公开(公告)号：US12097583B2

公开(公告)日：2024-09-24

申请号：US17729603

申请日：2022-04-26

Applicant: GM Global Technology Operations LLC

Inventor： Daniel J. Wilson ,  Liang Wang ,  Qigui Wang ,  Devin R Hess ,  Michelle A. Wood ,  Ali Shabbir ,  Ronald C. Daul ,  Dale A. Gerard ,  Gregory Melekian

IPC: B23P6/04

CPC classification number: B23P6/04

Abstract: 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.

公开(公告)号：US11879168B2

公开(公告)日：2024-01-23

申请号：US17462527

申请日：2021-08-31

Applicant: GM Global Technology Operations LLC

Inventor： Jianghuai Yang ,  Dale A. Gerard ,  Qigui Wang

IPC: C22C37/10 ,  F02F1/00 ,  C22C37/08

CPC classification number: C22C37/10 ,  C22C37/08 ,  F02F1/004

Abstract: A high elastic modulus, high ultimate tensile strength, and low alloy gray cast iron for cylinder liners. The gray cast iron includes from 2.60 wt % to 3.30 wt % Carbon (C); from 1.50 wt % to 2.30 wt % Silicon (Si); from 0.30 wt % to 0.80 wt % Manganese (Mn); from 0.15 wt % to 0.35 wt % Phosphorus (P); from 0.05 wt % to 0.11 wt % Sulphur (S); from 0.60 wt % to 1.20 wt % Copper (Cu); from 0.10 wt % to 0.30 wt % Chromium (Cr); from greater than 0.0 wt % to 0.1 wt % Nickle (Ni); from 0.15 wt % to 0.40 wt % Molybdenum (Mo); and balance wt % Iron (Fe). The total wt % of Si, Mn, P, S, Cu, Cr, Ni, and Mo is less than about 4.10 wt %. The gray cast iron has a Carbon Equivalent (CE) from 3.00 wt % to 3.90 wt % and the product of Mn %*S % is from 0.025 to 0.045.

公开(公告)号：US20220097130A1

公开(公告)日：2022-03-31

申请号：US17032518

申请日：2020-09-25

Applicant: GM Global Technology Operations LLC

Inventor： Qigui Wang ,  Wenying Yang ,  John M. Kremer ,  Daniel J. Wilson ,  Dale A. Gerard ,  Thomas W. Gustafson

IPC: B22D41/62

Abstract: A ladle, process, and system for casting an aluminum-based alloy includes a casting ladle. The casting ladle includes a cup and the cup defines an opening. The ladle also includes an ultrasonic transducer including an end immersed in the cup, wherein the cup exhibits a first depth and the ultrasonic transducer is immersed in the cup at a second depth in a range of 5 percent to 100 percent of the first depth. An aluminum-based alloy melt is introduced into an opening of a casting ladle, an ultrasonic transducer immersed in the aluminum-based alloy melt is activated, and the aluminum-based alloy melt is transferred onto a casting surface.

公开(公告)号：US20220074325A1

公开(公告)日：2022-03-10

申请号：US17014526

申请日：2020-09-08

Applicant: GM Global Technology Operations LLC

Inventor： Devin R. Hess ,  Qigui Wang ,  Thomas W. Gustafson ,  Dale A. Gerard

IPC: F01L3/22 ,  F02F1/24 ,  B22D19/00 ,  C23C2/12

Abstract: A cylinder head having a cast-in-place valve seat for an automobile vehicle includes a valve seat having an inner wall. At least one retaining feature integrally and homogeneously extends from the inner wall. The valve seat when positioned into a casting mold has the at least one retaining feature assisting in retaining the valve seat in the casting mold. A metal in a molten form is received in the casting mold. A cast component formed after cooling of the metal has the valve seat cast-in-place.

公开(公告)号：US11098672B2

公开(公告)日：2021-08-24

申请号：US16539269

申请日：2019-08-13

Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Inventor： Jianghuai Yang ,  Qigui Wang ,  Dale A. Gerard

IPC: F02F1/10 ,  F02F1/00 ,  F02F1/08

Abstract: A method of forming an engine component includes providing a cylinder liner main body having a curved interior wall forming a cylinder bore extending along a bore axis and a curved exterior wall formed circumferentially about the curved interior wall. The method includes disposing a coating layer onto the interior wall and the exterior wall. A cylinder liner is provided that includes a main body and a coating layer disposed on an exterior wall and on an interior wall of the main body.

公开(公告)号：US20200306825A1

公开(公告)日：2020-10-01

申请号：US16363526

申请日：2019-03-25

Applicant: GM Global Technology Operations LLC

Inventor： Jianghuai Yang ,  Qigui Wang ,  Dale A. Gerard ,  Michael J. Braskich

IPC: B22D19/00 ,  F02F1/00 ,  F02B77/04

Abstract: A method of manufacturing a cylinder block for an engine comprises providing a cylinder liner for the cylinder block and keeping the cylinder liner in a controlled atmosphere, removing the cylinder liner from the controlled atmosphere, removing moisture and gaseous contamination from the cylinder liner, and positioning the cylinder liner in a mold and over-casting a cylinder block in the mold.

公开(公告)号：US20200095655A1

公开(公告)日：2020-03-26

申请号：US16136445

申请日：2018-09-20

Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Inventor： Jianghuai Yang ,  James D. Cremonesi ,  Qigui Wang ,  Eduardo Velasco Orosco ,  Dale A. Gerard

IPC: C22C37/10 ,  C22C37/06

Abstract: A nodular iron alloy and automotive components, such as crankshafts, are provided. The nodular iron alloy may include iron, about 3.3-3.9 wt % carbon, about 0.2-0.5 wt % manganese, about 1.9-2.6 wt % silicon, about 0.15-0.30 wt % copper, about 0.03-0.06 wt % magnesium, about 0-0.02 wt % sulfur, about 0-0.1 wt % chromium, about 0-0.05 wt % phosphorus, and/or about 0-0.01 wt % tin. The nodular iron alloy may include a number of graphite nodules, each having a diameter between 15 and 120 micrometers, and the graphite nodules having a number density of at least 90 per square millimeter. Iron may surround the graphite nodules in an amount of 20-40% of a ferrite microstructure and 60-80% of a pearlite microstructure. The nodular iron alloy may have an ultimate tensile strength in the range of 550 MPa to 680 MPa as-cast and at least 80% nodularity.

公开(公告)号：US20180320259A1

公开(公告)日：2018-11-08

申请号：US15584554

申请日：2017-05-02

Applicant: GM Global Technology Operations LLC

Inventor： Qigui Wang ,  Jianghuai Yang ,  Maurice G. Meyer ,  William L. Miller ,  Dale A. Gerard

IPC: C22F1/04 ,  C22F1/00 ,  C22C21/00

CPC classification number: C22F1/04 ,  C22C21/00 ,  C22F1/002

Abstract: A multiple step method increases net tensile strengths of high pressure die cast (HPDC) aluminum components through an alloy- and process-dependent thermal treatment. The highest temperature feasible for solution treatment of an HPDC casting is determined by computational thermodynamics, kinetics and the gas laws based on the alloy composition and gas pressure in the finally solidified parts. Determining the maximum solution temperature involves mapping pressure in the bubbles of solidified material to avoid the formation of blisters by surface adjacent bubbles in the casting. To reduce residual tensile stress, the HPDC parts are air cooled after the solution treatment. Finally, a specific, multiple temperature aging cycle is utilized to improve the aging response of air cooled HPDC parts and increase net tensile strength.

公开(公告)号：US12276010B2

公开(公告)日：2025-04-15

申请号：US18064980

申请日：2022-12-13

Applicant: GM Global Technology Operations LLC

Inventor： Qigui Wang ,  Liang Wang ,  Daniel J. Wilson ,  Dale A. Gerard ,  Devin R. Hess ,  Paul Boone

IPC: C22C21/02 ,  B22D17/00 ,  B22D21/00 ,  C22F1/043

Abstract: 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.

公开(公告)号：US11821384B1

公开(公告)日：2023-11-21

申请号：US17731365

申请日：2022-04-28

Applicant: GM Global Technology Operations LLC

Inventor： Qigui Wang ,  Jeffrey B. Harris ,  Ante Tony Lausic ,  Paul J Wolcott ,  Dale A. Gerard ,  Tyson Whittier Brown

IPC: F02F3/00 ,  F16J9/00 ,  B22F10/28 ,  B33Y10/00 ,  B33Y80/00

CPC classification number: F02F3/0084 ,  B22F10/28 ,  B33Y10/00 ,  B33Y80/00 ,  F16J9/00 ,  F02F2200/00

Abstract: A method to manufacture an automobile vehicle engine aluminum piston, comprises: printing an aluminum piston crown portion including an additive manufacturing (AM) piston crown work piece using initial aluminum powders defining an initial aluminum powder bed; removing the aluminum piston crown portion from the initial aluminum powder bed; fixedly joining a cast iron ring carrier to the AM piston crown work piece; placing the aluminum piston crown portion together with the cast iron ring carrier into a secondary and a tertiary aluminum powder bed; and printing a piston skirt integrally connected to the AM piston crown work piece and to the cast iron ring carrier.