Abstract: In the context of a system that uses a pellet-type extruder head to form solid objects by moving the extruder relative to a build surface while melting and extruding pellets of raw material, systems and methods are provided which comprise cooling at least a portion of a pathway by which pellets of raw material are conveyed to a rotating extruder lead screw of the extruder head.

Abstract: An embodiment of a fitting assembly includes a fitting having at least a solid outer body, a pass-through bore, and at least one undercut region. The pass-through bore is defined by at least one pass-through bore wall, extending longitudinally through a length of the outer body from a first end to a second end. The at least one undercut region is formed into the at least one pass-through bore wall, and includes at least one expansion bearing surface disposed radially outward of at least one contraction bearing surface.

Abstract: System and method of producing multi-layered aluminum alloy products are disclosed. A multi-layered aluminum alloy product may be formed by first heating a first aluminum alloy to a first temperature where the first temperature is at least about 5° C. lower than the eutectic temperature of the first aluminum alloy, second heating a second aluminum alloy to a second temperature where the second temperature is at least about 5° C. higher than the liquidus temperature of the second aluminum alloy, and coupling the second aluminum alloy to the first aluminum alloy to produce a multi-layered aluminum alloy product.

Abstract: A cylinder liner with a plurality of protrusions on its outside surface and the manufacturing method thereof are disclosed. The protrusions are ?-shaped, P-shaped or taper-shaped, and the ?-shaped, P-shaped and taper-shaped protrusions are accounted for 50-99.5%, 0.5-30% and 0-20% of the total number of protrusions, respectively. The density of the protrusions on the outside surface of the cylinder liner is 15-65 per square centimeter. The outer surface of the protrusions of the cylinder liner is curved, and has a large contact area and a concave which can be filled by an aluminum sheath to improve the radial bearing capacity, so as to effectively improve the bite force between the cylinder liner and the outside aluminum sheath and prevent the cylinder liner from breaking away from the cylinder body.

Abstract: A method of forming an earth-boring tool includes introducing metal into a die, rotating the die to generate centrifugal forces on the metal, and cooling the metal in the rotating die. A rotary drill bit may include a unitary, centrifugally cast bit body including an integral shank, at least one blade, and at least one cutting element on the blade. A rotary drill bit or a roller cone may include a first centrifugally cast material and a second centrifugally cast material. Another rotary drill bit includes a bit body comprising a maraging steel alloy. A method of forming a rotary drill bit may include disposing cutting elements on a rotary drill bit comprising maraging steel and aging the rotary drill bit to form at least one intermetallic precipitate phase. Methods of repairing a rotary drill bit include annealing and aging at least a portion of a rotary drill bit.

Abstract: A method of casting an article includes positioning a first portion of the article, formed from a first material, in a rotatable mold. Additionally, the method includes, while rotating the mold, pouring a molten second material into the mold over the first portion to form a second portion of the article that is metallurgically bonded to the first portion of the article.

Abstract: The present invention relates to the fabrication of complicated electronic and/or mechanical structures and devices and components using homogeneous or heterogeneous 3D additive build processes. In particular the invention relates to selective metallization processes including electroless and/or electrolytic metallization.

Abstract: A method for protecting a turbomachine from corrosion may include creating a first sand mold in a drag of a casting flask, coupling a cope of the casting flask to the drag, removing the runner pin and the at least one riser pin from the cope to expose a runner and at least one riser, respectively, and pouring a molten first material in the runner to cast a first component of the turbomachine. The method may further include removing the first sand mold, creating a second sand mold utilizing the first component in the drag, coupling the cope to the drag, removing the runner pin and the at least one riser pin from the cope to expose a runner and at least one riser, respectively, and pouring a molten second material in the runner to cast a second component of the turbomachine integral with the first component.

Abstract: A packaging substrate includes a first dielectric layer; a plurality of first conductive pads embedded in and exposed from a first surface of the first dielectric layer; a first circuit layer embedded in and exposed from a second surface of the first dielectric layer; a plurality of first metal bumps disposed in the first dielectric layer, each of the first metal bumps having a first end embedded in the first circuit layer and a second end opposing the first end and disposed on one of the first conductive pads, a conductive seedlayer being disposed between the first circuit layer and the first dielectric layer and between the first circuit layer and the first metal bump; a built-up structure disposed on the first circuit layer and the first dielectric layer; and a plurality of second conductive pads disposed on the built-up structure. The packaging substrate has an over-warpage problem improved.

Abstract: A method of fabricating a metal part by selectively melting a powder, the method including: building up layer by layer on a plate and simultaneously with the part, at least one holder and support element for the part, the element being spaced apart and distinct from the part and being separated therefrom by a gap filled with non-melted powder; after the part has been made completely, removing at least some of the powder remaining in the gap between the part and the element, for example by suction, blowing, or vibration; and separating the part from the plate.

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

Abstract: Described herein is a method of selectively depositing molten bulk metallic glass (BMG). In one embodiment, a continuous stream or discrete droplets of molten BMG is deposited to selected positions. The deposition can be repeated as needed layer by layer. One or more layers of non-BMG can be used as needed.

Abstract: A micro-scaled bi-material lattice structure includes a frame comprising a first material having a first coefficient of expansion and defining a plurality of unit cells. The bi-material lattice structure further includes a plurality of plates comprising a second material having a second coefficient of expansion different from the first coefficient of expansion. One of the plates is connected to each unit cell. The bi-material lattice structure has a third coefficient of expansion different from both the first coefficient of the expansion and the second coefficient of expansion, and the bi-material lattice structure has a thickness of about 100 nm to about 3000 microns.

Abstract: System and method of producing multi-layered aluminum alloy products are disclosed. A multi-layered aluminum alloy product may be formed by first heating a first aluminum alloy to a first temperature where the first temperature is at least about 5° C. lower than the eutectic temperature of the first aluminum alloy, second heating a second aluminum alloy to a second temperature where the second temperature is at least about 5° C. higher than the liquidus temperature of the second aluminum alloy, and coupling the second aluminum alloy to the first aluminum alloy to produce a multi-layered aluminum alloy product.

Abstract: A method of forming an earth-boring tool includes introducing metal into a die, rotating the die to generate centrifugal forces on the metal, and cooling the metal in the rotating die. A rotary drill bit may include a unitary, centrifugally cast bit body including an integral shank, at least one blade, and at least one cutting element on the blade. A rotary drill bit or a roller cone may include a first centrifugally cast material and a second centrifugally cast material. Another rotary drill bit includes a bit body comprising a maraging steel alloy. A method of forming a rotary drill bit may include disposing cutting elements on a rotary drill bit comprising maraging steel and aging the rotary drill bit to form at least one intermetallic precipitate phase. Methods of repairing a rotary drill bit include annealing and aging at least a portion of a rotary drill bit.

Abstract: The present invention relates to a method and apparatus for producing rotatable sputtering targets by means of continuous casting. Target material is deposited around a cylindrical target holder (14) by means of a movable mold (30) surrounding the target holder. The mold (30) is fed with molten metal while it is translated along the target holder to progressively form the layer of molten metal on the outer surface of the target holder.

Abstract: A method and a device for manufacturing a cover including multiple metal layers are provided. The method includes: injecting a second metal in liquid form which is a metal different from a first metal layer onto a semi-finished cover disposed in a mold and formed of the first metal layer, so as to form a second metal layer on the first metal layer; and pressing the second metal layer with a pressure in the mold. Not only does the multi-layer metal cover manufactured according to the method have the strength and elasticity of a composite metal, but also subsequent surface treatment may be performed on the metal cover as required, such as anodizing surface treatment, and corrosion resistant treatment, to further improve the adhesiveness between metal layers, the strength and the corrosion resistance, and make the design of the cover more flexible.

Abstract: A method for manufacturing an engine component includes forming the component by deposition of powder, which is melted by a heat source, in subsequent Layers to form the component into a desired shape, the component having an outer surface, and re-melting at least part of the outer surface.

Abstract: The invention relates to an extruded or rolled clad metal article having a core metal layer and a cladding metal layer on at least one surface of the core layer, wherein the metals of the core metal layer and the cladding metal layer are each aluminium alloys, preferably an aluminium-magnesium alloy, having at least Sc in a range of 0.05% to 1%, and wherein the Sc-content in the core metal layer is lower than in the cladding metal layer. This further relates to a welded structure incorporating such a metal article.

Abstract: Single-crystalline or stem-shaped turbine blades are difficult to produce. A turbine blade is provided which has varying structures for different areas of the turbine blade, wherein the airfoil region always includes a stem-shaped or single crystalline structure and the other regions may deviate therefrom. A method for producing the turbine blade is also provided.

Abstract: A composite member suitable for a heat radiation member of a semiconductor element and a method of manufacturing the same are provided. This composite member is a composite of magnesium or a magnesium alloy and SiC, and it has porosity lower than 3%. This composite member can be manufactured by forming an oxide film on a surface of raw material SiC, arranging coated SiC having the oxide film formed in a cast, and infiltrating this coated SiC aggregate with a molten metal (magnesium or the magnesium alloy). The porosity of the composite member can be lowered by improving wettability between SiC and the molten metal by forming the oxide film. According to this manufacturing method, a composite member having excellent thermal characteristics such as a coefficient of thermal expansion not lower than 4 ppm/K and not higher than 10 ppm/K and thermal conductivity not lower than 180 W/m·K can be manufactured.

Abstract: The invention relates to a method for producing a light metal or plastic cylinder crankcase (2) of an internal combustion engine having a closed-deck design, comprising the steps of —casting a cylinder liner (4) using salt cores (6) corresponding at least to the cavities of the water jackets, —encapsulating the pre-cast cylinder liner in a pressure die-casting process in a light metal melt in order to achieve the cylinder crankcase (2) having a closed-deck design, wherein the cylinder liner (4) still contains the salt cores (6) at least in the water jackets during encapsulation.

Abstract: Molten metal is injected uniformly into a horizontal mold from a feed chamber in a horizontal or vertical direction at a controlled rate, directly on top of the metal already within the mold. A cooling medium is applied to the bottom surface of the mold, with the type and flow rate of the cooling medium being varied to produce a controlled cooling rate throughout the casting process. The rate of introduction of molten metal and the flow rate of the cooling medium are both controlled to produce a relatively uniform solidification rate within the mold, thereby producing a uniform microstructure throughout the casting, and low stresses throughout the casting.

Abstract: A method for producing a functionally gradient component, such a component having an outer layer of a first material, and an inner core of a second material, there being a gradual change in microstructure across the interface between the two materials, the method having particular application in producing a component formed from two or more aluminium alloys based on the aluminium-silicon (Al—Si) system, the method involving introducing a first molten metal into a mould, and allowing a layer of the first metal to partially solidify against a wall of the mould, decanting the remaining molten portion of the first metal, and introducing a second molten metal into the mould and allowing same to solidify.

Abstract: A method of casting an ingot of a metal having a susceptibility to hot-tearing while avoiding such hot tearing. The method involves co-casting a cladding metal on a surface of a metal core ingot as the ingot is being cast in a DC casting procedure. The cladding layer preferably contacts the core ingot at a position on the ingot surface where the metal of the ingot is incompletely solid, e.g. at a temperature between its solidus temperature and liquidus temperatures. The metal of the core ingot and the metal of the cladding layer are the same and, if they contain grain refiners, the are present in an amount of 0.005% by weight of the metal or less.

Abstract: A digital manufacturing system comprises a build chamber, a build platform disposed within the build chamber, at least one extrusion line configured to heat a metal-based alloy up to a temperature between solidus and liquidus temperatures of the metal-based alloy, a deposition head disposed within the build chamber and configured to deposit the heated metal-based alloy onto the build platform in a predetermined pattern, an umbilical having a first end located outside of the build chamber and a second end connected to the deposition head, and at least one gantry assembly configured to cause relative motion between the build platform and the deposition head within the build chamber, where the at least one gantry assembly comprises a motor disposed outside of the build chamber.

Abstract: An object of the present invention is to provide a material for a precious metal tip of a spark plug, which has more excellent durability, particularly oxidation wear resistance than a conventional one. The precious metal alloy for the spark plug according to the present invention contains 0.2 to 6.0 wt. % Cr as an essential component, further at least any one of Fe or Ni, and the balance being Ir. Here, the amount of Fe and Ni to be added is preferably 2.0 to 12.0 wt. % in total. According to the present invention, the surface may be oxidized to form an oxide layer made from a Cr—Fe oxide, a Cr—Ni oxide or a Cr—Fe—Ni oxide. The oxide layer is formed by a diffusion treatment by heating the precious metal alloy at 300 to 900° C. in an oxidative atmosphere, and preferably has a thickness of 5 to 100 ?m.

Abstract: A method for forming a surface layer on a substrate is provided. First, a mold having a cavity is provided. Next, a surface layer is formed on at least a part of the surface of the mold within the cavity. After that, a molding step is performed.

Abstract: Cast material rotor (200,300,500,800) with profiled helical outer surface (208,308,508,808). Cast material layer (502,802) can be disposed between core (504,804) and tube (506,806). Profiled helical outer surface (208,308) can be in tube 206 or cast material layer 302, respectively. Method of forming rotor 200 can include filling void between outer surface 212 of core 204 and longitudinal bore 210 of tube 206 having profiled helical outer surface 208 with cast material 202 in fluid state, and solidifying cast material 202. Tube 206 can be disposed within profiled helical bore 714 of mold 700, e.g., before solidifying cast material 202. Method of forming rotor 300 can include filling void between outer surface 312 of core 304 and profiled helical bore 714 in mold 700 with cast material 302 in fluid state, solidifying cast material 302 to impart profiled helical outer surface 308 thereto, and removing mold 700 from cast material 302.

Abstract: Molten metal is injected uniformly into a horizontal mold from a feed chamber in a horizontal or vertical direction at a controlled rate, directly on top of the metal already within the mold. A cooling medium is applied to the bottom surface of the mold, with the type and flow rate of the cooling medium being varied to produce a controlled cooling rate throughout the casting process. The rate of introduction of molten metal and the flow rate of the cooling medium are both controlled to produce a relatively uniform solidification rate within the mold, thereby producing a uniform microstructure throughout the casting, and low stresses throughout the casting.

Abstract: A lightweight part and process and device of making the same, the lightweight part including an inner core including a metal foam. A dense core surface layer is metallically joined to the inner core. An outer wall includes an essentially pore-free cast metal layer that is at least one of positively engaged with the dense core surface layer and surrounding the inner core, and metallically joined to the dense core surface layer and surrounding the inner core. The process includes creating a core part by forming the dense core surface layer, forming the inner core of a metal foam, and metallically joining together the inner core and the dense core surface layer. The process further includes creating a finished part by positioning the core part in a casting mold, feeding a melt material into the casting mold, and allowing the melt material to solidify so as to form the outer wall.

Abstract: A valve for controlling the flow of a gas therethrough which requires no machining in order to attain an effective seal between the valve seating surface and a rotatable plug element. The valve seat surface remains as cast while the plug consists of an overmolded plastic. The overmolding defines an array of pliable sealing ridges. The use of overmolding facilitates the use of cost-saving plastic materials, and obviates the need for expensive machining of the cooperating surfaces.

Abstract: A system and method of solid freeform work piece fabrication through layered deposition of feedstock material on a mold structure. An energy beam and feedstock are fed to a feed point adjacent to a mold structure, thereby forming a molten puddle. The feed point is moved relative to the mold structure, thereby advancing the molten puddle of presently fed feedstock and rapidly solidifying previously fed feedstock. The feed point is sequentially advanced within a predetermined geometric volume containing at least a portion of the mold structure, thereby sequentially fusing the feedstock, by action of the advancing molten puddle, into a near net shape work piece built-up upon the mold structure.

Abstract: A valve for controlling the flow of a gas therethrough which requires no machining in order to attain an effective seal between the valve seating surface and a rotatable plug element. The valve seat surface remains as cast while the plug consists of an overmolded plastic. The overmolding defines an array of pliable sealing ridges. The use of overmolding facilitates the use of cost-saving plastic materials, and obviates the need for expensive machining of the cooperating surfaces.

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: Method and apparatus incorporating an infrared sensor, in the form of a two-wavelength imaging pyrometer into a metallic spray form process for providing real-time measurement of the surface temperature distribution of a steel billet thereby formed. The steel billets may be advantageously used as tools in metal forming processes, injection molding, die casting tooling and other processes that require hard tooling, such as in the automotive industry. The steel billet is formed based on a goal of uniform surface temperature distribution thereby minimizing thermal stresses induced within the steel article thereby produced.

Abstract: Often, metal matrix composites (MMC's) lack adequate machinability and possess excessive abrasiveness because hard ceramic materials, such as silicon carbide, are used as the reinforcement phase. To make a metal matrix composite body having a more machinable and less abrasive surface, an MMC comprising an aluminum nitride reinforcement is formed on the surface of the body. In one embodiment, a layer is provided to a permeable mass or preform at the surface at issue, the layer featuring at least a reduced loading of ceramic filler material, and sometimes no ceramic material at all. The reduced loading is achieved by incorporating a fugitive material into the coating layer. Molten matrix metal is caused to infiltrate the permeable mass or preform and the coating layer to produce a macrocomposite body comprising a metal matrix composite coating and substrate.

Abstract: A process and apparatus for producing a brake drum or a brake disc include a carrier component formed of a light metal alloy which can be easily cast and machined and a friction lining component formed of a light metal alloy reinforced by short non-metallic fibers or particles by casting a first one of the components in a mold, cooling the cast component to achieve dimensional stability, casting the other component onto or around the first component, the components being designed to interlock mechanically as a unitary composite structure after cooling. The casting materials may be introduced into the die in a molten state or a thixotropic state. Core pullers are provided to create space in the die cavity for the second component after the first component has been cast and cooled to a dimensionally stable state.

Abstract: A cylinder block of an internal combustion engine has a portion between a cylinder block body and a cylinder liner which is sealed against a coolant so as to prevent the coolant from entering a crank case. The cylinder block body is made of a first material. The cylinder liner is cast in the cylinder block body. The cylinder liner is made of a second material different from the first material. The cylinder liner has an engaging portion contacting a portion of the cylinder block body from outside in a radial direction of the cylinder liner.

Abstract: A mold assembly for casting or molding a multiple portion article in sequential shots without opening the mold assembly. The mold assembly includes a movable mold insert that permits the portions to be interconnected as an integral part of the casting process. The mold insert includes a first or male void for defining a male end and a second or female void for defining a female end. In operation, the mold insert is placed in a first position and molten material is introduced into a first cavity portion to form a first portion with a male end. The mold insert is then placed in a second position with the female portion surrounding the male end of the first portion. Molten material is introduced into a second cavity portion to form a second portion with a female end at least partially surrounding the male end of the first portion.

Abstract: A first cavity is formed between a mold and a core. One of a cylinder block material and a liner material is supplied to the first cavity. A second cavity is formed by expanding or shrinking the core or replacing the core with another core. The other of the cylinder block material and the liner material is supplied to the second cavity. The cylinder block with a liner is produced successively using the same apparatus.

Abstract: A method of manufacturing a cylinder block comprising one or more cylinders, the or each cylinder being adapted to receive a piston therein, the method comprising making a cylinder liner by squeeze casting, in an aluminium-silicon alloy produced from a melt consisting essentially of the following composition by weight: Silicon 14% to 16%; Copper 1.9% to 2.2%; Nickel 1.0% to 1.4%; Magnesium 0.4% to 0.55%; Iron 0.6% to 1.0%; Manganese 0.3% to 0.6%; Silicon Modifier 0.02% to 0.1%, with the balance being aluminium and any avoidable impurities, the cylinder liner having an essentially eutectic microstructure containing not more than 10% primary alpha-aluminium dendrites and being substantially free from intermetallic particles exceeding 10 .mu. in diameter, placing the cylinder block in a mold and casting therearound an aluminium alloy to provide a main cylinder block body with the cylinder liner entrapped therein.

Abstract: A mold assembly for casting or molding a multiple portion article in sequential shots without opening the mold assembly. The mold assembly includes a movable mold insert that permits the portions to be interconnected as an integral part of the casting process. The mold insert includes a first or male void for defining a male end and a second or female void for defining a female end. In operation, the mold insert is placed in a first position and molten material is introduced into a first cavity portion to form a first portion with a male end. The mold insert is then placed in a second position with the female portion surrounding the male end of the first portion. Molten material is introduced into a second cavity portion to form a second portion with a female end at least partially surrounding the male end of the first portion.

Abstract: The height of a layer of material formed by molten metal disposition is measured by ejecting the material as elongate extrusions and measuring the time required for each extrusion to contact the workpiece, then using this time interval along with the speed at which the extrusion is ejected to measure the gap between the ejection head and the workpiece. This gap is then used for calculating the height of the previous layer. By making the workpiece and the ejected material electrically conductive, this time interval can be measured by noting when electric current flows through the extrusion.

Abstract: According to the present invention there are provided a highly reliable electrode of high strength which undergoes little change even with the lapse of time, and a method for making the same, as well as a vacuum valve using such electrode and a vacuum circuit breaker using such vacuum valve. The vacuum circuit breaker has a fixed electrode and a movable electrode, each comprising an arc electrode, an arc electrode support member for supporting the arc electrode, and a coil electrode contiguous to the arc electrode support member, the arc electrode, the arc electrode support member and the coil electrode being formed as an integral structure by melting, not by bonding, particularly the arc electrode support member and the coil electrode being constituted by a Cu alloy containing 0.05-2.5% by weight of at least one of Cr, Ag, W, V and Zr.

Abstract: A method for the accurate formation of a three-dimensional article comprises providing a supply of substantially uniform size droplets of a desired material wherein each droplet has a positive or negative charge. The supply of droplets is focused or aligned into a narrow stream by passing the droplets through or adjacent an alignment mechanism which repels each droplet toward an axis extending through the alignment mechanism. The droplets are deposited in a predetermined pattern at a predetermined rate onto a target to form the three-dimensional article without the use of a mold of the shape of the three-dimensional article.

Abstract: A method is provided for producing by centrifugal casting an alloy tubular article of manufacture in the form of a composite tubular product comprised of an outer alloy layer (first alloy) and at least one inner alloy layer (second alloy) while substantially inhibiting the formation of a metallurgical bond between layers in the final casting. The product is produced using a rotatable centrifugal casting mold having a cylindrical inner surface adapted to receive a molten metal alloy. A first layer of an alloy is poured into the rotatable mold, the alloy having a melting point of at least about 1300.degree. C. and generally at least about 1400.degree. C. Centrifugally casting said alloy as an outer layer during rotation of said mold. The outer layer is solidified and cooled to a temperature not exceeding about 92% of its absolute melting point in degrees Kelvin. At least one inner layer is poured into the outer layer, the alloy of the inner having a melting point of at least about 1300.degree. C.

Abstract: A fiber-organic composition includes from about 5% to 50% by volume of uniformly dispersed, non-planar or three dimensionally random oriented inorganic fibers or whiskers, and a thermoplastic material such as paraffin wax. The composition also includes surfactants to promote wetting and dispersion of the inorganic fibers or whiskers. These materials are subjected to high shear mixing to form a uniform randomly oriented three-dimensional dispersion of the inorganic fibers or whiskers. After molding the mixture in such a manner so as not to disrupt the uniform, three-dimensional orientation of the fibers or whiskers, a majority of the thermoplastic material is removed leaving a shaped body or preform having sufficient strength for handling. The shaped body or preform can then be infiltrated with molten metal or the like to form a metal matrix composite.

Abstract: Three-dimensional metal parts are fabricated by irradiating a thin layer of a mixture of metal powder and temperature equalization and unification vehicle to melt the metal powder and form a solid metal film. The vehicle also protects the molten metal from oxidation. The metal powder can contain an elemental metal or several metals, the vehicle can be an organic resin or an amalgam, and the irradiation can be selectively applied by a YAG laser.

Abstract: A free-form, three-dimensional, solid-phase object (30) is produced from droplets (24) of liquid-phase material having appreciable surface tension and well-defined solidification properties. The liquid-phase material is ejected from an ejection head (20) in discrete droplets onto a substrate (98). The temperature, frequency, size, and trajectory of the droplets and the relative speed of motion between the substrate and the ejection head are adjusted to compensate for the physical properties of the liquid-phase material and the heat dissipation characteristics of the growing object to form a desired object (212).