Abstract: The invention relates to a method for forming a green article for subsequent sintering or infiltration. This method includes providing a mold having an internal cavity that outlines the shape of the article, introducing metal or ceramic particles into the mold in an amount sufficient to provide the article in a desired size, adding a solution comprising an organic fluxing agent onto the particles with the solution carrying the organic fluxing agent into interstices between the particles, and freezing the solution to form a solid green article. The invention also relates to an apparatus and method for manufacturing dimensionally stable articles.

Abstract: The invention relates to a molten material processing device having an elongated thermal element like a heating element, a thermocouple, a sensor, a heatpipe and a cooling pipe which is characterised in that said elongated thermal element (2) is located in a recess (3) provided in a surface (6) of the molten material processing device (1), the recess (3), comprising a first portion (4) and a second portion (5), has a cross-section which is larger than a cross-section of the thermal element (2), so as to provide a clear space (7) between the thermal element (2) and the surface (6) of the processing device (1), the clear space (7) which is limited by the first portion (4) and the thermal element (2) is filled by a thermally sprayed material (8) and the second portion (5), which is adapted to the cross-section of the thermal element (2), partially surrounds and directly contacts same.

Abstract: A damped blade is provided that includes a blade structural member defining at least one coolant channel and a liner formed of a shape memory alloy extending at least partially along the at least one coolant channel defined by the blade structural member. The shape memory alloy that forms the liner is maintained generally at its transition temperature by means of coolant circulated through the coolant channel. The shape memory alloy that forms the liner will resist the onset of vibrations within the blade, thereby effectively damping blade vibrations. A method of fabricating a damped blade is also provided.

Abstract: A cylinder block production method is characterized by having, as a step prior to a cast-enclosing step of cast-enclosing a cast iron-made cylinder liner within a cylinder block body, an erosion-wash step of washing an outer peripheral wall surface of the cylinder liner and eroding a portion of a base structure of the cast iron forming the outer peripheral wall surface of the cylinder liner so as to form many small protrusions on the outer peripheral wall surface by jetting a high-pressure fluid onto the outer peripheral wall surface of the cylinder liner, in order to improve strength of adhesion between the cylinder liner and the cylinder block body. Since the base structure is partially eroded, complicated-shape small protrusions can be formed. Furthermore, sand and a mold release agent adhering to the outer peripheral wall surface of the cylinder liner can be removed. Therefore, the adhesion strength will improve.

Abstract: To prevent, in a cooled ring carrier (1) for pistons, durinh Alfin bonding, the formation of oxides induced by air that escapes due to porous ring carrier material and, as a consequence, an impairment of the ring carrier bond. To this end, the cooled ring carrier, once the ring carrier part and the sheet metal part (3) have been linked, is subjected to negative pressure in a vacuum tank.

Abstract: The method allows fabricating a bottle mold having dissimilar metal inserts embedded in regions where the bottle mold is most subject to attack by hot glass, and has a glass contact surface with refined grain size. To fabricate the bottle mold, rough castings are made by pouring cast-iron into a composite mold having dissimilar metal insert blanks fixably positioned therein. The dissimilar metal insert blanks become embedded in the cast-iron matrix to form rough dissimilar metal inserts in the rough casting. The composite mold has regions formed by metal chills that are partially embedded in a sand mix. The chills and the exposed surfaces of the rough dissimilar metal inserts define a cavity surface of the rough casting, which is subsequently machined to provide the glass contact surface of the bottle mold. The chills refine the grain size of the cast iron at the glass contact surface.

Abstract: A process of manufacturing an automobile component comprises molding a high strength first element of steel at a temperature about 1550° C.; removing dirt from a surface of the first element of steel and increasing a roughness of surface thereof by sand polishing; placing the first element of steel in a mold; casting a low tensile strength second element of iron on the first element of steel in the mold at a temperature about 1200° C.; cooling the mold; initially polishing a surface of the half-finished component; and diffusing a melted copper into gaps between the first element of steel and the second element of iron at a temperature ranged from about 1080° C. to about 1200° C. to produce the finished component.

Abstract: In a process for casting a metallic semi-finished product into a casting, the semi-finished product is roughened on a surface which faces the casting, then being placed in a defined position in a casting mold and surrounded with casting metal, after which a firm bond is formed between the semi-finished product and the solidified casting metal at the roughened surface. The surface of the semi-finished product is roughened by high-pressure water blasting.

Abstract: Disclosed are an insert of pour-around die casting, which is incorporated by an aluminum alloy die casting and has an organic film formed on the surface of the insert, wherein the organic film contains a higher fatty acid ester, a petroleum sulfonate and a mineral oil and has a thickness of from 0.5 to 2 &mgr;m, a rust preventive oil used therefor, and a method for incorporating the insert with an aluminum alloy die casting.

Abstract: To prevent, in a cooled ring carrier (1) for pistons, durinh Alfin bonding, the formation of oxides induced by air that escapes due to porous ring carrier material and, as a consequence, an impairment of the ring carrier bond. To this end, the cooled ring carrier, once the ring carrier part and the sheet metal part (3) have been linked, is subjected to negative pressure in a vacuum tank.

Abstract: A method for producing a composite structure in which a foamed metal core (1) is surrounded with a metal body (3). The method includes the following steps: a) producing a foamed metal core (1) with an essentially closed surface; b) introducing the foamed metal core (1) into a pressure die-casting mold; c) filling the pressure die-casting mold at a first casting pressure (p1); d) reducing the first casting pressure (p1) before the pressure die-casting mold has been filled; e) filling the pressure die-casting mold entirely, the first casting pressure (p1) being reduced to zero or almost zero; and f) applying a second casting pressure (p2) and maintaining the second casting pressure for a predetermined holding period.

Abstract: An intermediate material is formed by coating at least a half of the surface of a function selecting material having at least one of physical property values that are different from those of a casting metal material forming a cast product with a coating metal material and the casting metal material is cast together with the intermediate material to form a composite body in casting the product.

Abstract: The microstructure of a metal matrix composite comprising copper and reinforcement material is improved when the metal matrix composite comprises at least about 0.02% by weight of at least one of silver and gold. In one embodiment, the process for making a metal matrix composite comprises compacting powder particles of a reinforcement material to form a green compact, sintering the green compact to produce a porous skeletal body and infiltrating the porous skeletal body with an infiltrant comprising copper and at least about 0.1% of at least one of silver and gold, based on the weight of infiltrant. In another embodiment, the process comprises forming a mixture of particles of reinforcement material, copper and at least about 0.02% by weight of at least one of silver and gold, compacting the mixture to form a green compact, and sintering the green compact to form a near net shape metal matrix composite.

Abstract: A cylinder block production method is characterized by having, as a step prior to a cast-enclosing step of cast-enclosing a cast iron-made cylinder liner within a cylinder block body, an erosion-wash step of washing an outer peripheral wall surface of the cylinder liner and eroding a portion of a base structure of the cast iron forming the outer peripheral wall surface of the cylinder liner so as to form many small protrusions on the outer peripheral wall surface by jetting a high-pressure fluid onto the outer peripheral wall surface of the cylinder liner, in order to improve strength of adhesion between the cylinder liner and the cylinder block body. Since the base structure is partially eroded, complicated-shape small protrusions can be formed. Furthermore, sand and a mold release agent adhering to the outer peripheral wall surface of the cylinder liner can be removed. Therefore, the adhesion strength will improve.

Abstract: Bimetallic plate is produced by providing a substrate of a first metal and, with the preheated substrate positioned in a mold cavity with a major surface of the substrate facing upwardly and to fill a portion of the depth of the cavity, a second metal is cast against that surface to form a cladding component and, with the substrate, to form the bimetallic plate. Prior to the cladding being cast, the major surface is rendered substantially oxide-free and is protected against oxidation. The cladding is cast by a melt, of a composition required for it, being poured at a superheated temperature whereby, with the preheating of the substrate, an overall heat energy balance is achieved between the substrate and the cladding.

Abstract: In a process for casting a metallic semi-finished product into a casting, the semi-finished product is roughened on a surface which faces the casting, then being placed in a defined position in a casting mold and surrounded with casting metal, after which a firm bond is formed between the semi-finished product and the solidified casting metal at the roughened surface. The surface of the semi-finished product is roughened by high-pressure water blasting.

Abstract: An apparatus and method for pressure casting a battery part wherein the state of molten lead is monitored so that when the molten lead enters a liquid-to-solid transformation stage, the volume of the mold available for the lead to solidify therein is quickly reduced through a volume contraction step to thereby cause the molten lead to flow into the remaining volume at the same time one maintains pressure on the molten lead. As the molten lead solidifies under the reduced volume and high pressure it produces a battery part that is substantially free of both tears and cracks. In an alternate method, the lead is allowed to solidify and at least a portion of the lead is mechanically deformed through a volume contraction step to cause cracks or tears in the battery part to be eliminated thereby providing a battery part free of cracks or tears.

Abstract: A method for forming light-weight composite metal castings incorporating metallurgically bonded inserts for a variety of applications. Castings formed by the invention have particular utility as components of an internal combustion engine. A casting method includes the step of coating the insert with a first layer under conditions including sufficient temperature to cause a portion of the layer to be sacrificed by dissolving into the cast metal material while leaving at least a portion of the first layer as a diffusion barrier between the insert and the cast material. The molten casting material is treated and handled to keep the hydrogen content below 0.15 and preferably below 0.10 parts per million. The casting step takes place under a protective gas environment of dry air, argon or nitrogen with a moisture content of less than 3 parts per million.

Abstract: A method of joining an aluminum cast member to an aluminum component. The method includes the steps of coating a surface of an aluminum component with flux comprising cesium fluoride, placing the flux coated component in a mold, filling the mold with molten aluminum alloy, and allowing the molten aluminum alloy to solidify thereby joining a cast member to the aluminum component. The flux preferably includes aluminum fluoride and alumina. A particularly preferred flux includes about 60 wt. % CsF, about 30 wt. % AlF3, and about 10 wt. % Al2O3.

Abstract: Method of making articles comprising polycrystalline &agr;-Al2O3 fibers within a matrix of aluminum, or an alloy of aluminum and up to about 2% copper.

Abstract: A method for forming light-weight composite metal castings incorporating metallurgically bonded inserts for a variety of applications. Castings formed by the invention have a particular utility as components of an internal combustion engine. A casting method includes the step of coating the insert with a first layer which is followed by coating a second layer and concluded by a casting step under conditions including sufficient temperature to cause the second coated layer to be sacrificed by dissolving into the cast metal material while leaving at least a portion of the first layer as a diffusion barrier between the insert and the cast material. The molten casting material is treated and handled to keep the hydrogen content below 0.15 and preferably below 0.10 parts per million. The casting step takes place under a protective gas environment of dry air, argon or nitrogen with a moisture content of less than 3 parts per million.

Abstract: The present invention relates to a liquid-solid rolling bonding method for heterogeneous metals and an apparatus therefor. The method comprises: pouring a liquid metal onto the surface of a heterogeneous solid base metal coated with a soldering flux; rolling the liquid metal and the solid metal under pressure; solidifying the liquid metal and making it bond to the surface of the solid base metal under rapid cooling to realize metallurgical bonding of the two or more metals. The apparatus comprises an unrolling machine, a soldering flux tank, a drying-heating apparatus, a pouring nozzle, an interior water-cooling rollers and a roll-collecting machine arranged in order, a pouring basket is disposed above the pouring nozzle and a base frame is disposed below the pouring nozzle. The present invention has the advantages of high bonding strength, lower production cost, high production efficiency, good product quality, fewer investment for the apparatus and lower consumption of energy.

Abstract: A method of forming an aluminum alloy scroll machine component having improved lubricity.

Abstract: A process of fabricating a light alloy casting, such as an aluminum alloy casting, including at least one metal insert includes applying a coating of lampblack to a face of the insert intended to be in contact with the alloy of the component and casting the component with the molten alloy in a mold cavity in which the insert is positioned. Applications include fabricating engine blocks with integrally cast liners made of cast iron.

Abstract: A device for manufacturing an engine block has a casting mold with mold parts and cylinder liners. The mold parts have a seat with seat surfaces for each cylinder liner, and the opposed ends of the cylinder liner are seated in the seat surfaces. The cylinder liners become connected to the material cast in the casting mold and are removed together with the cast material from the mold parts after casting. The seat surfaces are conical and inclined at an incline angle relative to the cross-sectional plane of the cylinder liner seated in the seat such that the opposed ends of the cylinder liner remain seated at the seat surfaces upon heat expansion of the cylinder liner during preparation of the casting mold for casting and during casting.

Abstract: Metal matrix composite wires that include at least one tow comprising a plurality of substantially continuous, longitudinally positioned fibers in a metal matrix. The fibers are selected from the group of ceramic fibers carbon fibers, and mixtures thereof. The wires have certain specified characteristics such as roundness values, roundness uniformity values, and/or diameter uniformity values.

Abstract: Method of making wire comprising polycrystalline &agr;-Al2O3 fibers within a matrix of substantially pure elemental aluminum, or an alloy elemental aluminum and up to about 2% copper.

Abstract: Metal matrix composite wires that include a plurality of substantially continuous, longitudinally positioned fibers in a metal matrix. The wire exhibits zero breaks over a length of at least 300 meters when tested according to a specified test.

Abstract: Provided are a Fe-based metal porous preform capable of ensuring sufficient adhesiveness between a molten metal and a base material thereof even when a casting process having a time lag from completion of pouring of the molten metal till pressure impregnation is applied; and a manufacturing process for a metal composite member using such a preform. The Fe-based metal porous preform is a metal porous preform adopted in a casting process having a prescribed time lag from completion of pouring of a molten metal till impregnation of the molten metal when the metal porous preform set inside a mold is impregnated with the molten metal, and characterized by that the metal porous preform is made from an iron-based metal as a base, including chromium in the range of 10 to 40 wt % as a content.

Abstract: Surface activation is intended to ensure that a cylinder liner can be anchored in the casting material of a light-metal crankcase with greater bonding. For surface activation, the surface of the cylinder liner is roughened mechanically. Advantageously, copper particles are also implanted into the treated surface. It is necessary to ensure that the time span between surface activation and casting-in is short. Moreover, the activated surface, as far as possible, should not be touched by hand.

Abstract: A cylinder-liner blank which preferably consists of a hypereutectic aluminum/silicon alloy and is cast into a crankcase. A special surface treatment achieves better material bonding of the liner in the crankcase. The blank has a roughness of 30 to 60 &mgr;m on its outside, in the form of pyramid-like or lancet-like protruding material scabs or material accumulations. To obtain this roughness, the surface is blasted with particles which are broken so as to have sharp edges and consist of a brittle hard material, preferably high-grade corundum, with an average grain size of about 70 &mgr;m. A fine fraction is formed and is continuously separated off. The average grain size is maintained by adding new particles.

Abstract: An intermediate material is formed by coating at least a half of the surface of a function selecting material having at least one of physical property values that are different from those of a casting metal material forming a cast product with a coating metal material and the casting metal material is cast together with the intermediate material to form a composite body in casting the product.

Abstract: A method for forming a heat transfer apparatus wherein a conduit construct is formed between first and second construct ends and is disposed in a mold cavity with the first and second ends extending from the cavity, air is removed from the construct, body material in molten fluid form is provided in the cavity so as to cover the construct and the molten material is permitted to solidify. In addition, the invention includes a manganese/nickel barrier material which is placed on a conduit construct prior to introducing molten material into the cavity to reduce bubbles in the sink. The invention also includes a system for maintaining heat sink temperature despite fluctuating amount of heat generated by devices mounted to or adjacent a sink wherein the system includes a temperature sensor, a controller and a regulator, the controller controlling the regulator as a function of feedback signals received from the sensor.

Abstract: A core is formed and a prefabricated bearing bore is provided. Two separate projections are provided on the core wherein free projection edges of the two separate projections have a respective shaping radius between R=0.sub.mm and R.ltoreq.0.45.sub.mm. Subsequently indentations are produced in a circumferential area of the bearing bore by the two separate projections on the core wherein the indentations serve as fracture notches. The cast engine part is then formed by casting metal around the core using said fraction notches as incipient crack sites.

Abstract: Alumina tiles within aluminum framing jigs are fixedly positioned by lock ns within an internally coated mold for centrifugal casting within a block of an aluminum alloy material. Such jigs and the tiles framed therein are coated with silver before casting to prevent aluminum oxidation by heating of the aluminum material to a molten state for deposit into the mold. Bonding of the tiles and framing of the jigs with the aluminum material being cast is also enhanced by such silver coating.

Abstract: The aim is to improve the strength of an intermetallic bond between engine component made from an aluminium alloy and a reinforcing element made from austenitic cast iron. For that purpose, the reinforcing element is annealed in a decarbonising atmosphere before the known prior art alfin process is carried out, in order to obtain an alfin layer largely free of graphite scales.

Abstract: The article is produced by prepositioning nonwoven reinforcement, coated h a bond enhancing compound inside of a centrifugal casting mold that is surface coated for protective shielding of the reinforcement. Molten matrix metal is then introduced into the mold while being rotated about its longitudinal axis until the molten metal completely encapsulates the reinforcement.

Abstract: An aluminum-based composite member having an increased strength of bond between an aluminum-based body and a cast iron material portion which is incorporated into the aluminum-based body by casting is provided by an improved process. The following steps are employed in the process: a step of removing an oxide film on the surface of the cast iron material portion and activating such surface; a step of forming a protecting plated-layer having a thickness a in a range of 0.8 .mu.m.ltoreq.a.ltoreq.5 .mu.

Abstract: The present invention relates to a manufacturing method of aluminum alloy having high wear resistance, in particular, to manufacturing method of aluminum alloy by dispersing silicon particle on only required part of wear resistance, and infiltrating the molten metal into the preform of silicon particle.

Abstract: Inserts of powder compacts or metal matrix composite inserts in the form of rods, bars, plates, wires, wire mesh, ribbons, chaplets, mold coatings or machining chips are placed in the sprue, sprue basin, runner, or a mold in gate of a static sand mold. The molten metal stream partly or completely melts the inserts releasing the reinforcements which get mixed with the molten alloy streams to form the shaped casting of the composite.

Abstract: A preformed fiber reinforced metal matrix composite reinforcement insert is clad or covered with a material that is effective to avoid the adverse reactions between the insert/melt and any exposed insert fibers/matrix. The clad insert is suspended in the mold cavity and a melt is introduced into the mold cavity about the clad insert. The melt is solidified about the clad insert to provide a casting of the solidified melt having the clad insert disposed therein to reinforce the casting.

Abstract: In carrying out a cast-in process, a cast-in insert member is placed into a cast forming cavity in a casting mold, and a casting is conducted. The cast-in insert member has a barrier layer on its non-deposited surface for inhibiting the deposition of a molten metal. During casting, a portion of a molten metal is introduced to a heating chamber on the side of the barrier layer to come into contact with the barrier layer. Thus, the cast-in insert member can be heated not only from the side of its deposited surface, but also from the side of its non-deposited surface, thereby providing an enhanced strength of deposition of the cast-in insert member.

Abstract: This invention relates to the discovery of organometallic ceramic precursor binders used to fabricate shaped bodies by different techniques. Exemplary shape making techniques which utilize hardenable, liquid, organometallic, ceramic precursor binders include the fabrication of negatives of parts to be made (e.g., sand molds and sand cores for metalcasting, etc.), as well as utilizing ceramic precursor binders to make shapes directly (e.g., brake shoes, brake pads, clutch parts, grinding wheels, polymer concrete, refractory patches and liners, etc.). In a preferred embodiment, this invention relates to thermosettable, liquid ceramic precursors which provide suitable-strength sand molds and sand cores at very low binder levels and which, upon exposure to molten metalcasting exhibit low emissions toxicity as a result of their high char yields of ceramic upon exposure to heat. Another preferred embodiment of the invention involves the fabrication of preforms used in the formation of composite articles.

Abstract: A cast article having a reinforced structural composite core is disclosed. The cast article includes a structural element which is embedded in the otherwise cast metal article. The structural element is comprised of a metal matrix composite structural core. It includes a plurality of reinforcing fibers within a metal matrix. The fibers are generally a non-metallic material such as a ceramic which degrade at a temperature below the melting temperature of the cast metal comprising the article. The metal matrix composite structural core is encased with a sheath. The sheath, attached to and completely surrounding the core, is made of the same metal as the cast metal article. In a preferred embodiment, the article is a titanium alloy strut for a gas turbine engine.

Abstract: A cast article having a reinforced structural composite core is disclosed. The cast article includes a structural element which is embedded in the otherwise cast metal article. The structural element is comprised of a metal matrix composite structural core. It includes a plurality of reinforcing fibers within a metal matrix. The fibers are generally a non-metallic material such as a ceramic which degrade at a temperature below the melting temperature of the cast metal comprising the article. The metal matrix composite structural core is encased with a sheath. The sheath, attached to and completely surrounding the core, is made of the same metal as the cast metal article. In a preferred embodiment, the article is a titanium alloy strut for a gas turbine engine.

Abstract: A method for wetting and bonding refractory alumina or aluminosilicate fibers or particles with molten aluminum or aluminum alloys by forming a boron oxidized interface between the fiber and the metal is exists. The method comprises the steps of (a) coating alumina fibers with an effective amount of a thermally decomposable precursor of boron oxide; (b) heating the coated fiber sufficiently to form a boron oxide; and (c) forming a composite with aluminum metal or an aluminum alloy. Thermally decomposable precursors of boron oxide include ammonium pentaborate, ammonium diborate and orthoboric acid.

Abstract: Organometallic ceramic precursor binders are used to fabricate shaped bodies by different techniques. Exemplary shape making techniques which utilize hardenable, liquid, organometallic, ceramic precursor binders include the fabrication of negatives of parts to be made (e.g., sand molds and sand cores for metalcasting, etc.), as well as utilizing ceramic precursor binders to make shapes directly (e.g., brake shoes, brake pads, clutch parts, grinding wheels, polymer concrete, refractory patches and liners, etc.). A preferred embodiment of the invention involves the fabrication of preforms used in the formation of composite articles.

Abstract: A solid material is bonded to a metal cast thereagainst by means of a metallurgical diffusion bond. The solid material is coated with a latent exoergic coating which coating reacts exothermically to produce intermetallic phases at the surface of the solid when the metal is cast thereagainst. The heat generated by the intermetallic-phase-formation reaction promotes the diffusion bond.

Abstract: The invention produces a light metal alloy composite having a nickel coated graphite or carbon with a nickel-containing intermetallic phase within a portion of a casting. A mold is provided to cast a light metal into a predetermined shape. A nickel coated carbon phase structure is placed into a portion of the mold. The light metal is cast into the mold around the carbon structure to wet an interface between the light metal and the nickel coated carbon structure. A nickel-containing intermetallic phase is formed in the light metal proximate the nickel coated carbon to provide increased wear resistance. The light metal is then solidified to form the metal matrix composite.

Abstract: Composite casting process for making castings, consisting in particular of light metal alloys reinforced by fiber or foamed material inserts, in particular motor parts such as pistons, cylinders, cylinder heads and motor blocks of internal combustion engines. In this process, firstly, a preform reinforced by the fiber or foamed material inserts is made by embedding and the penetration of a fiber bundle or a foamed material body in molten matrix metal or by a molten matrix metal and subsequently solidifying it. Then, the preform is immersed in a molten metal bath and subsequently inserted into a casting mould for integrally casting or casting around the final casting.