Method of casting damped part with insert

• US 8,770,263 B2
• Filed: 05/23/2011
• Issued: 07/08/2014
• Est. Priority Date: 07/20/2007
• Status: Active Grant

• Current Assignee: GM Global Technology Operations LLC (General Motors Company)
• Original Assignee: GM Global Technology Operations LLC (General Motors Company)
• Inventors: Hanna, Michael D., Sundar, Mohan, Schertzer, Andrew
• Primary Examiner(s): Kerns, Kevin P
• Assistant Examiner(s): HA, STEVEN S
• Application Number:
  US13/113,619
• Publication Number:
  US 20110220313A1
• Time in Patent Office: 1,142 Days
• Field of Search: 164 98-112
• US Class Current: 164/98
• CPC Class Codes: B22D 19/00 Casting in, on, or around objects which form part of the product B22D23/04 takes precedence; alumino-thermic welding B23K23/00; coating by casting molten material on the substrate C23C6/00
• CPC Class Codes: B22D 19/0081 pretreatment of the insert, e.g. for enhancing the bonding between insert and surrounding cast metal
• CPC Class Codes: B22D 19/04 for joining parts
• CPC Class Codes: Y10T 428/24628 Nonplanar uniform thickness material

Abstract

A method including positioning an insert in a vertical mold including a first mold portion and a second mold portion; and casting a material including a metal around at least a portion of the insert.

Claims

1. A method comprising:

treating a first portion of the insert so that molten material comprising a metal does not wet the first portion of the insert and bond thereto upon solidification, and a second portion of the insert being constructed and arranged so that metal cast over the second portion bonds to the second portion upon cooling; and

pre-heating an insert to a temperature ranging from 50-80°

C. to remove moisture on the insert and thereafter loading the insert into a first mold portion of a vertical mold for casting metal, and casting metal over the insert and solidifying the metal so that the metal bonds to the second portion and not to the first portion wherein the insert comprises a bent tab so that the insert hangs on the first mold portion of the vertical mold.

2. A method as set forth in claim 1 wherein the pre-heating the insert comprises heating the insert in an oven.

3. A method as set forth in claim 1 wherein the temperature is about 75°

C.

4. A method as set forth in claim 1 further comprising closing a second mold portion and the first mold portion together and casting a material comprising a metal around at least a portion of the insert.

5. A method as set forth in claim 1 further comprising pre-treating the second portion of the insert before positioning the insert in the vertical mold.

6. A method as set forth in claim 5 wherein the pre-treating comprises at least one of sand blasting, grit blasting, glass bead blasting, chemical washing, or water jet degreasing.

7. A method as set forth in claim 1 wherein the treating comprises coating at least a portion of the insert to provide a non-wettable surface that prevented molten metal from bonding to the insert at the location of the coating.

8. A method as set forth in claim 7 wherein coating at least a portion of the insert comprises at least one of spraying, dipping, or painting.

9. A method as set forth in claim 7 further comprising baking the insert.

10. A method as set forth in claim 7 further comprising pouring the material into the vertical mold so that the metal is filled from the bottom of the mold up.

11. A method as set forth in claim 1 further comprising pouring the material into at least one gate located at the bottom of the vertical mold.

12. A method as set forth in claim 11 wherein the insert comprises at least two tabs and wherein only one gate is positioned in between two adjacent tabs.

13. A method as set forth in claim 10 wherein the flow rate of the material poured into the vertical mold is such that turbulent flow is avoided.

14. A method as set forth in claim 4 further comprising controlling the flow of the molten metal into the first and second mold portions to prevent the casting of the material comprising molten metal around the insert from washing away the coating.

15. A method as set forth in claim 1 wherein the coating comprising at least one of particles, flakes, or fibers.

16. A method as set forth in claim 1 wherein the loading the insert into a first mold portion comprises loading an insert into a setting fixture.

17. A method as set forth in claim 16 wherein the setting fixture comprises a vacuum component.

18. A method as set forth in claim 16 wherein the setting fixture comprises at least one ejector pin.

19. A method as set forth in claim 1 wherein the insert is pre-heated to a temperature ranging from 50-75°

C.

20. A method as set forth in claim 7 further comprising baking the insert with the coating to a temperature of 140-350°

C.