engine includes a structure defining a fluid passageway. The fluid passageway includes an impingement surface. A first opening into the fluid passageway is also included. The first opening is disposed opposite the impingement surface of the fluid passageway such that airflow entering the fluid passageway impacts the impingement surface. An agglomerate retention structure is disposed on the impingement surface. The agglomerate retention structure holds particulates impacting the impingement surface entering through the opening. A turbine engine is also disclosed.

Abstract: Example systems include a vacuum chamber enclosing a pouring cup and a platform configured to support a casting assembly. The casting assembly is configured to hold a plurality of joinable components and a mold defining at least one mating groove configured to join at least two joinable components of the plurality of joinable components when occupied with a metal or an alloy. Each respective mating groove is fluidically connected to a respective surface opening of a plurality of surface openings defined by the mold. The pouring cup and the respective surface opening are movable relative to each other by moving at least one of the pouring cup or the platform supporting the casting assembly to substantially align the pouring cup with the respective surface opening. The pouring cup is configured to pour a respective volume of molten metal or alloy in at least two surface openings.

Abstract: A high pressure press assembly along with related methods and components for the press assembly are provided. In one embodiment, a press assembly includes a first press base having one or more tie bar receiving holes extending therethrough. A second press base may also include one or more tie bar receiving holes extending therethrough. A tie bar extends between the first press base and the second press base. A tensioning assembly is operatively coupled to the tie bar to place the tie bar in tension.

Abstract: The present disclosure relates to a wear part having high wear resistance and strength and a method of making the same. The wear part is composed of a compound body of cemented carbide particles cast with a low-carbon steel alloy. The low-carbon steel alloy has a carbon content corresponding to a carbon equivalent Ceq=wt % C+0.3(wt % Si+wt % P) of about 0.1 to about 1.5 weight %. The wear part could include a body with a plurality of inserts of cemented carbide particles cast into a low-carbon steel alloy disposed in the body. Each of the plurality of cemented carbide inserts are coated with at least one layer of oxidation protection/chemical resistant material. The plurality of inserts are directly fixed onto a mold corresponding to the shape of the wear part. The cemented carbide inserts are then encapsulated with the molten low-carbon steel alloy to cast the cemented carbide inserts with the low-carbon steel alloy.

Abstract: An electrical connector includes an electrically conductive connector having a mechanical connector for removably receiving a conductor. The mechanical connector includes a translatable clamping member and a threaded portion. An arm extends from the electrically conductive connector. A component is connected to the arm at an interface. The interface includes an exothermic weld.

Abstract: A method of forming a bi-metallic casting. The method includes providing a metal preform of a desired base shape defining a substrate surface and removing a natural oxide layer and surface contamination from the substrate surface to yield a cleaned metal preform. The method further includes galvanizing the cleaned metal preform, yielding a galvanized metal preform followed by electroplating a thin nickel film on at least a portion of the substrate surface of the galvanized metal preform. Additionally, the method includes metallurgically bonding the portion of the metal preform having the nickel film with an overcast metal to form a bi-metallic casting. The nickel film promotes a metallurgical bond between the metal preform and the overcast metal.

Abstract: An assembly that includes a rotating shaft supported with respect to a stationary housing by at least one active magnetic bearing presenting a mean radial air gap and at least one auxiliary bearing having a bushing fixed to the housing and a sleeve fixed on the rotating shaft. The bushing and the sleeve have opposite surfaces that define a clearance (E2) which is less than the mean radial air gap (E1). The bushing and the sleeve each exhibit symmetry around a longitudinal axis of the shaft and have different profiles in a longitudinal cross-section including the longitudinal axis to optimize the contact pressure distribution when the rotating shaft lands on the auxiliary bearing.

Abstract: A method for manufacturing a forging includes forming a bi-material billet by enclosing a core material other than steel in a steel cylinder with a cylindrical wall and steel end caps. The cylindrical wall is heated. The method includes a first forging blow on the heated billet or on a disk-shaped rough forging forged from the heated billet with a first closed blocker die to produce a forging preform, and a second forging blow on the preform with a second closed blocker die to produce a netshape forging. An evacuation hole is formed in a steel shell of the netshape forging and the core material is removed from the netshape forging via the hole. At least 85 percent of the core material is in a liquid phase during the first and second forging blows, and removal of the core material.

Abstract: A method for manufacturing a gear includes forming a bi-material billet from a steel cylinder having a cylindrical wall, a first end closed with a first steel cap, and an open second end distal to the first end. The method includes disposing a core material other than steel into the steel cylinder, welding a second steel cap onto the steel cylinder to form the bi-material billet, and heating the cylindrical wall. The method includes a first forging blow on the heated billet or on a disk-shaped rough forging forged from the heated billet with a first closed blocker die to produce a partial toothed preform, and a second forging blow on the preform with a second closed blocker die to produce a netshape gear. The first closed blocker die has a die cavity including gear tooth forms, and the partial toothed preform includes a plurality of spaced gear teeth.

Abstract: A method is provided of producing a housing with two layers. The method includes casting an inner casting formed as an inner layer, and then casting an outer casting. The inner casting is used as a wall and the outer casting is formed as an outer layer. The inner layer is made of a more heat resistant material than the outer layer. Hooked formations are fitted on the inner casting in order to improve an integral bonding to the outer layer.

Abstract: There are provided a solder joint structure, a power module using the joint structure, a power module substrate with a heat sink and a method of manufacturing the same, as well as a solder base layer forming paste which is disposed and fired on a metal member to thereby react with an oxide film generated on the surface of the metal member and form the solder base layer on the metal member, capable of suppressing the occurrence of waviness and wrinkles on the surface of the metal member even at the time of loading the power cycle and heat cycle and improving the joint reliability with a joint member.

Abstract: A method of making optical fibers that includes controlled cooling to produce fibers having a low concentration of non-bridging oxygen defects and low sensitivity to hydrogen. The method may include heating a fiber preform above its softening point, drawing a fiber from the heated preform and passing the fiber through two treatment stages. The fiber may enter the first treatment stage at a temperature between 1500° C. and 1700° C., may exit the first treatment stage at a temperature between 1200° C. and 1400° C., and may experience a cooling rate less than 5000° C./s in the first treatment stage. The fiber may enter the second treatment stage downstream from the first treatment stage at a temperature between 1200° C. and 1400° C., may exit the second treatment stage at a temperature between 1000° C. and 1150° C., and may experience a cooling rate between 5000° C./s and 12,000° C./s in the second treatment stage.

Abstract: Provided in one embodiment is a method of making use of foams as a processing aid or to improve the properties of bulk-solidifying amorphous alloy materials. Other embodiments include the bulk-solidifying amorphous alloy/foam composite materials made in accordance with the methods.

Abstract: Provided in one embodiment is a method of forming a connection mechanism in or on a bulk-solidifying amorphous alloy by casting in or on, or forming with the bulk-solidifying amorphous alloy, a machinable metal. The connection mechanism can be formed by machining the machinable metal.

Abstract: A method of producing a Metal Matrix Composite (MMC) with uniform surface layers is disclosed. First, a low volume fraction compressible discontinuous ceramic fiber paper is set on the base of a mold cavity. Next, an array of reinforcement preform(s) (1×1,2×2, 4×4, 2×8, etc) are set in the mold on top of the ceramic fiber paper. A top layer of ceramic fiber paper is next placed on the array of reinforcement preforms and the mold cover seals the mold. The reinforcement porous preform(s) are held to the center of the mold cavity when the sealed mold compresses the top and bottom layers of ceramic fiber paper. The ceramic fiber paper exerts an equal and opposite force on the reinforcement preform(s) within the closed mold centering the preform(s) within the mold cavity. The mold cavity is next infiltrated under pressure with molten metal allowing for metal to penetrate into any open porosity of the ceramic fiber paper, reinforcement preform(s), and areas within the mold cavity that contain open spaces.

Abstract: Seam protected encapsulated arrays of solid ceramic elements are disclosed. Vulnerable seams between solid ceramic elements arranged adjacent to each other in encapsulated arrays of solid ceramic elements are protected by a seam protector arranged in-line with the vulnerable seams and fixed to the encapsulated array. A stiffener may be arranged in-line with the vulnerable seams and fixed to the encapsulated array opposite to the seam protector. The solid ceramic elements may be encapsulated in a barrier material to prevent the base metal from reacting with the ceramic material units during casting, and/or provide crush/compression protection during cooling.

Abstract: A method for assembling anodes used in electro winning processes that increases corrosion resistance. The method includes pre-coating the copper bus bar, introducing the copper bar into a mold, peripherally coating the copper bar with a lead-antimony alloy, moving the copper bar to the assembly table, filling a slot in the copper bus bar with a lead-bismuth alloy, introducing the end of a plate into the slot while the lead-bismuth alloy is in a liquid state, and once the lead-bismuth alloy in the slot has solidified, applying reinforcement solder.

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: A steering column has an overall hollow and cylindrical shape at least part of which is formed using a column member. The column member includes a main body portion having one-side end section and the other-side end section and a cylindrical member having one-side end section and the other-side section. The cylindrical member is joined in the axial direction with respect to the main body portion by fitting and fastening the other-side end section of the cylindrical member inside the one-side end section of the main body portion. The inner diameter of the end surface of the other-side end section of the cylindrical member is smaller than the inner diameter of a portion of the other-side end section of the cylindrical member. The portion of the other end section of the cylindrical member constitutes a joined section between the main body and the cylindrical member.

Abstract: In a method of processing a substrate in accordance with an embodiment, a trench may be formed in the substrate, a stamp device may be disposed at least in the trench; at least one part of the trench that is free from the stamp device may be at least partially filled with trench filling material; and the stamp device may be removed from the trench.

Abstract: A metal enclosure has a surface region which is coated with cladding material using a laser cladding process. The metal enclosure can form at least a portion of an electronic device housing. All or part of one or more surfaces of the enclosure can be coated with cladding material. The coating of cladding material can be varied at selective regions of the enclosure to provide different structural properties at these regions. The coating of cladding material can be varied at selective regions to provide contrast in cosmetic appearance.

Abstract: A cylinder head is formed by positioning a clad preform including a first and second layer in a casting die cavity with the second layer in communication with the die cavity and the first layer facing outwardly to define a combustion surface. Molten material provided to the die cavity is solidified to form a cast portion metallurgically bonded to the second layer. An aperture of the preform forms a port in fluid communication with a passage of the cast portion. A plurality of dome-shaped preforms may define the combustion chambers of a cylinder head formed by the method. The preform may define a cylinder head face. The first layer may be a steel-based layer, and the second layer and cast portion may be aluminum-based, such that the first layer and combustion surface has higher thermal fatigue strength relative to the cast portion.

Abstract: A composite material combining—a precious metal or an alloy containing a precious metal—and a boron-based ceramic having a melting point greater than that of said precious metal and a density at most equal to 4 g/cm3.

Abstract: A universal joint having a hub formed by molding a material around four stub axles which are arranged so that a first and second stub axle are axially aligned and a third and fourth stub axle are axially aligned. Furthermore, the axes of the first and second stub axles are perpendicular to and coplanar with the axes of the third and fourth stub axles. A bearing is positioned around each stub axle. A first yoke is then molded around two aligned stub axle bearings and an end of a first axle while, similarly, a second axle is molded around the bearings on the other pair of stub axles and an end of a second axle.

Abstract: A method for making a light alloy foundry part that includes at least one piping supported by a wall of the part. The method includes making the piping, making a mold reproducing a shape of the part without the piping, positioning the piping in the mold, and casting a metal for making the part. At least a portion of the piping is subjected, prior to the installation thereof in the mold, to a surface-processing to generate a thermal barrier between the portion of the piping and the casting metal, the mold including at least one hollow location around the piping for making a bridge for supporting the piping and extending from the wall of the foundry part.

Abstract: A bi-metallic component including a first member of a first metal and a second member of a second metal different than the first metal. The first member includes at least one perforation. The second member is directly cast-in-place about a sheet-like portion of the first member and through the perforation to rigidly secure the first and second members. When used in an automotive vehicle, the second metal of the second member is preferably of aluminum and the first metal of the first member is preferably a high strength steel for spot welding to other steel structures.

Abstract: A method of manufacturing a workpiece with multiple metal layers is disclosed as including steps (a) providing a mold with at least a runner and a cavity, (b) providing in the cavity of the mold a first metal layer made of a first metal, the first metal layer having a surface which is roughened and/or includes an engagement structure, and (c) injecting a molten second metal onto the surface of the first metal layer to form a second metal layer on the first metal layer in which the second metal layer engages with the roughened surface of the first metal layer or with the engagement structure of the surface of the first metal layer, and the molten second metal enters the cavity of the mold at a speed of at least 70 meters per second (m/s).

Abstract: This invention provides a mold for injection molding and a method of manufacturing thereof. The method of manufacturing a mold for injection molding includes the following steps. At least one temperature control element is provided. The temperature control element is covered with a first material. The first material is mechanically processed to form a mold body with a cavity. The mold for injection molding includes a mold body, a temperature control element, and a heat insulating layer.

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: A method of making a turbomachine part, wherein the can include machining a blank into a base having blades extending therefrom, the blades defining a channel therebetween. The method can also include forming a bridge in the channel between the blades, and forming a cover on the tops of the blades and over the channel, such that the base, the blades, and the cover form a single substantially homogenous turbomachine part once the bridge is removed.

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: A method of making a frictionally damped part including providing a frictional damping insert including downwardly extending support legs stamped out of a body portion of the insert.

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 structure, the body including lines of weakness constructed and arranged to segment the body into separate sections upon exposure to a molten material.

Abstract: A method of forming a brake rotor includes forming a plurality of metal insert portions. Each insert portion includes an inner side and an outer side with a plurality of attachment members coupled to the inner side. The method also includes positioning the plurality of insert portions into a mold such that the inner side of one of the plurality of insert portions faces the inner side of another one of the insert portions. The method also includes introducing a molten aluminum into the mold such that the molten aluminum contacts the inner side of each insert portion. The method further includes forming a mechanical bond between the aluminum and at least a portion of at least one of the inserts.

Abstract: A Coulomb friction damped disc brake rotor, wherein damping is provided Coulomb friction in generally coextensive relation with the braking surfaces of the one or more rotor cheeks. The Coulomb friction damped disc brake rotor has at least one interfacial boundary formed in at least one rotor cheek disposed in generally coextensive relation to the braking surface thereof. The interfacial boundary provides a mechanically distinguishable surface boundary between two surfaces which are in mutual contact such that a state of Coulomb friction exists therebetween.

Abstract: A method of making a turbomachine part, wherein the can include machining a blank into a base having blades extending therefrom, the blades defining a channel therebetween. The method can also include forming a bridge in the channel between the blades, and forming a cover on the tops of the blades and over the channel, such that the base, the blades, and the cover form a single substantially homogenous turbomachine part once the bridge is removed.

Abstract: A light weight cookware article has a foam core with exposed exterior surfaces. The foam core is formed of a carbon foam material and has a barrier layer on the exterior surfaces of the foam core. The cookware article has an upper facing food contacting side and a downward facing heat source side opposite the food contacting side.

Abstract: A brake disc arrangement has a mounting portion formed of a metal, with a plurality of radial protuberances extending radially outward therefrom. The radial protuberances each have a radially distal tip portion, and a ceramic coating is applied to the radially distal tip portion of the radial protuberances. The brake plate portion is cast so as to surround the radially distal tip portions. However, it is isolated therefrom by the ceramic coating. At least some of the radially distal tip portions are formed of metal having a microstructure created by electrical discharge machining to increase dampening. A sand core within a core box holds the mounting portion in a predetermined fixed orientation. The molten metal is poured into the core box mold, and the metal brake plate portion is prevented by the ceramic coating from welding to any of the plurality of radial protuberances.

Abstract: One embodiment includes an insert including a body portion; a plurality of tabs extending from the body portion, wherein the tabs are tapered; and wherein the insert is constructed and arranged to provide damping.

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 hybrid yoke for a vehicle driveshaft assembly includes a cast iron portion having a pair of opposed yoke arms at a first end. The hybrid yoke also includes a steel portion having a yoke end and a shaft end, the shaft end for coupling to the driveshaft assembly and the yoke end for insertion into a second end of the cast iron portion.

Abstract: The present disclosure is related to creating blocks of aluminum and/or copper material having embedded TPG elements for forming heatsinks. The metal blocks have an improved thermal conductivity in the X-Y plane. Furthermore, the TPG-embedded heatsinks can be created using methods capable of being performed using various machines and equipment in many various facilities.

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: Described are wrought forms of copper alloys for infiltrating powder metal parts, the method for preparing the copper alloys and their wrought forms, the method for their infiltration into a powder metal part, and the infiltrated metal part infiltrated with the novel alloys having a generally uniform distribution of copper throughout and exhibiting high transverse rupture strength, tensile strength and yield strength. Infiltrated metal parts prepared by infiltrating powder metal parts with reduced amounts of the novel infiltrant typically weigh less and have superior strengths compared to similarly prepared infiltrated metal parts prepared with standard methods and conventional infiltration.

Abstract: Method of making a composite casting involves providing a reinforcement insert with a ceramic coating, positioning the coated insert in a mold, and casting the molten metallic material into the mold where the metallic material is solidified. The composite casting produced includes the reinforcement insert disposed in a solidified metallic matrix with a ceramic coating between the reinforcement insert and the matrix.

Abstract: A method of manufacturing metallic components consisting of at least two different materials, one of them being an iron-based alloy and the other an aluminum-based alloy, and involving the steps of: depositing a metallic layer onto the body made from the iron-based alloy, said layer being an aluminum-based alloy, preferably based on Al—Si or Fe, placing the coated body in a casting mold and casting an aluminum-based alloy about the coated body. Prior to placing the body in the casting mold, the metallic layer of the body is sprayed and/or blasted with silicon powder and/or Borax (Na2B4O7—10H2O, hydrated sodium borate).

Abstract: A method for manufacturing cast components, in which method the cast mold and/or macroscopic inserts to be placed either totally or partly inside thereof are left totally or partly as a part of the final component to be used, after the casting the piece is further treated with temperature and/or pressure in order to improve the compactness of both the cast materials and the materials acting as inserts and to improve the bond between the cast material and the solid material attached thereto, and the portion of the solid or partly solid material (inserts) to be placed into the cast mold and remaining in the final component, inclusive the portion of the mold eventually remaining in the final component, of the weight of the total component is more than 3 percent by weight.

Abstract: In a method of manufacturing a cylinder head having a partition plate for an intake port, there is prepared a partition plate having an intake-side distal end and a cylinder-side distal end. The partition plate is located in a core to form the intake port and molten metal is supplied to a periphery of the partition plate. After solidifying the molten metal, the core is removed. At least the intake-side distal end of the partition plate is located in an expansion-permit space that permits thermal expansion of the partition plate caused by heat of molten metal.