Ford Motor Company Limited

Ford Global Technolgoies, LLC

John Edmond Allison

Christopher Mark Wolverton

Robert Jay Natkin

Thomas John Heater

Jacob Wesley Zindel

Bret Allen Oltmans

Grant K Tappen

Nagendra Palle

Ravi Vijayaraghavan

Joy Adair Hines

William Thomas Donlon

Dietmar Peiskammer

A crank shaft support assembly for increasing stiffness and reducing thermal mismatch distortion in a crank shaft bore of an engine comprising different materials. A cylinder block comprises a first material and at least two crank journal inserts are insert-molded into respective crank journal regions of the cylinder block and comprise a second material having greater stiffness and a lower thermal coefficient of expansion that the first material. At least two bearing caps are bolted to the respective crank journal inserts and define, along with the crank journal inserts, at least two crank shaft support rings defining a crank shaft bore coaxially aligned with a crank shaft axis. The bearing caps comprise a material having higher stiffness and a lower thermal coefficient of expansion than the first material and are supported on the respective crank journal inserts independently of any direct connection to the cylinder block.

Crank shaft support assembly

The present invention discloses a method for optimizing heat treatment of precipitation-hardened alloys having at least one precipitate phase by decreasing aging time and/or aging temperature using thermal growth predictions based on a quantitative model. The method includes predicting three values: a volume change in the precipitation-hardened alloy due to transformations in at least one precipitation phase, an equilibrium phase fraction of at least one precipitation phase, and a kinetic growth coefficient of at least one precipitation phase. Based on these three values and a thermal growth model, the method predicts thermal growth in a precipitation-hardened alloy. The thermal growth model is particularly suitable for Al&#x2014;Si&#x2014;Cu alloys used in aluminum alloy components. The present invention also discloses a method to predict heat treatment aging time and temperature necessary for dimensional stability without the need for inexact and costly trial and error measurements.

Method of optimizing heat treatment of alloys by predicting thermal growth

A method for quantitatively predicting and consequently minimizing the amount of critical phases such as eutectic Al,Cu formed during solidification of Al&mdash;Si&mdash;Cu alloys used in a vehicle engine component comprises developing a micromodel to simulate microstructure evolution in cast Al&mdash;Si or Al&mdash;Cu alloys. The micromodel is calibrated using experimental thermal analysis cooling curves and an optimization process. Microstructure evolution and cooling curves are simulated for a casting using the calibrated micromodel. Precipitation of critical phases such as Al,Cu in the casting is predicted as a function of solidification conditions. The model allows casting process variables to be varied with predictable results so that the casting process can be controlled via the micromodel.

Method for optimizing mechanical strength of a casting using microstructure predictions

A method is disclosed for making a dual microstructure titanium based engine valve, wherein a first zone of the valve contains essentially a mixture of fine, equiaxed alpha and transformed beta crystalline grains which exhibit high tensile strength and high fatigue resistance, and a second zone of the valve which contains essentially a colony type microstructure exhibiting resistance to high temperature creep. The method comprises: (a) preparing a valve stock of forgeable mixed phase alpha/beta titanium based material; (b) hot working said first zone at a temperature below the beta transus temperature, (c) forging said second zone and, either simultaneously with said forging or subsequent thereto, heat treating said second zone at a temperature above (e.g., 25.degree.-200.degree. F. above) the beta transus temperature for a period of time to achieve beta processing followed by cooling to 1400.degree. F. at a rate of 0.1.degree.-10.0.degree. F./second; and (d) heat treating, immediately subsequent to either step (b) or step (c), at least the first zone at a temperature below the beta transus temperature (e.g., 25.degree.-200.degree. F. below) for a period of time to achieve alpha/beta processing.

Titanium engine valve and method of making

A method is disclosed for making a dual microstructure titanium based engine valve, wherein a first zone of the valve contains essentially a mixture of fine, equiaxed alpha and transformed beta crystalline grains which exhibit high tensile strength and high fatigue resistance, and a second zone of the valve which contains essentially a colony type microstructure exhibiting resistance to high temperature creep. The method comprises: (a) preparing a valve stock of forgeable mixed phase alpha/beta titanium based material; (b) hot working said first zone at a temperature below the beta transus temperature, (c) forging said second zone and, either simultaneously with said forging or subsequent thereto, heat treating said second zone at a temperature above (e.g., 25.degree.-200.degree. F. above) the beta transus temperature for a period of time to achieve beta processing followed by cooling to 1400.degree. F. at a rate of 0.1-10.0.degree. F./second; and (d) heat treating, immediately subsequent to either step (b) or step (c), at least the first zone at a temperature below the beta transus temperature (e.g., 25.degree.-200.degree. F. below) for a period of time to achieve alpha/beta processing.

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Ann Arbor, MI, United States of America

John Edmond Allison