Ford Motor Company Limited

Anthony T Anderson

Nathaniel L Field

Adam M Janotik

Charles A Stickels

David A Donovan

Method of dimensionally stabilizing the interface between metal parts of differing thermal expansion characteristics (TEC), regardless of temperature variations under normal designed use of such parts, comprising: (a) hot extruding a mixture of ceramic fibers (i.e., Si.sub.3 N.sub.4, SiC, Al.sub.2 O.sub.3) and a powder of the metal having the higher TEC (i.e., Al, Ti, Mg) while aligning the fibers generally along the direction of extrusion, to form an insert; (b) shaping the insert to align its fibers generally in at least one direction of anticipated thermal growth that may interfere with the interface; (c) casting the insert in place within a first part compound of the higher TEC metal and with the insert's fibers (i) oriented as above, and (ii) preheated to a temperature no greater than 35-45% of the temperature of the molten light metal; and (d) bringing together the first metal part with a second part of lower TEC metal (i.e., Fe or steel) to form the interface. The insert may be located in a mold in a manner to be totally enveloped by the molten light metal with the insert having a surface spaced a uniform, predetermined distance from the exterior of the cast light metal part, or the insert may be located to expose a surface thereof upon completion of the casting.

Method of dimensionally stabilizing interface between dissimilar metals

A low friction finger follower rocker arm is fabricated from flat metal strip sheet stock having a stamped configuration with a centralized opening adapted to be bent later into a channel; the shaping and hardening of the stock section is carried out prior to such bending. The method comprises: (a) (i) shaping the stock to have a pair of aligned journal openings, a pivot surface at one end, a stud contacting surface at the other end, and a pair of grooves aligned with the extremities of the centralized opening and containing the surface therebetween, (ii) locally hardening the surfaces and the edges of the opposed openings; (b) bending the shaped stock along the grooves to form a partial channel having side walls with an included angle of no greater than 40.degree. and with the journal openings approaching alignment on a common axis; and (c) inserting a journalized low friction wear assembly in the opposed journal openings, and then completing the bending of the stock so that the sides of the channel are substantially parallel.

Method of making low friction finger follower rocker arms

A low friction finger follower rocker arm is fabricated by starting with a flat metal strip sheet stock section having a stamped configuration with a centralized opening being adapted to be bent later into a channel for such rocker arm. The shaping and hardening of the stock section is carried out prior to such bending. The method steps comprise the following: (a) while substantially in the flat condition (i) shaping the strip sheet stock section to have at least a pair of journal openings aligned on opposite sides of said centralized opening, a pivot surface at one end of the strip sheet stock section, a stud contacting surface at the other end of the strip sheet stock section, such surfaces being aligned with the centralized opening along a line transverse to the alignment of said journal openings, and a pair of grooves aligned with the extremities of the centralized opening and containing the surfaces therebetween, (ii) locally hardening the surfaces and the edges of the opposed openings; (b) bending the shaped strip sheet stock section along the grooves to form a partial channel having side walls with an included angle of no greater than 40.degree. and with said journal openings approaching alignment on a common axis; and (c) inserting a journalized low friction wear assembly with its journals in said opposed journal openings, and then completing the bending of said strip sheet stock section so that the sides of the channel are substantially parallel and locking the wear assembly journals to the channel side walls.

A method (and resulting product) for preparing bearing components is disclosed. Utilizing a low alloy steel shape containing carbon in the range of 0.6-1.5% and containing alloying ingredients in the range of 1-2% selected from the group consisting of Cr, Mn, Ni, Cu and Mo (and preferably the ingredients of SAE 52100 steel), the steel shape is subjected sequentially to a spheroidizing-anneal heat treatment, a rough forming treatment, and a hardening-heat treatment. Immediately prior to the hardening-heat treatment, a fine bainitic or preferably pearlitic microstructure is established having relatively thin carbide films at prior austenite grain boundaries. Austenitizing of said pearlitic or bainitic microstructure is carried out at a temperature in the range of 1625.degree.-1675.degree. F for a period of time preferably between 15 seconds and one-half hour, but operationally for a period of time as short as 5 seconds and as long as 1 hour.

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Romulus, MI, United States of America

Anthony T Anderson