Gm Global Technology Operations LLC

Gm Global Technologies LLC

Qigui Wang

Dale A Gerard

Daniel J Wilson

Jianghuai Yang

Yucong Wang

Liang Wang

Wenying Yang

Devin R Hess

Lokesh Choudhary

Steven L Burkholder

Ronald Charles Daul

Richard Jack Osborne

James Dwight Cremonesi

Peggy E Jones

Tiruttani Munikamal

Thomas W Gustafson

Cherng-Chi Chang

Huaxin Li

Christopher D Cogan

Gregory Melekian

Anil Kumar Sachdev

Michael J Walker

Ali Shabbir

Jeffrey B Harris

Yi Liu

James W Knight

Paul J Boone

David A Wulbrecht

Ronald John Petrus

William A Berry

Bing Ye

Zhe Li

John Stilianos Agapiou

Bing Li

Tyson W Brown

Brennon L White

Martin Stephen Kramer

Mark A Osborne

Jason R Traub

Margarita P Thompson

Kevin P Coleman

Paul Noles Crepeau

Paul J Gelazin

David Charles Klemstine

Brian Christopher Leuenhagen

Michelle A Wood

Stephen M Fitch

Shasha Vali Shaik

Suresh Kumar K

Andrew J Genualdi

Richard M Nichols, Iii

Guirong Cao

Kiran Mistry

Oliver Patrick Jordan

Hengcheng Liao

Lei Hao

Richard Murray Kleber

Andrew Thomas Cunningham

Bob Ross Powell

Ming Liu

Song He

Joshua L Solomon

Seongchan Pack

Brian Daniel Kaminski

Kestutis A Sonta

Marie-Christine G Jones

Herbert William Doty

Paul J Wolcott

Xinyu Zhou

Maurice G Meyer

Gerald Peter Backer

Garrold A DeGrace

David M Zini

Joseph C Kopchick

Jason J Coryell

James T Singer

Michael John Braskich

Xiaoshan Liu

Richard D Ricchi

Marcel Taran

Jared Matthew Satkowiak

Richard D Sisson

Lei Zhao

Ante Tony Lausic

Andrew J Buckland

Angela P Willis

Richard L Metcalf

Yunpeng Geng

Ye Pan

Patricia E Shaw

Eugene C Tuohy

Arunkumar R

Guoqiu He

Chengshu Chen

Zhengfei Hu

Defeng Mo

Michael J DeWyse

Jayaraman Sivakumar

Michael R Harper

A conductive cable for a battery electric vehicle is provided. The conductive cable comprises a plurality of first members in alignment to define a longitudinal axis of the conductive cable. Each first member comprises a first conductive wire about which a first outer layer is disposed for electric current to flow therethrough relative to the longitudinal axis. The first outer layer comprises a first metal substrate having a first side and an opposite second side. The first outer layer comprises a first copper-graphene (Cu-Gr) multilayer composite disposed on the first side and a second Cu-Gr multilayer composite disposed on the second side of the first metal substrate. Each first conductive wire comprises a first metallic material. The plurality of first members is disposed together along the longitudinal axis to define a cable bundle. The conductive cable further comprises a non-conductive layer disposed about the cable bundle.

Conductive cable for a battery electric vehicle

A conductive composite stator unit for an electric motor of a vehicle is provided. The stator unit comprises a stator core comprising a body having a first core end and an opposing second core end. The stator unit further comprises a plurality of conductive bars extending from the first core end to the second core end. Each conductive bar comprises a straight portion disposed in one of the slots such that the respective conductive bar is in contact with the stator core. Each conductive bar comprising a central portion and an outer layer disposed thereabout for electrical current to flow therethrough relative to the longitudinal axis, the outer layer comprises at least two copper-graphene (Cu-Gr) layers. Each Cu-Gr layer comprises a copper layer and a graphene layer. The stator unit further comprises an insulator layer disposed about each of the plurality of conductive bars.

Conductive composite stator unit for an electric motor of a vehicle

A magnesium (Mg) alloy housing for a drive unit of an electric vehicle (EV) having a drive shaft connected to an electric motor is provided. The Mg alloy housing comprises a body comprising Mg alloy. The body is arranged to house the drive unit of the EV. The housing further comprises a cylindrical hub disposed on the body. The hub has a bore formed therethrough and arranged to couple the drive shaft of the electric motor to the drive unit. The hub comprises a Mg portion having an inner surface. The hub further comprises an aluminum (Al) insert having an outerface. The Al insert is arranged to be disposed on the Mg portion such that the inner surface is aligned with the outerface defining a weld interface. The Al insert comprises iron (Fe) and Manganese (Mn) and having a Fe/Mn weight ratio of between 1:20 and 1:30.

Magnesium alloy housing for an electric vehicle drive unit

A method for mass-producing graphene composite vehicle components is provided. The method includes injecting a first flux into molten metal contained in a furnace using a first flux injection system and injecting a graphene flux into the molten metal using a second flux injection system. The method includes agitating and homogenizing the molten metal and the graphene flux within the furnace using an agitator. The method includes transferring the molten metal into a mold having an electromagnetic stirring system and then stirring the molten metal with the electromagnetic stirring system until the molten metal solidifies. The electromagnetic stirring system maintains homogenization of the molten metal and the graphene flux.

Method for production of graphene composite components having enhanced thermal conductivity

An aluminum alloy for high pressure die casting of ultra-large vehicle body structures. The aluminum alloy includes about 4.00 to about 12.00 weight percent silicon (Si); about 0.20 weight percent maximum (Max) copper (Cu); about 0.40 weight percent Max magnesium (Mg); about 0.20 to about 0.60 weight percent iron (Fe); about 1.00 weight percent Max manganese (Mn); about 0.50 weight percent Max zinc (Zn); about 0.02 weight percent Max strontium (Sr); about 0.50 weight percent Max cerium (Ce); about 0.01 weight Max percent boron (B); and a remaining weight percent aluminum (Al). The aluminum alloy provides an as-cast yield strength of greater than 130 Megapascals (MPa), ultimate tensile strength of greater than 260 MPa, and elongation of greater than 6% without the need for heat treatment.

Aluminum alloy for high pressure die casting of ultra-large vehicle body structures

An engine block for a vehicle includes a bore surface defining a cylinder bore. The bore surface exhibits a first microstructure and includes a pattern of a plurality of cycloidal features formed in the bore surface. The plurality of cycloidal features each exhibit a first length in a first axis and a second length in a second axis arranged 90 degrees from the first axis. The plurality of cycloidal features also exhibit a ratio of the first length to the second length in a range of 1:1.5 to 1.5:1. The plurality of cycloidal features further exhibit a second microstructure including tempered martensite, wherein the second microstructure is different from the first microstructure. The engine block is included in a vehicle. The cycloidal features are formed with a laser.

Laser hardened pattern array in cylinder bores

An induction rotor assembly having conductive bars is provided. The assembly comprises a lamination stack comprising a body having a first end and second ends to define a longitudinal axis. The body has an outer circumferential portion extending from the first end to the second end. The outer portion has a plurality of walls defining open slots formed from the first end through the second end. The assembly further comprises a first ring disposed on the first end and a second ring disposed on the second end. The assembly further comprises a plurality of conductive bars extending between the first and second rings. Each conductive bar is disposed in one of the slots such that the respective conductive bar is in contact with the lamination stack and connects the first and second rings. Each bar comprises an inner portion and a conductive outer skin disposed about the inner portion.

System and method of making a cast induction rotor assembly having conductive bars

A high pressure die casting (HPDC) system for casting ultra-large single-piece castings for vehicles. The HPDC system includes a clear feeding path from at least one ingate to a predetermined thicker section of a mold cavity, a last to solidify ingate having an equivalent or larger feeding modulus than the highest feeding modulus of the other ingates, and thermal management elements. The clear feeding path, last to solidify ingate, and thermal management elements ensure sufficient supplemental molten metal flow to the thicker portion of the mold cavity to accommodate for shrinkage of the thicker portion of an ultra large casting during the casting and solidification process.

System of high-pressure die casting of ultra-large aluminum castings

A system and method of manufacturing an aluminum fuel cell cradle includes providing a negative cast mold having cavities to form the cradle having a length greater than a width to define a longitudinal axis and providing a feeding mechanism disposed about the mold and in fluid communication with the cavities thereof. The feeding mechanism includes primary risers connected to and in fluid communication with the cavities. The method further includes melting a first metallic material to define a molten metallic material, moving the mold to a vertical orientation about the longitudinal axis while feeding molten metallic material through the runner to the cavities, and moving the cast mold to a horizontal orientation. A second solidification time in the risers is greater than a first solidification time in the mold such that shrinkage of the solidified metallic material occurs in the risers away from the mold.

System and method of making a cast reverse tilt-poured fuel cell cradle

A casting die includes a first ingate defining a first annular chamber and a second ingate defining a second annular chamber and spaced from the first ingate. The die includes a first end ring gate concentric with the first ingate and defining a first end ring chamber in fluid communication with the first annular chamber, and a second end ring gate concentric with the second ingate and defining a second end ring chamber in fluid communication with the second annular chamber. The die includes runners interconnecting the first and second end ring gates. Each of the runners defines a conductor bar channel in fluid communication with the first and second end ring chambers. The die includes an overflow gate disposed between the first and second ingates, wherein the overflow gate defines an annular overflow chamber in fluid communication with the conductor.

Casting die and method of mitigating entrained air in a cast article

A system and method of manufacturing an aluminum fuel cell cradle includes providing a negative cast mold having cavities to form the cradle and providing a feeding mechanism disposed about the mold and in fluid communication with the cavities thereof. The feeding mechanism includes a plurality of primary risers connected to and in fluid communication with cavities. The method further includes melting a first metallic material to define a molten metallic material, and moving the mold to a vertical casting orientation about a rotational axis, while feeding molten metallic material through the runner to the cavities, and cooling the molten metallic material to define a solidified metallic material. A second solidification time in the risers is greater than a first solidification time in the mold such that shrinkage of the solidified metallic material occurs in the risers away from the mold.

System and method of making a tilt-poured cradle for a fuel cell

A method of repairing an ultra-large single-piece cast component of a vehicle body. The method includes the steps of locating a damaged portion of the cast component, determining an extent of the damaged portion of the ultra-large cast component, defining a cut-line sectioning off the damaged portion from an undamaged portion of the ultra-large cast component, cutting along the cut-line to excise the damaged portion from the undamaged portion of the ultra-large cast component, and joining a replacement piece to the undamaged portion of the ultra-large cast component. The replacement piece is fabricated based on the original manufacturer's geometry and dimensional data of the excised damaged portion. The undamaged portion of the ultra-large cast component remains on the vehicle body during the repair.

Method of in-situ repair of an ultra-large single-piece casting

A design for repair casting having a repairable ultra-large single-piece casting and a replacement part. The ultra-large single-piece casting includes a main body portion, at least one predefined replaceable portion integrally cast with the main body portion, and a cut-guide delineating the predefined replaceable portion from the main body portion. The cut-guide includes a continuous channel defined on an exterior surface of the single-piece casting. The cut-guide further includes a rib extending from a channel wall on the main body portion. A damaged replaceable portion is excisable from the main-body portion by cutting through the single-piece casting along the cut-guide. The excised damaged replaceable portion may be replaced with the replacement part, which has substantially the same geometry, dimensions, and mechanical properties as an undamaged replaceable portion. The replacement part may be joined to the main body portion by mechanical means or by welding.

Repair ultra-large casting

An automobile vehicle crankshaft including a crankshaft casting of a nodular iron. The crankshaft casting includes multiple main journals coaxially aligned on a common crankshaft casting axis. Multiple crankpin journals are fixedly connected to the main journals by individual webs. Multiple lightening holes have individual ones of the multiple lightening holes integrally formed within individual ones of the crankpin journals during casting. A bubble space is located proximate to a mid-portion of selected ones of the multiple lightening holes of the crankpin journals. The bubble space locally increases a passage size of the selected ones of the multiple lightening holes and reduces a mass of the individual ones of the crankpin journals.

Lightweight nodular iron crankshaft for heavy duty engine

A three-dimensional part as well as a method and system for creating the three-dimensional part. The three-dimensional part including a first portion of a three-dimensional part formed from a first plurality of successively deposited layers, with a cavity defined in the first portion of the three-dimensional part. A magnet is inserted in the cavity and a cover disposed on the magnet in the cavity. In addition, a second portion of the three-dimensional part is formed form a second plurality of successively deposited layers deposited on the first portion of the three-dimensional part and the cover.

Method for creating part with localized magnetic properties using material extrusion additive manufacturing

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Rochester Hills, MI, United States of America

Qigui Wang