公开(公告)号：US20240246142A1

公开(公告)日：2024-07-25

申请号：US18158725

申请日：2023-01-24

Applicant: GM Global Technology Operations LLC

Inventor： Qigui Wang ,  Liang Wang ,  Tiruttani Munikamal ,  Shasha Vali Shaik ,  Suresh Kumar K ,  Steven L. Burkholder ,  Thomas W. Gustafson

IPC: B22D25/04 ,  B22D21/00 ,  B22D35/04

CPC classification number: B22D25/04 ,  B22D21/007 ,  B22D35/04

Abstract: A system and method of manufacturing an aluminum fuel cell cradle are provided. The method comprises 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 comprises primary risers connected to and in fluid communication with the cavities. The method further comprises 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.

公开(公告)号：US20230398600A1

公开(公告)日：2023-12-14

申请号：US17839680

申请日：2022-06-14

Applicant: GM Global Technology Operations LLC

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

IPC: F16C3/10 ,  B22D19/04 ,  B22D25/06 ,  B22C9/02

CPC classification number: F16C3/10 ,  B22D19/04 ,  B22D25/06 ,  B22C9/02 ,  F16C2204/60 ,  F16C2220/06 ,  F16C2360/22 ,  F16C2202/10 ,  F16C2202/06

Abstract: Systems and methods of making a cast steel alloy crankshaft for an internal combustion engine are provided. The method comprises providing a mold of the crankshaft. The mold has cavities to form the crankshaft. The method further comprises melting a first metallic material at between 1400 degrees Celsius (° C.) and 1600° C. to define a molten metallic material. In addition, the method further comprises feeding the molten metallic material at a riser connection angle of between 30° and 75° in the cavities of the negative sand cast mold. The method further comprises cooling the molten metallic material at a solidification time of between 5 seconds (sec) and 20 sec in the negative sand cast mold with at least one chill member to define a solidified metallic material having dimensions of the cast steel alloy crankshaft. Furthermore, the method comprises separating the solidified metallic material from the negative sand cast mold to define the cast steel alloy crankshaft.

公开(公告)号：US20230339052A1

公开(公告)日：2023-10-26

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：US11654476B2

公开(公告)日：2023-05-23

申请号：US17034530

申请日：2020-09-28

Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Inventor： Lokesh Choudhary ,  Tiruttani Munikamal ,  Qigui Wang ,  Liang Wang

IPC: B22C9/10 ,  B22D15/00 ,  B22D17/22

CPC classification number: B22C9/103 ,  B22D15/00 ,  B22D17/22

Abstract: A hybrid core for manufacturing a cast component, the hybrid core including a sand core portion having an exterior shape configured to define an interior feature of the cast component. The hybrid core also includes a metal chill element embedded within the sand core portion. The metal chill element is configured to locally absorb heat energy from the cast component during cooling of the cast component and solidification thereof. The metal chill element is constructed and arranged within the sand core portion to be removed during shake out from the cast component subsequent to the solidification thereof. A system and a method for manufacturing a cast component using such a hybrid core are also envisioned.

公开(公告)号：US20220161362A1

公开(公告)日：2022-05-26

申请号：US17101316

申请日：2020-11-23

Applicant: GM Global Technology Operations LLC

Inventor： Huaxin Li ,  Liang Wang ,  Daniel J. Wilson ,  Jatinder P. Singh

IPC: B23K26/323 ,  B32B15/01 ,  C22C9/06 ,  B23K35/30 ,  B23K33/00 ,  B23K26/211 ,  B23K26/342 ,  B23K26/60

Abstract: A method of welding a component made from a ferrous alloy to a component made from an aluminum alloy includes machining and cleaning a fay surface on the ferrous alloy component, machining and cleaning a fay surface on the aluminum alloy component, depositing a layer of copper alloy material onto the fay surface of the ferrous alloy component, forming a weld groove on at least one of the layer of copper alloy material deposited on the fay surface of the ferrous alloy component and the fay surface of the aluminum alloy component, and laser welding the layer of copper alloy deposited on the fay surface of the ferrous alloy component and the fay surface of the aluminum alloy component to one another.

公开(公告)号：US20210402504A1

公开(公告)日：2021-12-30

申请号：US16913406

申请日：2020-06-26

Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

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

IPC: B23K20/12 ,  B23K20/227 ,  B23K20/02

Abstract: A method of joining first and second parts formed of dissimilar materials is provided. The first part defines a first part contacting surface having a frustoconical shape. The first and second parts are brought into contact with one another, with one of the first and second parts being rotated while the other remains stationary, so as to generate frictional heat between the contacting surfaces of the parts, the generated frictional heat producing softened adjacent regions in the first and second parts. A force is applied to the first and second parts to plastically deform the softened adjacent regions and to forge together the first and second parts to form a solid-state joint. A composite torsional damper hub assembly includes a steel stem and a damper hub welded to the stem at an interface. The damper hub is formed of aluminum or an aluminum alloy, and the interface is generally frustoconical.

公开(公告)号：US20240191326A1

公开(公告)日：2024-06-13

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

CPC classification number: C22C21/02 ,  B22D17/00 ,  B22D21/007

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：US11986879B2

公开(公告)日：2024-05-21

申请号：US17719737

申请日：2022-04-13

Applicant: GM Global Technology Operations LLC

Inventor： Liang Wang ,  Qigui Wang ,  Dale A. Gerard ,  Steven L. Burkholder ,  Ronald C. Daul

IPC: B22C3/00 ,  B22C9/02 ,  B22C9/06 ,  B22C9/10 ,  B22D15/02

CPC classification number: B22D15/02 ,  B22C3/00 ,  B22C9/02 ,  B22C9/061 ,  B22C9/101

Abstract: 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.

公开(公告)号：US20240100592A1

公开(公告)日：2024-03-28

申请号：US17935769

申请日：2022-09-27

Applicant: GM Global Technology Operations LLC

Inventor： Liang Wang ,  Qigui Wang ,  Tiruttani Munikamal ,  Shasha Vali Shaik ,  Suresh Kumar K ,  Steven L. Burkholder ,  Thomas W. Gustafson

IPC: B22D30/00 ,  B22D21/00 ,  B22D25/02 ,  B22D41/04

CPC classification number: B22D30/00 ,  B22D21/007 ,  B22D25/02 ,  B22D41/04

Abstract: A system and method of manufacturing an aluminum fuel cell cradle are provided. The method comprises providing a negative cast mold having cavities to form the cradle, and comprises providing a feeding mechanism disposed about the mold and in fluid communication with the cavities thereof. The feeding mechanism comprises a plurality of primary risers connected to and in fluid communication with cavities. The method further comprises melting a first metallic material to define a molten metallic material, and comprises moving the mold to a vertical casting orientation about a rotational axis, while feeding molten metallic material through the runner to the cavities. The method further comprises 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.

公开(公告)号：US11794285B2

公开(公告)日：2023-10-24

申请号：US17387278

申请日：2021-07-28

Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Inventor： Daniel J. Wilson ,  Qigui Wang ,  Liang Wang ,  Huaxin Li ,  Jason J. Coryell ,  Joshua L. Solomon

IPC: B23K26/70 ,  B23K26/24 ,  B23K103/10

CPC classification number: B23K26/702 ,  B23K26/24 ,  B23K2103/10

Abstract: The concepts described herein provide a method, system, and apparatus for joining, via welding, first and second members fabricated from an aluminum alloy including aluminum, zinc, and manganese, such as 7000-series aluminum alloys, and a resultant workpiece. A junction is formed by a first member being disposed contiguously to a second member. A welding machine generates a weld pool at the junction that includes liquified aluminum alloy. An ultrasonic transducer directs ultrasonic energy in proximity to the weld pool. In some embodiments, an electro-magnetic transducer directs electro-magnetic energy in proximity to the weld pool. The first member is fused to the second member at the junction upon solidification of the weld pool.