Ford Motor Company Limited

Ford Global Technolgoies, LLC

Howard D Blair

Andre Ezis

Tsung-Yu Pan

Furqan Zafar Shaikh

Elaine C Beckwith

John Michael Nicholson

Morton E Milberg

A method and apparatus for directly making rapid prototype tooling from a computer model having a free-form shape. The method steps comprise essentially: (a) machining a soft metal tooling base so as to contour at least one free-form surface in conformity with the computer model; (b) cold-gas dynamic spraying the contoured surface to form superimposed impact welded metal particle layers, the layers consisting of at least one thermal management under-layer comprising primarily copper, and at least an outer wear resistant layer comprising primarily tool steel.

Method of directly making rapid prototype tooling having free-form shape

A metal matrix composite includes a plurality of fibers having an average diameter of about eight micrometers with a coating, and a metal or alloy distributed with said fibers, a fibers-to-metal or alloy ratio has a range is has a range of about 9:1 to less than about 1:1.

Low-temperature, high-strength metal-matrix composite for rapid-prototyping and rapid-tooling

A method of enhancing a joint in a metal assembly. At least two metal members are joined together. Each member has a joining surface that mates with the other joining surface. The metal members are contacted against one another such that the joining surfaces mate. The mated joining surfaces are welded together at multiple locations. The welding process leaves a small gap between the metal members between these welding locations. Heat is applied to the joining surfaces adjacent to the gap. A solder is applied to the heated joining surfaces. The joining surfaces cause the solder to melt and to be wicked into the gap by the capillary force. The solder fills the length, width and thickness of the gap and joins the metal members together with a metallurgical bond. The entire joint including areas between the welding locations becomes joined.

Method of enhancing a joined metal assembly

Method of making densified Si.sub.3 N.sub.4 /oxynitride composite with

Method of making yttrium silicon oxynitrides

Method of making a densified silicon nitride/oxynitride composite

A method of joining silicon nitride based ceramic bodies is disclosed. At least one interfacing surface of shaped bodies (one or both of which may be hot-pressed or reaction-sintered) receives a layer of metallic aluminum based material. The bodies with the metallic aluminum based material therebetween are subjected to heating at 1400.degree.1900.degree. C. for a period typically 0.5-2 hours in a nitriding atmosphere to effect a chemical bond consisting of a conversion of the interfacing ceramic to a Si--Al--O--N system.

Process for joining silicon nitride based ceramic bodies

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Romulus, MI, United States of America

Howard D Blair