Abstract: One or more ductile metal inserts may be selectively incorporated into articles of limited ductility, including castings and molded polymers. The inserts are positioned at joint locations for joining of the article to other articles using self-piercing riveting (SPR). The inserts are of suitable ductility, thickness and strength to receive and retain self-piercing rivets and enable a strong riveted joint between the article and a second article. In an embodiment the articles are magnesium alloy castings formed by any of sand casting, die casting and semi-solid metal casting. The chemical composition of the insert may be informed by the anticipated corrosive environment of the joint and the casting temperature of the magnesium alloy. For magnesium alloy castings which may be exposed to corrosive environments, aluminum alloy inserts are preferred.

Abstract: A light weight alloy part is molded in a mold containing at least one weldable metal insert, so that portions of portions of the alloy part lap portions of the insert to securely lock the weldable insert to the light weight alloy part. The resulting hybrid part is thus both light weight and weldable to other assemblies and sub-assemblies.

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 base plate of a disk drive apparatus includes a motor base disposed around a central axis and a base body portion extending radially outward of the motor base. The motor base is made of a metallic material of a first type. The base body portion is made of a metallic material of a second type. The base body portion is a casting product in which the motor base is an insert component. An upper protruding portion and a lower protruding portion are defined in one of an outer end portion of a bottom plate portion of the motor base and an inner end portion of the base body portion.

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 tire vulcanization mold manufacturing method can manufacture a tire vulcanization mold having an exhaust mechanism capable of ensuring sufficient exhaust with fewer processing steps. When a mold having a surface of a gypsum mold transferred to the mold is to be manufactured by pouring molten metal onto the surface of the gypsum mold and solidifying the molten metal, a tubular body having a slit allowing hollow inside to communicate with the outside is disposed in such a way that the slit is brought into contact with the surface of the gypsum mold. Thereafter, the molten metal is poured onto the surface of the gypsum mold in such a way that the tubular body is buried in the mold while the slit is exposed on a tire molding surface of the mold.

Abstract: Provided is a method of manufacturing an impeller, the method including: providing a disc comprising a plurality of blades; casting a shroud to a first state in a mold; providing a mounting space in the mold; mounting the disc in the mounting space and casting the shroud to a second state with the mounted disc.

Abstract: A brake calliper for a vehicle brake system includes a housing produced in the form of a casting. At least one guide structure configured to receive a corresponding brake piston is provided in the housing. A method and a device are configured to produce a casting having at least one guide structure. The at least one guide structure is formed in the housing by at least one prefabricated insert having a defined production quality, which is encapsulated by the casting material of the housing.

Abstract: Process and casting mould for producing a cast wheel. A core, which remains in the cast wheel and has a circumferential rim, is inserted into a casting mould having at least one lower mould part and an upper mould part moved relative to one another to close casting mould. Core is positioned by at least one positioning element in a predetermined position in casting mould, so that an end region of positioning element is fixed with a force fit or frictional fit in circumferential rim of the core. A free end region of positioning element, which protrudes from circumferential rim of the core, is placed on a contact surface, which is preferably arranged substantially horizontally during operation, of lower mould part during positioning of core in casting mould. Core is positioned in the predetermined position under the action of the force of gravity.

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: Casting preforms are provided comprising a casting preform assembly; and a plurality of geometrically shaped bodies, wherein the plurality of geometrically shaped bodies are arranged or interconnected to form the casting preform assembly. Also provided is a method of using a casting preform, comprising forming a casting preform assembly, wherein the casting preform assembly comprises a plurality of geometrically shaped bodies; anchoring the casting preform to an outer surface of a casting mold; introducing a fluid casting material into the casting mold; applying centrifugal force to the casting mold; forming a molded article, wherein at least a portion of the surface of the molded article is reinforced with the plurality of geometrically shaped bodies.

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 composite ballistic armor or other composite component may be formed by encapsulating one or more ceramic elements in a casting shell and introducing molten base metal into the casting shell, such that the molten base metal encapsulates the one or more ceramic elements to form the composite component. Prior to the pouring process, the ceramic elements are pre-heated to, or near, the melting point temperature or pouring temperature of the encapsulating metal. Additionally, the cooling rate following the metal pour may be less than a predetermined rate for a predetermined period of time. The encapsulating metal may comprise, for example, a steel alloy, such as 4140 or 8630 AISI, a stainless steel alloy, or FeMnAl.

Abstract: In a heat-dissipating module and a method for manufacturing the same, a hollow aluminum tube is put on a corresponding heat pipe to form an aluminum-skinned heat pipe. Then, one or more aluminum-skinned heat pipes are disposed in a casting space of a die casting mold. Fins are disposed into the die casting mold. Molten aluminum materials are filled in the casting space of the die casting mold to form a heat-dissipating module. By using a die casting process, molten aluminum materials are used to cover at least one aluminum-skinned heat pipe and connect with the fins, thereby finishing the heat-dissipating module.

Abstract: A process for producing a twist-beam axle is provided. Related thereto, the twist-beam axle has a light metal longitudinal link and an iron metal transverse arm. The process contains the following steps: producing a casting mold for the respective longitudinal link; inserting one end of the transverse arm into a corresponding recess in the casting mold; then pouring the liquid light metal into the casting mold for the longitudinal link; cooling the poured light metal; and removing the transverse arm joined to the cooled light metal from the casting mold.

Abstract: A method for forming a casted component using a porous structure. The casted component may include a visible design feature formed in part by the casted component and in part by a body material also forming other parts of the component. The casted component may be a brake rotor having a mixed-material composite formed in part by the casted component and in part by a body material also forming other parts of the rotor. The porous structure can include a ceramic foam or a metal mesh.

Abstract: A method for die casting a hybrid component includes defining a cavity within a die element of a die and inserting a spar into the cavity. Molten metal is injected into the die element. The molten metal is solidified within the cavity to cast the hybrid component. The spar establishes an internal structure of the hybrid component. The spar includes a high melting temperature material that defines a first melting temperature greater than a second melting temperature of the molten metal.

Abstract: A down hole casting assembly and a method for assembling the down hole casting assembly. The down hole casting assembly includes a mold and a blank coupled to the mold. The mold includes an internal surface surrounding a cavity formed therein and one or more junk slot displacements formed along at least a portion of the internal surface. The junk slot displacement includes a top edge. The blank includes an upper portion, a lower portion, and a bottom edge extending from at least a portion of the upper portion to at least a portion of the lower portion. At least a portion of the bottom edge is coupleable to at least a portion of the top edge. The portion of the bottom edge that couples to the portion of the top edge is complementary in shape so that the blank is positionable within the cavity in a repeatable manner.

Abstract: In one aspect, the invention is directed to a half-cradle for use in a vehicle frame, comprising a cast end member formed from a first material and first and second tubular cross-member stubs extending from the cast end member. The first and second tubular cross-member stubs are made from a second material. Each of the stubs has an end buried in the cast end member, wherein the buried end is uncapped. Each of the tubular cross-member stubs has an interior that is configured to sealingly receive a core for use in preventing the filling of the stub with molten first material during casting of the cast end member.

Abstract: A kettlebell comprising a handle and a main body portion. The handle comprising a loop handle having a grip portion and first and second arm portions extending from opposite ends of a centre portion attaching the grip portion of the handle to the cast body portion. The arm portions have distal ends and the cast main body portion is cast around the distal ends of the handle arms. The main body weight portion is cast around a portion of the handle to thereby secure the handle to the cast main body portion. The body portion is cast onto the end of the handle such that the body portion is both formed and attached to the handle in a single operation thereby providing a secure connection between the main body and the handle. The body may only become detached from the handle through fracture of the handle or the body.

Abstract: A moldable wire thread insert 1 for reinforcing a screw-in opening of a component has the following characteristics: a cylindrical spiral 20 made of a helically, wound wire 10, the neighboring coils 30 of which are arranged such that a closed cylindrical spiral wall 22, 24 is present, while at least one end of the cylindrical spirals 20 has a fastening flange 40, which extends radially outwards over the cylindrical spiral wall 22, 24 and with which the wire thread insert 1 is anchorable in the component and/or one end of the cylindrical spiral 20 is designed in a planar manner in order to form an even axial front surface of the cylindrical spiral 20.

Abstract: An iron-type golf club includes a conventional-weight section, a lightweight section and a heavyweight section. The conventional-weight section includes the hitting face and at least a portion of the hosel. The heavyweight section, made of a denser material than the conventional-weight section, includes the sole and an optional back flange. The lightweight section, made of a material less dense than either of the other sections, includes a core to which the other two sections are secured, such as by co-molding the core to the other two sections. The heavyweight section includes anchoring structures to which the lightweight section can securely attach. This arrangement maintains the overall weight of the club head compared to a similarly proportioned conventional club head while shifting the center of gravity low and aft. As such, the club head provides benefits such as forgiveness for thin shots, heel/toe shots, and provides longer drives with less roll.

Abstract: A composite ballistic armor or other composite component may be formed by placing one or more ceramic cores in a mold and introducing molten base metal into the mold, such that the molten base metal encapsulates the one or more ceramic cores to form the composite component. The ceramic cores may comprise, for example, porous packed-particle ceramic cores or pre-cast porous ceramic cores. The base metal may comprise, for example, a steel alloy, such as FeMnAl.

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 heat-dissipation structure and a manufacturing method thereof are disclosed. The heat-dissipation structure includes a base having a main body and a tube. The tube has an inlet, an outlet, and a tube body; and the tube body is correspondingly embedded in the main body to serve as a flow passage while the inlet and the outlet are exposed from the main body. The heat-dissipation structure can be manufactured by pour molding or insert molding to embed the tube in the base for serving as a flow passage. With the manufacturing method, the heat-dissipation structure can be formed at reduced material, labor and time costs without the risk of water leakage.

Abstract: A method of making a casting is disclosed. At least one support member has at least one first portion and a plurality of second portions connected to a mold core. The mold core is positioned at least in part in a sealed interior volume of a negative mold. The first portion is positioned outside the interior volume. The second portions are positioned at least in part inside the interior volume. A consumable pattern material is introduced into the negative mold to create a consumable pattern. The support member is disposed at least in part outside the consumable pattern. The consumable pattern is removed from the negative mold. A shell is formed around the consumable pattern. A casting material is introduced into an interior of the shell to create a final casting. The support member is disposed at least in part outside the final casting. A mold core is also described.

Abstract: An apparatus for manufacturing metal articles, in particular of light, alloy, includes a die including a pair of portions which can be separated to each other, which, in the closed condition, delimitate forging cavities having a shape corresponding to one or more articles to be forged, and a furnace adapted to melt the metal and to control the reaching by the molten metal of the hollow impressions of the die, as a result of overflowing through a duct connected to the furnace. A portion of the die includes, for each hollow impression, a movable punch adapted to apply a predetermined pressure on the relevant article during the forging step. Each punch is moveable in a manner independent from the other punches, and the apparatus includes a controller for controlling the pressure applied by each punch during the forging step, which allow to level the pressure applied by all the punches on the relevant article.

Abstract: A method including: placing a first insert and a second insert in a casting mold and wherein the first insert and second insert including a plurality of connecting posts extending in between so that the first insert and second insert are in spaced-apart relationship in the mold, each of the first insert and the second insert including a first material; casting a molten second material into the casting mold so that the second material flows between the first insert the second insert and solidifying the second material.

Abstract: There is provided an aluminum bonding member capable of being simply and inexpensively produced and capable of being used as a cooling member having a high cooling power. The aluminum bonding member 10 has an aluminum member 12 of aluminum or an aluminum alloy exposed to the outside, and a tubular member 14 of a material which does not melt at a temperature close to the melting point of aluminum or the aluminum alloy. Both of the opening end portions of the tubular member are open to the outside of the aluminum member 12. A portion of the tubular member 14 between the opening end portions extends in the aluminum member 12, and the outer peripheral surface of the portion of the tubular member 14 extending in the aluminum member 12 is bonded directly to the aluminum member 12.

Abstract: A method of forming a coated article is disclosed. The method involves heating a magnesium alloy component, positioning the component in a mold such that a gap exists between component outer surfaces and mold inner surfaces, and heating a magnesium-containing alloy material above its melting temperature, which is lower than that of the component. The material is formed from magnesium alloyed with i) the component element, but at a higher concentration, ii) at least one element that is different than the component element, or iii) the component element and at least one other element. The method further includes introducing the material into the gap, thereby covering at least the outer surfaces of the component, and cooling the material to form a substantially evenly distributed solidified coating on the outer surfaces of the component. The coating has a higher wear and/or corrosion resistance than that of the magnesium alloy component.

Abstract: The invention relates to a monolithically cast axle support (12) for motor vehicles. A steering box (10) is provided which is monolithically produced as a whole or in part along with the axle support or which is integrally bonded to the axle support as a whole or in part.

Abstract: A method of forming a casting includes providing a preform to a mold cavity. The preform is formed from one of a first metal and a second metal and defines an interface surface. A molten portion of the other of the first metal and the second metal is cast into the mold such that the molten portion proximately contacts the interface surface of the preform. An interface layer at the interface surface, a first portion defined by the mold cavity and the interface layer, and a second portion defined by the interface layer, are formed during casting. The interface layer may define a metallurgical bond between the first portion and the second portion. In the non-limiting example provided herein, the first portion is substantially comprised of aluminum and the second portion is substantially comprised of magnesium. In a non-limiting example, the casting may be configured as a vehicle wheel.

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: One exemplary embodiment includes a method that calls for supporting an insert in a mold cavity of a casting die by way of one or more spacers, introducing a molten material into the mold cavity such that the one or more spacers are melted and consumed by the molten material, and wherein the one or more spacers and the molten material are of the same composition.

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: 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: An apparatus and method for manufacturing a down hole tool that reduces manufacturing costs and enhances the tool's performance. A belted mold assembly includes a casting assembly, a belt assembly, and a mid-belt. The belted mold assembly is used to fabricate a casting that allows for a larger diameter blank to be used which displaces the more expensive casting material and for using a smaller outer diameter thin-walled mold. The casting assembly is disposed within the belt assembly and the mid-belt is loaded in the volume created between the casting assembly's outer surface and the belt assembly's inner surface. The mid-belt provides a bracing for the casting assembly during the casting process. Optionally, a cap can be disposed on top of the blank for preventing metallurgical bonds from forming between the binder material and the upper portion of the blank. This allows for the excess binder material to remain high in purity so that it can be reprocessed.

Abstract: A metal casting has a metal casting base body into which at least one metal insert body (1) is cast. The metal insert body has anti-twisting part-contours and is connected to the metal casting base body in a positively locking manner by the casting-in. To simplify the production of a stable metal casting, the metal insert body (1) has an elongate shape with a longitudinal axis and an outer mold contour with an unround cross section interrupted in the longitudinal direction by annular grooves (11-13) that fix the cast-in metal insert body (1) in the axial direction.

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 camshaft assembly configured to rotate about an axis of rotation within the engine of a motor vehicle to provide timing between cyclic operation of engine components is provided. The camshaft assembly includes a member for providing timing to a first engine component. The member includes a cam surface configured to drive the timing of the first engine component, and an opening. The camshaft assembly also includes a camshaft body cast to the member and configured to engage the opening of the member. The camshaft body includes a lobe configured to drive the timing of a second engine component, and a journal configured to allow efficient rotation of the camshaft body about the axis of rotation. The member is formed from a first material and the camshaft body is formed from a second material, thereby allowing the camshaft assembly to withstand two levels of stress.

Abstract: One embodiment includes a friction plate and method of manufacture thereof wherein the friction plate is fabricated from a thixomolded magnesium or titanium material or alloy thereof, which is lighter than comparable steel friction plates.

Abstract: The invention provides an exhaust system including a cylinder head having a plurality of exhaust ports. Integrally formed with the cylinder head are a plurality of independent and separate tubes. The tubes are cast, molded or otherwise integrally formed with the exhaust ports of the cylinder head. The cylinder head and tubes eliminate the need for an exhaust flange, welding the tubes to the exhaust flange and securing the exhaust flange to the cylinder head. As a result, the present invention has less weight and improved performance over prior art cylinder head and exhaust assemblies.

Abstract: System and method for fusing a chaplet to a casting. The method includes placing the chaplet on an upper surface of a mold; distributing a heater around the chaplet such that the heater is not exposed to the casting; placing a core on the chaplet such that the mold and the core define a component of a machine; heating the chaplet with the heater to a predetermined temperature; and pouring the casting in the mold, around the core and the chaplet, when the chaplet is at the predetermined temperature.

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: An MMC cylinder liner comprises an inner tubular portion and an outer tubular portion. The inner tubular portion includes a metal matrix composite formed of a compact impregnated with an Al—Si alloy wherein the compact is made of a reinforcing material. The outer tubular portion is formed of the Al—Si alloy. The Si concentration of the Al—Si alloy impregnated into the compact of the inner tubular portion is different from the Si concentration of the Al—Si alloy of the outer tubular portion.

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: The invention relates to a casting tool for producing workpieces from light metal alloys. The system includes a positioning element, a core part, a first mold part structured to carry the positioning element and be movable toward the core part, and a core part support structured to support the core part. The system also includes at least one stop structured to limit movement of the front mold part toward the core part and to allow the positioning element to be introduced into the core part, whereby the positioning element holds the core part in a predetermined position for casting.

Abstract: Cookware in the form of a grill plate, griddle plate, waffle iron, panini press or the like is made from a cast composite including a graphite core plate encapsulated within a cast metal shell of aluminum or stainless steel, and a method for manufacturing same.

Abstract: A method of forming a molded porous product is provided. The method comprises injecting a material into a mold to form a molded product, and removing the molded product from the mold. The mold comprising multiple layers of shaping elements extending through a cavity, each layer of shaping elements including multiple shaping elements. The molded product produced after removal from the mold has a porous structure formed by at least some of the shaping elements of the layers of shaping elements. The mold used to make the molded porous product may include a relatively large number of shaping elements within a small area.