Gm Global Technolgoy Operations, Inc.

Daniel J Wilson

Qigui Wang

Huaxin Li

Liang Wang

Jianghuai Yang

James Dwight Cremonesi

Dale A Gerard

Devin R Hess

Kestutis A Sonta

Ali Shabbir

Ronald Charles Daul

Zhe Li

Steven L Burkholder

Paul J Boone

Yi Liu

Gregory Melekian

Michelle A Wood

Paul J Gelazin

Cheonjae Bahk

Vincent A Baxter

Lei Hao

Xingcheng Xiao

Brian James Koch

John Stilianos Agapiou

Pete R Garcia

Martin Stephen Kramer

Edward J Keating

Jing Gao

Wenying Yang

Joshua L Solomon

Yanyan Zhang

Thomas W Gustafson

Gregory S Layser

Jatinder P Singh

Jason J Coryell

Stephen R McKenny

Gary P Sorensen

Raphael Gordon

Sean Madden

A conductive cable for a battery electric vehicle is provided. The conductive cable comprises a plurality of first members in alignment to define a longitudinal axis of the conductive cable. Each first member comprises a first conductive wire about which a first outer layer is disposed for electric current to flow therethrough relative to the longitudinal axis. The first outer layer comprises a first metal substrate having a first side and an opposite second side. The first outer layer comprises a first copper-graphene (Cu-Gr) multilayer composite disposed on the first side and a second Cu-Gr multilayer composite disposed on the second side of the first metal substrate. Each first conductive wire comprises a first metallic material. The plurality of first members is disposed together along the longitudinal axis to define a cable bundle. The conductive cable further comprises a non-conductive layer disposed about the cable bundle.

Conductive cable for a battery electric vehicle

A conductive composite stator unit for an electric motor of a vehicle is provided. The stator unit comprises a stator core comprising a body having a first core end and an opposing second core end. The stator unit further comprises a plurality of conductive bars extending from the first core end to the second core end. Each conductive bar comprises a straight portion disposed in one of the slots such that the respective conductive bar is in contact with the stator core. Each conductive bar comprising a central portion and an outer layer disposed thereabout for electrical current to flow therethrough relative to the longitudinal axis, the outer layer comprises at least two copper-graphene (Cu-Gr) layers. Each Cu-Gr layer comprises a copper layer and a graphene layer. The stator unit further comprises an insulator layer disposed about each of the plurality of conductive bars.

Conductive composite stator unit for an electric motor of a vehicle

A battery cell includes an anode, a cathode, a liquid electrolyte, and a battery cell case. The battery cell case is configured to house the anode, the cathode, and the liquid electrolyte and includes a case interior wall arranged proximate one of the anode and the cathode, a battery case ceiling, and a battery case floor catching and collecting the liquid electrolyte due to force of gravity. The case interior wall defines a pattern of surface tension varying between hydrophobic and hydrophilic along the case interior wall between the battery case floor and the battery cell ceiling. The pattern of surface tension thereby facilitates self-propulsion of the liquid electrolyte in opposition to the force of gravity and a predetermined distribution of the liquid electrolyte along the battery cell wall.

Battery cell enclosure with anti-gravity electrolyte distribution

An aluminum alloy for high pressure die casting of ultra-large vehicle body structures. The aluminum alloy includes about 4.00 to about 12.00 weight percent silicon (Si); about 0.20 weight percent maximum (Max) copper (Cu); about 0.40 weight percent Max magnesium (Mg); about 0.20 to about 0.60 weight percent iron (Fe); about 1.00 weight percent Max manganese (Mn); about 0.50 weight percent Max zinc (Zn); about 0.02 weight percent Max strontium (Sr); about 0.50 weight percent Max cerium (Ce); about 0.01 weight Max percent boron (B); and a remaining weight percent aluminum (Al). The aluminum alloy provides an as-cast yield strength of greater than 130 Megapascals (MPa), ultimate tensile strength of greater than 260 MPa, and elongation of greater than 6% without the need for heat treatment.

Aluminum alloy for high pressure die casting of ultra-large vehicle body structures

An induction rotor assembly having conductive bars is provided. The assembly comprises a lamination stack comprising a body having a first end and second ends to define a longitudinal axis. The body has an outer circumferential portion extending from the first end to the second end. The outer portion has a plurality of walls defining open slots formed from the first end through the second end. The assembly further comprises a first ring disposed on the first end and a second ring disposed on the second end. The assembly further comprises a plurality of conductive bars extending between the first and second rings. Each conductive bar is disposed in one of the slots such that the respective conductive bar is in contact with the lamination stack and connects the first and second rings. Each bar comprises an inner portion and a conductive outer skin disposed about the inner portion.

System and method of making a cast induction rotor assembly having conductive bars

A high pressure die casting (HPDC) system for casting ultra-large single-piece castings for vehicles. The HPDC system includes a clear feeding path from at least one ingate to a predetermined thicker section of a mold cavity, a last to solidify ingate having an equivalent or larger feeding modulus than the highest feeding modulus of the other ingates, and thermal management elements. The clear feeding path, last to solidify ingate, and thermal management elements ensure sufficient supplemental molten metal flow to the thicker portion of the mold cavity to accommodate for shrinkage of the thicker portion of an ultra large casting during the casting and solidification process.

System of high-pressure die casting of ultra-large aluminum castings

A method of repairing an ultra-large single-piece cast component of a vehicle body. The method includes the steps of locating a damaged portion of the cast component, determining an extent of the damaged portion of the ultra-large cast component, defining a cut-line sectioning off the damaged portion from an undamaged portion of the ultra-large cast component, cutting along the cut-line to excise the damaged portion from the undamaged portion of the ultra-large cast component, and joining a replacement piece to the undamaged portion of the ultra-large cast component. The replacement piece is fabricated based on the original manufacturer's geometry and dimensional data of the excised damaged portion. The undamaged portion of the ultra-large cast component remains on the vehicle body during the repair.

Method of in-situ repair of an ultra-large single-piece casting

A design for repair casting having a repairable ultra-large single-piece casting and a replacement part. The ultra-large single-piece casting includes a main body portion, at least one predefined replaceable portion integrally cast with the main body portion, and a cut-guide delineating the predefined replaceable portion from the main body portion. The cut-guide includes a continuous channel defined on an exterior surface of the single-piece casting. The cut-guide further includes a rib extending from a channel wall on the main body portion. A damaged replaceable portion is excisable from the main-body portion by cutting through the single-piece casting along the cut-guide. The excised damaged replaceable portion may be replaced with the replacement part, which has substantially the same geometry, dimensions, and mechanical properties as an undamaged replaceable portion. The replacement part may be joined to the main body portion by mechanical means or by welding.

Repair ultra-large casting

A method for manufacturing a crankshaft for an internal combustion engine with a plurality of journals having a hardened case with a first microstructure. The crankshaft is comprised of a steel comprising between about 0.3 wt % and 0.77 wt % Carbon. The first microstructure of the hardened case of the journals comprises between about 15% and 30% ferrite and a balance of martensite and the resultant subsurface residual stress between 310 MPa and 620 MPa.

Crankshaft and method of manufacture

A method of making a die cast part having high wear resistance is provided. The method comprises providing a mold and an insert pin. The mold comprises an interior surface defining a cavity. The mold comprises a bore formed through the interior surface. The insert pin has a magnetic core having a magnetic field and a barrier disposed about the magnetic core. The insert pin is disposed in the bore and extends into the cavity. The method comprises filling the mold with metallic material such that the metallic material is in contact with the insert pin to define a contact layer. The method comprises modifying iron content within the contact layer with the magnetic field to define an outer layer and an inner layer formed between the outer layer and the insert pin. The inner layer has 3-5 wt % Fe and the outer layer has 0.01-0.5 wt % Fe.

System and method of making a die cast part having high wear resistance

The concepts described herein provide a method, system, and apparatus for joining, via welding, first and second members fabricated from an aluminum alloy including aluminum, zinc, and manganese, such as 7000-series aluminum alloys, and a resultant workpiece. A junction is formed by a first member being disposed contiguously to a second member. A welding machine generates a weld pool at the junction that includes liquified aluminum alloy. An ultrasonic transducer directs ultrasonic energy in proximity to the weld pool. In some embodiments, an electro-magnetic transducer directs electro-magnetic energy in proximity to the weld pool. The first member is fused to the second member at the junction upon solidification of the weld pool.

Method and apparatus for welding an aluminum alloy

Methods and systems are provided for continuously producing cast metal components. An exemplary method includes feeding molten metal into a first mold at a fill station; maintaining a pressurized chamber at an elevated pressure; moving the first mold into the pressurized chamber, wherein the molten metal solidifies in the first mold under the elevated pressure; and removing the first mold from the pressurized chamber.

In-line pressurization chamber for casting

A method of joining a first piece of an automotive component that is made from a first material to a second piece of the automotive component that is made from a second material includes machining a fay surface onto each of the first and second pieces of the automotive component, cleaning the fay surfaces of each of the first and second pieces of the automotive component, placing a metal filler between the fay surfaces of the first and second pieces of the automotive component, holding the first and second pieces together with the metal filler positioned between the fay surfaces of the first and second pieces, and passing an electric current through the first piece, the metal filler and the second piece to melt the metal filler and weld the first piece to the second piece.

Capacitive discharge welding of dissimilar metals

Angled, single laser weld and a method of forming an angled, single laser weld including arranging a first and second faying surfaces of a first and second component adjacently to form an interface between the components; irradiating at least one of the first and second components at the interface with a laser, wherein the first faying surface defines a plane formed at an angle alpha in the range of +/&#x2212;5 degrees to 60 degrees from an axis A perpendicular to the first front surface and the second faying surface matches the first faying surface; and forming a junction at the interface with an hourglass shaped weld.

Method of forming a single, angled and hourglass shaped weld

A valve seat formed within an aluminum engine component includes a valve seat surface machined within the aluminum engine component, a layer of copper alloy material laser clad onto the valve seat surface of the aluminum engine component, the layer of copper alloy material having a thickness of less than 2.0 millimeters, and a layer of copper alloy/tool steel carbide material laser clad onto the layer of copper alloy material, the layer of copper alloy/tool steel carbide material having an average thickness of less than 0.5 millimeters, wherein the layer of copper alloy/tool steel carbide material has an outer surface that is machined to a final valve seat profile.

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Linden, MI, United States of America

Daniel J Wilson