Gm Global Technolgoy Operations, Inc.

Other

Sandia National Laboratories

Progressive Blasting Systems, Inc.

Progressive Technologies, Inc.

Martin Stephen Kramer

Larry Edward Byrnes

Yucong Wang

Dale A Gerard

Jianghuai Yang

Su Jung Han

Roger L Briggs

Qigui Wang

Zhe Li

Huaxin Li

Seongchan Pack

Richard Earl Teets

Lewis L VanKuiken, Jr

David R Sigler

John Stilianos Agapiou

Thomas Arthur Perry

Daniel J Wilson

Steven J Ross

Song He

John Robert Smith

Paul Richard Meernik

Lokesh Choudhary

Brian W Geiser

Richard A Neiser

Brian Christopher Leuenhagen

Chester J Rivard

William L Oberkampf

Frank A Koltuniak

Gary L Holmes

Narasimha Kramadhati

Ronald P Buffa

Matthew P Werner

Leslie K Sumner

Peter J Toth

Charles D Valerius, Ii

Michael Herold

A composite article configured for mitigating noise, vibration, and harshness includes a substrate having a first stiffness. The composite article includes a structural film formed from a composition and disposed on the substrate in a pattern that is arranged to dampen a sound wave having a first frequency and a first amplitude and propagatable in a first direction to a second frequency that is less than the first frequency and a second amplitude that is less than the first amplitude. The composite article includes a coating layer disposed on the pattern and configured to dampen the sound wave in the first direction and in a second direction that is perpendicular to the first direction. The composite article has a second stiffness that is greater than the first stiffness. A method of forming the composite article is also described.

Composite article for mitigating noise, vibration, and harshness

An integrated power electronics component configured for mitigating noise, vibration, and harshness includes a case formed from metal and configured to dampen a sound wave having a first frequency and a first amplitude and propagatable in a first direction. The case has a first surface and a second surface spaced apart from the first surface, a first stiffness, and a first strength, and the first and second surfaces include a structure defining a plurality of recessions therein. The component includes a cured polymer formed from a composition disposed on at least one of the first and second surfaces in each of the recessions to thereby dampen the sound wave in the first direction and in a second direction that is perpendicular to the first direction to a second frequency that is less than the first frequency and a second amplitude that is less than the first amplitude.

Integrated power electronics component for mitigating noise, vibration, and harshness

A cylinder block for use in an internal combustion engine includes a first and second cylinder bores, a first and second cylinder bore liners, and a Siamese insert. The first and second cylinder bores are disposed adjacent to each other. The first and second cylinder bores each comprise a first cylinder bore wall and a second cylinder bore wall, respectively, and a shared cylinder bore wall. The first cylinder bore liner is disposed on a first inner surface of the first cylinder bore wall and the second cylinder bore liner is disposed on a second inner surface of the second cylinder bore wall. The Siamese insert is disposed in a top portion of the shared cylinder bore wall.

Method of manufacturing an engine block

An engine block, an automotive structure, and a method of coating an inner surface of an engine cylinder bore of an engine cylinder are provided. The method includes providing an inner bore substrate defining an inner surface of the engine cylinder bore, the inner bore substrate being formed of a first material. The method further includes disposing a thermal spray coating onto the inner surface of the engine cylinder bore. The thermal spray coating is formed of a second material that is different than the first material. The method also includes melting at least a portion of the thermal spray coating with a laser after performing the step of disposing the thermal spray coating onto the inner surface of the engine cylinder bore. The automotive structure and the engine block have a substrate covered by a thermal spray coating and laser remelted sections anchoring the coating to the substrate.

Laser remelting to enhance cylinder bore mechanical properties

A tool insert includes first, second, and third teeth arranged on a surface of the tool insert. The first tooth is arranged at a proximal end of the tool insert surface and has an angled leading end and a first tooth height. The second tooth is spaced from the first tooth by a first distance along the surface of the tool insert and has a second tooth height greater than the first tooth height. The third tooth is spaced from the second tooth by a second distance along the surface of the tool insert and has an extending angled portion. The first tooth forms a first groove in a bore surface. The second tooth increases the depth of the first groove. The third tooth provides at least one micro-scratch to one of the first groove and the bore surface.

Surface roughening tool and method

An improved surface activation technique improves the adhesion of thermal spray coatings, which is useful for engine cylinder bores. The new method includes compressing the cylinder bore surface to create a surface profile on the surface, such as through rolling a roller along the surface. An engine block is also provided, which includes a plurality of cylinder bores, each cylinder bore having an inner surface, and each inner surface having a surface profile that includes a helical groove and other surface profiles formed in the inner surface. A thermal spray coating is formed on the inner surface of each cylinder bore, the thermal spray coating being adhered to the surface profile of the inner surface. A roller assembly for activating the surface is also provided.

Adhesion of thermal spray using compression technique

A system for inspecting thermal spray coated cylinder bores of aluminum alloy cylinder blocks, the system includes a failure detection apparatus, a heating apparatus, a cooling apparatus, and a control unit in electronic communication with each of the failure detection apparatus, the heating apparatus, and the cooling apparatus, and wherein the control unit includes a memory and a control logic sequence for operating the system.

Cylinder block inspection method and system

An engine block and a method of coating an inner surface of an engine cylinder bore of an engine cylinder are provided. The method includes attaching a strengthening layer or ring onto an upper portion of the inner surface of the cylinder bore. The strengthening layer or ring may be attached by laser cladding. The method also includes depositing a thermal spray coating onto the inner surface of the cylinder bore and the strengthening layer or ring.

Strengthening layer attached to cylinder bore

An improved substrate surface texture i.e., roughness, significantly improves the adhesion of thermal spray coatings. The surface texture is defined by two metrology parameters and the invention comprehends a range of average roughness (Sa) between 9 and 15 &#x3bc;m and developed interfacial area ratio (Sdr) of greater than 100%. This surface texture is achieved by methods such as water jet erosion, mechanical roughening, laser texturing, chemical etching and plasma etching. The surface texture is especially beneficial for walls of cylinders of internal combustion engines, hydraulic cylinders and similar components to which a thermal spray coating is adhered and which are exposed to sliding or frictional wear.

Surface texture providing improved thermal spray adhesion

A method of treating the surface of an aluminum-based engine block cylinder bore that has been mechanically roughened. In one form, this method includes using vibratory stress relief, elevated temperature stress relief or cryogenic stress relief so that residual stresses imparted to the surface by the roughening process are reduced. In this way, a protective coating that is also applied to the bore surface will exhibit better adhesion and lower incidence of stress-induced or fatigue-induced cracking.

Stress relief of mechanically roughened cylinder bores for reduced cracking tendency

A pulley for a continuously variable transmission and a method of creating an engineered surface on an outer surface of a pulley of a continuously variable transmission, with the engineered surface engaging with a belt or chain of the continuously variable transmission. The method comprising the steps of: determining an actual engineered roughness (Rpk) on the outer surface needed to obtain a predetermined friction between the engineered surface and the belt or chain; and etching microgrooves in at least a portion of the outer surface to create the engineered surface by employing a laser to etch the microgrooves, the microgrooves being formed to a depth that produces the actual engineered roughness (Rpk).

CVT pulley with engineered surface

A method of re-manufacturing a shaft-hub assembly to be used in a transfer case, the method including the steps of: determining an initial diameter of a journal bearing of a main shaft that has been used in the transfer case; comparing the determined initial diameter to a predetermined minimum threshold, and discarding the main shaft if the determined initial diameter is below the predetermined minimum threshold; if the determined initial diameter is above the predetermined minimum threshold, preparing the bearing surface of the journal bearing for a thermal spray process; thermally spraying an aluminum bronze material onto the bearing surface; and machining the aluminum bronze material to achieve an outside diameter that provides a desired running clearance with a corresponding finished inside diameter of a central bore for a hub to which the main shaft will be assembled in the transfer case.

Main shaft remanufacturing

A method is provided for repairing a cylinder head having corrosion and erosion of the gasket sealing surface around the coolant inlet. The engine is disassembled and the corroded material is machined to a selected depth and width creating a pocket having a bottom wall surface and an annular side wall surface surrounding the coolant inlet port. An annular insert is provided having an annular outer side wall, a top wall, a bottom wall, and a central opening. The insert has a thickness greater than the depth of the machined pocket. An adhesive is applied the insert is pressed into the pocket. After curing of the adhesive, the top wall of the insert is machined to a dimension flush with the sealing surface of the head thereby creating a proper sealing surface for the subsequent seating of a replacement gasket.

Repair method for corroded engine cylinder head

The cylinder walls of light metal engine blocks are thermally spray coated with a ferrous-based coating including aluminum using an HVOF device. A ferrous-based wire is fed to the HVOF device to locate a tip end of the wire in a high temperature zone of the device. Jet flows of oxygen and gaseous fuel are fed to the high temperature zone and are combusted to generate heat to melt the tip end. The oxygen is oversupplied in relation to the gaseous fuel. The excess oxygen reacts with and burns a fraction of the ferrous-based feed wire in an exothermic reaction to generate substantial supplemental heat to the HVOF device. The molten/combusted metal is sprayed by the device onto the walls of the cylinder by the jet flow of gases.

Method of producing thermally sprayed metallic coating with additives

A nozzle assembly for a HVOF thermal metallic spray coating system includes an inner tube, a middle tube and an outer tube which are concentrically arranged about an axis of the nozzle assembly and are spaced to provide annular, concentric gas flow passages for oxygen and gaseous fuel along with a central wire feed passage in an efficient, compact arrangement. A slotted nib and plug are fitted to the discharge end at the assembly and defined, together with the middle tube, an annular premix chamber for the combustible gases, and a plurality of circumferentially spaced mixing slots and a downstream mix end portion of the nib where complete mixing of the gases occurs prior to entry into the combustion chamber provided in an air cap. An annular passage between the air cap and outer tube communicates with a high pressure air source for establishing an envelope of air against the inside surface of the air cap to serve as a protective barrier layer from the atomized metal.

Growing community of inventors

Clarkston, MI, United States of America

Martin Stephen Kramer