Richard H. Wykoff - Commerce Township MI, US Matthew John Zaluzec - Canton MI, US Joy Hines Forsmark - Saint Clair Shores MI, US Jacob Wesley Zindel - Ann Arbor MI, US Brian J. Schneider - Royal Oak MI, US
Assignee:
Ford Global Technologies, LLC - Dearborn MI
International Classification:
B60J 7/00
US Classification:
29621608, 29619304
Abstract:
A vehicle roof module includes a front extruded cross member, a first pair of nodes each received in an end region of the front cross member, a first and a second extruded side rail with each end region receiving one of the first pair of nodes, a second pair of nodes each received in another end region of the first and second rails, a rear extruded cross member with each end region receiving one of the second pair of nodes, and a panel mounted to the front cross member, rear cross member, and first and second side rail. Each end region of each side rail defines an interior hollow portion and has at least one nodule extending from the side rail into the hollow portion to maintain a bond gap between the side rail and the node received into the side rail end region for receiving adhesive.
A High Strength Cast Aluminum Alloy With Accelerated Response To Heat Treatment
Christopher Wolverton - Saline MI, US Jacob Zindel - Ann Arbor MI, US Larry Godlewski - Fenton MI, US
Assignee:
FORD GLOBAL TECHNOLOGIES, LLC - Dearborn MI
International Classification:
C22C021/04
US Classification:
420/530000, 420/537000
Abstract:
The invention relates to an improved cast Al alloy designed to provide an accelerated response to heat treatment; specifically, the alloy's response to thermal growth during aging is accelerated, leading to a dimensionally more stable casting. This improvement is achieved by the addition of trace amounts of Sn, In, Ge or Cd to an Al—Si—Cu cast alloy. The improved alloy has particular application for cast Al engine blocks and cylinder heads.
Method For Optimizing Mechanical Strength Of A Casting Using Microstructure Predictions
Nagendra Palle - Ann Arbor MI Ravi Vijayaraghavan - Farmington Hills MI Jacob Wesley Zindel - Ann Arbor MI William Thomas Donlon - Dearborn MI John Edmond Allison - Ann Arbor MI
Assignee:
Ford Global Technologies, Inc - Dearborn MI
International Classification:
B22D 2700 G01N 1700
US Classification:
702136
Abstract:
A method for quantitatively predicting and consequently minimizing the amount of critical phases such as eutectic Al. sub. 2 Cu formed during solidification of Al--Si--Cu alloys used in a vehicle engine component comprises developing a micromodel to simulate microstructure evolution in cast Al--Si or Al--Cu alloys. The micromodel is calibrated using experimental thermal analysis cooling curves and an optimization process. Microstructure evolution and cooling curves are simulated for a casting using the calibrated micromodel. Precipitation of critical phases such as Al. sub. 2 Cu in the casting is predicted as a function of solidification conditions. The model allows casting process variables to be varied with predictable results so that the casting process can be controlled via the micromodel.
Advanced Cast Aluminum Alloys For Automotive Engine Application With Superior High-Temperature Properties
- Cearborn MI, US Jacob Wesley Zindel - Ann Arbor MI, US Larry Alan Godlewski - Fenton MI, US Bita Ghaffari - Ann Arbor MI, US Yang Huo - Dearborn MI, US Carlos Engler-Pinto - Dearborn MI, US Wei-jen Lai - Dearborn MI, US
Assignee:
Ford Global Technologies, LLC - Dearborn MI
International Classification:
C22F 1/043 C22C 21/02 B22D 21/00 C22C 21/04
Abstract:
A process of heat treating an Al—Si—Cu—Mg—Fe—Zn—Mn—Sr-TMs alloy, where the TMs include Zr and V, includes heat treating the alloy to produce a microstructure having a matrix with Zr and V in solid solution after solidification. The solid solution Zr, in wt. %, is at least 0.16%, the solid solution V, in wt. %, is at least 0.20% after heat treatment, and Cu and Mg are dissolved into the matrix during the heat treatment and subsequently precipitated during the heat treatment. The composition of the alloy, in wt. %, includes Cu between 3.0-3.5%, Fe between 0-0.2%, Mg between 0.24-0.35%, Mn between 0-0.40%, Si between 6.5-8.0%, Sr between 0-0.025%, Ti between 0.05-0.2%, V between 0.20-0.35%, Zr between 0.2-0.4%, maximum 0.5% total of other alloying elements, and balance Al.
Cast Aluminum Alloys For Automotive Applications By Microstructure Refinement Using Tsp Treatment
A method of casting an aluminum alloy is provided. The method includes casting a master aluminum alloy having a trisilanol phenyl polyhedral oligomeric silsesquioxanes (TSP) modifier into an ingot and adding the master aluminum alloy ingot into a molten base aluminum alloy to form a modified aluminum alloy. The modified aluminum alloy is heated for a period of time and then cast into a cast component. A variation of the method includes mixing a powdered aluminum alloy with a powdered TSP and pressing the mixture of powdered TSP and powdered aluminum alloy into a compacted preform prior to casting the master aluminum alloy. The compacted preform is melted during the step of casting the master aluminum alloy.
Advanced Cast Aluminum Alloys For Automotive Engine Application With Superior High-Temperature Properties
- Dearborn MI, US Jacob Wesley Zindel - Ann Arbor MI, US Larry Alan Godlewski - Fenton MI, US Bita Ghaffari - Ann Arbor MI, US Yang Huo - Dearborn MI, US Carlos Engler-Pinto - Dearborn MI, US Wei-jen Lai - Dearborn MI, US
Assignee:
Ford Global Technologies, LLC - Dearborn MI
International Classification:
C22F 1/043 C22C 21/04 B22D 21/00
Abstract:
A high fatigue strength aluminum alloy comprises in weight percent copper 3.0-3.5%, iron 0-1.3%, magnesium 0.24-0.35%, manganese 0-0.8%, silicon 6.5-12.0%, strontium 0-0.025%, titanium 0.05-0.2%, vanadium 0.20-0.35%, zinc 0-3.0%, zirconium 0.2-0.4%, a maximum of 0.5% other elements and balance aluminum plus impurities. The alloy defines a microstructure having an aluminum matrix with the Zr and the V in solid solution after solidification. The matrix has solid solution Zr of at least 0.16% after heat treatment and solid solution V of at least 0.20% after heat treatment, and both Cu and Mg are dissolved into the aluminum matrix during the heat treatment and subsequently precipitated during the heat treatment. A process for heat treating an Al—Si—Cu—Mg—Fe—Zn—Mn—Sr-TMs alloy comprises heat treating the alloy to produce a microstructure having a matrix with Zr and V in solid solution after solidification.
Three-Dimensional Printed Tooling For High Pressure Die Cast Tooling
- Dearborn MI, US Jacob Wesley ZINDEL - Ann Arbor MI, US Harold P. SEARS - Livonia MI, US Larry Alan GODLEWSKI - Fenton MI, US John PHILLIPS - Ann Arbor MI, US
A high pressure casting die is disclosed. The high pressure casting die may include a die half that defines a recessed area and a build plate that may nest within the recessed area of the die half. The high pressure die casting may further include an additive section that is disposed on the build plate. The additive section may include a plurality of metallic powder layers, the thermal conductivity or the thermal expansion coefficient of the build plate and the additive section may be within 10% of each other.
Casting Assembly And Method To Provide Magnetic Retention For Over-Molded Inserts In Die Cast Tooling
An exemplary casting assembly for an engine block includes, among other things, an insert and at least one magnet configured to retain the insert in a predefined position within an engine block mold cavity. An exemplary engine block casting method includes, among other things, positioning at least one insert in a mold cavity, retaining the insert in position with at least one magnet, introducing material into the mold cavity to form an engine block, and solidifying the material to secure the insert within the engine block.
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