公开(公告)号：US11618937B2

公开(公告)日：2023-04-04

申请号：US16657146

申请日：2019-10-18

Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Inventor： Jianghuai Yang ,  Qigui Wang ,  Dale A. Gerard ,  James D. Cremonesi ,  Daniel J. Wilson

IPC: C22C37/08 ,  F16C3/06 ,  C22C37/10

Abstract: A nodular iron alloy and automotive components, such as a crankshaft, are provided. The nodular iron alloy may include iron, about 2.2-3.2 wt % carbon, about 1.7-2.3 wt % silicon, about 0.2-0.6 wt % manganese, a maximum of 0.03 wt % phosphorus, a maximum of 0.02 wt % sulfur, about 0.2-0.6 wt % copper, about 0.1-0.4 wt % chromium, about 0.4-0.8 wt % nickel, about 0.15-0.45 wt % molybdenum, about 0.2-1.0 wt % cobalt, about 0.02-0.06 wt % magnesium, and a maximum of 0.002 wt % rare earth element(s). The nodular iron alloy may have a Young's modulus in the range of 175-195 GPa and an as-cast ultimate tensile strength in the range of 750-950 MPa. This alloy possesses favorable strength, stiffness and noise/vibration/harshness qualities, making it suitable in crankshaft applications. A method of forming the nodular iron alloy includes feeding a magnesium-based material into a molten iron alloy through a continuous system at a constant amount.

公开(公告)号：US20200063248A1

公开(公告)日：2020-02-27

申请号：US16106445

申请日：2018-08-21

Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Inventor： Jianghuai Yang ,  Qigui Wang ,  Daniel J. WILSON ,  James D. Cremonesi ,  Paul J. Gelazin

IPC: C22C38/60 ,  C22C38/42 ,  C22C38/54 ,  C22C38/50 ,  C22C38/46 ,  C22C38/44 ,  C22C38/06 ,  C22C38/02 ,  C22C38/04 ,  C22C38/00

Abstract: A steel alloy and automotive components, such as crankshafts, produced therefrom are provided. The steel alloy includes iron, about 0.34 to about 0.40 weight percent carbon, about 0.8 to about 1.2 weight percent manganese, about 0.40 to about 0.60 weight percent silicon, about 0.04 to about 0.07 weight percent sulfur, about 0.9 to about 1.2 weight percent chromium, about 0.20 to about 0.35 weight percent molybdenum, about 0.08 to about 0.15 weight percent vanadium, and about 0.02 to about 0.06 weight percent aluminum. The steel alloy may also include up to 0.03 weight percent phosphorus, up to 0.25 weight percent nickel, up to 0.20 weight percent copper, up to 0.03 weight percent titanium, up to 0.03 weight percent nitrogen, and up to 0.002 weight percent boron.

公开(公告)号：US10526996B2

公开(公告)日：2020-01-07

申请号：US15233254

申请日：2016-08-10

Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Inventor： Jianghuai Yang ,  Qigui Wang ,  Martin S Kramer ,  Dale A Gerard

IPC: F02F1/00 ,  B24B5/06 ,  C23C4/12 ,  F02F1/18 ,  F02F7/00

Abstract: An improved surface activation technique improves the adhesion of thermal spray coatings, which is useful for engine cylinder bores. The new method includes compressing the cylinder bore surface to create a surface profile on the surface, such as through rolling a roller along the surface. An engine block is also provided, which includes a plurality of cylinder bores, each cylinder bore having an inner surface, and each inner surface having a surface profile that includes a helical groove and other surface profiles formed in the inner surface. A thermal spray coating is formed on the inner surface of each cylinder bore, the thermal spray coating being adhered to the surface profile of the inner surface. A roller assembly for activating the surface is also provided.

公开(公告)号：US20180304346A1

公开(公告)日：2018-10-25

申请号：US15494774

申请日：2017-04-24

Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Inventor： Jianghuai Yang ,  Qigui Wang ,  Daniel J Wilson ,  James D Cremonesi

IPC: B22C9/22 ,  B22C3/00 ,  B22C9/02 ,  B22C9/10 ,  B22D25/02 ,  B22D25/06 ,  F16C3/08

CPC classification number: B22C9/22 ,  B22C3/00 ,  B22C9/02 ,  B22C9/10 ,  B22D25/02 ,  B22D25/06 ,  F16C3/08 ,  F16C2220/02

Abstract: A sand casting apparatus, a method of forming a sand casting apparatus, and an automotive component are provided. The sand casting apparatus includes a sand casting base comprising a sand mold and/or a sand core comprising a base sand mixture, where the base sand mixture includes a sand material and a binder material. The sand casting apparatus further comprises an outer layer disposed on the sand casting base. The outer layer comprises silicon, magnesium, calcium, zirconium, manganese, carbon, aluminum, and iron. The automotive component has portions defining an aperture therein. The automotive component is formed of cast iron and has a nodular graphite structure from interior matrix to surface, where the nodular graphite structure on the surface is formed by a sand core having an outer layer that has reacted with the cast iron automotive component to form the nodular graphite structured surface.

公开(公告)号：US20170130307A1

公开(公告)日：2017-05-11

申请号：US14934225

申请日：2015-11-06

Applicant: GM Global Technology Operations LLC

Inventor： Huaxin Li ,  Martin S. Kramer ,  Jianghuai Yang ,  Ronald Sanders

IPC: C22C38/58 ,  C23C4/073 ,  C22C38/50 ,  C22C38/44 ,  C22C38/38 ,  F02F7/00 ,  C22C38/22 ,  C22C38/06 ,  C22C38/04 ,  C22C38/02 ,  C22C38/00 ,  F02F1/00 ,  C23C4/134 ,  C22C38/28

CPC classification number: C22C38/58 ,  C22C38/002 ,  C22C38/02 ,  C22C38/04 ,  C22C38/06 ,  C22C38/22 ,  C22C38/28 ,  C22C38/38 ,  C22C38/44 ,  C22C38/50 ,  C23C4/06 ,  C23C4/073 ,  C23C4/131 ,  C23C4/134 ,  C23C4/18 ,  F02F1/004 ,  F02F1/18 ,  F02F7/0007 ,  F02F7/0085

Abstract: An iron-based alloy for use in a plasma transferred wire arc thermal spray apparatus includes a high sulfur steel alloy in a stainless and non-stainless forms including a high aluminum and high titanium content. The alloy has significant improvements in the elimination of spray coating cracking, reduction of machining cost, and improved lubrication performance.

公开(公告)号：US11759849B1

公开(公告)日：2023-09-19

申请号：US17823238

申请日：2022-08-30

Applicant: GM Global Technology Operations LLC

Inventor： Liang Wang ,  Qigui Wang ,  Jianghuai Yang ,  Kiran Mistry ,  Oliver Patrick Jordan

IPC: B22C9/08 ,  B22D25/02 ,  C22C37/08 ,  C22C37/10 ,  F16C3/08

CPC classification number: B22C9/088 ,  B22D25/02 ,  C22C37/08 ,  C22C37/10 ,  F16C3/08 ,  B23P2700/07 ,  F16C2202/06 ,  F16C2202/08 ,  F16C2202/10 ,  F16C2204/66 ,  F16C2220/02 ,  F16C2240/02 ,  F16C2240/30 ,  F16C2240/48 ,  Y10T29/17 ,  Y10T29/49286

Abstract: A method and system for manufacturing a cast iron crankshaft for a vehicle are provided. The system comprises a molding unit arranged to form a negative sand cast mold of the cast iron crankshaft. The mold comprising at least one molded cavity having a pattern with dimensions of the cast iron crankshaft. The system further comprises a feeding mechanism comprising a riser having a connector through which molten metallic material flows to the cast mold. The feeding mechanism feeds the molten metallic material at a riser connection angle in the at least one mold cavity. The riser connection angle corresponds to a connector modulus. The connector modulus is 20% greater than a cast modulus. The riser geometry corresponds to a riser modulus. The riser modulus is 20% greater than the connector modulus. The system further comprises a furnace, a cooling area, a separation unit, a controller and a power source.

公开(公告)号：US11173568B2

公开(公告)日：2021-11-16

申请号：US16032880

申请日：2018-07-11

Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Inventor： Daniel J. Wilson ,  Huaxin Li ,  Jianghuai Yang ,  James D. Cremonesi ,  Qigui Wang

IPC: F16H55/06 ,  B23K20/12 ,  F16D3/79 ,  F16H55/17 ,  F16F15/30

Abstract: A composite metal flexplate is disclosed that includes an aluminum center plate and a steel ring gear joined to the aluminum center plate by a solid-state joint. The solid-state joint that joins together the aluminum center plate and the steel ring gear may be formed by friction welding. During the friction welding process, a surface of an annular body of the steel ring gear is preheated, followed by bringing the preheated surface of the annular body into contact with a surface of a periphery of a circular body of the aluminum center plate. The two contacting surfaces are then caused to experience relative rotational contacting movement, which generates frictional heat therebetween and softens adjacent regions of the steel ring gear and the aluminum center plate. Once this occurs, an applied force is administered to compress and forge the contacting surfaces together, thereby establishing the solid-state joint.

公开(公告)号：US20210115540A1

公开(公告)日：2021-04-22

申请号：US16657146

申请日：2019-10-18

Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Inventor： Jianghuai Yang ,  Qigui Wang ,  Dale A. Gerard ,  James D. Cremonesi ,  Daniel J. Wilson

IPC: C22C37/08 ,  C22C37/10 ,  F16C3/06

Abstract: A nodular iron alloy and automotive components, such as a crankshaft, are provided. The nodular iron alloy may include iron, about 2.2-3.2 wt % carbon, about 1.7-2.3 wt % silicon, about 0.2-0.6 wt % manganese, a maximum of 0.03 wt % phosphorus, a maximum of 0.02 wt % sulfur, about 0.2-0.6 wt % copper, about 0.1-0.4 wt % chromium, about 0.4-0.8 wt % nickel, about 0.15-0.45 wt % molybdenum, about 0.2-1.0 wt % cobalt, about 0.02-0.06 wt % magnesium, and a maximum of 0.002 wt % rare earth element(s). The nodular iron alloy may have a Young's modulus in the range of 175-195 GPa and an as-cast ultimate tensile strength in the range of 750-950 MPa. This alloy possesses favorable strength, stiffness and noise/vibration/harshness qualities, making it suitable in crankshaft applications. A method of forming the nodular iron alloy includes feeding a magnesium-based material into a molten iron alloy through a continuous system at a constant amount.

公开(公告)号：US20200048727A1

公开(公告)日：2020-02-13

申请号：US16056990

申请日：2018-08-07

Applicant: GM Global Technology Operations LLC

Inventor： Jianghuai Yang ,  James D. Cremonesi ,  Paul J. Gelazin ,  Qigui Wang ,  Daniel J. Wilson

IPC: C21D9/30 ,  F16C3/08 ,  C21D1/18 ,  C21D1/58 ,  C22C38/00

Abstract: A method for manufacturing a crankshaft for an internal combustion engine with a plurality of journals having a hardened case with a first microstructure. The crankshaft is comprised of a steel comprising between about 0.3 wt % and 0.77 wt % Carbon. The first microstructure of the hardened case of the journals comprises between about 15% and 30% ferrite and a balance of martensite and the resultant subsurface residual stress between 310 MPa and 620 MPa.

公开(公告)号：US20200016688A1

公开(公告)日：2020-01-16

申请号：US16032880

申请日：2018-07-11

Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Inventor： Daniel J. Wilson ,  Huaxin Li ,  Jianghuai Yang ,  James D. Cremonesi ,  Qigui Wang

IPC: B23K20/12 ,  F16D3/79 ,  F16F15/30 ,  F16H55/06 ,  F16H55/17

Abstract: A composite metal flexplate is disclosed that includes an aluminum center plate and a steel ring gear joined to the aluminum center plate by a solid-state joint. The solid-state joint that joins together the aluminum center plate and the steel ring gear may be formed by friction welding. During the friction welding process, a surface of an annular body of the steel ring gear is preheated, followed by bringing the preheated surface of the annular body into contact with a surface of a periphery of a circular body of the aluminum center plate. The two contacting surfaces are then caused to experience relative rotational contacting movement, which generates frictional heat therebetween and softens adjacent regions of the steel ring gear and the aluminum center plate. Once this occurs, an applied force is administered to compress and forge the contacting surfaces together, thereby establishing the solid-state joint.