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 turbine blade assembly includes a turbine blade having a pressure sidewall and an opposed suction sidewall and a first snubber assembly associated with one of the pressure sidewall and the suction sidewall. The first snubber assembly includes a first base portion extending outwardly from the one of the pressure sidewall and the suction sidewall, and a first snubber portion. The first base portion is integrally cast with the turbine blade and includes first connection structure. The first snubber portion is bicast onto the first base portion and includes second connection structure that interacts with the first connection structure to substantially prevent separational movement between the first base portion and the first snubber portion.

Abstract: Damage of a rotor and a side plate are suppressed with a simple construction to prevent reduction in durability of a vacuum pump. A casing manufacturing method comprises a step (step S2) of disposing a cylinder liner forming a cylinder chamber in a mold, and casting a casing main body integrally with the cylinder liner by using molten metal, and a step (step S3) of processing an intercommunication hole and an exhaust hole so that the intercommunication hole and the exhaust hole penetrate through both the cylinder liner and the casing main body together and intercommunicate with the cylinder chamber.

Abstract: Anti-ballistic component including encapsulated preformed ceramic shapes are disclosed. Preformed ceramic shapes having a preformed geometry are encapsulated in a metal alloy to stiffen and lighten an anti-ballistic component. The preformed ceramic shapes may be arranged in layers of uniform arrays of preformed ceramic shapes and contained in a porous container to receive the metal alloy during a casting process. A truss structure may be integrated in the preformed ceramic shapes to compartmentalize the preformed ceramic shapes into multiple isolated sub regions to stiffen the anti-ballistic component.

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

Abstract: A metal matrix composite article is described that includes a metal component, a ceramic component, and a lubricious component. The metal matrix composite article has a first surface and a second surface. The lubricious component is present in an amount that is highest at the first surface and is lowest at the second surface. The ceramic component is present in an amount that is highest at the first surface and is lowest at the second surface. The metal component is present in an amount that is highest at the second surface and is lowest at the first surface. In some cases, the metal matrix composite article is a wear plate for a fifth wheel hitch.

Abstract: According to one embodiment, the invention relates to a laser gain module (1) comprising: a laser rod (5) having a shaft and two optical interfaces (7, 9) facing each other, the rod (5) being used for longitudinal or quasi-longitudinal optical pumping; and a metal cooling body (3), at least one part of which is moulded around the laser rod (5) in order to cover all of the surfaces other than the optical interfaces in such a way that the laser gain module (1) forms a solid body that cannot be disassembled at ambient temperature.

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 cathode configuration for an aluminum electrolysis cell has at least one cathode block based on carbon and/or graphite. At least one groove is formed in the cathode block and the groove is lined with a graphite foil, at least in certain regions. At least one busbar is disposed in the groove and has an encasement of cast iron at least in certain regions. At least one recess is formed in the wall of the cathode block that delimits the at least one groove, and the encasement of cast iron engages into the at least one recess, at least in certain portions. A cathode block for such a cathode configuration is provided and also a process for producing a cathode configuration for an aluminum electrolysis cell.

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: 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: Various apparatuses, methods, and systems are provided for cooling electronic components. For example, an apparatus includes an electronics enclosure having multiple ribs configured to separate electronic components. The apparatus also includes at least one fluid transport structure encased within the electronics enclosure. Each fluid transport structure includes multiple pipes and multiple flow channels. The flow channels are located within the ribs of the electronics enclosure, and the pipes are configured to transport cooling fluid to and from the flow channels. The fluid transport structure(s) and the electronics enclosure are formed from different materials. The at least one fluid transport structure can be resistant to corrosion caused by the cooling fluid, and the electronics enclosure can be susceptible to corrosion caused by the cooling fluid.

Abstract: Encapsulated arrays with tiles covered with a barrier layer are disclosed. Tiles formed of silicon carbide, and wrapped with a barrier layer, are encapsulated with a base metal formed of a steel alloy. During a casting process, to fabricate the encapsulated arrays, the barrier layer prevents the steel alloy and/or the silicon carbide from compromising each other.

Abstract: A method of forming a metal matrix composite (MMC),such as a brake drum, by impregnating a preform, which is formed of ceramic particles and ceramic fibers, with a support element, such as a metal. The MMC has a wear surface defined by both the preform and the support element.

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

Abstract: A Method of Producing a hybrid tile metal matrix composite armor is disclosed. First, dense ceramic plates are placed within the mold cavity and may rest on spacer(s) that separate the bottom surface of the ceramic plates from the base of the mold cavity to create a space therebetween. The plates are further positioned within the mold cavity to create a controlled space between any adjacent plates. A second set of spacers may be placed on the plates top surface to create a space between the mold cavity cover and the ceramic plates top surface. A plurality of ceramic plates and spacers may also be stacked into multiple layers according to the shape of the mold cavity and desired ballistic resistance. The mold cavity is next infiltrated with liquid metal under pressure forming a hybrid metal matrix composite structure with an encapsulating aluminum rich skin.

Abstract: A method of manufacturing an optical component that is provided with an optical element, and an optical element holding component that holds an outer circumferential portion of the optical element includes: placing the optical element on an interior side of a metal die that molds the optical element holding component, and in which an incident side protective component that protects an optical surface on an incident side of the optical element is placed against this optical surface on the incident side, and placing an emission side protective component that protects an optical surface on an emission side of the optical element against this optical surface on the emission side; and filling the interior of the metal die with a molten metal material so that the optical element holding component which is formed from an amorphous alloy is injection molded integrally with the optical element.

Abstract: An apparatus and method for pressure casting a battery part wherein an extendible piston includes sidewalls for shutting off the supply of molten lead and an impact surface that extends in a side-to-side condition to form an end surface of a battery part cavity so that when the extendible piston is brought into an intensifying condition the extendible piston shuts off further supply of molten metal while a heat source maintains the lead in a molten state as the impact surface of the piston forms a side-to-side mold cavity surface to complete the mold cavity surface thereby eliminating unevenness in the surface of the finished battery part by generating a force with the extendible piston which is sufficient to form a battery part so that upon removal from the mold the batter part is substantially free of tears and cracks as well as surface irregularities.

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: A cast component having localized areas of improved physical properties is disclosed. The component may initially be produced having a void portion in a predetermined area requiring improved physical properties. A second molten material may be added to the void portion such that it chemically bonds to the void portion. The component may then be finished such to a final shape with a localized area of improved physical properties.

Abstract: The present invention relates to a heat-conducting module and a method for manufacturing the same. A hollow aluminum tube (110) is put on a corresponding heat pipe (111) to form an aluminum-skinned heat pipe (11). Then, one or more aluminum-skinned heat pipes (11) are disposed in a casting space (22) of a die casting mold (2). Molten aluminum materials are filled in the die casting space (11) of the die casting mold (2) to form a heat-conducting module (1). By using a die casting process, molten aluminum materials are used to cover at least one aluminum-skinned heat pipe (11), thereby finishing the heat-conducting module (1).

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 heat dissipating device includes a base and a plurality of heat dissipating fins. Each of the heat dissipating fins includes a heat dissipating portion, a fixing portion and an overflow-proof structure. The fixing portion is fixed in the base. The overflow-proof structure is connected between the heat dissipating portion and the fixing portion. A width of the overflow-proof structure is larger than a width of the heat dissipating portion and larger than a width of the fixing portion.

Abstract: A mirror or mirror assembly fabricated by molding, pressing, assembling, or depositing one or more bulk metal glass (BMG), bulk metal glass composite (BMGMC), or amorphous metal (AM) parts and where the optical surface and backing of the mirror can be fabricated without machining or polishing by utilizing the unique molding capabilities of this class of materials.

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

Abstract: Method to make a curved tubular element in order to convey abrasive materials such as concrete or suchlike, which comprises a first step of making at least a curved component made of a material highly resistant to wear, having an arched transverse development comprised between 90° and 360°, a second step of inserting said curved component into a shaping mold with a molding surface with a shape mating with the outer surface of at least a part of the curved tubular element to be made, so that, together with said molding surface, said curved component defines a casting chamber, and a third step in which material with a low resistance to wear is cast in said casting chamber in order to make, externally to said curved component, at least a part of a tubular body of said curved tubular element.

Abstract: A vibration-damped precision cast aluminum alloy automotive member for a vehicle powertrain and a method of its manufacture are disclosed. The vibration-damped precision cast aluminum alloy automotive member includes an internally disposed aluminum or aluminum alloy insert. An exterior surface of the insert, which includes an exposed oxide film, establishes a non-bonded interface with an interior surface of the automotive powertrain member. This non-bonded interface damps vibration propagation through the automotive powertrain member by experiencing frictional contacting movement when the automotive powertrain member is vibrationally excited.

Abstract: A component includes a cast portion and an insert. The cast portion includes a sacrificial suspension device. The insert is configured to provide damping to the component. The sacrificial suspension device is dissolved during a casting process, into a molten material, forming the cast portion such that the insert is fully encapsulated by the cast portion, including the dissolved suspension device.

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 femoral implant (10) comprises a distal end and a proximal end. A stem (12) is provided at the distal end of the implant (10) and comprises a rounded tip (16) for insertion into a femur, in use, and a body (18) of generally tapering form extending in a distal direction from a base to said tip (16). A femoral head (14) is provided at the proximal end of the implant (10) and extends from the base (20) of the stem (12). The body (18) of the stem (12) includes a plurality of discrete steps (22, 24, 26, 28, 30), located between the tip (16) and the base (20), wherein the steps (22, 24, 26, 28, 30) are concentrated more towards the base (20) of the stem (12) than towards the tip (16).

Abstract: A method for producing a shaft with a roller bearing. The roller bearing has an inner ring with an outer surface for rolling elements to roll on. The inner ring of the roller bearing is embedded, at least partially, into the shaft, which has been produced using primary forming methods, and the outer surface of the inner ring is exposed, at least in a part, in the axial direction and over its entire circumference.

Abstract: A method of manufacturing a vehicle wheel is provided with the steps of forming a wheel rim preform by injection molding a material made of alloy wherein the wheel rim preform includes a holed center, a grooved rim, a plurality of spokes interconnecting the holed center and an inner surface of the grooved rim, and a plurality of openings each formed in the spoke; preparing an endless CFRP work piece; cutting the CFRP work piece into a plurality of CFRP members; placing the CFRP members in the openings of the spokes; and heating the wheel rim perform at a predetermined temperature for a predetermined period of time to melt the CFRP members, thereby forming a finished wheel.

Abstract: Diecasting tool for the production of a cylinder crankcase (2), comprising a salt core (4) and at least one cylinder sleeve (6), wherein the cylinder sleeve (6) comprises an upper end (8) on the cylinder head side, and a lower end (10) on the crankshaft side, and the cylinder sleeve (6) is supported on at least one center sleeve that is disposed on the diecasting tool, and the salt core (4) at least partially surrounds the cylinder sleeve (6) in the manner of a cladding, wherein the salt core (4) comprises a crown (12) that at least partially bears on one of the ends (8, 10) of the cylinder sleeve (6), and the core (4) comprising openings (14) that extend vertically beneath the end (8) of the cylinder sleeve (6) on the cylinder head side.

Abstract: A method of making a sputtering target includes providing a backing structure, and forming a die cast copper indium gallium sputtering target material on the backing structure.

Abstract: The present invention includes systems and methods for insert-molding. In some embodiments, a hook can be formed in a metal part by passing die-steel of a die-cast mold through the metal part during a die-casting process. This may, however, result in a hole in the metal part that is beneath the hook area. When plastic material is insert-molded over the metal part, the plastic material may flow through the hole and into the metal part. Accordingly, in some embodiments the plastic material can be prevented from flowing through the hole during the insert-molding. As one example, a tape material can be coupled over the hole. As another example, a wedge can be press-fit into the hole. As yet another example, a plug can be inserted into the hole.

Abstract: A method of manufacturing an optical component that is provided with an optical element, and an optical element holding component that holds an outer circumferential portion of the optical element includes: placing the optical element on an interior side of a metal die that molds the optical element holding component, and in which an incident side protective component that protects an optical surface on an incident side of the optical element is placed against this optical surface on the incident side, and placing an emission side protective component that protects an optical surface on an emission side of the optical element against this optical surface on the emission side; and filling the interior of the metal die with a molten metal material so that the optical element holding component which is formed from an amorphous alloy is injection molded integrally with the optical element.

Abstract: A Moineau style stator includes a helical reinforcement component that provides an internal helical cavity. A resilient liner is deployed on an inner surface of the helical reinforcement component. The helical reinforcement component includes a solder or braze material and is typically metallurgically bonded to an inner wall of a stator tube. In exemplary embodiments, the helical reinforcement component includes a composite mixture of solder and aggregate. Exemplary embodiments of this invention address the heat build up and subsequent elastomer breakdown in the lobes of prior arts stators by providing a helical reinforcement component. Solder reinforced stators tend to be less expensive to fabricate than reinforced stators of the prior art.

Abstract: A method of supporting a metal tube during an overcasting process includes radially supporting the metal tube from within an interior opening of the metal tube with a compressed granular material. The compressed granular material is held in place by a first stop and a second stop positioned at opposite axial ends of the metal tube. A tensile connector, such as a rod or a cable, interconnects and attaches the first stop and the second stop. Compressive radial forces exerted onto the metal tube during the overcasting process are transferred through the granular material and resisted by a tensile force in the tensile connector.

Abstract: A process for the production of an aluminum-diamond composite, characterized by comprising the step of preparing a diamond powder having a specific diameter, the step of adding a colloidal silica to the diamond powder to form a slurry, the step of subjecting the slurry to press forming or slip casting to produce a compact of the diamond particles, the step of firing the compact either in air or in a nitrogen atmosphere to form a porous diamond preform, the step of heating the porous diamond preform, the step of heating an aluminum alloy to a temperature equal to or above the melting point of the alloy and impregnating the molten alloy into the porous diamond preform to make a flat plate-like aluminum-diamond composite wherein both surfaces are covered with surface layers containing an aluminum-base metal, and the step of working the aluminum-diamond composite into an aluminum-diamond composite.

Abstract: A soldering iron (and a desoldering iron) with a replaceable tip, which is releasably securable on the forward heat-conducting end of a soldering (or desoldering) iron heat assembly. The tip has a heat conducting core in a tip cap. Methods of manufacturing and using the tip are also disclosed. A method of manufacturing a replaceable soldering or desoldering iron tip can comprise preparing a cap having a base opening and at least substantially filling the cap through the base opening with a heat conducting material so that a tip core is formed in the cap, the tip core having a core face at the base opening.

Abstract: A method of making a treating wash includes mixing brass granules with acetone, mixing carbon nanotube material, iron pyrite granules and copper granules in the acetone brass mixture, and straining the liquid from the remaining solid material. Methods of treating materials such as brass granules, iron pyrite granules, carbon nanotube material, and brass granules comprises washing the materials in the treating wash, followed by straining and drying the materials.

Abstract: Method and apparatus employing a casting mould including a liquid feed end for supplying the casting mould with molten second alloy and an exit end with an outlet for casting molten second alloy downwardly. While continuously moving the mould and an elongated solid first alloy substrate relative to one another, casting molten second alloy passes downwardly through at least one outlet of the mould onto an upper surface of the substrate at a temperature wherein the substrate locally at least partly remelts beginning at a reference point of a remelting zone and mixes at least partly with molten second alloy to form an alloy pool. After remelting the molten alloy pool continuously cools and solidifies at a location away from the reference point and joins the substrate to form composite ingot including at least two separately formed layers of one or more alloys before discharging from the mould.

Abstract: A backing plate comprises a front side configured to engage a friction material, a rear side opposite the front side, a first edge, a second edge generally opposing the first edge, and at least one channel disposed between the front side and the rear side and extending from the first edge toward the second edge. The rear side is configured to engage a caliper assembly. The backing plate is configured to achieve a resonant frequency that attenuates vibration.

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 tubular support member includes a plurality of undulations extending along a longitudinal axis of the tubular support member and angularly spaced about the longitudinal axis. The undulations form a plurality of alternating peaks and valleys in the tubular support member. A cast member is overcast from a molten metal onto and around the undulations in interlocking engagement with the undulations, and extends from the tubular support member to a cantilevered distal end.

Abstract: The invention relates to a cast-iron cover fitted with at least one traffic-bearing surface which in turn comprises at least segment-wise a wear-resistant layer constituted by chilling the cast iron. Preferably the wear-resistant layer exhibits a Brinell hardness larger than 275 HBW but less than 350 HBW. A method of the invention furthermore relates to manufacturing a cast-iron cover, first manufacturing a shaped body. Then an activation layer is made within the shaped body. Cast iron is poured-in in a way to be at least partly chilled at a contact surface with the activation layer.

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

Abstract: An armor includes a metallic matrix; a plurality of ceramic rods disposed in the metallic matrix, the plurality of ceramic rods and the metallic matrix forming a core; and a spall liner disposed adjacent a rear face of the core. The metallic matrix places a compressive stress on the plurality of ceramic rods. A method for making an armor includes the steps of providing a plurality of ceramic rods in a desired configuration and embedding the plurality of ceramic rods in a metallic matrix to form a core, such that the metallic matrix provides a compressive stress to the plurality of ceramic rods. The method further includes providing a spall liner and disposing the spall liner adjacent a rear surface of the core to form an armor.

Abstract: A method for assembling a heat-dissipating module includes a step of mechanically pressing one time or multiple times a heat pipe into a trough of a metallic base, whereby at least one end of the heat pipe can be pressed into the trough of the metallic base and thus firmly combined with the metallic base. In this way, the time and the cost for assembly are reduced, and the yield is increased.

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.