Gm Global Technolgoy Operations, Inc.

Other

Lockheed Martin Energy Research Corporation

James Gregory Schroth

David R Sigler

Thomas Arthur Perry

Michael D Hanna

Richard Harry Hammar

Michael J Karagoulis

Blair E Carlson

John Stilianos Agapiou

Paul Edward Krajewski

Hongliang Wang

Omar S Dessouki

Mark William Verbrugge

Mark T Riefe

David S Yang

Brent D Lowe

Anil Kumar Sachdev

Gary A Kruger

Sean R Wagner

Jeremy W Short

Richard Murray Kleber

John E Carsley

Michael J Walker

John Robert Bradley

Xiaohong Gayden

Ryan Curtis Sekol

Yen-Lung Chen

Teresa J Rinker

Chongmin Kim

Mohan Sundar

Chen Zhou

Ronald Michael Lesperance

Megan E McGovern

Andrew Schertzer

Michael J Bland

Edward W Bennett

Yelena Myasnikova

Susan Elizabeth Hartfield-Wunsch

Ronald George Lanzi

Michael P Balogh

Jan Henning Aase

Jon T Carter

John C Morgante

Chih-Cheng Hsu

Glenn S Daehn

John D Campbell

Mark G Konopnicki

Jessica A Schroeder

Frederick W Rhoads

Edward Frank Ryntz

Diana Marie Wegner

Thomas C Zebehazy

John D Allen, Jr

Shung H Sung

John Norman Johnson

Frederick Irvin Saunders

Theresa M Lee

Curtis L Shinabarker

Matthew T Doescher

Leonard L Pollum

Michelle R Goff

Edwin H Chang

Thomas Zacharia

Matthew T Vanderlip

A method for manufacturing an electro-mechanical device includes creating a plurality of substrates using a first additive manufacturing process. Each of the substrates includes a polymeric material. The substrates include a first substrate and a second substrate. The first substrate includes a first main body and defines a protrusion extending from the first main body. The second substrate includes a second main body and a recess defined in the second main body. The method includes coupling the first substrate to the second substrate by inserting the protrusion into the recess such that the protrusion elastically deforms to an elastically averaged configuration. The protrusion and the recess together form an elastic averaging coupling. The method includes creating a plurality of electrically conductive components using a second additive manufacturing process and then coupling the electrically conductive components to at least one of the substrates.

Hybrid additive manufacturing assisted prototyping for making electro-mechanical components

Stator cores and methods for fabricating stator cores are provided. An exemplary stator core includes a stack of laminations. Each lamination in the stack of laminations comprises a yoke and a plurality of tooth segments fixed to the yoke.

Segmented stator laminations

A computer software product adapted for use in a weld inspection system is executed by a processor and is stored in an electronic storage medium of the weld inspection system adapted to facilitate the inspection of a weld of a work product. The computer software product includes a first module and a combination module. The first module is configured to transform first and second raw thermal images, associated with respective first and second heat pulses of at least a portion of the work product having the weld, into respective first and second binary images. The combination module is configured to transform the first and second binary images into a combined binary image for the reduction of noise.

Weld inspection system and method

A resistance spot welding method may involve spot welding a workpiece stack-up that includes a steel workpiece and an aluminum alloy workpiece. A pair of opposed welding electrodes are pressed against opposite sides of the workpiece stack-up with one welding electrode contacting the aluminum alloy workpiece and the other welding electrode contacting the steel workpiece. The welding electrodes are constructed so that, when an electrical current is passed between the electrodes and through the workpiece stack-up, the electrical current has a greater current density in the steel workpiece than in the aluminum alloy workpiece to thereby concentrate heat within a smaller zone in the steel workpiece. Concentrating heat within a smaller zone in the steel workpiece is believed to modify the solidification behavior of the resultant molten aluminum alloy weld pool in a desirable way.

Aluminum alloy to steel welding process

A modular stator includes a first stator module and a second stator module. The first stator module includes a plurality of first coil end regions and a plurality of first junctions. The second stator module includes a plurality of second coil end regions and a plurality of second junctions. The first stator module and the second stator module are joined at the plurality of first junctions and the plurality of second junctions.

Modular stator

A method of spot welding a workpiece stack-up that includes a steel workpiece and an aluminum alloy workpiece involves passing an electrical current through the workpieces and between welding electrodes that are constructed to affect the current density of the electrical current. The welding electrodes, more specifically, are constructed to render the density of the electrical current greater in the steel workpiece than in the aluminum alloy workpiece. This difference in current densities can be accomplished by passing, at least initially, the electrical current between a weld face of the welding electrode in contact with the steel workpiece and a perimeter region of a weld face of the welding electrode in contact with the aluminum alloy workpiece.

Electrode for resistance spot welding of dissimilar materials

A weld inspection system is adapted to inspect a weld of a work product via thermographic technology. The weld inspection system includes a heat source assembly, a thermal imaging camera, and a controller. The heat source assembly is adapted to sequentially direct a plurality of heat pulses upon the work product from varying perspectives and within a pre-determined time period. Thea thermal imaging camera is configured to thermally image the weld over the pre-determined time period and collect thermal imaging data of heat dissipation from the work product. The thermal imaging data is associated with the weld and the plurality of heat pulses. The controller is configured to control the heat source assembly and the thermal imaging camera. The controller includes a processor configured to receive and transform the thermal imaging data into a binary image for evaluation of the weld.

A rotor stack assembly includes multiple plates each including multiple elongated slots each oriented radially outward from a longitudinal central axis of each plate toward an outer perimeter wall of the plate. Multiple openings are each positioned proximate to one of the slots and directed outwardly through the outer perimeter wall. Multiple runners individually extend through the plate and individually open into one of opposed ends of each of the slots. Multiple bars of a conductive material are each extended through aligned ones of the slots of each of the multiple plates.

Low porosity and consistent metallurgical bonding for hybrid motor rotors

A method of resistance spot welding a steel workpiece and an aluminum or aluminum alloy workpiece, and a welding electrode used therein. In one step of the method a workpiece stack-up is provided. The workpiece stack-up includes a steel workpiece and an aluminum or aluminum alloy workpiece. Another step of the method involves contacting the aluminum or aluminum alloy workpiece with a weld face of the welding electrode. The welding electrode has a body and an insert. The insert is composed of a material having an electrical resistivity that is greater than an electrical resistivity of the material of the body. The weld face has a first section defined by a surface of the insert and has a second section defined by a surface of the body. Both the first and second sections make surface-to-surface contact with the aluminum or aluminum alloy workpiece amid resistance spot welding.

Resistance spot welding steel and aluminum workpieces with electrode having insert

A rotor for an induction motor includes a first shorting end ring, a second shorting end ring, and a plurality of conductor bars. Each conductor bar has a first end and a second end and is coated with an electrically conductive material. The first end of each conductor bar is in electrical and mechanical contact with the first shorting end ring, and the second end of each conductor bar is in electrical and mechanical contact with the second shorting end ring. The conductive material is disposed between each conductor bar and the respective shorting end rings.

Rotor for an induction motor

A cutting tool that can simultaneously cut and restore asymmetric weld face geometries of two welding electrodes that are subject to different degradation mechanisms is disclosed along with a method of using such a cutting tool during resistance spot welding of workpiece stack-ups that include dissimilar metal workpieces. The cutting tool includes a first cutting socket and a second cutting socket. The first cutting socket is defined by one or more first shearing surfaces and the second cutting is defined by one or more second shearing surfaces. The first shearing surface(s) and the second shearing surface(s) are profiled to cut and restore a first weld face geometry and a second weld face geometry, respectively, that are different from each other upon receipt of electrode weld faces within the cutting sockets and rotation of the cutting tool.

Welding electrode cutting tool and method of using the same

A method of forming a weld interface between a first workpiece and a second workpiece includes arranging a reactive braze material at a first joining surface of the first workpiece. The reactive material is selected to react upon being heated to a temperature below the solidus temperature of the first and second workpieces to form a liquid-containing reaction product. Furthermore, an assembly is prepared of the first workpiece and the second workpiece with the first joining surface of the first workpiece and a second joining surface of the second workpiece separated by the reactive material. The second workpiece is then heated with a first laser beam following a first path and with a second laser beam following a second path.

Laser welding of copper with reaction materials

A method of forming a rotor includes isolating a bridge area of an electrical steel lamination. The bridge area is disposed between a first portion of the electrical steel lamination and a second portion of the electrical steel lamination that is adjacent to the first portion. Each of the first portion, the second portion, and the bridge area has an initial hardness, and the electrical steel lamination has an initial magnetic permeability. After isolating, the method includes hardening only the bridge area so that the bridge area has a treated hardness that is greater than the initial hardness. Concurrent to hardening, the method includes decreasing the initial magnetic permeability at only the bridge area.

Method of forming a rotor

A method of joining together adjacent overlapping copper workpieces by way of resistance spot welding involves providing a workpiece stack-up that includes a first copper workpiece and a second copper workpiece that lies adjacent to the first copper workpiece. The faying surface of the first copper workpiece includes a projection that ascends beyond a surrounding base surface of the faying surface and makes contact, either directly or indirectly, with an opposed faying surface of the second copper workpiece. Once provided, a compressive force is applied against the first and second copper workpieces and an electric current is passed momentarily through the first and second copper workpieces. The electric current initially flows through the projection to generate and concentrate heat within the projection prior to the projection collapsing. This concentrated heat surge allows a metallurgical joint to be established between the first and second copper workpieces.

Resistance spot welding of copper workpieces

A welding electrode for use in resistance spot welding an assembly of overlying metal workpieces that includes an aluminum alloy workpiece is disclosed. The welding electrode includes a body, a convex weld face at one end of the body, and ringed protrusions that project outwardly from the convex weld face. The ringed protrusions are positioned to make contact with, and indent into, a surface of the aluminum alloy workpiece when the convex weld face is pressed against the aluminum alloy workpiece during a spot welding event. When brought into contact with the surface of the aluminum alloy workpiece, the ringed protrusions disrupt the oxide film present on the aluminum alloy workpiece surface, which improves the spot welding process.

Weld electrode for attractive weld appearance

Growing community of inventors

Troy, MI, United States of America

James Gregory Schroth