METHODS AND APPARATUS TO PRODUCE HIGH PERFORMANCE AXISYMMETRIC COMPONENTS

• US 20160214429A1
• Filed: 09/05/2013
• Published: 07/28/2016
• Est. Priority Date: 09/05/2013
• Status: Active Grant

• Current Assignee: GM Global Technology Operations LLC (General Motors Company)
• Original Assignee: GM Global Technology Operations LLC (General Motors Company)
• Inventors: GAO, LEI, HU, BIN, WANG, JIANFENG, SACHDEV, ANIL K.
• Granted Patent: US 10,442,241 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B21J 5/004 Thixotropic process, i.e. forging at semi-solid state
• CPC Class Codes: B21K 1/28 wheels; discs
• CPC Class Codes: B21K 1/38 rims; tyres
• CPC Class Codes: B22D 17/00 Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
• CPC Class Codes: B22D 21/007 with low melting point, e.g. Al 659 degrees C, Mg 650 degrees C
• CPC Class Codes: B60B 1/08 formed by casting
• CPC Class Codes: B60B 2310/202 by casting
• CPC Class Codes: B60B 2310/204 by moulding, e.g. injection moulding, i.e. casting of plastics material
• CPC Class Codes: B60B 2310/208 by forging
• CPC Class Codes: B60B 2310/228 by machining
• CPC Class Codes: B60B 2310/54 Hardening
• CPC Class Codes: B60B 3/02 with a single disc body integral with rim
• CPC Class Codes: C21D 9/0068 for particular articles not mentioned below
• CPC Class Codes: C22C 21/02 with silicon as the next major constituent
• CPC Class Codes: C22F 1/043 of alloys with silicon as the next major constituent

Abstract

A material and method for manufacturing components. The method includes squeeze casting the material into a component of a desired shape and flow-forming the component that has been squeeze cast to refine the shape of the component. The method also includes heat treating the component to enhance the microstructure of the component and machining the component to further refine the shape.

Claims

1. A method for manufacturing components, said method comprising:

squeeze casting a material into a component with a desired shape, wherein the material is a liquid and is poured into a mold and cooled under pressure;

flow-forming the component that has been squeeze cast to refine the shape of the component;

heat treating the component; and

machining the component to further refine the shape of the component.

2. The method according to claim 1 wherein the material is an alloy that includes 3-6 wt. % Si content and 2-5 wt. % Cu+Mg+Zn content.

3. The method according to claim 1 wherein squeeze casting the material creates a component with a refined microstructure that exhibits strength and ductility that is superior to components made from low pressure die casting.

4. The method according to claim 1 wherein flow-forming the component elongates the component and creates a desired annular or ring shape with a desired thickness.

5. The method according to claim 1 further comprising performing a semi-solid forging process after the component has been squeeze cast and before the component has cooled to a completely sold state.

6. The method according to claim 1 further comprising performing an in-die forging process after the component has cooled to a sold state.

7. The method according to claim 1 wherein squeeze casting the material includes rapidly cooling the component to create a refined microstructure of the component that has strength and ductility that is superior to components that are squeeze cast without rapid cooling.

8. The method according to claim 7 wherein rapidly cooling the component is achieved by providing cooling channels in a squeeze cast mold.

9. The method according to claim 1 wherein heat treating the component includes heat treating the component for a time and temperature that varies according to the material being used.

10. The method according to claim 1 wherein the material includes an Fe content of 0.1-0.3 wt. % and a Cr+Mn content of 0.2-0.4 wt. %.

11. A method for manufacturing components using an alloy material, said method comprising:

providing an alloy material that includes 3-6 wt. % Si and 2-5 wt. % Cu+Mg+Zn;

squeeze casting the material into a component with a desired shape, wherein the material is a liquid and is poured into a mold and cooled under pressure;

treating the component with a T4 treatment;

flow-forming the component that has been squeeze cast to refine the shape of the component;

heat treating the component with a T5 treatment; and

machining the component to further refine the shape and to create a component that is in final form.

12. The method according to claim 11 wherein squeeze casting the material creates a component with a refined microstructure that exhibits strength and ductility that is superior to components made from low pressure die casting.

13. The method according to claim 11 wherein flow-forming the component elongates the component and creates a desired annular or ring shape with a desired thickness.

14. The method according to claim 11 further comprising a semi-solid forging process ater the component has been squeeze cast and before the component has cooled to a completely solid state.

15. The method according to claim 11 further comprising performing an in-die forging process after the component has cooled to a solid state.

16. The method according to claim 11 wherein squeeze casting the material includes rapidly cooling the component to create a microstructure of the component that has strength and ductility that is superior to components that are squeeze cast without rapid cooling.

17. The method according to claim 16 wherein rapidly cooling the component is achieved by providing cooling channels in a squeeze cast mold.

18. The method according to claim 11 wherein heating treating the component includes heat treating the component for a time and temperature that varies according to the material being used.

19. The method according to claim 11 wherein the material includes an Fe content of 0.1-0.3 wt. % and a Cr+Mn content of 0.2-0.4 wt. %.

20. A material for manufacturing components using a squeeze casting process followed by a flow-forming process, said material comprising:

a Si content of approximately 3-6 wt. %;

a Cu+Mg content of approximately 2-5 wt. %;

an Fe content of approximately 0.1-0.3 wt. %; and

a Cr+Mn content of approximately 0.2-0.4 wt. %.

21. The material according to claim 20 wherein the material is treated with a T4 treatment to dissolve Cu, Mg and Zn to increase ductility and obtain a flow-formable structure.

22. The material according to claim 20 wherein the material is treated with a T5 treatment to balance strength and ductility.

23. The material according to claim 20 wherein the material is liquefied and poured into a mold for squeeze casting to create a component.

24. The material according to claim 23 wherein the component is flow-formed following squeeze casting to refine the shape of the component.

25. The material according to claim 24 wherein the component is heat treated and machined after flow-forming to further refine the shape and microstructure of the component.

26. The material according to claim 23 wherein the component is forged using a semi-solid forging process ater the component has been squeeze cast and before the component has cooled to a completely solid state.

27. The material according to claim 23 wherein the component is forged using an in-die forging process after the component has cooled to a solid state.

28. The material according to claim 23 wherein the squeeze cast component is rapidly cooled to create a microstructure of the component that has strength and ductility that is superior to components that are squeeze cast without rapid cooling.