Gm Global Technolgoy Operations, Inc.

Steven L Burkholder

Qigui Wang

Liang Wang

Thomas W Gustafson

Anil Kumar Sachdev

Daniel J Wilson

Tiruttani Munikamal

Suresh Kumar K

Shasha Vali Shaik

Lei Hao

John Stilianos Agapiou

Dale A Gerard

Jianghuai Yang

Ronald Charles Daul

Gregory Melekian

William A Berry

David Charles Klemstine

Guirong Cao

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 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 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 low-pressure sand-casting system includes a sand-casting mold receiving a molten casting material to cast an automobile vehicle cylinder head. A port is created in the automobile vehicle cylinder head. A manifold port metal core assembly includes a metal core. A compressible material coating is applied on the manifold port core metal core.

Method to increase local cooling rate and improve material properties in a low-pressure sand-casting head

Methods and systems are provided for continuously producing cast metal components. An exemplary method includes feeding molten metal into a first mold at a fill station; maintaining a pressurized chamber at an elevated pressure; moving the first mold into the pressurized chamber, wherein the molten metal solidifies in the first mold under the elevated pressure; and removing the first mold from the pressurized chamber.

In-line pressurization chamber for casting

A system and method of increasing a cooling rate of a metal sand casting during solidification. The system includes a 3-D printed manufactured sand mold defining a mold cavity, a coolant inlet port extending into the manufactured sand mold, a myriad of coolant passageways surrounding a portion of the mold cavity, and a coolant outlet port in fluid communication with the coolant passageways. The system further includes a coolant vapor extraction system having a collection manifold in fluid connection with the outlet port of the sand mold. A molten metal is poured into the mold cavity and a liquid coolant is introduced into the sand mold. The liquid coolant changes state into a gas phase as it permeates through the sand mold, thereby increasing the cooling rate of the casting. The liquid coolant may be that of a liquid nitrogen.

System and method of increasing cooling rate of metal sand casting during solidification

A crankshaft for an internal combustion engine is provided. The crankshaft comprises at least four main journals aligned on a crankshaft axis of rotation defining a centerline. The crankshaft further comprises at least three pin journals. Each pin journal is disposed about a respective pin journal axis and positioned between the main journals. Each of the pin journals is joined to a pair of crank arms. Each pair of crank arms is joined to a respective main journal. Each of the main journals, pin journals, and crank arms is made of a first metallic material. Each crank arm has an over-molded counterweight metallurgically bonded thereto. Each counterweight is disposed opposite a respective pin journal relative to the centerline for balance and stability. Each counterweight is made of a second metallic material. The crankshaft has a weight ratio of the second metallic material to the first metallic material of between 0.20 to 0.50.

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Archbold, OH, United States of America

Steven L Burkholder