Gm Global Technolgoy Operations, Inc.

Gregory Melekian

Qigui Wang

Lokesh Choudhary

Daniel J Wilson

Ronald Charles Daul

Anil Kumar Sachdev

Dale A Gerard

Liang Wang

Wenying Yang

Brian Daniel Kaminski

Devin R Hess

Ali Shabbir

Tiruttani Munikamal

Steven L Burkholder

David A Wulbrecht

Thomas W Gustafson

Michelle A Wood

Marcel Taran

Kurt T Hilvers

Alexey Rubin

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 parking pawl assembly having a housing, a parking pawl having a pin bore, a support sleeve fitted in the pin bore, and a pivot pin inserted through the support sleeve. The pivot pin is attached to the housing, thus pivotally attaching the parking pawl to the housing. The parking pawl includes a first end and a second end spaced from the first end. The first end defines the pin bore having an interior bore surface. The support sleeve includes an exterior surface fitted to the interior bore surface of the parking pawl. The exterior surface of the support sleeve may include outer diameter rolled threads or other locking features. The interior bore surface of the parking pawl may include inner diameter rolled threads operable to receive the outer diameter rolled threads of the support sleeve.

Parking pawl pin bore support

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

An engine for a vehicle. The engine includes a cast engine block having a hybrid insert disposed in a fastener bore having rolled internal threads. The hybrid insert includes an internal surface having cut inner diameter (ID) threads and an external surface having rolled outer diameter (OD) threads. The rolled OD threads of the hybrid insert are received in the rolled internal threads of the fastener bore. The hybrid threaded insert may include a bi-metal in which the ID threads are formed of one metal alloy and the OD threads are formed of another metal alloy. Alternatively, the external surface of the hybrid insert may define locking features and the engine block is cast onto these locking features, thereby locking the hybrid insert to the engine block.

Cast engine block having a hybrid threaded insert

A method of manufacturing a threaded hole in a workpiece includes providing the workpiece having a region with a hole. The method also includes cutting a threading for the hole. Furthermore, the method includes, independent of cutting the threading, densifying the region proximate the hole to reduce material porosity in the region.

Methods of manufacturing part with hole having cut threads

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Clarkston, MI, United States of America

Gregory Melekian