Ford Global Technolgoies, LLC

Ford Motor Company Limited

Visteon Global Technolgoies, Inc.

Other

David Robert Collins

Grigoriy Grinberg

Paul Earl Pergande

Jeffrey Alan Kinane

Richard L Allor

Allen Roche

Matthew M Shade

Matthew John Zaluzec

John Michael Nicholson

David J Klassen

Thomas Randall Peterman

Morgan Merritt Whitney, Jr

Jim Welniak

Joseph A Szuba

Oludele Olusegun Popoola

Armando Mateo Joaquin

Deborah Rose Pank

David A Boyle

Kevin Patrick Regan

Horton H Morris

Rick Thomas Heaman

Tony Leung Wong

Charles Chen

Catherine M Dentan

Ellen Forbus

John R Whyte, Jr

Allen Dennis Roche

Sink saddle

A method for generating a variable flow of melted material is disclosed. The method includes providing first and second members having a potential energy difference between them. One or more members is extended at a first average extension rate for a first period while producing an electrical arc. One or more members is extended at a second average extension rate for a second period while producing an electrical arc. One or more members is extended at a third average extension rate for a third period while producing an electrical arc. A transport medium is flowed across one or more members during one or more of the extending steps.

Method for producing a variable flow of melted material and articles therefrom

Method and arrangement for spray forming an article. The method includes spraying a plurality of metal streams upon a low-heat resistant model and thereby forming a spray formed article. Each of the plurality of metal streams is composed of moltenized droplets, and as between the plurality of metal streams, each is composed of different constituent elements. In the spray form process, conditions of the metal streams are controlled, particularly around the time that the droplets land, to prevent adverse affects such as melting or burning the master model. The spray conditions are controlled in such a manner that the individual metal droplets forming the metal streams remain substantially segregate. The segregated state is maintained through out solidification so that the resulting spray formed article is composed at least partially of psuedo-alloy.

Spray-formed articles made of pseudo-alloy and method for making the same

The present invention relates to a method of spray forming a boron steel metal article, and to the formed article. In at least one embodiment, the method comprises (a) providing a spray forming pattern, (b) spraying metallic particles onto the spray forming pattern, and (c) allowing the sprayed metallic particles to cool to form a metal article. In at least one embodiment, the metallic particles are sprayed from a carbon steel feedstock having a boron content of 0.25-2.25 weight percent, based on the total weight of the feedstock.

Spray formed articles made of boron steel

A method of making a spray formed article includes the steps of providing a sand pattern and spraying metal material toward the sand pattern to form the desired article. The sand pattern is made from a sand molding composition comprising refractory materials and binder. The refractory material comprises at least about 15 weight percent alumina, based on the total weight of the refractory material.

Method of making a spray formed article

Spray formed articles made of boron steel and method for making the same

One method of the present invention relates to a method for spray forming metal deposits. The method is comprised of providing a ceramic substrate having a spraying pattern for receiving sprayed metal particles, spraying metal particles onto the spraying pattern to form a metal deposit on the spraying pattern for at least a first spray period, controlling the spraying step during the first spray period so that the temperature of the deposited metal particles increases at an average rate of less than or equal to about 15&deg; per minute. The first spray period can be defined as lasting until the temperature of the deposited metal particles is at or about a steady state temperature. The steady state temperature is preferably in the range of about 330&deg; C. to about 370&deg; C.

Method for spray forming metal deposits

The present invention relates to a method of providing a spray formed composite article. The method comprises providing a first article. The first article is a spray formed article. A second article is located adjacent the first article. Metallic particles are sprayed onto the articles and allowed to form a metal deposit that extends between and connects the first and second articles.

Method of spray joining articles

Spray form cell including a two-wavelength imaging pyrometer adapted to provide real-time measurement of the surface temperature distribution of a metal 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.

Automated spray form cell

Method and arrangement for utilizing a psuedo-alloy composite for rapid prototyping and low-volume production tool making by thermal spray form techniques

A method of making a spray formed rapid tool includes the steps of making a model of a desired tool and constructing a ceramic pattern as the inverse of the model. The method also includes the steps of heating the ceramic pattern and thermally spraying a metal material against the ceramic pattern to form a desired tool.

Method of making a spray formed rapid tool

A method of spray forming a weldable metal deposit. The method comprises (a) providing a ceramic spray forming pattern, (b) heating the spray forming pattern to a sustained temperature sufficient to prevent internal stress formation in deposited carbon steel having a carbon content of less than about 0.3 weight percent when deposited on the heated spray forming pattern, (c) spraying metallic particles onto the spray forming pattern heated to the sustained temperature, and (d) allowing the sprayed metallic particles to cool to form a metal deposit. The metallic particles have a carbon content which is sufficient to result in metal particles having a carbon content of less than about 0.3 weight percent when deposited on the heated spray forming pattern. The resulting deposit has a carbon content of less than about 0.3 weight percent.

Method of spray forming readily weldable and machinable metal deposits

A multilayer, monolithic electrical interconnection device includes a substrate and a plurality of overlaying, alternating conducting and insulating layers deposited atop the substrate and one another. The layers are deposited by thermal spraying of respective insulating or conducting material through defined apertures in respective spray masks. Interlayer electrical connections are intrinsically formed by direct metallurgical bonding between the conducting material of an overlaying layer and the conducting material of a previously sprayed layer.

Multilayer electrical interconnection device and method of making same

The present invention relates to a method of making a molding tool comprising a core die and a cavity die. The method comprises (a) providing a first metal deposit comprising one of the cavity die or the core die, the first metal deposit having a die face, (b) providing a spray forming pattern on a portion of the die face of the first metal deposit,(c) spraying metal particles onto the first metal deposit and the spray forming pattern to form a second metal deposit comprising the other of the cavity die or the core die, and (d) removing the spray forming pattern from the first and second metal deposits.

Method of making tools having a core die and a cavity die

A method of integrating wear plates into a spray formed rapid tool includes the steps of making a model of a desired tool and constructing a ceramic pattern as the inverse of the model. The method also includes the steps of locating at least one wear plate on the ceramic pattern and thermally spraying a metal material against the wear plate and ceramic pattern to form the desired tool and embedding the wear plate into the desired tool.

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Southgate, MI, United States of America

David Robert Collins