Gm Global Technolgoy Operations, Inc.

Mark A Osborne

Qigui Wang

Thomas Arthur Perry

Michael J Walker

Joseph C Kopchick

Anil Kumar Sachdev

Dale A Gerard

Wenying Yang

Shekhar G Wakade

Peggy E Jones

Paul J Boone

Barry L Priem

Scott W Biederman

James T Singer

Edward C Wall

William L Miller

Kenneth George Stahl, Jr

Eugene C Tuohy

Venkatramanan Srinivasan

One embodiment includes providing a first layer including a first powder material and a second layer including a second powder material over the first layer, and compacting the first powder material and the second powder material using at least a first magnetic field.

Method of compacting a first powder material and a second powder material

A piston with a cast bi-metallic dome feature and a method of making the piston. In one form, the piston is for use in a diesel engine, while in another, the piston is for use in a gasoline engine. The dome feature may include a laminate of a relatively high-temperature material (such as stainless steel) and a relatively low temperature material (such as aluminum or aluminum alloys) such that the portion of the dome made from the relatively high-temperature material is directly exposed to combustion within a cylinder into which the piston is placed. In another form, an aluminum coated stainless steel layer is used to form the dome. In one form, an ablation casting process may be used to manufacture the dome.

Piston with bi-metallic dome

A diesel piston with a cast bi-metallic dome and a method of making the piston. In one form, the dome may include a laminate of a relatively high-temperature material, for example, stainless steel, and a relatively low temperature material, for example, aluminum or aluminum alloys, such that the portion of the dome made from the relatively high-temperature material is directly exposed to combustion within a cylinder into which the piston is placed. In another form, an aluminum coated stainless steel ring is used to form the dome. In one form, an ablation casting process may be used to manufacture the dome.

Diesel piston with bi-metallic dome

Methods of making squirrel cage rotors of aluminum based material end rings joined with high conductive and durable material (such as copper) conductor bars for use in electric motors. The methods include forming conductor bars by casting or other metal forming methods in the slots of laminate steel stack, or positioning the preformed or premade solid conductor bars in the longitudinal slots of the stacked laminated steel, with bar ends extending out of the laminated steel stack ends, optionally coating the extended part of the conductors (bars) with a latent exoergic coating containing Al and one or more conductor bar chemical elements, positioning the laminated steel stack having conductors (bars) in a casting mold that forms the cavity of both end rings of the rotor, filling the end ring cavities with aluminum melt, and allowing the end rings to solidify under pressure. Alternatively, the conductor bars and end rings can be made separately and mechanically joined together.

Methods of manufacturing induction rotors with conductor bars having high conductivity

A rotor for an induction motor and a method of preparing same. The method includes making a squirrel-cage rotor made up of a cage and a laminate stack by forming a mold around the stack, heating the stack and introducing a molten metal into the mold such that the molten metal substantially fills a space defined in the stack that corresponds to the cage. In one form, the space includes slots or related channels formed in the stack that upon filling with the molten metal become longitudinal bars that form electric current loops with end rings of the cage. By heating the stack and maintaining it at a temperature high enough to keep the molten metal in a substantially molten state at least long enough for it to flow through the slots of the stack, premature freezing of the molten metal is avoided. In addition, by providing low pressure to the molten metal in conjunction with the elevated temperature in the stack, flow is promoted to ensure a substantially porosity-free, fully dense squirrel-cage for the rotor.

Pressure casting of electric rotors

A procedure for centrifugally casting a shorted structure around induction motor rotors is described. The method is commonly applied to a plurality of rotors disposed and arranged for rotational balance and supported on a suitable support, or optionally, on a plurality of supports arranged in layered fashion about a common rotational axis. The method comprises forming a wax representation of the shorted structure around a lamination stack; mounting a plurality of such lamination stacks in a mounting fixture and-attaching a suitable gating and runner system; forming an investment by coating the structure with refractory followed by melting out the wax; casting molten metal into the investment while it is rotating and aligning the mold to allow the centrifugal force generated to promote mold filling; and, continuing to rotate the investment until solidification is substantially complete.

Centrifugally-cast shorted structure for induction motor rotors

A mold for forming a plurality of rotors includes a plurality of lamination stacks, wherein each lamination stack defines at least one void therethrough; a tube having a central longitudinal axis, wherein each lamination stack is concentrically spaced apart from the tube to define a channel therebetween; a plurality of washers each having a shape defined by a first diameter and a second diameter that is greater than the first diameter, wherein each washer is configured to concentrically abut the tube and define a feed conduit interconnecting with the channel; and a shell disposed in contact with each lamination stack and concentrically spaced apart from each washer to define a plurality of ducts, wherein each duct is interconnected with the at least one void of at least one lamination stack. A mold system and a method of forming a plurality of rotors are also described.

Method, mold, and mold system for forming rotors

A casting design system () is provided which comprises (a) a database () which contains casting design data and rules, (b) a user interface (), in communication with the database, which accepts as input a product design () that is to be cast by a casting process, and (c) an inference engine () which is adapted to generate casting designs () from the input product design by searching the database and retrieving data therefrom.

Casting design optimization system (CDOS) for shape castings

A casting mold and method for its use to achieve in-mold modification of the casting metal is disclosed. One or more chambers are located within the casting mold's runner system. Each chamber can contain metallurgical modifiers for adjusting the chemical composition of the metal to improve the mechanical and physical properties of an article cast from the metal. One or more modifiers can be placed in the chamber(s) as the casting mold is assembled for use. As the melt is introduced to the casting mold, it passes through the chamber(s) and liquefies the modifier. Amounts of the liquid modifier, then, are carried away and become dispersed in the melt as it continues through the runner system and into the mold cavity. The metallurgical modifiers can be selected from any number of known additives or alloying elements, including strontium, among others.

Growing community of inventors

Grand Blanc, MI, United States of America

Mark A Osborne