Magna International Inc.

The P.o.m. Group

Other

Timothy Walter Skszek

Frank A Horton

Seetarama S Kotagiri

Gregory Paul Kiselis

Jyoti Mazumder

Mark Francis Werner

Jeffrey Jay Mellis

Warren Edward Young

Dalip K Matharoo

Daniel Sulisz

Dwight Morgan

DeWayne Dale Egle

Gianfranco Gabbianelli

Ryan Robert Warpup

Pascal P Charest

Eric deNijs

Erryn Leigh Langlois

Ying Zhang

P Gregory Kiselis

Thomas James Oetjens

Frank Gabbianelli

Xiaoping Niu

Joseph K Kelly

Erryn Leigh Ashmore

Matthew T J Lowney

Matthew Lowney

Joohyun Choi

A method of manufacturing a structural component having tailored material properties by applying an IR-absorbent coating to a substrate formed of a ferrous-based, aluminum-based, magnesium-based, or fiber reinforced composite material is provided. The coating is preferably formed of iron oxide (FeO) decorated multiwall carbon nanotubes. Alternatively, the coating is wax-based or polymer-based and includes TriSilanollsooctylt POSS and additives. Different coating compositions may be applied to different zones of the substrate so that the emissivity coefficient varies along the substrate. The coated substrate is heated and formed between a pair of dies to achieve a complex shape or features. The IR-absorbent coating increases the infrared absorption rate during the heating step, which improves formability of the substrate. The iron oxide (FeO) decorated multiwall carbon nanotubes can also be applied to an engine component to increase the thermal efficiency of the engine by reducing friction and enabling the use of light weight materials.

Tailored material properties using infrared radiation and infrared absorbent coatings

An automotive component including a composite casting is provided. The composite casting includes a steel member and an end cap fastened to an end portion of the steel member. A cast coupling member is cast about the end portion of the steel member including the end cap, thereby positively and rigidly securing the cast coupling member to the steel member. The automotive component can comprise an engine cradle, a control arm, an instrument panel support structure, a bumper assembly, or a twist axle. The cast coupling member is typically formed by casting-in-place aluminum about the end cap and the end portion of the steel member. The steel member is typically a tubular member, and the end cap typically includes a flange designed to provide a mechanical interlock surface with the cast coupling member. For example, the flange can have a polygonal shape, an outwardly extending member, or notches.

Controlled pressure casting

A hybrid torsion beam axle assembly is provided, which includes a steel torsion beam. An end cap is fastened to an end portion of the steel torsion beam, and a cast trailing arm is cast about the end portion of the steel torsion beam including the end cap. In this way, the cast trailing arm is positively and rigidly secured to the steel torsion beam.

Hybrid component

A method of forming metal castings, including positioning a first end of a structural member in a first mold cavity and a second end of the structural member in a second mold cavity. The first and second mold cavities being fluidly coupled to a reservoir of molten metal. Applying a main pressure to the molten metal in the reservoir to force the molten metal into the first mold cavity and the second mold cavity. Then, applying a first auxiliary pressure to the first mold cavity and a second auxiliary pressure to the second mold cavity to densify the casting formed in the first mold cavity and the second mold cavity. Also, a method for casting including maintaining a main pressure at or less than an initial, mold-filling pressure after first and second mold cavities have been filled. Additionally, a method for detecting whether a first mold cavity is sufficiently filled with molten metal by monitoring a moveable element.

Direct-metal deposition (DMD), preferably under closed-loop control, is used to fabricate alloy-variant material structures which provide a combination of desirable physical and mechanical properties. Use of the invention facilitates the production of high-strength, high-wear, and impact-resistant structures which decrease the likelihood of erosion, heat checking and brittle failure in injection molds, die casting, thixomolding and other, more exotic tooling. The invention uses DMD to deposit a first material or alloy in an area exposed to high wear, such as the tooling gate area, with a second material or alloy being used elsewhere in the tool for greater impact resistance. Advantageously, the areas may be of a user-defined thickness to further improve longevity. The resulting composite material structure has mechanical properties (i.e., yield strength, hardness and abrasion resistance) which exceed that of the homogeneous compositions currently used for mold materials, thereby enhancing productivity while improving part quality in these and other applications.

Fabrication of alloy variant structures using direct metal deposition

A hybrid component for lightweight, structural uses, including a steel member formed of a high strength steel; and a cast coupling member cast on a portion of the steel member by casting-in-place a semi-solid aluminum about the portion of the steel member, thereby positively and rigidly securing the coupling member to the steel member. A method of forming a hybrid component for lightweight, structural uses, including: forming a steel member formed of a high strength steel into a predetermined configuration; and casting a coupling member on a portion of the steel member by casting-in-place a semi-solid aluminum about the portion of the steel member, thereby positively and rigidly securing the coupling member to the steel member.

A method of forming metal castings includes positioning a first end of a structural member in a first mold cavity and a second end of the structural member in a second mold cavity. The first and second mold cavities are fluidly coupled to a reservoir of molten metal. A main pressure is applied to the molten metal in the reservoir to force the molten metal into the first and second mold cavities. First and second auxiliary pressures are applied to the first and second mold cavities to densify the castings formed in the first and second mold cavities. Another method for casting includes maintaining a main pressure at or less than an initial, mold-filling pressure after the first and second mold cavities have been filled. Additionally, a method for detecting whether a first mold cavity is sufficiently filled with molten metal includes monitoring a moveable element.

The present invention incorporates one or more diode lasers for the high-power COor Nd-YAG lasers currently used in closed-loop DMD systems. Being semiconductor-based, such devices are almost instantaneously responsive to the electrical input. As such, a DMD system driven by a diode laser according to the invention provides a much faster response compared to other sources. The faster response time, in turn, provides for enhanced dimensional control and capability to produce intricate components with better dimensional accuracy.

Direct metal deposition apparatus utilizing rapid-response diode laser source

An assembly including a control arm and a steering knuckle, one of the control arm and the steering knuckle having a first end with a ball, the other of the control arm and the steering knuckle having a socket that includes a bearing structure formed so as to surround a portion of the ball to securely fasten the ball to the socket. The control arm has a bayonette configuration to receive a first node and a second node is cast directly onto the control arm.

Control arm and knuckle assembly

Continuously adjustable focusing optics for use in laser-assisted direct metal deposition (DMD&trade;) processes provide for adaptive deposition width to increase deposition rate while maintaining the dimensional tolerances. The focusing optics and method may be adapted for variable deposition road width under closed-loop feedback, so that complicated features may be fabricated with close tolerance, stress and microstructure control to improve the lead-time and design flexibility. The preferred embodiment uses adaptive mirror arrangements and beam movement for variable deposition width and geometry. Conceptually, an infinite number of mirror arrangements can be made to adapt to a particular deposit shape.

Focusing optics for adaptive deposition in rapid manufacturing

A laminate material composite structure is fabricated using a laser-based direct-metal deposition process to provide unique physical and mechanical properties. The relative difference in physical properties such as thermal conductivity between dissimilar pure metals or metal alloys provides the ability to deposit highly conductive materials having a low level of porosity using the DMD laser-based process. The proximity of a pure metal or metal alloy which has relatively high mechanical properties, compared to that of thermally conductive material, provides the structural strength, hardness and wear resistance required of mold materials. The combination of physical and mechanical properties associated with the laminate material composite structure provide thermal management benefits which result in a reduction in molding process cycle times and improved part quality.

Fabrication of laminate structures using direct metal deposition

Overhang and undercut features, as well as cavities, channels, pipes and three-dimensional voids and other structures are fabricated using a laser-aided direct-metal deposition (DMD) processes. In the preferred embodiment, this is accomplished through the selective deposition of a lower melting point sacrificial material. Following the integrated deposition of both sacrificial and non-sacrificial materials using DMD, the part is soaked in a furnace at a temperature sufficiently high to melt out the sacrificial material. As preferred options, the heating is performed in an inert gas environment to minimize oxidation, with a gas spray also being used to blow out remaining deposits. Using this technique, articles having integral sensors and cooling channels may be used as part of an automated system for controlling the temperature, stress and strain during the shaping or forming of a product using the resultant smart die or mold. Such a system would preferably include means of controlling the inlet flow of coolant and means for controlling or terminating the forming or injection process. The control is preferably mediated through a computer which analyzes and evaluates the inputs from the sensors and transmits the resulting information to a flow controller and to a process controller or logic gate, so that appropriate actions are carried out on a continuous basis.

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Saline, MI, United States of America

Timothy Walter Skszek