Patent application number | Description | Published |
20100028190 | METHOD OF MAKING POWDER METAL PARTS USING SHOCK LOADING - A method of preparing a titanium-based metal matrix composite component. The method includes combining a titanium alloy-based matrix and a titanium-based ceramic reinforcement to form one or more mixtures, placing the mixture or mixtures into a mold, compacting the mixture or mixtures by shock loading, and sintering the compacted mixture or mixtures. In one form, the various mixtures may include differing levels of reinforcement concentration. In this way, different portions of a component produced by the present method may be made up of different mixtures from other portions of the manufactured component, thereby facilitating tailored mechanical or related structural properties. | 02-04-2010 |
20100040500 | METHOD OF MAKING TITANIUM ALLOY BASED AND TiB REINFORCED COMPOSITE PARTS BY POWDER METALLURGY PROCESS - A method of preparing a titanium-based metal matrix composite. In one form, titanium hydride can be added to substantially pure titanium, an alloying material and a source of boron such that a mixture of these materials can be compacted and sintered in a powder metallurgy process to produce a component made up of a titanium boride reinforced titanium alloy. In another form, the substantially pure titanium, alloying material and source of boron could be vigorously mixed (with or without the titanium hydride) to such an extent that oxide films that may have built up on the titanium precursor can be removed to minimize the presence of oxygen in the manufactured component. | 02-18-2010 |
20100185312 | SYSTEM FOR EVALUATING MANUFACTURABILITY OF A CASTING DESIGN - A system for evaluating a manufacturability of a casting design. The system includes at least one of a geometry analyzer, a casting evaluation tool, a residual stress evaluation tool, and a machining evaluation tool. The geometry analyzer analyzes a geometric design of the casting design to determine its geometric design-ability, the casting evaluation tool evaluates the casting design to determine its cast-ability, the residual stress evaluation tool evaluates the casting design to determine its heat treat-ability, and the machining evaluation tool evaluates the casting design to determine a machine-ability of the casting design. If the casting design is determined as not geometrically design-able, not cast-able, not heat treat-able, or not machine-able by the geometry analyzer, the casting evaluation tool, the residual stress evaluation tool, or the machining evaluation tool, respectively, then modifications to the casting design are recommended to optimize the casting design for manufacturing. | 07-22-2010 |
20100235110 | SYSTEMS AND METHODS TO PREDICT FATIGUE LIVES OF ALUMINUM ALLOYS UNDER MULTIAXIAL LOADING - A system to predict a fatigue life of an aluminum alloy is disclosed herein. The system comprises a computer-readable medium cooperative with micromechanics-based fatigue life models for cyclic multiaxial loading. The fatigue life models predict the fatigue life by processing information received by the system relating to the aluminum alloy and the stress state present in the aluminum alloy. The received information comprises at least one of: a critical shear plane, a damage factor, a hardening factor defined by at least one of a plurality of uniaxial cyclic hardening factor parameters related to probabilistics of defects and microstructure characteristics in the aluminum alloy, an additional hardening factor related to non-proportionality, and thermophysical and mechanical properties of the aluminum alloy. The defects and microstructure characteristics can be calculated using mathematical modeling of casting, solidification and heat treatment processes or by an extreme value statistics based on metallography measurements. | 09-16-2010 |
20110151245 | ELECTRICALLY-INSULATIVE COATING, COATING SYSTEM AND METHOD - An electrically-insulative coating for minimizing an electrical conductivity of a metal substrate includes a polymer component formed from a monomer precursor, and a powder component substantially dispersed in the polymer component. The powder component is present in the electrically-insulative coating in an amount of from about 5 parts to about 80 parts by weight based on 100 parts by weight of the electrically-insulative coating. The electrically-insulative coating does not substantially degrade when exposed to from about 100 V to about 330 V at a temperature of from about −50° C. to about 500° C., and has a dielectric strength of at least about 2,000 VAC/mil. An electrically-insulative coating system and a method of forming an electrically-insulative coating on a metal substrate are also disclosed. | 06-23-2011 |
20110163627 | ALUMINUM BASED COMPOSITE SQUIRREL CAGE FOR INDUCTION ROTOR AND METHODS OF MAKING - A method of making a rotor is provided. The method includes mixing aluminum and carbon nanotubes; forming the mixture into an aluminum-carbon nanotube composite conductor bar; providing a laminated steel stack having a plurality of longitudinal slots; placing a plurality of the conductor bars in the longitudinal slots, first and second ends of the plurality of conductor bars extending out of the logitudinal slots; placing the laminated steel stack with the plurality of conductor bars in a casting mold having cavities for a pair of end rings wherein the first and second ends of the plurality of conductor bars extend into the cavities; and filling the cavities with aluminum, aluminum alloys, an aluminum composite, or combinations thereof. Rotors made from aluminum-carbon nanotube composite are also described. | 07-07-2011 |
20120000578 | CAST ALUMINUM ALLOYS - Aluminum alloys having improved properties are provided. The alloy includes about 0 to 2 wt % rare earth elements, about 0.5 to about 14 wt % silicon, about 0.25 to about 2.0 wt % copper, about 0.1 to about 3.0 wt % nickel, approximately 0.1 to 1.0% iron, about 0.1 to about 2.0 wt % zinc, about 0.1 to about 1.0 wt % magnesium, 0 to about 1.0 wt % silver, about 0.01 to about 0.2 wt % strontium, 0 to about 1.0 wt % scandium, 0 to about 1.0 wt % manganese, 0 to about 0.5 wt % calcium, 0 to about 0.5 wt % germanium, 0 to about 0.5 wt % tin, 0 to about 0.5 wt % cobalt, 0 to about 0.2 wt % titanium, 0 to about 0.1 wt % boron, 0 to about 0.2 wt % zirconium, 0 to 0.5% yttrium, 0 to about 0.3 wt % cadmium, 0 to about 0.3 wt % chromium, 0 to about 0.5 wt % indium, and the balance aluminum. Methods of making cast aluminum parts are also described. | 01-05-2012 |
20120182102 | METHOD OF MAKING ND-FE-B SINTERED MAGNETS WITH DY OR TB - A method of making a permanent magnet is described. In one embodiment, the method includes providing a first alloy powder having a desired composition, the alloy powder containing neodymium, iron, and boron; coating the first alloy powder with dysprosium, dysprosium alloy. terbium, or terbium alloy so that the first alloy powder has a surface concentration of dysprosium, terbium, or both in excess of a bulk concentration of dysprosium, terbium, or both; and forming the permanent magnet from the coated alloy powder using a powder metallurgy process, the permanent magnet having a non-uniform distribution of dysprosium, terbium, or both therein. Permanent magnets are also described. | 07-19-2012 |
20120210563 | METHOD OF MANUFACTURING AN END RING OVER PRE-FORMED CONDUCTOR BARS OF A ROTOR FOR AN ELECTRIC DEVICE - A method of manufacturing a rotor assembly includes positioning a laminated stack of electric steel sheets with a plurality of conductor bars positioned within longitudinal grooves defined by the laminated stack in a mold, and casting an end ring in place over ends of the conductor bars. In order to cast the end ring in place, heated liquid aluminum is injected into a cavity defining the end ring, and circulated within the cavity and around the ends of the conductor bars to create relative movement between the liquid aluminum and the ends of the conductor bars to heat the conductor bars and flush oxides away from an outer surface of the conductor bars. | 08-23-2012 |
20120232685 | SYSTEMS AND METHODS FOR COMPUTATIONALLY DEVELOPING MANUFACTURABLE AND DURABLE CAST COMPONENTS - A method and system for optimizing a simulated casting of a light weight alloy component. The simulation includes passing component design data through various computational modules relating to casting designs, process modeling and optimization, material microstructure and defects and product performance. Variations in microstructure and defects across various very small size scales are extended to increasingly larger scales to permit structural performance calculations of the cast component to take such non-uniformities into consideration. At least some of the modules employ an expert system-based approach to achieve the optimized results. The results can be compared to end user needs to determine if redesign of the part geometry or manufacturing process is needed. | 09-13-2012 |
20130043760 | ROTOR FOR ELECTRIC MOTOR AND BRAZING PROCESS - A plurality of conductor bars are positioned within slots of a laminated electric steel disc stack, and the ends of the conductor bars are brazed to end rings to manufacture a rotor. The method includes inserting the conductor bars into the slots of the disc stack, providing the end rings with slots for receiving the ends of the conductor bars; positioning spacers of braze material adjacent each end of each of the conductor bars to create a gap between the end rings and the steel disc stack; and applying heat to melt the braze material of the spacers whereby braze material is furnished by the spacers of braze material to braze the first and second ends of the conductor bars to the first and second end rings. Channels are provided in the face of the end rings facing the steel disc stack to drain away excess braze material. | 02-21-2013 |
20130084204 | METHOD OF MAKING ND-FE-B SINTERED MAGNETS WITH REDUCED DYSPROSIUM OR TERBIUM - A method of making a permanent magnet and a permanent magnet. The method includes providing combining a core material and a surface material so that the surface concentration of dysprosium, terbium, or both in the surface material is high while simultaneously keeping the bulk concentration of dysprosium, terbium, or both low. From this, the magnet has a non-uniform distribution of dysprosium, terbium or both. Varying approaches to preparing the combined core and surface materials may be used to ensure that the surface powder effectively wraps around the core powder as a way to achieve the high surface concentration and low bulk concentration. In one form, the core material may be made from a neodymium-iron-boron permanent magnet precursor material. | 04-04-2013 |
20130266471 | Vibration Machines for Powder Coating - A method of making a permanent magnet includes a step of forming a coating on an alloy powder by physical vapor deposition. The alloy powder includes neodymium, iron, boron and other metals. The coating includes a component selected from the group consisting of dysprosium, terbium, iron, and the alloys thereof. The alloy powder is vibrated during formation of the coating. Finally, a permanent magnet is formed from the coated powder, the permanent magnet having a non-uniform distribution of dysprosium and/or terbium. A method of making a permanent magnet using a vibrating transport belt is also provided. | 10-10-2013 |
20130266472 | Method of Coating Metal Powder with Chemical Vapor Deposition for Making Permanent Magnets - A method of making a permanent magnet includes a step of contacting a powder with a metal-containing vapor to form a coating on the powder. The alloy powder includes neodymium, iron, and boron. The metal-containing vapor includes a component selected from the group consisting of dysprosium, terbium, iron and alloys thereof. A permanent magnet is formed from the coated powder by compaction, sintering and subsequent heat treatment. | 10-10-2013 |
20130266473 | Method of Producing Sintered Magnets with Controlled Structures and Composition Distribution - A method of making a permanent magnet includes a step of providing an alloy powder comprising at least one rare earth element. The alloy powder is shaped and then exposed to microwave radiation or a pulsed electric current to form a sintered magnet. | 10-10-2013 |
20140271323 | MANUFACTURING ND-FE-B MAGNETS USING HOT PRESSING WITH REDUCED DYSPROSIUM OR TERBIUM - A method of making a magnetic material for a permanent magnet using hot-pressing or die-upset methods, or both, by combining two powders and optimizing grain boundary diffusion of Dy or Tb. The method can include making magnetic material for a permanent magnet using hot pressing using a core powder containing Nd, Fe and B and a surface powder containing Dy or Tb in metallic alloy form, combining the materials, forming a solid material in a shaped mold under a magnetic field in vacuum, heating the solid material, hot pressing it to form a magnetic material in a die, heat treating it if necessary, and then cooling it. | 09-18-2014 |
20140314611 | METHOD OF MAKING NON-RECTANGULAR MAGNETS - A number of variations may include a method including providing a first powder comprising iron; compacting the first powder into a compacted powder product having a non-planar surface, wherein the compacting includes dynamic magnetic compaction or combustion driven compaction; and increasing the magnetic coercivity of at least one of the first powder or compact powder product. | 10-23-2014 |