Abstract: An EC motor with a rotor. The rotor has a hub with outwardly extending silicon steel laminates with gaps between. Rectangular neodymium permanent magnets are positioned in the gaps. Wedge-shaped ferrite permanent magnets are positioned radially between the silicon steel laminates and the hub of the rotor.

Abstract: Disclosed is a muffler for a water-cooled chiller or air-cooled of a vapor-compression or absorption refrigeration system, the muffler having: an upstream case (110) having a fluid inlet (120); a downstream case (115) connected to the upstream case at a downstream end of the upstream case, the downstream case having a fluid outlet (125); the upstream case having a plurality of axially adjacent outer muffler rings (145) and a plurality of axially adjacent inner muffler rings (155), the outer muffler rings being axially coextensive and a radially exterior to the inner muffler rings and defining a fluid inlet passage (140) therebetween, wherein the outer muffler rings and inner muffler rings are a metal mesh material.

Abstract: A method of preheating an unfinished stator as an intermediate product before a stator as a final product for a motor is provided in order to preheat a mold for molding together with the unfinished stator in short time by using preheating facilities with simplified structures. In the method, the mold has a hollow and longitudinal barrel portion and a flange portion extending outward from an end of the barrel portion. The flange portion is arranged at a horizontal position to turn the barrel portion upward and an end of a cylindrical and longitudinal frame is put on the flange portion in a state where a core of the unfinished stator is fitted in the frame. A heat-resistant box of which an underside is opened covers the frame and the mold to surrounded outsides of the frame and the mold.

Abstract: Various embodiments include a rotor for an electric machine comprising: an electric coil arrangement; and a winding carrier mechanically carrying the coil arrangement and at least partially enclosing the coil arrangement on a radially outer side of the coil arrangement. The rotor includes an inner cavity for circulating a fluid coolant such that the coil arrangement comes into contact with the liquid coolant on its radially inner side as the rotor rotates.

Abstract: A rotor of rotary electric machines includes a rotor core which include first and second core blocks. The first core block is formed by stacking the steel plates in a state where the steel plates are engaged by a first crimping portion and skewed in a first direction in a circumferential direction. The second core block is formed by stacking the steel plates in a state where the steel plates are engaged by a second crimping portion and skewed in a second direction facing the first direction. The first and second core blocks are connected in an axial direction in the rotor core. A hole for inserting the first crimping portion is provided in an intermediate steel plate which is part of the annular steel plates. This intermediate steel plate is provided at a block boundary position of the second core bock and is connected to the first core block.

Abstract: A mould for forming battery components includes a first mould body having a first plurality of mould cavities and a second mould body having a second plurality of mould cavities. The first mould body and the second mould body are configured to be moveable between a moulding position in which the first plurality and second plurality of mould cavities are aligned, and a fill position in which the first plurality and second plurality of mould cavities are displaced from the aligned position and are proximal to a molten metal feed.

Abstract: The invention relates to a method for producing a material composite composed of metal and plastic to form a plastic-metal hybrid component, in which method, to improve the adhesion of the metal surface and at least one plastic component, stochastically random macroscopic and/or microscopic undercuts are made by means of short-pulse laser radiation in the metal surface in order to roughen it, these undercuts each being filled at least partially with the at least one plastic component in an injection moulding process such that said plastic component engages into the macroscopic and/or microscopic undercuts, wherein, following the roughening of the metal surface and before and/or during the injection moulding process for the at least one plastic component, at least the roughened surface of the metal is heated to a temperature which, during processing, lies in the range of room temperature up to 100° C. above the processing temperature of the plastic.

Abstract: A resolver is installed inside a housing of a motor. A stator of the resolver has a three layered core. a main layer of an electric steel sheet, a first shielding layer of a magnetic metal, a second shielding layer interposed between the domain layer and the first to shielding layer. The second shielding layer is made of a non-magnetic material.

Abstract: An apparatus for starting an engine, including a motor, an output shaft driven by the motor, a pinion provided along the output shaft, and an electro-magnetic solenoid device. The electro-magnetic solenoid device is configured to push the pinion axially toward a ring gear of the engine to mesh the pinion with the ring gear and transfer a rotational force, which is referred to as a motor torque, generated by energization of the motor from the pinion to the ring gear, thereby starting the engine. The apparatus is configured such that, at starting of the engine in its warmed-up state, the motor torque can continue to be applied from the pinion to the ring gear until at least the second compression stroke even when an engine speed varies.

Abstract: An exemplary casting assembly for an engine block includes, among other things, an insert and at least one magnet configured to retain the insert in a predefined position within an engine block mold cavity. An exemplary engine block casting method includes, among other things, positioning at least one insert in a mold cavity, retaining the insert in position with at least one magnet, introducing material into the mold cavity to form an engine block, and solidifying the material to secure the insert within the engine block.

Abstract: The rotor includes a shaft, and a rotor core that is fitted and fixed to the shaft. The shaft includes a knurled portion on an end side and a small-diameter portion formed in a tip side via a first stepped surface. The rotor core includes a small diameter hole formed in a tip side end portion of the fitting hole press-fitted onto the small diameter portion, a large diameter hole formed in an end side of the small diameter hole via a second stepped surface, and a press-fitting portion press-fitted onto the knurled portion and is formed on an end side end portion of the large diameter hole. A space part is disposed between the first stepped surface and the second stepped surface.

Abstract: A device and a method for adjusting stirring blades on a stirring blade receptacle of a stirrer, wherein the stirring blades can be fixed with a stirring blade axis in receiving bores, which are arranged transversely to an axis of rotation and are a part of the stirring blade receptacle, at intended predetermined angle of attack relative to a virtual plane that is arranged transversely to the axis of rotation of the stirrer. An associated device body is provided with a receiving element for receiving the stirring blade receptacle with unfixed stirring blades. A stop is arranged on the device body for each lower face, which faces the receiving element and is a part of the stirring blades, outside the respective stirring blade axis. Each respective stirring blade is then brought into abutment against its associated stop, to place it into the predetermined angle of attack.

Abstract: An assembly may comprise a first part including a first surface, and a second part including a second surface and a bottom edge having sloped regions and at least one well between the sloped regions. The assembly may further comprise a brazed joint joining the first surface to the second surface. The at least one well may be configured to collect excess braze material from the brazed joint.

Abstract: In a setting step, a plurality of steel plates configuring a rotor core stacked in an axial direction of a rotor is set in a predetermined position in a mold that is capable of being opened and closed by relative movement in the axial direction. In a casting step, molten metal is fed into a molten metal introduction passage to form a conductive member of the rotor. The molten metal introduction passage has a ring-shaped gate that is opened so as to oppose one axial end surface of the steel plates set in the mold. In a cutoff step, the molten metal is cut off in the molten metal introduction passage so as to be separated into a gate side and a molten metal introduction opening side. In a mold-releasing step, the mold is opened such that a casting configuring the rotor is removed from the mold.

Abstract: Disclosed herein is a centrifugal casting machine, including: a rotating plate rotating by means of a motor; a cylindrical sleeve installed on the rotating plate and having an internal diameter corresponding to an external diameter of silicon steel plates constituting a core in the sleeve; an upper mold internally installed on the sleeve to define a first molding space into which a molten metal is introduced to mold an end ring; a lower mold internally installed on the sleeve to define a second molding space into which a molten metal is introduced to mold an end ring; a dummy shaft fitted in the center of the core and coupled to the lower mold; a cap coupled to an upper end of the dummy shaft to press the core; and a hydraulic ram coupled to the lower mold to move the lower mold up and down and coupled to the rotating plate to rotate therewith.

Abstract: A method for producing a cage rotor for an asynchronous machine is provided. The method includes providing a rotor body having a conductor bar segment in which conductor bars are provided, producing conductor bar slots in the conductor bar segment, wherein one conductor bar slot is provided for each of the conductor bars and producing short circuit ring recesses for short circuit rings, wherein the conductor bar slots each open into the short circuit ring recesses, pressure die casting cage material in the conductor bar slots, in situ, so that the conductor bars are formed of the conductor bar material in the conductor bar slots and the short circuit rings are formed in the short circuit ring recesses, and generating an area in the conductor bar material and the rotor body material including a metallurgical bond between the conductor bar material and the rotor body material at interfaces between the conductor bars and the rotor body.

Abstract: A rotor core for an electric motor includes a stack of laminations having peripherally spaced openings receiving copper bars with opposite end portions projecting from the stack. The core is mounted on an arbor and is inserted into a mold on a vertical die cast press having a shot chamber. The mold has upper and lower mold members defining annular cavities receiving end portions of the bars. Molten copper or aluminum is poured into the shot chamber and forced upwardly by a shot piston through passages in the lower mold member and into the cavity around the lower end portions of the bars. The pressurized molten metal solidifies and shrinks around the bar end portions to form an endring for the rotor. The core, endring and arbor are inverted and confined in the mold, and the casting steps are repeated to form the opposite endring.

Abstract: An induction rotor assembly having an induction cage that is formed using a combination of liquid and solid materials. The first and second end plates of the induction cage may be fabricated before the casting of the conductors of the induction cage. According to certain embodiments, the first and second end plates may be assembled with first and second molds and a rotor core to form a casting assembly. A liquid casting material may be injected into the casting assembly, wherein the liquid casting material may solidify within one or more core passageways of the rotor core, thereby forming the conductors of the induction cage. The first and second end plates may also include flow channels that may be configured to facilitate the flow of the liquid casting material in the casting assembly, and increase the area of contact between the liquid casting material, when solidified, and the end plates.

Abstract: A method for forming a rotor assembly including a cast rotor frame includes positioning a preheated rotor core defining a plurality of passages in a mold cavity such that the mold cavity and the rotor core define the rotor frame including a plurality of conductor bars defined by the plurality of passages in fluid communication with first and second end portions of the mold cavity. Molten metal is quiescently introduced into the mold cavity through an ingate and simultaneously flowed through the plurality of passages prior to filling at least one of the first and second end portions of the mold cavity to form the cast rotor frame. Entrained air and impurities may be displaced from the passages by the flow of molten metal and vented or entrapped by a biscuit. The rotor frame and conductor bars thus formed may be characterized by high conductivity, negligible porosity, and minimal oxides.

Abstract: A line-start synchronous motor has a housing, a rotor shaft, and an output shaft. A soft-start coupling portion is operatively coupled to the output shaft and the rotor shaft. The soft-start coupling portion is configurable to enable the synchronous motor to obtain synchronous operation and to drive, at least near synchronous speed during normal steady state operation of the motor, a load having characteristics sufficient to prevent obtaining normal synchronous operation of the motor when the motor is operatively connected to the load in the absence of the soft-start coupling. The synchronous motor is sufficiently rated to obtain synchronous operation and to drive, at least near synchronous speed during normal steady state operation of the motor, a load having characteristics sufficient to prevent obtaining normal synchronous operation of the motor when the motor is operatively connected to the load in the absence of the soft-start coupling.

Abstract: Methods of making squirrel cage rotors of aluminum based material end rings joined with high conductive and durable material (such as copper) conductor bars for use in electric motors. The methods include forming conductor bars by casting or other metal forming methods in the slots of laminate steel stack, or positioning the preformed or premade solid conductor bars in the longitudinal slots of the stacked laminated steel, with bar ends extending out of the laminated steel stack ends, optionally coating the extended part of the conductors (bars) with a latent exoergic coating containing Al and one or more conductor bar chemical elements, positioning the laminated steel stack having conductors (bars) in a casting mold that forms the cavity of both end rings of the rotor, filling the end ring cavities with aluminum melt, and allowing the end rings to solidify under pressure. Alternatively, the conductor bars and end rings can be made separately and mechanically joined together.

Abstract: A rotor core for an electric motor includes a stack of laminations having peripherally spaced openings receiving copper bars with opposite end portions projecting from the stack. The core is mounted on an arbor and is inserted into a mold on a vertical die cast press having a shot chamber. The mold has upper and lower mold members defining annular cavities receiving end portions of the bars. Molten copper or aluminum is poured into the shot chamber and forced upwardly by a shot piston through passages in the lower mold member and into the cavity around the lower end portions of the bars. The pressurized molten metal solidifies and shrinks around the bar end portions to form an endring for the rotor. The core, endring and arbor are inverted and confined in the mold, and the casting steps are repeated to form the opposite endring.

Abstract: A metal/ceramic bonding substrate includes: a ceramic substrate; a metal plate bonded directly to one side of the ceramic substrate; a metal base plate bonded directly to the other side of the ceramic substrate; and a reinforcing member having a higher strength than that of the metal base plate, the reinforcing member being arranged so as to extend from one of both end faces of the metal base plate to the other end face thereof without interrupting that the metal base plate extends between a bonded surface of the metal base plate to the ceramic substrate and the opposite surface thereof.

Abstract: A method for forming a rotor for an induction motor includes providing a rotor core including a plurality of conductor bar grooves having first and second ends corresponding to first and second ends of the rotor core wherein the conductor bar grooves are progressively larger closer to the ends of the conductor bar grooves. The rotor core is placed into a casting mold, and molten metal is introduced into a first end of the casting mold. The molten metal flows from the first end of the casting mold through the plurality of conductor bar grooves to a second end of the casting mold. The molten metal solidifies to form conductor bars in the plurality of conductor bar grooves and to form shorting rings across exterior portions of the end elements within the first and second ends of the casting mold.

Abstract: A rotor for an induction motor and a method of preparing same. The method includes making a squirrel-cage rotor made up of a cage and a laminate stack by forming a mold around the stack, heating the stack and introducing a molten metal into the mold such that the molten metal substantially fills a space defined in the stack that corresponds to the cage. In one form, the space includes slots or related channels formed in the stack that upon filling with the molten metal become longitudinal bars that form electric current loops with end rings of the cage. By heating the stack and maintaining it at a temperature high enough to keep the molten metal in a substantially molten state at least long enough for it to flow through the slots of the stack, premature freezing of the molten metal is avoided. In addition, by providing low pressure to the molten metal in conjunction with the elevated temperature in the stack, flow is promoted to ensure a substantially porosity-free, fully dense squirrel-cage for the rotor.

Abstract: A mold for forming a plurality of rotors includes a plurality of lamination stacks, wherein each lamination stack defines at least one void therethrough; a tube having a central longitudinal axis, wherein each lamination stack is concentrically spaced apart from the tube to define a channel therebetween; a plurality of washers each having a shape defined by a first diameter and a second diameter that is greater than the first diameter, wherein each washer is configured to concentrically abut the tube and define a feed conduit interconnecting with the channel; and a shell disposed in contact with each lamination stack and concentrically spaced apart from each washer to define a plurality of ducts, wherein each duct is interconnected with the at least one void of at least one lamination stack. A mold system and a method of forming a plurality of rotors are also described.

Abstract: A dual temperature mold assembly for maintaining a mold cavity used in a cast on strap process at two different temperatures facilitates the removal of the solidified strap after the molten metal is solidified. The mold assembly includes a mold cavity having walls attached to different mold assembly segments that are heated or cooled by thermal energy input and coolant processes which can maintain the mold cavities at different temperatures, so that molten metal around the battery plate lugs in a mold cavity segment is solidified while the sides of the mold cavity are exposed to at least one adjacent heated segment to provide thermal energy thereinto, resulting in a reduction of the amount of molten metal necessary for a cast on strap, and reducing the amount of thermal energy input into the process for manufacturing the straps.

Abstract: A portion of a reinforcing member has a stacked structure 102 in which plural iron plates having openings 106 are stacked. A hollow portion 107 is formed inside the stacked structure 102, so that the reinforcing member is reduced in weight. Porous bodies 103 composed of non-woven fabric of metal fibers are disposed on surfaces contacting matrixes, so that adhesion between the reinforcing member and the matrix is improved, and peeling therebetween is prevented. A cast product which is composed of light metal and has the above reinforcing member has a small thermal expansion. For example, the cast product is desirable for use for a journal portion of an engine block.

Abstract: A method of assembling a rotor assembly is provided, without the use of a rotor steel hub. The method comprises forming first, second and third lamination stacks by stacking individual rotor laminations together. The first, second and third lamination stacks are cast to lock the individual rotor laminations together. The rotor laminations in the first, second and third lamination stacks have a generally ring-like shape with a variable inner diameter and a substantially common outer diameter. The rotor laminations in the first, second and third lamination stacks have substantially the same outer diameter, whereas the rotor laminations in the second lamination stack have a substantially larger inner diameter than the first and third rotor laminations. The elimination of the hub results in reducing total cost and manufacturing cycle time, and in improved features, performance and efficiency of the rotor assembly.

Abstract: A method and a mold for fabricating heat sinks with fins, which includes steps of: providing a casting mold having a casting channel and multiple lamination cavities communicating with the casting channel defined therein; inserting multiple laminations being capable of heat dissipating into the lamination cavities of the casting mold respectively to make each lamination having an edge protruding from the lamination cavity; pouring a liquid material into the casting channel to solidify and integrate with the edges of the laminations to form a casting; and removing the casting from the casting mold. Accordingly, the method and the casting mold not only accelerates and facilitates manufacturing of heat sinks, but also allows a high-density of fins to be formed on a heat sink.

Abstract: A process for the injection of an electric motor rotor, said rotor comprising: a lamination stack (10) having a central axial bore (11) and a plurality of axial channels (12); and a cage (30) of aluminum, which is formed by an upper end ring (31) and a lower end ring (32), which are interconnected by a plurality of bars (33) molten in the axial channels (12).

Abstract: A method of assembling and manufacturing a laminated rotor is provided which uses laminations having a thin bridge thickness. Different techniques are provided for preventing the molten material used in the casting or injection molding operation from leaking or seeping between the laminations during casting. In one technique, the laminations are stacked and oriented in the conventional way, and then both axial and radial pressures are applied to the stacked laminations to hold the laminations in position for the casting process. In another technique, the laminations are formed or extruded with a lip or collar portion that fit in a countersunk portion of an adjacent lamination and forms a wall or barrier between the laminations to prevent the leakage of the molten material during the casting or injection molding operation.

Abstract: A method of assembling and manufacturing a laminated rotor is provided which uses laminations having a thin bridge thickness. Different techniques are provided for preventing the molten material used in the casting or injection molding operation from leaking or seeping between the laminations during casting. In one technique, the laminations are stacked and oriented in the conventional way, and then both axial and radial pressures are applied to the stacked laminations to hold the laminations in position for the casting process. In another technique, the laminations are formed or extruded with a lip or collar portion that fit in a countersunk portion of an adjacent lamination and forms a wall or barrier between the laminations to prevent the leakage of the molten material during the casting or injection molding operation.

Abstract: A heat sink of metal material, in particular a light metal alloy, for semi-conductor elements or similar components, has plate-like cooling ribs projecting from a base plate at intervals (f) and approximately parallel to each other, protrude with a connection strip into the base plate in which they are cast. A molding tool designed for production of the heat sink includes a casting mold with a mold chamber for the base plate. The mold chamber contains an area to receive the connection strips of the cooling ribs. Two parallel side walls of the casting mold and intermediate layers arranged parallel between them, each defining a receiver gap, are arranged displaceably on at least one shaft passing through them. The walls can be moved to produce the compact casting mold after insertion of the cooling ribs in the receiver gaps.

Abstract: The present invention provides a method and apparatus for die-casting copper and other metals that are cost-effective and practical for production use in die-casting, for example, copper motor rotors. In motor rotors, the incorporation of die-cast copper for conductor bars and end rings in place of aluminum is known to result in improvements in motor energy efficiency. Previous attempts to die-cast copper motor rotors in a commercially feasible manner have failed because copper's high melting point places too great a stress on the die material, resulting in cracking and fracturing of the molds. High temperature die materials such as nickel, tungsten and molybdenum based alloys with a high melting point are employed, and a die casting apparatus is provided to pre-heat the molds prior to injection of the molten copper. Pre-heating and high operating temperatures provide extended die life.

Abstract: A method of joining a lamination stack of an electromagnetic actuator to a housing of the actuator includes providing a lamination stack having at least one surface feature. A mold is provided to define the housing. The lamination stack is inserted into the mold such that the surface feature of the lamination stack will define a mating surface feature in the housing. Material is cast around at least a portion of lamination stack to define the housing such that the surface feature of the lamination stack is engaged with the surface feature of the housing, thereby joining the lamination stack to the housing. The assembly of the lamination stack and housing is then removed from the mold.

Abstract: A process for manufacturing a heat sink, in which a plate-shaped base portion is formed by the diecasting method integrally with the one-end portions of a plurality of fins arrayed at a constant pitch and in parallel with each other.

Abstract: A cast-on method and its apparatus for joining battery plates to a post in which heat capacity of a mold for forming a post and a strap is less than five times of heat capacity of metals to be introduced in the mold. The mold is made of materials having less linear thermal expansion coefficient preferably less than 18×10−6/° K. The mold may be dipped into calmly flowing molten metal keeping a constant level.

Abstract: A fixture to evaluate stator production quality is placed about a stator core so as to introduce a test winding about the stator without need for hand winding. The fixture includes an inner annulus and an outer annulus each with axial conductors thereon, and top and bottom plates each with conductors thereon. The core is fitted between the inner and outer annuli, and between the top and bottom plates. The inner axial conductors and outer axial conductors are connected to one another at their lower ends through the bottom plate conductors and at their upper ends through the top plate conductors. Once testing is complete, the fixture is easily removed.

Abstract: A method of making a squirrel-cage rotor employs a forging die assembly including a receiving die receiving one end of a rotor core and having a first annular concavity corresponding to one of two end rings and a pressing die movable relative to the other end of the rotor core to form a second annular concavity corresponding to the other end ring. The one end of the rotor core is set in the receiving die, and a forging material such as aluminum is set at the other end of the rotor core. Subsequently, the pressing die is moved relative to the other end of the rotor core so that the forging material is pressurized to be plastically deformed. The forging material is caused to enter the first concavity through slots of the rotor core. Consequently, the first and second concavities and the slots of the rotor core are filled by the forging material such that a squirrel-cage conductor is formed.

Abstract: A method and apparatus for more efficiently fusing the straps of pre-formed terminal post members with plate lugs of a battery plate group utilizing a non-reusable, inexpensive plastic mold insert. The method includes positioning the battery plate group into an open top container with the lugs of the positive plates in one row and the lugs of the negative plates in another row, positioning the plastic insert into the container with the lugs of the plate group extending upwardly through the mold insert, positioning the terminal post members on the plastic mold insert with fingers of the straps thereof disposed between plate lugs of the respective rows, supplying additional unmelted lead into remaining spaces between the plate lugs, and heating, melting, and fusing the plate lugs, strap fingers, and added lead by induction heating to form interconnections between the positive and negative plates in the respective terminals.

Abstract: A stamped, steel insert for use in metal die cast articles. The insert includes first and second interconnected stamped steel insert halves spaced from one another at certain locations to define a void. Openings communicating with the void extend through each insert half to facilitate material flow and to improve interlock of the insert and die cast material. The edges of the insert lie below the surface of the casting to avoid bimetallic machining. The insert halves cooperate to define a pair of elongated passages, which are bored following die casting to form fastener holes. At least one of the passages has an elongated cross section to allow for expansion and contraction of the insert during casting.

Abstract: An electric motor includes a stator having a stator core, a start winding and first and second main windings. The first main winding and the start winding are configured to form a lower number of poles than the second main winding. The stator core forms a stator bore. The motor also includes a rotor having a rotor shaft concentrically arranged axially of the stator core and a rotor core positioned concentrically with the rotor shaft. Secondary conductors are arranged axially of the rotor shaft and extend through the rotor core. A plurality of permanent magnets are located at an outer periphery of the rotor core and are magnetized to form a number of poles equal to the number of poles formed by the second main winding.

Abstract: A method of producing a squirrel-cage rotor for an induction motor, which includes a plurality of secondary conductors arranged respectively in through holes (16) of a laminated core (14), and a pair of end rings connecting the secondary conductors with one another at both axial ends of the laminated core (14). Each of a pair of reinforcing members (22) includes a cylindrical wall (26), an annular multi-aperture wall (28) provided with apertures (32) and extending in a radial inward direction from one edge of the cylindrical wall (26), and an annular end wall (30) extending generally parallel to the multi-aperture wall (28) in a radial inward direction from another edge of the cylindrical wall (26). Each reinforcing member (22) is arranged in a manner in which the multi-aperture wall (28) is brought into contact with one of the axial end faces of the laminated core (14) while the apertures (32) communicate with the through holes (16).

Abstract: An ingot having a predetermined amount of electrolytic copper and a small percentage of boron copper alloy is rapidly heated to about 2,100.degree. F. in a clay graphite crucible by induction coils surrounding the crucible. The crucible and the entire amount of molten copper are automatically transferred to a cavity defined within a shot cylinder above a vertically movable shot piston of a vertical die casting press. A shuttle moves a lower end ring mold and a stack of connected rotor laminations into a position above the shot cylinder, and the press moves an upper end ring mold downwardly to clamp the stack between the molds and against the cylinder. The molten copper is rapidly injected upwardly through gates within the lower mold and into end ring cavities within the molds and also through connecting aligned bar slots within the stack of laminations with a shot pressure of about 2250 psi.

Abstract: A die cast, two pole, insulated magnet assembly and method of manufacture. A magnetic body of preferably ceramic ferrite material is sandwiched between two pole pieces such that each pole has a free end which projects beyond the magnetic body. The sandwiched pieces are then inserted into a female mold having a main mold cavity and a pair of opposed pole cavities formed therein to receive the projecting ends of the poles, thereby correctly aligning them. A metal sleeve is then inserted into the main mold cavity such that an annular space is created between the sandwiched magnet assembly and the sleeve. Molten zinc is then poured into the mold and sleeve to encapsulate the magnet except for the projecting ends of the poles. After the zinc has solidified, the assembly is removed from the mold.

Abstract: Composites of ceramic and metal exhibiting high fracture strength and toughness are formed from layers of the ceramic that have unequal concentrations and unequal porosity. The composites are made by a process that involves arranging layers of the ceramic in a predetermined pattern to provide a body that can be fully infiltrated by the metal.

Abstract: The present invention relates to a novel process for forming a plurality of thin metal matrix composite bodies. Particularly, an infiltration enhancer and/or an infiltrating atmosphere are in communication with a filler material or preform, at least at some point during the process, which permits molten matrix metal to spontaneously infiltrate the plurality of filler materials or preforms. Such spontaneous infiltration occurs without the application of any pressure or vacuum and occurs in a single step. In an embodiment of the present invention, the filler material may be sprayed upon a thin sheet of matrix metal. Alternatively, the filler material may be shaped via tape casting, slip casting, etc. to provide a thin preform. In another embodiment of the present invention, a body of matrix metal may be coated with a filler material such that upon spontaneous infiltration a metal matrix composite body is produced which inversely replicates the configuration of the original body of matrix metal.

Abstract: A method for the mass production of squirrel-cage rotors for electric motors includes the step of die casting-in-place rotor bars within the slots formed by stacked steel laminations. The molten metal alloy utilized in the method consists essentially of aluminum having an iron content of at least 0.4%. The incorporation of this amount of iron in the otherwise pure aluminum substantially reduces the number of defective rotors produced without degrading motor performance to any significant degree.

Abstract: A die casting apparatus for forming rotors for electric motors. The apparatus includes a frame having at least two opposed stationary pressure plates and a rotating turret rotatively mounted betewen these stationary plates. The turret includes three apertures at three equally spaced locations around the turret. Tooling is arranged at each of the respective locations for forming a rotor. Compensating and casting tooling is located at a first station, pin pressing and trimming tooling is located at the second station and unloading and loading tooling is located at the third station. The operations at the respective stations proceed simultaneously. The operations are selected so that the combined operations of each of the stations will take approximately equal amounts of time.