U.S. patent application number 12/165729 was filed with the patent office on 2009-02-05 for method for securing an insert in the manufacture of a damped part.
This patent application is currently assigned to GM GLOBAL TECHNOLOGY OPERATIONS, INC.. Invention is credited to Michael D. Hanna, Mohan Sundar.
Application Number | 20090032211 12/165729 |
Document ID | / |
Family ID | 40337029 |
Filed Date | 2009-02-05 |
United States Patent
Application |
20090032211 |
Kind Code |
A1 |
Hanna; Michael D. ; et
al. |
February 5, 2009 |
METHOD FOR SECURING AN INSERT IN THE MANUFACTURE OF A DAMPED
PART
Abstract
One embodiment of the invention includes a method including
providing an insert, wherein at least a portion of the insert is
attracted to a magnet; providing a mold including a first mold
portion, a second mold portion, and a magnet having at least a
portion thereof in or adjacent to at least one of the first mold
portion or the second mold portion; positioning the insert in one
of the mold portions such that the at least one magnet at least
assists in holding the insert in place; and closing the mold and
casting a molten material into the mold and around or adjacent to
at least a portion of the insert and solidifying the material.
Inventors: |
Hanna; Michael D.; (West
Bloomfield, MI) ; Sundar; Mohan; (Troy, MI) |
Correspondence
Address: |
General Motors Corporation;c/o REISING, ETHINGTON, BARNES, KISSELLE, P.C.
P.O. BOX 4390
TROY
MI
48099-4390
US
|
Assignee: |
GM GLOBAL TECHNOLOGY OPERATIONS,
INC.
Detroit
MI
|
Family ID: |
40337029 |
Appl. No.: |
12/165729 |
Filed: |
July 1, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60953793 |
Aug 3, 2007 |
|
|
|
Current U.S.
Class: |
164/498 ;
164/146; 164/148.1 |
Current CPC
Class: |
B22D 19/00 20130101;
B22D 17/24 20130101 |
Class at
Publication: |
164/498 ;
164/146; 164/148.1 |
International
Class: |
B22D 19/00 20060101
B22D019/00; B22D 23/00 20060101 B22D023/00; B22D 45/00 20060101
B22D045/00 |
Claims
1. A method for manufacturing a part comprising: providing an
insert, wherein at least a portion of the insert is attracted to a
magnet; providing a mold comprising a first mold portion, a second
mold portion, and a magnet having at least a portion thereof in or
adjacent to at least one of the first mold portion or the second
mold portion; positioning the insert in one of the mold portions
such that the at least one magnet at least assists in holding the
insert in place; and closing the mold and casting a molten material
into the mold and around or adjacent to at least a portion of the
insert and solidifying the material.
2. A method as set forth in claim 1 further comprising a coating
overlying at least a portion of the insert.
3. A method as set forth in claim 1 wherein the insert comprises at
least one of cast iron, gray cast iron, steel, stainless steel,
aluminum, magnesium, titanium, alloys thereof, or metal matrix
composite.
4. A method as set forth in claim 1 wherein the material comprises
at least one of cast iron, gray cast iron, aluminum, titanium,
steel, stainless steel, alloys thereof, or metal matrix
composite.
5. A method as set forth in claim 1 wherein the magnet is an
electromagnet.
6. A method for manufacturing a part as set forth in claim 5
further comprising activating the electromagnet after the insert is
positioned in one of the mold portions.
7. A method as set forth in claim 1 further comprising removing the
magnet from the mold before casting the material into the mold.
8. A method as set forth in claim 1 wherein the magnet is
instrumented.
9. A method as set forth in claim 1 wherein the magnet is in the
shape of one of a circle, oval, triangle, square, rectangle, or
Y-shape.
10. A method as set forth in claim 1 wherein the magnet is
partially enclosed by one of the first mold portion or the second
mold portion and the magnet comprises an end portion extending
beyond one of the first mold portion or the second mold
portion.
11. A method as set forth in claim 1 wherein the magnet is
completely enclosed in one of the first mold portion or the second
mold portion.
12. A method as set forth in claim 1 wherein the mold is oriented
vertically.
13. A method as set forth in claim 1 wherein the mold is oriented
horizontally.
14. A method as set forth in claim 1 wherein the insert comprises
at least one tab.
15. A method as set forth in claim 1 further comprising machining
off the tab after solidifying the material.
16. A method as set forth in claim 1 wherein the mold is a sand
mold.
17. A method as set forth in claim 1 further comprising providing a
layer comprising particles or fibers over at least a portion of the
insert.
18. A method as set forth in claim 1 further comprising treating at
least a portion of the insert so that the molten material does not
wet the portion of the insert and bond thereto upon
solidification.
19. A product comprising: a mold; and at least one magnet
positioned to at least assist in holding a magnetically attachable
insert in the mold.
20. A product as set forth in claim 19 wherein the mold comprises a
first mold portion and a second mold portion, and wherein the
magnet is received in at least one of the first mold portion or the
second mold portion.
21. A product as set forth in claim 19 wherein the magnet is an
electromagnet.
22. A product as set forth in claim 19 wherein the magnet is
instrumented.
23. A product as set forth in claim 19 wherein the magnet is in the
shape of one of a circle, oval, triangle, square, rectangle, or
Y-shape.
24. A product as set forth in claim 20 wherein the magnet is
partially enclosed by one of the first mold portion or the second
mold portion and the magnet comprises an end portion extending
beyond one of the first mold portion or the second mold
portion.
25. A product as set forth in claim 19 wherein the insert comprises
a coating over at least a portion of the insert.
26. A product as set forth in claim 19 further comprising a layer
comprising particles or fibers over at least a portion of the
insert.
27. A product as set forth in claim 19 wherein the insert comprises
at least one of cast iron, gray cast iron, steel, stainless steel,
aluminum, magnesium, titanium, alloys thereof, or metal matrix
composite.
28. A product as set forth in claim 19 wherein the insert comprises
at least one tab.
Description
[0001] This application claims the benefit of U.S. Provisional
Application No. 60/953,793, filed Aug. 3, 2007.
TECHNICAL FIELD
[0002] The field to which the disclosure generally relates includes
a method of manufacturing a damped part including an insert.
BACKGROUND
[0003] Parts subjected to vibration may produce unwanted or
undesirable vibrations. Similarly, a part or component may be set
into motion at an undesirable frequency for a prolonged period. For
example, parts such as brake rotors, brackets, pulleys, brake
drums, transmission housings, gears, and other parts may contribute
to noise that gets transmitted to the passenger compartment of a
vehicle. In an effort to reduce the generation of this noise and
thereby its transmission into the passenger compartment, a variety
of techniques have been employed, including the use of polymer
coatings on engine parts, sound absorbing barriers, and laminated
panels having visco elastic layers. The undesirable vibrations in
parts or components may occur in a variety of other products
including, but not limited to, sporting equipment, household
appliances, manufacturing equipment such as lathes,
milling/grinding/drilling machines, earth moving equipment, other
non-automotive applications, and components that are subject to
dynamic loads and vibration. These components can be manufactured
through a variety of means including casting, machining, forging,
welding, die-casting, etc.
SUMMARY OF EXEMPLARY EMBODIMENTS OF THE INVENTION
[0004] One embodiment of the invention includes a method including
providing an insert, wherein at least a portion of the insert is
attracted to a magnet; providing a mold including a first mold
portion, a second mold portion, and a magnet having at least a
portion thereof in or adjacent to at least one of the first mold
portion or the second mold portion; positioning the insert in one
of the mold portions such that the at least one magnet at least
assists in holding the insert in place; and closing the mold and
casting a molten material into the mold and around or adjacent to
at least a portion of the insert and solidifying the material.
[0005] Other exemplary embodiments of the invention will become
apparent from the detailed description provided hereinafter. It
should be understood that the detailed description and specific
examples, while disclosing exemplary embodiments of the invention,
are intended for purposes of illustration only and are not intended
to limit the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] Exemplary embodiments of the present invention will become
more fully understood from the detailed description and the
accompanying drawings, wherein:
[0007] FIG. 1 illustrates a product according to one embodiment of
the invention;
[0008] FIG. 2 illustrates a product according to another embodiment
of the invention;
[0009] FIG. 3 illustrates a product and a method, according to one
embodiment of the invention;
[0010] FIG. 4 illustrates a product and a method, according to one
embodiment of the invention;
[0011] FIG. 5 illustrates a product and a method according to one
embodiment of the invention;
[0012] FIG. 6 illustrates a product and a method according to one
embodiment of the invention;
[0013] FIG. 7 illustrates a product and a method according to one
embodiment of the invention;
[0014] FIG. 8 illustrates a product and a method according to one
embodiment of the invention;
[0015] FIG. 9 is a sectional view with portions broken away of one
embodiment of the invention including an insert;
[0016] FIG. 10 is a sectional view with portions broken away of one
embodiment of the invention including an insert having a layer
thereon to provide a frictional surface or damping;
[0017] FIG. 11 is an enlarged view of one embodiment of the
invention;
[0018] FIG. 12 is a sectional view with portions broken away of one
embodiment of the invention;
[0019] FIG. 13 is an enlarged sectional view with portions broken
away of one embodiment of the invention;
[0020] FIG. 14 is an enlarged sectional view with portions broken
away of one embodiment of the invention;
[0021] FIG. 15 is an enlarged sectional view with portions broken
away of one embodiment of the invention;
[0022] FIG. 16 illustrates one embodiment of the invention;
[0023] FIG. 17 is a sectional view with portions broken away of one
embodiment of the invention;
[0024] FIG. 18 is a sectional view with portions broken away of one
embodiment of the invention;
[0025] FIG. 19 is a plan view with portions broken away
illustrating one embodiment of the invention;
[0026] FIG. 20 is a sectional view taken along line 20-20 of FIG.
19 illustrating one embodiment of the invention;
[0027] FIG. 21 is a sectional view with portions broken away
illustrating one embodiment of the invention; and
[0028] FIG. 22 is a sectional view with portions broken away
illustrating another embodiment of the invention.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0029] The following description of the embodiment(s) is merely
exemplary in nature and is in no way intended to limit the
invention, its application, or uses.
[0030] In one embodiment of the invention, a method of
manufacturing a product is provided. Referring to FIG. 1, an
exemplary product produced by an embodiment of the invention may
include a product or part 500. In one embodiment, the part 500 may
be a rotor assembly 12. In various other embodiments (not shown),
the product or part 500 may be, for example, but is not limited to
a bracket, pulley, brake drum, transmission housing, gear, motor
housing, shaft, bearing, engine, baseball bat, lathe machine,
milling machine, drilling machine, or grinding machine. The rotor
assembly 12 may include a hub portion 14, a first rotor cheek 16,
and an insert 18. The insert 18 may or may not be coextensive with
the first rotor cheek 16. In one embodiment (not shown), the insert
may be completely encapsulated by the first rotor cheek 16. The
insert 18 may be annular or it may take other suitable shapes.
[0031] The first rotor cheek 16 may include a first cheek face 20
and a second cheek face 22. In one embodiment, the hub portion 14
may include a central aperture 24. The hub portion 14 may also
include a plurality of bolt holes 26. The hub portion 14 and the
first rotor cheek 16 may comprise one of cast iron, gray cast iron,
titanium, aluminum, steel, stainless steel, any of a variety of
other alloys, or metal matrix composite. At least a portion of the
insert 18 may comprise a material attracted to a magnet. In various
embodiments, at least a portion of the insert 18 may comprise at
least one of a ferrous based material including, but not limited
to, cast iron, gray cast iron, steel, or stainless steel, or a
nonferrous based material including, but not limited to, aluminum,
magnesium, or titanium, or any of a variety of other alloys, or
metal matrix composite. In one embodiment, the insert 18 may be
about 0.1 mm to about 20 mm thick. The insert 18 may include a
coating. In one embodiment, the coating may prevent cast metal from
bonding to the insert during the manufacturing process, in order to
ensure that the insert dampens the vibration of the product using
frictional or Coulomb damping.
[0032] In another embodiment shown in FIG. 2, the rotor assembly 12
may be vented and may include a first rotor cheek 16 with a first
cheek face 20 and a second rotor cheek 17 with a second cheek face
22. The first cheek face 20 and the second cheek face 22 may be
separated by a plurality of vanes 28 therebetween. The insert 18
may be located in the first rotor cheek 16. In another embodiment
(not shown), the insert 18 may be located in the second rotor cheek
17. In yet another embodiment (not shown), an insert 18 may be
located in each of the first rotor cheek 16 and the second rotor
cheek 17.
[0033] Referring to FIGS. 3-4, products and methods for casting the
part 500 including the insert 18 are provided. The method may
secure and position the insert 18 in a mold 30 in order to prevent
any undesirable movement during assembly of the mold 30 and
subsequent introduction of a material 60 into the mold 30.
Referring to FIG. 3, the mold 30 may include a first mold portion
or shell 32 and a second mold portion or shell 34. In some
embodiments, the orientation of the mold 30 may be vertical. In
other embodiments, the orientation of the mold 30 may be
horizontal. In various embodiments, the orientation of the mold 30
may be at any suitable angle.
[0034] The first mold portion 32 and the second mold portion 34 are
configured to manufacture the part 500. The two portions of the
mold 32 and 34 form a cavity 36 for casting the part 500. In one
embodiment, the first mold portion 32 and the second mold portion
34 may be sand molds. The first mold portion 32 may also include a
generally cylindrical protrusion 38 configured to produce the
central aperture 24 on the part 500 (shown in FIGS. 1-2). But in
other embodiments, the central aperture 24 may be produced by a
subsequent machining process. In one embodiment, the plurality of
bolt holes 26 (shown in FIGS. 1-2) may be produced by a plurality
of smaller protrusions (not shown) in the first mold portion 32 or
by a subsequent machining process.
[0035] FIG. 3 also shows the insert 18 positioned within the second
mold portion 34. The insert 18 may have a variety of geometries and
is not limited to the embodiment shown in the drawings. In one
embodiment, the insert 18 may have a plurality of tabs 40 which
rest on cutout portions 42 of the second mold portion 34. The
insert 18 may have any suitable number of tabs 40 which may extend
from a main body portion, for example, the tabs 40 may extend
radially inward or outward from an annular body portion. In one
embodiment, the insert 18 but not the tabs 40 may have a coating
over a portion thereof. In another embodiment, the insert 18 and
the tabs 40 may have a coating over at least a portion thereof. The
tabs 40 may have any suitable shape. For example, the tabs 40 may
be the shape of a square, rectangle, triangle, semi-circle, or
oval. However, in other embodiments, the insert 18 may not have
tabs 40 or it may have a small number of tabs 40.
[0036] Still referring to FIG. 3, the first mold portion 32 may
include at least one magnet 44. The magnet 44 may be used to
position the insert 18 in the second mold portion 34 and secure the
insert 18 in the second mold portion 34 during the molding and
casting process. In one embodiment, the magnet 44 may at least
assist in holding the insert 18 in place. The loading of the insert
18 into the mold 30 may be manual or automatic. The loading of the
magnet 44 into the mold 30 may be manual or automatic.
[0037] In one embodiment, the magnet 44 may be an electromagnet.
The magnet 44 may be instrumented and activated after loading the
insert 18 and while closing the second mold portion 34. The magnet
44 may be any suitable shape, for example, the shape of a circle,
oval, triangle, square, rectangle, or Y-shape. In one embodiment,
the magnet 44 may be the same general shape as the insert 18. The
magnet 44 may be positioned inside the first mold portion 32 with
an end magnet portion 45 extending beyond the first mold portion
32. The magnet 44 may be removed from the first mold portion 32
using the end magnet portion 45, for example by pulling the magnet
44 out of the first mold portion by pulling the end magnet portion
45. The magnet 44 may be positioned inside the second mold portion
34 at a distance 46 from the edge of the second mold portion 34
that will allow the magnet 44 to at least assist in securing the
insert 18. In other embodiments, the magnet 44 may be positioned at
any suitable location that will allow the magnet 44 to at least
assist in securing the insert 18 in the mold 30.
[0038] In an embodiment where the magnet 44 is an electromagnet,
the electromagnet may be activated after the insert is loaded onto
the second mold portion 34. The electromagnet may then at least
assist in holding the insert in place until the first mold portion
32 engages the second mold portion 34, as shown in FIGS. 5-6. The
magnet 44 may be removed from the mold 30 before the material 60 is
introduced into the mold 30. The removal of the magnet 44 from the
mold 30 may be manual or automatic. In an embodiment where the
magnet 44 is an electromagnet, the magnet 44 may be removed from
the first mold portion 32 using the end magnet portion 45, for
example by pulling the magnet 44 out of the first mold portion by
pulling the end magnet portion 45. In the embodiments shown in
FIGS. 5-6, the magnet 44 has already been removed. In another
embodiment (not shown) the magnet 44 may be positioned adjacent the
first mold portion 32 or second mold portion 34 to hold the insert
18 in place.
[0039] A compressive force may be applied to the first mold portion
32 and the second mold portion 34, for example to push the mold
portions 32 and 34 together. The tabs 40 of the insert 18 may be
supported between the cutout portions 42 of the second mold portion
34 and lands 48 of the first mold portion 32. According to one
embodiment, the material 60 is then introduced, for example
injected, into the cavity 36 to form the part 500. In one
embodiment, the material 60 may be cast (charging) into the mold
and around or immediately adjacent to at least a portion of the
insert or a coating thereon. For exemplary embodiments, the
material 60 may be one of cast iron, gray cast iron, aluminum,
steel, titanium, stainless steel, any of a variety of other alloys,
or metal matrix composite. The material 60 may be molten. In
another embodiment, the material 60 is a semi-solid material and
may be introduced into the cavity 36 in accordance with the well
known semi-solid forging process. In other embodiments, the
material 60 may be introduced into the mold 30 by any suitable
method. In other embodiments, the mold portions 32 and 34 may be
attached to a molding device with ingates for the material 60, and
the material 60 may enter the mold through the ingates (not
shown).
[0040] In the embodiments shown in FIGS. 3 and 5, the material 60
may be introduced through a first inlet 64 into a first channel 62.
The magnet 44 may be removed from the mold 30 before the material
60 is introduced through the first inlet 64 into the first channel
62. In one embodiment (not shown), the first channel 62 may extend
through a portion of both the first mold portion 32 and the second
mold portion 34.
[0041] Referring to FIGS. 4 and 6, in various embodiments the
material 60 may be introduced through a second inlet 66 into a
second channel 68 in the second mold portion 34. The magnet 44 may
be removed from the mold 30 before the material 60 is introduced
through the second inlet 66 into the second channel 68. In other
embodiments, the material 60 may be introduced through any inlet
located in a suitable place on the mold 30. In one embodiment, the
second channel 68 may extend through a portion of both the first
mold portion 32 and the second mold portion 34.
[0042] Referring now to FIGS. 7-8, after the material 60 has
cooled, the first mold portion 32 and the second mold portion 34
are separated and the finished part 500 is removed from the open
mold 30. In one embodiment, the part 500 is a rotor assembly 12 and
includes the hub portion 14, the first rotor cheek 16, and the
insert 18. The part 500 may then be further machined. For example,
the tabs 40 may be machined off. When the mold portions 32 and 34
are returned to the open position, the next insert 18 may be
positioned in the open mold 30 and the manufacturing process of the
part 500 may repeat.
[0043] Referring to FIGS. 9-22, one embodiment of the invention
includes a product or part 500 having a frictional damping means.
The frictional damping means may be used in a variety of
applications including, but not limited to, applications where it
is desirable to reduce noise associated with a vibrating part or
reduce the vibration amplitude and/or duration of a part that is
struck, dynamically loaded, excited, or set in motion. In one
embodiment the frictional damping means may include an interface
boundary conducive to frictionally damping a vibrating part. In one
embodiment the damping means may include frictional surfaces 502
constructed and arranged to move relative to each other and in
frictional contact, so that vibration of the part is dissipated by
frictional damping due to the frictional movement of the surfaces
502 against each other.
[0044] According to various illustrative embodiments of the
invention, frictional damping may be achieved by the movement of
the frictional surfaces 502 against each other. The movement of
frictional surfaces 502 against each other may include the movement
of: surfaces of the body 506 of the part against each other; a
surface of the body 506 of the part against a surface of the insert
18; a surface of the body 506 of the part against the layer 520; a
surface of the insert 18 against the layer 520; a surface of the
body 506 of the part against the particles 514 or fibers; a surface
of the insert 18 against the particles 514 or fibers; or by
frictional movement of the particles 514 or fibers against each
other or against remaining binder material.
[0045] In embodiments wherein the frictional surface 502 is
provided as a surface of the body 506 or the insert 18 or a layer
520 over one of the same, the frictional surface 502 may have a
minimal area over which frictional contact may occur that may
extend in a first direction a minimum distance of 0.1 mm and/or may
extend in a second (generally traverse) direction a minimum
distance of 0.1 mm. In one embodiment the insert 18 may be an
annular body and the area of frictional contact on a frictional
surface 502 may extend in an annular direction a distance ranging
from about 20 mm to about 1000 mm and in a transverse direction
ranging from about 10 mm to about 75 mm. The frictional surface 502
may be provided in a variety of embodiments, for example, as
illustrated in FIGS. 9-22.
[0046] Referring again to FIG. 9, in another embodiment of the
invention one or more of the outer surfaces 522, 524 of the insert
18 or surfaces 526, 528 of the body 506 of the part 500 may include
a relatively rough surface including a plurality of peaks 510 and
valleys 512 to enhance the frictional damping of the part. In one
embodiment, the surface of the insert 18 or the body 506 may be
abraded by sandblasting, glass bead blasting, water jet blasting,
chemical etching, machining or the like.
[0047] Each frictional surface 502 may have a plurality of peaks
510 and a plurality of valleys 512. The depth as indicated by line
V of the valleys 512 may vary with embodiments. In various
embodiments, the average of the depth V of the valleys 512 may
range from about 1 .mu.m-300 .mu.m, 50 .mu.m-260 .mu.m, 100
.mu.m-160 .mu.m or variations of these ranges. However, for all
cases there is local contact between the opposing frictional
surfaces 502 during component operation for frictional damping to
occur.
[0048] In another embodiment of the invention the damping means or
frictional surface 502 may be provided by particles 514 or fibers
provided on at least one face of the insert 18 or a surface of the
body 506 of the part 500. The particles 514 may have an irregular
shape (e.g., not smooth) to enhance frictional damping, as
illustrated in FIG. 16. One embodiment of the invention may include
a layer 520 including the particles 514 or fibers which may be
bonded to each other or to a surface of the body 506 of the part or
a surface of the insert 18 due to the inherent bonding properties
of the particles 514 or fibers. For example, the bonding properties
of the particles 514 or fibers may be such that the particles 514
or fibers may bind to each other or to the surfaces of the body 506
or the insert 18 under compression. In another embodiment of the
invention, the particles 514 or the fibers may be treated to
provide a coating thereon or to provide functional groups attached
thereto to bind the particles together or attach the particles to
at least one of a surface of the body 506 or a surface of the
insert 18. In another embodiment of the invention, the particles
514 or fibers may be embedded in at least one of the body 506 of
the part or the insert 18 to provide the frictional surface 502
(FIGS. 11-12).
[0049] In embodiments wherein at least a potion of the part 500 is
manufactured such that the insert 18 and/or the particles 514 or
fibers are exposed to the temperature of a molten material such as
in casting, the insert 18 and/or particles 514 or fibers may be
made from materials capable of resisting flow or resisting
significant erosion during the manufacturing. For example, the
insert 18 and/or the particles 514 or fibers may include refractory
materials capable of resisting flow or that do not significantly
erode at temperatures above 1100.degree. F., above 2400.degree. F.,
or above 2700.degree. F. When molten material, such as metal, is
cast around the insert 18 and/or the particles 514, the insert 18
or the particles 514 should not be wet by the molten material so
that the molten material does not bond to the insert 18 or layer
520 at locations wherein a frictional surface 502 for providing
frictional damping is desired.
[0050] Illustrative examples of suitable particles 514 or fibers
include, but are not limited to, particles or fibers including
silica, alumina, graphite with clay, silicon carbide, silicon
nitride, cordierite (magnesium-iron-aluminum silicate), mullite
(aluminum silicate), zirconia (zirconium oxide), phyllosilicates,
or other high-temperature-resistant particles. In one embodiment of
the invention the particles 514 may have a length along the longest
dimension thereof ranging from about 1 .mu.m-350 .mu.m, or 10
.mu.m-250 .mu.m.
[0051] In another embodiment of the invention, the layer 520 may be
a coating over the body 506 of the part or the insert 18. The
coating may include a plurality of particles 514 which may be
bonded to each other and/or to the surface of the body 506 of the
part or the insert 18 by an inorganic or organic binder 516 (FIGS.
10, 15) or other bonding materials. Illustrative examples of
suitable binders include, but are not limited to, epoxy resins,
phosphoric acid binding agents, calcium aluminates, sodium
silicates, wood flour, or clays. In another embodiment of the
invention the particles 514 may be held together and/or adhered to
the body 506 or the insert 18 by an inorganic binder. In one
embodiment, the coating may be deposited on the insert 18 or body
506 as a liquid dispersed mixture of alumina-silicate-based,
organically bonded refractory mix.
[0052] In another embodiment, the coating may include at least one
of alumina or silica particles, mixed with a lignosulfonate binder,
cristobalite (SiO.sub.2), quartz, or calcium lignosulfonate. The
calcium lignosulfonate may serve as a binder. In one embodiment,
the coating may include IronKote. In one embodiment, a liquid
coating may be deposited on a portion of the insert and may include
any high temperature ceramic coating, such as but not limited to,
Ladle Kote 310B. In another embodiment, the coating may include at
least one of clay, Al.sub.2O.sub.3, SiO.sub.2, a graphite and clay
mixture, silicon carbide, silicon nitride, cordierite
(magnesium-iron-aluminum silicate), mullite (aluminum silicate),
zirconia (zirconium oxide), or phyllosilicates. In one embodiment,
the coating may comprise a fiber such as ceramic or mineral
fibers.
[0053] When the layer 520 including particles 514 or fibers is
provided over the insert 18 or the body 506 of the part the
thickness L (FIG. 10) of the layer 520, particles 514 and/or fibers
may vary. In various embodiments, the thickness L of the layer 520,
particles 514 and/or fibers may range from about 1 .mu.m-400 .mu.m,
10 .mu.m-400 .mu.m, 30 .mu.m-300 .mu.m, 30 .mu.m-40 .mu.m, 40
.mu.m-100 .mu.m, 100 .mu.m-120 .mu.m, 120 .mu.m-200 .mu.m, 200
.mu.m-300 .mu.m, 200 .mu.m-250 .mu.m, or variations of these
ranges.
[0054] In yet another embodiment of the invention the particles 514
or fibers may be temporarily held together and/or to the surface of
the insert 18 by a fully or partially sacrificial coating. The
sacrificial coating may be consumed by molten metal or burnt off
when metal is cast around or over the insert 18. The particles 514
or fibers are left behind trapped between the body 506 of the cast
part and the insert 18 to provide a layer 520 consisting of the
particles 514 or fibers or consisting essentially of the particles
514 or fibers.
[0055] The layer 520 may be provided over the entire insert 18 or
only over a portion thereof. In one embodiment of the invention the
insert 18 may include a tab 534 (FIG. 10). For example, the insert
18 may include an annular body portion and a tab 534 extending
radially inward or outward therefrom. In one embodiment of the
invention at least one wettable surface 536 of the tab 534 does not
include a layer 520 including particles 514 or fibers, or a
wettable material such as graphite is provided over the tab 534, so
that the cast metal is bonded to the wettable surface 536 to attach
the insert 18 to the body 506 of the part 500 but still allow for
frictional damping over the remaining insert surface which is not
bonded to the casting.
[0056] In one embodiment of the invention at least a portion of the
insert 18 is treated or the properties of the insert 18 are such
that molten metal will not wet or bond to that portion of the
insert 18 upon solidification of the molten metal. According to one
embodiment of the invention at least one of the body 506 of the
part or the insert 18 includes a metal, for example, but not
limited to, a ferrous based material including, but not limited to,
cast iron, gray cast iron, steel, or stainless steel, or a
non-ferrous based material including, but not limited to, aluminum,
magnesium, or titanium, or any of a variety of other alloys, or
metal matrix composite including abrasive particles. In one
embodiment of the invention the insert 18 may include a material
such as a metal having a higher melting point than the melting
point of the molten material being cast around a portion
thereof.
[0057] In one embodiment the insert 18 may have a minimum average
thickness of 0.2 mm and/or a minimum width of 0.1 mm and/or a
minimum length of 0.1 mm. In another embodiment the insert 18 may
have a minimum average thickness of 0.2 mm and/or a minimum width
of 2 mm and/or a minimum length of 5 mm. In other embodiments the
insert 18 may have a thickness ranging from about 0.1-20 mm,
0.1-6.0 mm, or 1.0-2.5 mm, or ranges therebetween.
[0058] Referring now to FIGS. 13-14, again the frictional surface
502 may have a plurality of peaks 510 and a plurality of valleys
512. The depth as indicated by line V of the valleys 512 may vary
with embodiments. In various embodiments, the average of the depth
V of the valleys 512 may range from about 1 .mu.m-300 .mu.m, 50
.mu.m-260 .mu.m, 100 .mu.m-160 .mu.m or variations of these ranges.
However, for all cases there is local contact between the body 506
and the insert 18 during component operation for frictional damping
to occur.
[0059] In other embodiments of the invention improvements in the
frictional damping may be achieved by adjusting the thickness (L,
as shown in FIG. 10) of the layer 520, or by adjusting the relative
position of opposed frictional surfaces 502 or the average depth of
the valleys 512.
[0060] In one embodiment the insert 18 is not pre-loaded or under
pre-tension or held in place by tension. In one embodiment the
insert 18 is not a spring. Another embodiment of the invention
includes a process of casting a material comprising a metal around
an insert 18 with the proviso that the frictional surface 502
portion of the insert used to provide frictional damping is not
captured and enclosed by a sand core that is placed in the casting
mold. In various embodiments the insert 18 or the layer 520
includes at least one frictional surface 502 or two opposite
friction surfaces 502 that are completely enclosed by the body 506
of the part. In another embodiment the layer 520 including the
particles 514 or fibers that may be completely enclosed by the body
506 of the part or completely enclosed by the body 506 and the
insert 18, and wherein at least one of the body 506 or the insert
18 comprises a metal or consists essentially of a metal. In one
embodiment of the invention the layer 520 and/or insert 18 does not
include or is not carbon paper or cloth.
[0061] Referring again to FIGS. 9-10, in various embodiments of the
invention the insert 18 may include a first face 522 and an
opposite second face 524 and the body 506 of the part may include a
first inner face 526 adjacent the first face 522 of the insert 18
constructed to be complementary thereto, for example nominally
parallel thereto. The body 506 of the part includes a second inner
face 528 adjacent to the second face 524 of the insert 18
constructed to be complementary thereto, for example parallel
thereto. The body 506 may include a first outer face 530 overlying
the first face 522 of the insert 18 constructed to be complementary
thereto, for example parallel thereto. The body 506 may include a
first outer face 532 overlying the second face 524 of the insert 18
constructed to be complementary thereto, for example parallel
thereto. However, in other embodiments of the invention the outer
faces 530, 532 of the body 506 are not complementary to associated
faces 522, 524 of the insert 18. When the damping means is provided
by a narrow slot-like feature 508 formed in the body 506 of the
part 500, the slot-like feature 508 may be defined in part by a
first inner face 526 and a second inner face 528 which may be
constructed to be complementary to each other, for example parallel
to each other. In other embodiments the surfaces 526 and 528; 526
and 522; or 528 and 524 are mating surfaces but not parallel to
each other.
[0062] Referring to FIGS. 17-18, in one embodiment of the invention
the insert 18 may be an inlay wherein a first face 522 thereof is
not enclosed by the body 506 of the part. The insert 18 may include
a tang or tab 534 which may be bent downward as shown in FIG. 17.
In one embodiment of the invention a wettable surface 536 may be
provided that does not include a layer 520 including particles 514
or fibers, or a wettable material such as graphite is provided over
the tab 534, so that the cast metal is bonded to the wettable
surface 536 to attach the insert 18 to the body of the part but
still allow for frictional damping on the non-bonded surfaces. A
layer 520 including particles 514 or fibers may underlie the
portion of the second face 524 of the insert 18 not used to make
the bent tab 534.
[0063] In another embodiment the insert 18 includes a tab 534 which
may be formed by machining a portion of the first face 522 of the
insert 18 (FIG. 18). The tab 534 may include a wettable surface 536
having cast metal bonded thereto to attach the insert 18 to the
body of the part but still allow for friction damping by way of the
non-bonded surfaces. A layer 520 including particles 514 or fibers
may underlie the entire second face 524 or a portion thereof. In
other embodiments of the invention all surfaces including the tabs
534 may be non-wettable, for example by way of a coating 520
thereon, and features of the body portion 506 such as, but not
limited to, a shoulder 537 may be used to hold the insert 18 in
place.
[0064] Referring now to FIG. 19, one embodiment of the invention
may include a part 500 having a body portion 506 and an insert 18
enclosed by the body part 506. The insert 18 may include through
holes formed therein so that a stake or post 540 extends into or
through the insert 18.
[0065] Referring to FIG. 20, which is a sectional view of FIG. 19
taken along line 20-20, in one embodiment of the invention a layer
520 including a plurality of particles 514 or fibers (not shown)
may be provided over at least a portion of the insert 18 to provide
a frictional surface 502 and to prevent bonding thereto by cast
metal. The insert 18 including the layer 520 may be placed in a
casting mold and molten metal may be poured into the casting mold
and solidified to form the post 540 extending through the insert
18. An inner surface 542 defining the through hole of the insert 18
may be free of the layer 520 or may include a wettable material
thereon so that the post 540 is bonded to the insert 18.
Alternatively, in another embodiment the post 18 may not be bonded
the insert 18 at the inner surface 542. The insert 18 may include a
feature such as, but not limited to, a shoulder 505 and/or the post
540 may include a feature such as, but not limited to, a shoulder
537 to hold the insert in place.
[0066] Referring now to FIG. 21, in another embodiment, the insert
may be provided as an inlay in a casting including a body portion
506 and may include a post 540 extending into or through the insert
18. The insert 18 may be bonded to the post 540 to hold the insert
in place and still allow for frictional damping. In one embodiment
of the invention the insert 18 may include a recess defined by an
inner surface 542 of the insert 18 and a post 540 may extend into
the insert 18 but not extend through the insert 18. In one
embodiment the post 18 may not be bonded to the insert 18 at the
inner surface 542. The insert 18 may include a feature such as, but
not limited to, a shoulder 505 and/or the post 540 may include a
feature such as, but not limited to, a shoulder 537 to hold the
insert in place.
[0067] Referring now to FIG. 22, in another embodiment of the
invention, an insert 18 or substrate may be provided over an outer
surface 530 of the body portion 506. A layer 520 may or may not be
provided between the insert 18 and the outer surface 530. The
insert 18 may be constructed and arranged with through holes formed
therethrough or through a recess therein so that cast metal may
extend into or through the insert 18 to form a post 540 to hold the
insert in position and still allow for frictional damping. The post
540 may or may not be bonded to the insert 18 as desired. The post
540 may extend through the insert 18 and join another portion of
the body 506 if desired.
[0068] When the term "over," "overlying," overlies," "under,"
"underlying," or "underlies" is used herein to describe the
relative position of a first layer or component with respect to a
second layer or component such shall mean the first layer or
component is directly on and in direct contact with the second
layer or component or that additional layers or components may be
interposed between the first layer or component and the second
layer or component.
[0069] The above description of embodiments of the invention is
merely exemplary in nature and, thus, variations thereof are not to
be regarded as a departure from the spirit and scope of the
invention.
* * * * *