Ford Motor Company Limited

Ford Global Technolgoies, LLC

Samir Samir

Allen Roche

Richard L Allor

Chijoke Mgbokwere

Dawn Roberta White

Mark Thomas Lusk

John Scott Badgley

Joseph A Szuba

John Michael Nicholson

Tyann Sue Chappell

A method and arrangement for implementing post-heat treatment after spray forming is ended to achieve stress control in the manufacture of a spray formed metallic tool involves providing a spray-formed metallic tool by applying a spray-forming material on a mold substrate and causing substantially homogenous metallic phase transformations of the spray forming material within the spray-formed metallic tool to a substantially homogenous distribution of commingled metallic phases consisting, for example, of predetermined proportions of at least a bainite phase and a martinsite phase.

Method and arrangement implementing heat treatment after the execution of sprayform techniques

Method and apparatus for controlling stresses in a spray form process makes use of one dimensional modeling in which characteristics of a geometrical point are quantified by iterative detection, such as taking a surface temperature reading using a pyrometer. This temperature information is used in a one dimensional simulation to predict characteristics for a column from the point down through a spray-formed article to an interface with a substrate. The modeling technique can used with a plurality of geometrical points to model the whole article, and the one dimensional simulation can be integrated with robotic spray-forming controls to minimize residual stress in the spray-formed article.

Method and arrangement for controlling stresses based on one-dimensional modeling in sprayform techniques

Method and apparatus for controlling a spray-forming process incorporating time, temperature, and transformation dependent stress relief techniques involves the manipulation of both temperature and time for strategic phase changes that result in a specific and planned volumetric increase. This manipulation is made based on controlling ongoing spray parameters to spray-form an article having a mixed-phase and interspersed makeup of metallic phases that minimizes residual stress in the article.

Method and arrangement for affecting time, temperature and transformation dependent stress relief in sprayform techniques

A method for implementing post-heat treatment during spray forming to achieve stress control in the manufacture of a spray formed metallic tool involves applying a metallic spray-forming material onto a mold substrate and causing substantially homogenous metallic phase transformations from the austenite phase, for example, via manipulation of either or both of the substrate temperature and the spray forming cell environment temperature.

Method and arrangement for implementing heat treatment during the execution of spray-form techniques

A method for implementing pre-heat treatment before spray forming begins to achieve stress control in the manufacture of a spray formed metallic article involves preheating either or both of a spray forming cell environment and a mold substrate, initiating application of the metallic spray forming material onto the mold substrate, and causing substantially homogenous initial metallic phase transformations from the austenite phase via a predetermined relationship between the initial application temperature of the spray-forming material and the initial temperature of either or both of the preheated cell environment and the preheated mold substrate.

Method and arrangement for heat treatment before the execution of sprayform techniques

One method of the present invention includes introducing a slurry into a mold unit comprised of a mold contained within a casting receptacle and lowering the temperature of the slurry to freeze the slurry and form a freeze-cast substrate while controlling temperature gradients within the mold unit to minimize distortion in the freeze-cast substrate. Another method includes introducing a slurry into a mold unit comprised of a mold contained within a casting receptacle, placing insulation material around at least a portion of the casting receptacle to minimize distortion in the freeze-cast substrate by controlling temperature gradients within the mold unit, and lowering the temperature of the slurry to freeze the slurry to form a freeze-cast substrate.

Method for producing a freeze-cast substrate

Method of aligning a metallic solderable object to a glass plate comprising loading a solderable object onto an end effector of a robotically supported spindle of a spindle assembly, handing a support from the spindle assembly that extends beneath the axis of the spindle and has camming surfaces precisely aligned with the spindle axis, resiliently cradling a backing member on the support by use of a cam member adapted to fit against the support camming surface when the resiliency is overcome, positioning a glass plate on the backing member to overcome the resiliency of the backing member and cause the cam to engage the camming surfaces of the support and automatically obtain normality of the spindle axis with respect to the glass plate. An end effector assembly for facilitating friction soldering of a metal object to a glass plate, comprising a rotary spindle applicator having a support structure carrying a linearly moveable spindle along its axis, a hanging support depending from the support structure that extends beneath the axis of a spindle and carries camming surfaces precisely aligned with the spindle axis, a backing member resiliently carried on the hanging support, the backing member having a cam member depending therefrom and adapted to fit against the support camming surfaces when a glass plate is loaded onto the backing member to overcome such resiliency.

Self-aligining end effector for friction soldering metals to glass plate

There is disclosed herein a method for attaching a terminal to a metallic mating surface on a workpiece by friction joining, comprising the steps of: (1) providing the terminal and the workpiece, wherein the terminal comprises an electrically conductive body having a top end to which an electrical connector may be attached, a bottom end having a bottom surface generally conforming to the mating surface of the workpiece, a rotational axis substantially orthogonal to the bottom surface about which the terminal may be rotated, and a layer of solder attached to the bottom surface wherein the layer has an outer perimeter and defines a central solder-free region about the axis; (2) rotating the terminal about its rotational axis at a predetermined rotational speed while holding the workpiece stationary; (3) pressing together the rotating terminal and the stationary workpiece using a predetermined forging force for a predetermined length of time, so as to promote a galling bond between the mating surfaces; and (4) abruptly stopping the rotation of the terminal. During the pressing together step, the solder is generally maintained at an average temperature below its melting temperature.

Method for attaching a terminal connector to a metallic surface

There is disclosed herein a terminal connector 20 attachable to a metallic mating surface 52 on a workpiece 50 by friction joining. One embodiment of the connector 20 comprises an electrically conductive body 22 having a top end 24 to which an electrical connector 70 may be attached, a bottom end 26 having a bottom surface 28 generally conforming to the mating surface 52 of the workpiece 50, and an axis R substantially orthogonal to the bottom surface 28 about which the terminal 20 may be rotated. Attached to the bottom surface 28 is a layer of solder 30 having an outer perimeter 32 and defining a central solder-free region 34 about the axis R. In a preferred embodiment, the bottom surface 28 of the terminal 20 is substantially circular in shape, and the layer of solder 30 is substantially annular in shape with the central solder-free region 34 being substantially circular and generally centered about the rotational axis R. The solder layer 30 may further define a plurality of evenly spaced radial grooves 38 therein.

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Saline, MI, United States of America

Samir Samir