Abstract:
An enhanced aluminum alloy galvanically compatible with a magnesium alloy component is disclosed. The aluminum alloy comprises aluminum, less than 0.2 weight percent copper, less than 0.2 weight percent iron, 6.0 to 9.0 weight percent silicon, 0.6 to 1.5 weight percent magnesium, and greater than 0.8 weight percent manganese. The aluminum alloy further comprises less than 2 weight percent zinc, less than 0.1 weight percent nickel, less than 0.2 weight percent tin, less than 0.05 weight percent titanium; and 0.008 to 0.02 weight percent strontium. Manganese and iron have a weight ratio of at least 30:1. Furthermore, iron and manganese combined content is less than 2.0 weight percent.
Abstract:
An aluminum alloy suitable for casting transmission clutch housings, the aluminum alloy includes about 12 to about 16 weight percent silicon; about 0.0 to about 6.0 weight percent copper; about 0.2 to about 0.5 weight percent magnesium; about 0.1 to about 0.5 weight percent chromium; about 0 to about 1.0 weight percent each of iron, manganese, and zinc; less than 0.1 weight percent each of strontium and phosphorous; and about 0.0 to about 0.25 weight percent other trace elements. Also disclosed is a high pressure die cast article, such as a transmission clutch housing.
Abstract:
Aluminum alloys having improved properties are provided. The alloy includes about 13 to about 17 weight percent silicon, about 0.3 to about 0.6 weight percent magnesium, and at least 75 weight percent aluminum. The alloy may include copper up to about 2.0 weight percent; iron up to about 0.8 weight percent; manganese up to about 1.0 weight percent; nickel up to about 1.0 weight percent; zinc up to about 0.8 weight percent; titanium up to about 0.5 weight percent; zirconium up to about 0.5 weight percent; vanadium up to about 0.5 weight percent; and other trace elements up to about 0.1 weight percent. In addition, the alloy may contain about 50 to about 1000 ppm of strontium and about 10 about 100 ppm phosphorus. Also disclosed is a die cast article, such as transmission clutch housing.
Abstract:
A quantitative metallographic method to measure skin layer thickness in high pressure die cast aluminum components. Because the faster-cooling skin layer region exhibits a higher volume fraction of eutectic phases than that of a slower-cooling inner region, measurements showing such higher eutectic phases can be used to quantify such layer thickness. An image at various thicknesses of a location of interest in a cast component sample is first obtained using an image analyzer, from which eutectic volume fractions within each of the received images may be determined. Comparisons of the determined volume fractions can be made against a known or predicted quantity for a particular alloy composition, and then correlated to the skin layer thickness via differences between the received or measured quantities and those of the known standard.
Abstract:
A method of eliminating microstructure inheritance of hypereutectic aluminum-silicon alloys. The method includes heating a first amount of the Al—Si alloy to a predetermined temperature above a liquidus temperature of the Al—Si alloy to form a first amount melt; holding the first amount melt at the predetermined temperature for a predetermined amount of time; stirring the first amount melt during the predetermined amount of time; heating a second amount of the Al—Si alloy above the liquidus temperature of the Al—Si alloy to form a second amount melt; and mixing the first amount melt and the second amount melt to form a processed Al—Si casting alloy. The predetermined temperature is between about 750° C. to 850° C. The predetermined amount of time is between 0.1 hour to 0.5 hour. The processed Al—Si casting alloy contains about 30 wt % to about 40 wt % of the first amount of the Al—Si alloy.
Abstract:
A wear-resistant component includes a substrate formed from a metal, defining a bore, and having a bore surface. The substrate includes a first region having a first microstructure adjacent the bore surface and a first average particle size. The substrate also includes a second region having a second microstructure adjacent the first microstructure and a second average particle size. The first average particle size is larger than the second average particle size. A system and a method of forming the wear-resistant coating are also described.
Abstract:
An apparatus for localized patterned surface hardening for light-weight alloys to increase wear resistance under lubricated contact is provided. The apparatus includes a first metallic structure and a second metallic structure. The second metallic structure includes a contact surface and is disposed in lubricated contact with the first metallic structure at the contact surface, wherein the second metallic structure is constructed with a lighter-than-steel material and wherein the contact surface includes a localized surface hardened pattern.
Abstract:
A wear-resistant component includes a substrate formed from a metal, defining a bore, and having a bore surface. The substrate includes a first region having a first microstructure adjacent the bore surface and a first average particle size. The substrate also includes a second region having a second microstructure adjacent the first microstructure and a second average particle size. The first average particle size is larger than the second average particle size. A system and a method of forming the wear-resistant coating are also described.
Abstract:
Copper-free aluminum alloys suitable for high pressure die casting and capable of age-hardening under elevated temperatures are provided. The allow includes about 9.5-13 wt % silicon, about 0.2 to 0.6 wt % Magnesium, about 0.1 to 2 wt % iron, about 0.1 to 2 wt % manganese, about 0.1 to 1 wt % nickel, about 0.5 to 3 wt % zinc, and 0 to 0.1 wt % strontium, with a balance of aluminum. Methods for making high pressure die castings and castings manufactured from the alloy are also provided.
Abstract:
A bearing outer face construction system includes a bearing having a bearing outer race. The bearing outer race includes an outer race surface. At least one circumferential groove is recessed into the bearing outer race. An expanding member is received in the at least one circumferential groove. A housing receives the bearing having a gap between a housing inner face and the bearing outer race. The expanding member expands to radially extend across the gap into direct contact with the housing inner face to mitigate against motion between the bearing and the housing inner face.