Abstract: The invention provides a method for manufacturing a friction damped disc brake rotor, including the steps of: (A) providing a ceramic coating on an insert, wherein the insert has a body with tabs extending therefrom to hold the insert in a desired position within a mold; (B) washing the ceramic coating off of the tabs; (C) positioning the insert into the mold; and (D) casting a rotor cheek of the disc brake rotor in the mold around the insert such that a portion of each tab is bonded with the rotor cheek, and such that the coating is substantially non-bonded with the rotor cheek so that the coating provides a proper interfacial boundary between the body and the cheek for damping, and the at least partial bonding of each tab with the rotor cheek prevents corrosion-causing exterior elements from reaching the interfacial boundary when the friction damped disc brake rotor is in use.

Abstract: A composite element is provided. The composite element includes a ceramic component defining a cavity having a first end and a second end, and a metallic component comprising a head and a body. At least a portion of the body of the metallic component is disposed in the cavity, and the head of the component is disposed on the first end of the cavity. A cross-sectional area of a portion of the body is greater than an area of the first end. In addition, the ceramic and metallic components are interlocked. Methods of making a composite element and of making a clearance sensor part are also provided.

Abstract: After a molten metal of aluminum or an aluminum alloy having a temperature, which is higher than the liquidus line temperature of aluminum or the aluminum alloy by 5 to 200° C., is injected into a mold, when the mold is cooled to solidify the molten metal, the molten metal injected into the mold is pressurized at a pressure of 1.0 to 100 kPa from a high-temperature side to a low-temperature side, and the mean cooling rate is set to be 5 to 100° C./minute while the mold is cooled from the liquidus line temperature to 450° C., the temperature gradient formed in the mold being set to be in the range of from 1° C./cm to 50° C./cm.

Abstract: A hybrid torsion beam axle assembly is provided, which includes a steel torsion beam. An end cap is fastened to an end portion of the steel torsion beam, and a cast trailing arm is cast about the end portion of the steel torsion beam including the end cap. In this way, the cast trailing arm is positively and rigidly secured to the steel torsion beam.

Abstract: A brake disc arrangement has a mounting portion formed of a metal, with a plurality of radial protuberances extending radially outward therefrom. The radial protuberances each have a radially distal tip portion, and a ceramic coating is applied to the radially distal tip portion of the radial protuberances. The brake plate portion is cast so as to surround the radially distal tip portions. However, it is isolated therefrom by the ceramic coating. At least some of the radially distal tip portions are formed of metal having a microstructure created by electrical discharge machining to increase dampening. A sand core within a core box holds the mounting portion in a predetermined fixed orientation. The molten metal is poured into the core box mold, and the metal brake plate portion is prevented by the ceramic coating from welding to any of the plurality of radial protuberances.

Abstract: A battery part such as a battery terminal and method of making the same with the battery part having a sealing region or sealing bead located on a lateral face of the acid ring with the beveled sealing region increasing the resistance to leakage therepast as the container shrinks. Another embodiment of the invention comprises a battery part with a bifurcated acid ring end and a beveled end face. The invention further includes the method of forming a battery terminal with an end face of the acid ring having a bifurcated end lip and a beveled face that permits one to either use the battery terminal in an as is condition or in a flared condition wherein a lip on the acid ring is flared to form a beveled sealing region on the lateral face of the acid ring.

Abstract: A composite material can include a carrier material that is coated, at least over part of the surface, with a corrosion protection layer made of an aluminum alloy. The composite material can provide a defined, effective, durable corrosion protection and simultaneously have a high recycling potential. The aluminum alloy of the corrosion protection layer can have the following composition in % by weight: ? 0.8 ?Mn ? 1.8 Zn ? 0.05 Cu ? 0.05 Si ? 1.0 Cr ? 0.25 Zr ? 0.25 Mg ? 0.10 remainder aluminum and unavoidable impurities, individually a maximum of 0.05% by weight, in total a maximum of 0.15% by weight.

Abstract: The object of the invention is to provide a highly reliable organic functional element such as an organic EL element or an organic semiconductor element exemplified by an organic TFT element which can be manufactured without requiring a vapor deposition process for forming an electrode on an organic material layer. Consequently, such an organic functional element can be large-sized easily and produced at lower cost. In addition, no damage is caused to the organic material layer during formation of the electrode, and the organic functional element is not affected by environmental changes. Also disclosed is a method for manufacturing such an organic functional element. To attain the above-mentioned object, the present invention provides an organic functional element comprising at least a plurality of electrodes and an organic material layer which is characterized in that at least one of the electrodes is composed of a metal having a melting point not higher than a temperature that is higher by 30° C.

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: An article in the form of one of a plate, a sheet, a cylinder, and a portion of a cylinder, which is adapted for use as at least a portion of a wear resistant working surface of a roll is disclosed. The article includes a metal matrix composite comprising a plurality of inorganic particles dispersed in a matrix material. The matrix material includes at least one of a metal and a metal alloy, wherein the melting temperature of the inorganic particles is greater than the melting temperature of the matrix material. A plurality of hard elements are embedded in the metal matrix composite. The wear resistance of the metal matrix composite is less than the wear resistance of the hard elements, and the metal matrix composite preferentially wears away when the article is in use, thereby providing or preserving gaps between each of the plurality of hard elements at a working surface of the article.

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: 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: A method for fabricating a reinforced matrix composite comprising the step of providing a composite preform having a fibrous structure and applying matrix material onto the preform in locations along the preform. A barrier material is applied to at least a portion of the coated preform to direct the flow of matrix material into the preform. The composite preform is heated to a temperature sufficient to render the matrix material viscous and insufficient to cure the matrix material. The pressure to the interior of the composite preform is reduced, while the pressure to the barrier material is increased. The temperature is maintained to flow the matrix material into the composite preform and to force gases from the fibrous structure. The composite preform is then cured and cooled to form a reinforced matrix composite having a low void content and a substantially uniform matrix distribution.

Abstract: Magnesium or magnesium alloy components having galvanic corrosion protection isolators secured in place by metallurgical bonding during casting of the magnesium or magnesium alloy component. The isolators are formed of materials that are characterized by an absolute potential difference that is between that of magnesium and a contacting metallic component.

Abstract: A power tool has a housing a housing having an electronically commutated motor disposed therein. The motor has a rotor and a stator. The rotor has permanent magnets. The stator has a lamination stack and windings wound therein. Features are provided to provide double insulation.

Abstract: A major engine casting, such as an engine block or a cylinder head, fabricated of either magnesium or aluminum alloy, has a cast-in-place metal tube or form embedded within it. The tube or form enables circulation of liquid while substantially physically isolating the casting alloy from the circulating liquid and thereby restricting or eliminating corrosive interaction between them.

Abstract: One embodiment includes an insert including a body portion; a plurality of tabs extending from the body portion, wherein the tabs are tapered; and wherein the insert is constructed and arranged to provide damping.

Abstract: A lining support plate includes a base plate of cast metal and a plurality of pins which extend into the base plate and project from a support surface to anchor a friction lining material on the base plate. In the manufacture of the lining support plate, a support plate pattern (1) with a. plurality of cavities (4) in a lateral face is provided. Pins (6a-6d) are inserted into the cavities and partially protrude from the support plate pattern (1). The support plate pattern (1) and the protruding portions of the pins (6a-6d) are surrounded by a moulding compound which is compressed and/or cured. When the support plate pattern (1) is removed, the pins (6a-6d) are left behind in the moulding compound and a support plate casting cavity is formed. A melt is poured into the cavity, surrounding the portions of the pins (6a-6d) protruding into the cavity. Once the melt has solidified, the lining support plate can be removed from the mould.

Abstract: The present invention relates to a metal matrix composite (MMC) and the method of manufacturing the MMC. The MMC includes a preform formed from a composition having ceramic particles and ceramic fibers. The metal matrix composite also includes a support element formed from a metal where the metal impregnates through the preform. The method of forming the MMC includes the step of extruding the composition through a multi-screw extruder to form an extrudate. The method also includes the step of heating the preform and positioning the preform within a mold. The method further includes the step of heating the metal for forming a molten metal and injecting the molten metal into a cavity of the mold under pressure for infiltrating the preform with the molten metal. The method also includes cooling the molten metal to solidify the molten metal and form the metal matrix composite and removing the metal matrix composite from the mold.

Abstract: Described are wrought forms of copper alloys for infiltrating powder metal parts, the method for preparing the copper alloys and their wrought forms, the method for their infiltration into a powder metal part, and the infiltrated metal part infiltrated with the novel alloys having a generally uniform distribution of copper throughout and exhibiting high transverse rupture strength, tensile strength and yield strength. Infiltrated metal parts prepared by infiltrating powder metal parts with reduced amounts of the novel infiltrant typically weigh less and have superior strengths compared to similarly prepared infiltrated metal parts prepared with standard methods and conventional infiltration.

Abstract: The present invention relates to compositions and methods for forming a bit body for an earth-boring bit. The bit body may comprise hard particles, wherein the hard particles comprise at least one of carbide, nitride, boride, and oxide and solid solutions thereof, and a binder binding together the hard particles. The binder may comprise at least one metal selected from cobalt, nickel, and iron, and, optionally, at least one melting point reducing constituent selected from a transition metal carbide in the range of 30 to 60 weight percent, boron up to 10 weight percent, silicon up to 20 weight percent, chromium up to 20 weight percent, and manganese up to 25 weight percent, wherein the weight percentages are based on the total weight of the binder.

Abstract: A method of producing a clad sheet article having superplastic properties, and the resulting clad sheet article. The method involves producing a cladding layer onto at least one rolling face of a core ingot made of a metal having superplastic properties, preferably by co-casting, to form a clad ingot and then rolling said clad ingot to produce a sheet article. The core ingot includes an element that diffuses from an interior of the ingot to a surface at superplastic forming temperatures thereby deteriorating surface properties of the ingot. The cladding layer is provided with an element (dopant) that reacts with the element of the core to reduce the ability of the element to diffuse through the cladding layer.

Abstract: To provide a carbon fiber Ti—Al composite material having hardness, heat resistance and abrasion resistance, having reduced weight, improved strength, elastic modulus and thermal conductivity and being excellent in the uniformity of the quality. A carbon fiber Ti—Al composite material which is prepared by pressure impregnating a molded product containing fine carbon fibers having a fiber diameter of from 0.5 to 500 nm and a carbon length of at most 1,000 ?m and having a hollow-structured central axis, carbon long fibers having a fiber diameter of from 5 to 15 ?m and a titanium powder or a titanium oxide powder, with aluminum or an aluminum alloy by molten metal forging.

Abstract: An exemplary embodiment includes an automotive brake component, such as a brake drum or a brake rotor, and an inlay coupled to the automotive brake component. The inlay constituting at least a portion of a braking surface that is acted upon during a braking event. The inlay damping vibrations in the automotive brake component when the component is vibrated.

Abstract: The present invention includes a step of cooling a molten metal within a fine space present in the inside of an object and hardening it while applying a forced external force exceeding atmospheric pressure to the molten metal. The fine space is opened on the outer surface of the object in terms of one end thereof. The forced external force is given by at least one member selected among a pressing pressure, an injection pressure and a rolling compaction and applied to the molten metal from the opening surface side on which the fine space is opened, in a state that the other end side of the fine space is closed.

Abstract: To increase the strength of a shaped metal body of metal foam, an insert element may be embedded in the shaped metal body. For this purpose, the invention uses as the insert element a freely shearing chain mail of loosely interlinked rings, whereby particularly high strength can be achieved.

Abstract: A composite material having a high thermal conductivity and a small thermal expansion coefficient, which is obtained by impregnating a porous graphitized extrudate with a metal; the composite material having such anisotropy that the thermal conductivity and the thermal expansion coefficient are 250 W/mK or more and less than 4×10?6/K, respectively, in an extrusion direction; and that the thermal conductivity and the thermal expansion coefficient are 150 W/mK or more and 10×10?6/K or less, respectively, in a direction perpendicular to the extrusion direction.

Abstract: Thick-walled parts made via a casting method often exhibit, in those thick zones, the worst mechanical properties since the solidification speed in the zones is reduced relative to the thin-walled zone and frequently induces the worst mechanical properties. There is described a method incorporating solidification control elements in a melting charge, the elements increase locally the solidification speed of the melting charge.

Abstract: A first component portion including a first material and that may have a flange. The flange may have one or more ribs located on a surface thereof. A second component portion including a second material that is different from the first material. The second component portion may be cast-in-place over a part of, or substantially all of, the flange and over the ribs. An interconnection is formed between the first and second component portions so that relative movement between the component portions is substantially prevented. Also, thermal expansion and contraction which may occur during use of the first and second component portions is accommodated at the interconnection.

Abstract: Cold plate apparatuses and methods of fabrication are provided for facilitating cooling of an electronics component. The fabrication approach includes: forming a tube with a first metal and having first and second ends with a heat transfer region disposed therebetween; positioning the heat transfer region of the tube within a mold and casting a heat sink member around the tube by contacting a second metal in molten form over the tube, wherein the first and second metals react peritectically to form an alloy layer between the tube and the heat sink member, and a metallurgical bond is formed between the tube and heat sink member with cooling of the molten second metal; and controlling casting of the heat sink member to minimize a thickness of the alloy layer to enhance a heat transfer characteristic of the metallurgical bond formed between the tube and the heat sink member.

Abstract: Disclosed are compositions comprising a MAX phase material having the formula Mn+1AXn, wherein M is an early transition metal, A is an A-group element, X one or both of C and N, and n=1-3, wherein the MAX phase material defines a plurality of pores; and, a metal component comprising a low melting point metal, wherein the metal occupies at least some of the pores. Also disclosed are method comprising providing a porous green body comprising a particulate material having the formula Mn+1AXn, wherein M is an early transition metal, A is an A-group element, X one or both of C and N, and n=1-3; and, infiltrating at least some of the pores of the green body with a low melting point metal, thereby providing a composite material.

Abstract: A lightweight spray device with spray body that is suitable for precision cast molding, solving general casting problems, such as shrinkage and bubbling; and a process for manufacturing the same. The spray device is one with magnesium spray body provided with a spray part and a handle part, characterized in that the magnesium spray body is one formed with the use of a mold for magnesium spray body wherein a first slide pin is provided at a region where the spray part and the handle part cross each other and wherein around the first slide pin, there is provided a product melt orifice.

Abstract: The invention provides a method for manufacturing a powertrain component enclosure member, including the steps of: (A) positioning at least one insert into a mold, wherein the insert is provided with a coating to prevent bonding between the insert and the casting material; and (B) casting a wall of the powertrain component enclosure member in the mold around the insert such that a major portion of the insert is substantially non-bonded with the casting material to provide a proper interfacial boundary with the casting material for damping.

Abstract: A method is provided of in-situ casting well equipment wherein a metal is used which expands upon solidification. A body of such metal is placed in a cavity in a well. Before or after placing the metal in the cavity in the well, the body is brought at a temperature above the melting point of the metal. The metal of the body in the cavity is solidified by cooling it down to below the melting point of the metal.

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

Abstract: An impact resistant clad composite armor which includes a ceramic core, and a layer of bulk amorphous alloy surrounding the ceramic core and preferably bonded chemically to the ceramic core and a method of manufacturing such armor is provided.

Abstract: The invention relates to a method for producing a cast component 1 of an internal combustion engine with a cast-in pipe 3 in a casting process with expendable moulds and a permanent pattern or in a casting process with permanent moulds in which a solid core mould 4 is mounted in a split outer mould. To solve the problem of the pipe changing its position during the casting of the component 1, it is proposed according to the invention that a separat pipe holder 5 is integrated into the outer mould or the core mould 4. The pipe 3 is inserted into a retaining section 6 of the pipe holder 5 that is configured in such a manner that it locally surrounds the outer circumference 8 of the pipe 3 at least in part and with little play so that the pipe 3 can expand in the axial direction during casting but is secured against displacements in radial directions caused by buoyancy forces of the liquid casting material. Subsequently the component 1 is cast by the respective method.

Abstract: The invention relates to a method for the manufacture of light open porous components of metal, metal alloys, plastic or ceramic of any geometry. Here, the component is produced through casting liquid material into a casting device (01), wherein a core stack (04) is mounted, cast and removed in a casting mold (03). The core stack (04) here is designed as a regular multi-dimensional core lattice (09) with defined core lattice planes (12), where each core lattice plane (12) is constructed of individual regular core bodies (10).

Abstract: A hybrid yoke for a vehicle driveshaft assembly includes a cast iron portion having a pair of opposed yoke arms at a first end. The hybrid yoke also includes a steel portion having a yoke end and a shaft end, the shaft end for coupling to the driveshaft assembly and the yoke end for insertion into a second end of the cast iron portion.

Abstract: Endoprostheses including composites, and methods of making the endoprosthesis, are disclosed. The composites include at least a first material and a second material having different chemical compositions from each other.

Abstract: A side rail for installation in a shredder and method of fabrication in which the side rail has fingers that are partially embedded in a base. The fingers are made from steel and the base is made from cast aluminum. The fingers have a dovetail shape at an outer end thereof that is immersed in molten aluminum in a mold. When the aluminum is allowed to harden the fingers are embedded in the base. The side rails are much lighter weight than previous side rails, and are still sufficiently strong to be used in a mobile shredder.

Abstract: A cylinder block has a cast cylinder liner. A different level portion with a predetermined width is provided in a projected part formed along the lower end-face of the cylinder liner, in the centrifugal direction of the cylinder liner. In this case, the different level portion has a width corresponding to the dimensional tolerance range with respect to a finished inside diameter dimension position, and a outer circumference edge of the different level portion is provided in the outer circumference side farther than the finished inside diameter dimension position. Displacement of a hole is detected by checking the different level portion after machining the internal circumference of the cylinder liner.

Abstract: A cast composite material is prepared by furnishing an aluminum-based matrix alloy and forming a mixture of free-flowing boron carbide particles and the aluminum-based matrix alloy in molten form which is stirred to wet the matrix alloy to the boron carbide particles and to distribute the particles throughout the volume of the melt. The molten mixture is then cast. The fluidity of the molten mixture is maintained by (a) maintaining the magnesium content of the matrix metal below about 0.2% by weight, or (b) starting with a matrix metal containing less than 0.2% by weight magnesium and adding further magnesium to the mixture a short time before casting, or (c) having at least 0.2% by weight titanium present in the mixture.

Abstract: A composite material member is made of a light metal, and strength and durability in a joined part between constituent materials of the composite material member are improved, and production cost is decreased. The composite material member of the present invention contains a main material composed of a light metal or a light metal alloy which can be molded by casting; and a secondary material composed of a metallic material different from the main material or an inorganic material, the secondary material being joined to the main material by integrally casting with the main material, wherein a porous material is arranged on a part of a boundary area or entire boundary area between the main material and the secondary material.

Abstract: A method of processing a stabilizer bar assembly includes casting a metal anti-shift collar onto a prefabricated stabilizer bar. The metal anti-shift collar may be a zinc alloy, an aluminum alloy, or a magnesium alloy, for example.

Abstract: A metal fitting finding particular application as a corner fitting for an ISO freight container. The corner fitting is preferably cuboidal and comprises walls formed from a first material that define an internal cavity. At least one support member is encapsulated within the walls and is formed from a different material to that of the walls and comprises a greater yield strength. A reinforced corner fitting is therefore provided comprising enhanced load bearing capacity.

Abstract: A wear part made in a foundry is provided having a structure reinforced with at least one type of metallic carbide, and/or of metallic nitride, and/or of boride, and/or of metallic oxides, and/or of intermetallic compounds, hereafter called components. The raw materials acting as reagents for the components are put into a mold before casting in the form of inserts or preformed shapes of compacted powders or in the form of barbitones. The reaction of the powders is triggered in situ by the molten metal casting, forming a porous conglomerate in situ. The metal infiltrates the porous conglomerate, thereby making a reinforced structure so as to result in inclusion of the components in the structure of the metal used for the casting, thus creating a reinforcing structure on the wear part.

Abstract: Support members for a reciprocating piston internal combustion engine are disclosed. Embodiments include an engine block with support members extending between portions of the cylinder cavity and/or enhancing coolant flow for cooling the combustion cylinders. Also disclosed are support members for connection to the side walls of the cylinder cavity and support members with ears and/or holes to enhance combustion cylinder cooling. Further disclosed are methods for modifying an internal combustion engine to increase its internal support and/or cooling.

Abstract: An x-ray tube electron shield is disclosed for interposition between an electron emitter and an anode configured to receive the emitted electrons. The electron shield is configured to withstand the elevated levels of heat produced by electrons backscattered from the anode and incident on the electron shield. This in turn equates to a reduced incidence of failure in the electron shield. In one embodiment the electron shield includes a body that defines a bowl-shaped aperture having a narrowed throat segment. The body of the electron shield includes a first body portion, a second body portion, and a disk portion. These portions cooperate to define the bowl and the throat segment. The throat segment and the lower portion of the bowl are composed of a refractory material and correspond with the regions of the electron shield that are impacted by relatively more backscattered electrons from the anode surface.

Abstract: An aluminum-silicon carbide composite suitable as e.g. a base plate for power module is provided. An aluminum-silicon carbide composite comprising a flat plate-shaped silicon carbide porous body infiltrated with a metal containing aluminum as the main component, aluminum layers made of a material containing aluminum as the main component formed on both principal planes of the porous body, wherein the aluminum-silicon carbide composite has side faces formed by abrasive jet fabrication and the side faces do not have the aluminum layers made of a metal containing aluminum as the main component.