Abstract:
Steel alloys and steel alloy cylinder liners are provided. Steel alloys can comprise iron, about 0.8% to about 2.1% manganese, about 0.10% to about 0.40% silicon, about 0.05% to about 0.30% sulfur, about 0.06% to about 0.16% phosphorus, about 0.09% to about 0.21% titanium, about 0.09% to about 0.21% aluminum, and either low carbon and about 0.0005% to about 0.0055% boron, or medium carbon. The steel alloy cylinder liners can be capable of achieving a mirror-like finish. The steel alloy cylinder liners can comprise ultra-thin wall thickness of less than about 1.5 mm or about 1.0 mm to about 0.5 mm. The steel alloy cylinder liners can comprise a Young's modulus of at least 200 GPa. The steel alloy cylinder liners can comprise a Young's modulus to density ratio of at least about 25.64 GPa/(g/cm3).
Abstract:
A method of manufacturing a sliding camshaft for an internal combustion engine includes providing the sliding camshaft from a steel alloy having a carbon content between 0.25% and 0.60%. The sliding camshaft is then processed with a carbon infusing heat treatment process, such as carburization or carbonitriding. After the sliding camshaft has been processed with the carbon infusing heat treatment process, the sliding camshaft is then processed with a quenching heat treatment process, such as a mar-quenching heat treatment process.
Abstract:
A method of manufacturing a sliding camshaft for an internal combustion engine includes providing the sliding camshaft from a steel alloy having a carbon content between 0.25% and 0.60%. The sliding camshaft is then processed with a carbon infusing heat treatment process, such as carburization or carbonitriding. After the sliding camshaft has been processed with the carbon infusing heat treatment process, the sliding camshaft is then processed with a quenching heat treatment process, such as a mar-quenching heat treatment process.
Abstract:
A method and device for enhancing friction-stir-welding joint strength between aluminum and steel that has a surface coating by forming a local texture of points of raised elevation on the steel by stamping the steel, and then mechanically intermixing the steel and the aluminum with friction-stir-welding to form the joint.
Abstract:
A conductive composite stator unit for an electric motor of a vehicle is provided. The stator unit comprises a stator core comprising a body having a first core end and an opposing second core end. The stator unit further comprises a plurality of conductive bars extending from the first core end to the second core end. Each conductive bar comprises a straight portion disposed in one of the slots such that the respective conductive bar is in contact with the stator core. Each conductive bar comprising a central portion and an outer layer disposed thereabout for electrical current to flow therethrough relative to the longitudinal axis, the outer layer comprises at least two copper-graphene (Cu-Gr) layers. Each Cu-Gr layer comprises a copper layer and a graphene layer. The stator unit further comprises an insulator layer disposed about each of the plurality of conductive bars.
Abstract:
A rotor for an electric machine includes strengthened structural elements effected through surface alloying and heating via an induction heating fixture. A rotor includes laminations formed to have internal cavities and structural members adjacent the cavities. A number of the laminations are stacked to form a lamination stack. An alloying material is applied to the lamination stack at the structural members. The lamination stack is placed in a fixture so that an inductor extends along the structural members and cooling elements extend through the cavities. A current is applied to the inductor to heat the structural members, alloying the alloying material into the structural members.
Abstract:
An electric machine may have a stator and a rotor including stacked plurality of electrical steel laminations forming a slot including a first end and opposing sides, the first end defined by a bridge extending between electrical steel on opposing sides of the slot, the bridge being located between the first end of the slot and an outer diameter surface of the rotor and beneath the outer diameter surface of the rotor, the bridge forming a base of a channel open at an outer diameter surface of the rotor.
Abstract:
A method of joining a first piece of an automotive component that is made from a first material to a second piece of the automotive component that is made from a second material includes machining a fay surface onto each of the first and second pieces of the automotive component, cleaning the fay surfaces of each of the first and second pieces of the automotive component, placing a metal filler between the fay surfaces of the first and second pieces of the automotive component, holding the first and second pieces together with the metal filler positioned between the fay surfaces of the first and second pieces, and passing an electric current through the first piece, the metal filler and the second piece to melt the metal filler and weld the first piece to the second piece.
Abstract:
A method of joining two ferrous alloy component parts. The method includes hot metal casting a portion of a first ferrous alloy component part onto a first joining surface of a low carbon intermediate element; friction fitting a joining surface of a second ferrous alloy component part against a second joining surface of the low carbon intermediate element; and fusion welding with a concentrated energy source the intermediate element to the second ferrous alloy component part. The hot metal casting includes flowing a molten ferrous alloy onto the textured first joining surface, wherein the molten ally encompasses tabs extending from the first joining surface and filling apertures defined in the intermediate element. Then cooling the molten ferrous alloy such that a metallurgical and mechanical bond is formed between the portion of the first ferrous alloy component part and the first joining surface of the low carbon intermediate element.
Abstract:
A method of joining a first piece of an automotive component that is made from a first material to a second piece of the automotive component that is made from a second material includes machining a fay surface onto each of the first and second pieces of the automotive component, cleaning the fay surfaces of each of the first and second pieces of the automotive component, placing a metal filler between the fay surfaces of the first and second pieces of the automotive component, holding the first and second pieces together with the metal filler positioned between the fay surfaces of the first and second pieces, and passing an electric current through the first piece, the metal filler and the second piece to melt the metal filler and weld the first piece to the second piece.