GB2291370A - Casting around a rigid porous ceramic material - Google Patents

Casting around a rigid porous ceramic material Download PDF

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Publication number
GB2291370A
GB2291370A GB9514934A GB9514934A GB2291370A GB 2291370 A GB2291370 A GB 2291370A GB 9514934 A GB9514934 A GB 9514934A GB 9514934 A GB9514934 A GB 9514934A GB 2291370 A GB2291370 A GB 2291370A
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GB
United Kingdom
Prior art keywords
receptacle
vol
light metal
article
metal alloy
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
GB9514934A
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GB9514934D0 (en
GB2291370B (en
Inventor
John Barlow
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Sankey Holding Ltd
Original Assignee
GKN Sankey Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
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Publication of GB9514934D0 publication Critical patent/GB9514934D0/en
Publication of GB2291370A publication Critical patent/GB2291370A/en
Application granted granted Critical
Publication of GB2291370B publication Critical patent/GB2291370B/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D19/00Casting in, on, or around objects which form part of the product
    • B22D19/02Casting in, on, or around objects which form part of the product for making reinforced articles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D19/00Casting in, on, or around objects which form part of the product
    • B22D19/14Casting in, on, or around objects which form part of the product the objects being filamentary or particulate in form
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60GVEHICLE SUSPENSION ARRANGEMENTS
    • B60G7/00Pivoted suspension arms; Accessories thereof
    • B60G7/001Suspension arms, e.g. constructional features

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Vehicle Body Suspensions (AREA)
  • Compositions Of Oxide Ceramics (AREA)

Description

2291370
T=: An Article and Method for its Production Description of Invention:
This invention relates to an article adapted to receive a component therein and it is an object of the invention to provide an article having a light metal alloy body part for receiving a said component which will offer certain advantages over prior art articles for the same purpose.
In accordance with the invention there is provided an article comprising a body part formed of a light metal alloy and a receptacle having internal dimensions adapted to the reception of a component therein, the receptacle being formed of a rigid porous ceramic material pre-form incorporated in said body part and being infiltrated with the light metal alloy material of the body part whereby the said internal dimensions of the receptacle may be maintained independent of the deformations or stresses to which the body part is subjected under normal conditions of use.
Also in accordance with the invention there is provided a method of producing such an article comprising the steps of forming a rigid porous ceramic receptacle pre-form and casting light metal alloy around said receptacle pre-form to form a body part of said article and to infiltrate the pore structure of said receptacle pre-form with said light metal alloy.
Such an article produced in accordance with the invention finds application for example wherein the receptacle has internal dimensions optimised to receive a component therein with an interference fit. The said body part of the article may be subject to variations in temperature causing expansion and contraction but such expansion and contraction of the body part will only cause stresses and strains to be created in the incorporated receptacle and the internal dimensions of the receptacle will not be changed. Hence the interference fit with the said component will be maintained.
Such an article also has the advantage of providing an inert receptacle/body part interface whereby neither the receptacle nor the article as 2 a whole will be liable to corrosive attack generated at such interface. Such an "interface" does in fact comprise a plurality of small interfaces where the pore structure of the ceramic receptacle is infiltrated with the light metal alloy material of the body part of the article.
lle ceramic material comprising the receptacle is selected to have the properties to withstand the conditions to which it is subjected in use. nus for some applications it may be advantageous for the receptacle to have good thermal conductivity properties and for other applications it may be advantageous for the receptacle to have good wear resistance. A good wear resistant and thermally conductive material is silicon carbide although other ceramic materials such as alumina or zirconia or silicon nitride may be selected.
The rigid porous ceramic receptacle pre-form is conveniently formed by sintering ceramic particles into a coherent mass to provide an interconnected pore structure for receiving infiltrant molten light metal alloy such as an aluminium alloy during production of the article. The degree of porosity is such as to ensure that the pore structure of the receptacle is capable of receiving the infiltrant molten light metal alloy and is thus related to the selected method of infiltration. The pre- form may have a porosity lying in the range 25 vol.% to 45 vol.% voids. Tle receptacle may comprise 55 vol.% to 75 vol.% of said rigid porous preform and 45 vol.% to 25 vol.% of said light metal alloy. The pre-form may have a pore size lying in the range 0.02nun to 2.00min.
Such method of infiltration preferably comprises the casting technique known as squeeze casting wherein, whilst still molten, the light metal alloy is subjected to conditions of sustained temperature and pressure. In such a squeeze casting technique a more dense porous ceramic receptacle pre-form may be employed than would be possible if for example a gravity casting technique were to be utilised for production of the article and infiltration of the receptacle preform.
One example of an article having a body part within which a component is received with an interference fit comprises a suspension component k_ 3 for a vehicle such as a wishbone arm. Hitherto such components have been produced as steel pressings; welded together to fabricate a complete suspension arm. It has also been proposed to utilise forged aluminium alloys to produce suspension components including wishbone arms. A lightweight material such as an aluminium alloy does of course have the major advantage of weight reduction when compared with steel but can suffer the disadvantage of corrosive attack at any ferrous/aluminium alloy interface. In particular, where a ball joint bearing is provided, the casing of the joint is usually steel and this can react with the aluminium alloy material in a damaging manner. Forged aluminium alloy components are relatively expensive to produce in view of the usually quite extensive post-forging machining which is required.
Thus in accordance with the invention the said article may comprise a suspension component wherein the receptacle incorporated in the light metal body part of the suspension component receives a ball joint assembly therein with an interference fit of the outer, usually steel, casing of the ball joint assembly within the receptacle. In one particular embodiment of the invention the said article may comprise a wishbone arm for use in a vehicle suspension system wherein the said receptacle provides a cylindrical internal surface for receiving the outer casing of a ball joint assembly therein with an interference fit.
A further example of an article having a body part within which a component is received with an interference fit comprises a wheel hub. Hitherto wheel hubs have been proposed to be formed of a light metal alloy with a steel bearing race or races received therein with an interference fit. In an attempt to maintain the dimensional stability of the interference fit it has been necessary to provide a relatively massive amount of metal in the hub but even this may not be successful in preventing relaxing of the interference fit due to the stresses and strains to which the hub is subjected in use. Also, there is the known problem of corrosive attack at the inter-face between the bearing races, which are usually steel cased, and the light metal alloy of the hub such as an aluminium alloy.
4 Thus also in accordance with the invention the said article may comprise a wheel hub wherein the receptacle incorporated in the light metal body part of the hub receives a bearing race or races with an interference fit of the outer, usually steel, casing of the bearing within the infiltrated ceramic said receptacle.
Other features of the invention will become apparent from the following description given herein solely by way of example with reference to the accompanying drawings wherein:-
Figure 1 is a somewhat diagrammatic perspective view of a wishbone arm suspension component for a vehicle constructed in accordance with the invention; Figure 2 is a sectional view taken on the line A-A of Figure 1; Figure 3 is a side sectional view of a wheel hub in accordance with the invention; and Figure 4 is a micro-photograph taken at a magnification of x 176 showing a sample taken from a receptacle of an article embodying the invention and on which a scale of 1,um has been marked.
An article constructed in accordance with the invention is described and illustrated herein with reference to Figures 1 and 2 as comprising a suspension component for a vehicle in the form of a lower wishbone arm 10 incorporating a receptacle 12 adjacent one end thereof. In the particular embodiment illustrated, the wishbone arm is of generally triangular plan configuration having one apex 14 containing the receptacle 12 and the two other apices 16 and 18 being adapted for mounting the wishbone arm for pivotal movement relative to a vehicle chassis or sub-frame.
In accordance with the invention the arm 10 is formed of a light metal alloy and the receptacle 12 is formed of a rigid porous ceramic material pre-form infiltrated with the light metal alloy material of the arm. As illustrated, the receptacle 12 comprises a generally cylindrical bushing having a radially inner generally cylindrical surface 20 for receiving with an interference fit the outer a cylindrical steel casing 22 of a ball joint assembly of a pivot post of a vehicle wheel.
The pre-form for the receptacle 12 is conveniently formed as a sintered coherent mass of ceramic particles which are typically silicon carbide particles whereby the sintered mass thereof will have properties of good wear resistance and good thermal conductivity. Other ceramic particles may be utilised such as for example alumina or zirconia or silicon nitride. The rigid porous ceramic receptacle pre-form may be produced as a ceramic foam structure. The light metal alloy of the wishbone arm 10 conveniently comprises an aluminium alloy.
The article of the invention is preferably produced by the casting technique known as squeeze casting which is known per se and which comprises the introduction of molten metal into a first part of a mould, closing the mould under pressure so that the liquid metal fills the mould cavity without entrapping air, maintaining the metal under pressure whilst solidification thereof takes place to ensure that any shrinkage cavities are closed and filled, and then opening the mould and removing the cast article. The pressure applied to the molten metal is typically of the order of 45MPa to 10OMPa and is typically sustained for a period of time of the order of 15 to 90 seconds. At the start of this sustained pressure the temperature of the molten metal is typically between 70WC and 770T whereas at the end of the sustained pressure the temperature is typically between 25TC and 40WC.
Thus to produce the wishbone arm suspension component illustrated in the drawings, a generally cylindrical rigid porous ceramic pre-form for the receptacle 12 is placed in a first part of a mould cavity and molten aluminium alloy introduced therein. In accordance with the invention the molten alloy will infiltrate the pore structure of the pre-form of the receptacle during the casting technique and the pre-form of the receptacle will become mechanically bonded or keyed to the alloy matrix. Use of a squeeze casting technique enables a near net-shape product to be obtained whereby any subsequent machining to shape is minimal.
6 The pre-forTn for the receptacle may have a porosity within the range 25% to 45% voids by volume (vol.%). In the present example the aluminium alloy comprises about 35 vol.% of the receptacle and the ceramic preform 65 vol.%. The pre-form may have a pore size lying in the range 0.02mm to 2.Omm.
Figure 4 illustrates a typical microstructure of the receptacle 12, the microstructure of which is substantially uniform; the light areas are the aluminium alloy phase and the dark areas the ceramic phase.
When the cast component is removed from the mould it may be necessary to broach the bore of the receptacle 12 to remove any skin of metal which covers the radially inner surface thereof and which may be present as a result of the casting process. After such broaching the radially inner infiltrated ceramic surface 20 of the receptacle will be exposed and no machining thereof will normally be necessary.
Since the pre-form and hence receptacle is mechanically bonded to the alloy matrix of the body part of the article there is no risk of loosening of the receptacle or of movement thereof relative to the remainder of the article. Also there will be provided improved noise, vibration and harshness properties of the suspension component as a whole in comparison with those provided by steel suspension arms with steel bearings due to the inherent damping effect provided by the multiple alloy-ceramic interfaces in the pore structure of the infiltrated receptacle.
In Figure 3 of the drawings there is illustrated a wheel hub constructed in accordance with the invention and comprising a hub body 24 incorporating two axially spaced apart receptacles 26 and 28 within each of which is to be located a steel cased bearing (not illustrated) by means of an interference fit. By an 1nterference fif' we mean the external diameter of the steel cased bearing is the same or substantially the same as the internal diameter of the receptacle - fitment is made by cooling the bearing and press fitting into the receptable. In the embodiment illustrated the hub body 24 is of generally conventional configuration 7 having a through bore 30 for the reception of a shaft (not illustrated), the hub and the shaft being rotatable relative to one another via the said bearings.
In accordance with the invention the hub body 24 is formed of a light metal alloy, preferably an aluminium alloy, and each receptacle 26 and 28 is formed of a rigid porous ceramic material pre-form infiltrated with the light metal alloy of the hub body. As illustrated, each receptacle 26 and 28 comprises a generally cylindrical bushing having a radially inner generally cylindrical surface 32 for receiving with an interference fit the outer casing of a respective bearing.
Each receptacle 26 and 28, and the hub body 24 incorporating said receptacles, is conveniently formed in the same manner as described hereinbefore with reference to the forming of the receptacle 12 and the wishbone arm 10. Thus each receptacle 26 and 28 may comprise a sintered coherent mass of ceramic particles, typically silicon carbide particles of similar pore size and porosity to that described in connection with the receptacle 12, whereby the sintered mass thereof will have properties of good wear resistance and good thermal conductivity. Other ceramic particles may be utilised such as for example alumina or zirconia or silicon nitride, and the rigid porous ceramic receptacle 26 and 28 may be produced as a ceramic foam structure.
The hub body 24 as a whole is preferably produced by the squeeze casting technique described hereinbefore wherein, during casting, the molten alloy will infiltrate the pore structure of the pre-form for each receptacle 26 and 28 whereby each receptacle will become mechanically bonded or keyed to the alloy matrix. As illustrated in Figure 3, the as- cast configuration of the hub body 24 is shown in full line and the as- machined configuration of the hub body is shown in dotted line.
In all embodiments the light metal alloy may comprise a suitable aluminium based alloy or the light metal alloy may be made of other metal such as a magnesium based alloy.
The features disclosed in the foregoing description, or the following claims, or the accompanying drawings, expressed in their specific forms or in
8 v terms of a means for performing the disclosed function, or a method or process for attaining the disclosed result, as appropriate, may, separately or in any #_ combination of such features, be utilised for realising the invention in diverse forms thereof.
f.
9

Claims (26)

CLAIMS:
1. An article comprising a body part formed of a light metal alloy and a receptacle having internal dimensions adapted to the reception of a component therein, the receptacle being formed of a rigid porous ceramic material pre-form incorporated in said body part and being infiltrated with the light metal alloy material of the body part whereby the said internal dimensions of the receptacle may be maintained independent of the deformations or stresses to which the body part is subjected under normal conditions of use.
2.
An article according to claim 1 wherein the receptacle has internal dimensions to receive a component therein with an interference fit.
3. An article according to any one of the preceding claims wherein the ceramic material comprising the receptacle is selected to have good thermal conductivity properties and/or good wear resistance.
4. An article according to any one of the preceding claims wherein the ceramic material comprises silicon carbide or alumina or zirconia or silicon nitride.
5. An article according to any one of the preceding claims wherein the rigid porous ceramic receptacle pre-form comprises a coherent mass of sintered ceramic particles providing an interconnected pore structure within which the infiltrant light metal alloy is received.
6. An article according to any one of the preceding claims wherein the light metal also comprises an aluminium alloy.
7. An article according to any one of the preceding claims wherein the rigid porous pre-form has a porosity lying in the range 25 vol.% to 45 vol.% voids.
8. An article according to any one of the preceding claims wherein the receptacle comprises 55 vol.% to 75 vol.% of said rigid porous pre-form and 45 vol.% to 25 vol.% of said light metal alloy.
9. An article according to any one of the preceding claims wherein the rigid porous pre-form has a pore size lying in the range 0.02mrn to 2.Omm.
10. An article according to any one of the preceding claims wherein the article comprises a suspension component wherein the receptacle incorporated in the light metal body part of the suspension component receives a ball joint assembly therein with an interference fit of the outer casing of the ball joint assembly within the receptacle.
11. An article according to claim 10 wherein the article comprises a wishbone arm for use in a vehicle suspension system wherein the receptacle provides a cylindrical internal surface for receiving the outer casing of a ball joint assembly therein with an interference fit.
12. An article according to any one of claims 1 to 9 wherein the article comprises a wheel hub wherein the receptacle incorporated in the light metal body part of the hub receives a bearing race or races with an interference fit of the outer casing of the bearing within the receptacle.
13. An article substantially as hereinbefore described with reference to Figures 1, 2 or 3 of the accompanying drawings.
11
14. A method of producing an article comprising a body part formed of a light metal alloy and a receptacle having internal dimensions adapted to the reception of a component therein, comprising the steps of forming a rigid porous ceramic receptacle pre-form and casting light metal alloy around said receptacle pre-form to form a body part of said article and to infiltrate the pore structure of said receptacle pre-form with said light metal alloy.
15. A method as claimed in claim 14 wherein the rigid porous pre-form has a porosity lying in the range 25 vol.% to 45 vol.% voids.
16. A method as claimed in claim 15 wherein the receptacle comprises 55 vol.% to 75 vol.% of said rigid porous body and 45 vol.% to 25 vol.% of said light metal alloy.
17. A method as claimed in claim 15 or claim 16 wherein the rigid porous pre-form has a pore size lying in the range 0.02mrn to 2mm.
18. A method as claimed in any one of claims 14 to 17 wherein the rigid porous ceramic pre-form is formed by sintering ceramic particles into a coherent mass to provide an interconnected pore structure for receiving infiltrant molten light metal alloy during production of the receptacle.
19. A method as claimed in any one of claims 14 to 18 wherein the method of infiltration comprises a casting technique wherein a said porous ceramic pre-form. is located in a mould and molten light metal alloy is cast around said body so as to infiltrate the pore structure thereof.
20. A method as claimed in claim 19 wherein the casting technique is a squeeze casting technique.
12
21. A method as claimed in any one of claims 14 to 20 wherein the rigid porous ceramic pre-form is formed to provide a receptacle having a cylindrical internal surface.
22. A method according to any one of claims 14 to 21 wherein the rigid pre-form has a porosity lying in the range 25 volA to 45 volA voids.
23. A method according to any one of claims 14 to 22 wherein the receptacle comprises 55 vol.% to 75 vol.% of said rigid pre-form and 45 vol.% to 25 vol.% of said light metal alloy.
24. A method according to any one of claims 14 to 23 wherein the rigid pre-form has a pore size lying in the range 0.02mm to 2.Omm.
25. A method of producing an article substantially as hereinbefore described.
26. Any novel feature or novel combination of features described herein and/or in the accompanying drawings.
GB9514934A 1994-07-20 1995-07-20 An article and method for its production Expired - Fee Related GB2291370B (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB9414660A GB9414660D0 (en) 1994-07-20 1994-07-20 An article and method for its production

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GB9514934D0 GB9514934D0 (en) 1995-09-20
GB2291370A true GB2291370A (en) 1996-01-24
GB2291370B GB2291370B (en) 1997-11-12

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GB9514934A Expired - Fee Related GB2291370B (en) 1994-07-20 1995-07-20 An article and method for its production

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2010344A2 (en) * 2006-03-30 2009-01-07 Z F Group North American Operations, Inc. Method of making a multilayered duplex material article
WO2014096274A2 (en) * 2012-12-21 2014-06-26 Jaguar Land Rover Limited Sleeve member and method of casting

Families Citing this family (4)

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DE19653149A1 (en) * 1996-12-19 1998-06-25 Bayerische Motoren Werke Ag Workpiece made of a lightweight material and process for producing the workpiece
DE19712624C2 (en) * 1997-03-26 1999-11-04 Vaw Motor Gmbh Aluminum matrix composite and process for its manufacture
DE10035202A1 (en) * 2000-07-20 2002-01-31 Opel Adam Ag Casting process and core for use in this process
DE102004005799A1 (en) * 2004-02-06 2005-09-01 Daimlerchrysler Ag Method for producing a local reinforcement for a component of an internal combustion engine

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US4318438A (en) * 1977-09-27 1982-03-09 Honda Giken Kogyo Kabushiki Kaisha Method for casting a fiber-reinforced composite article
EP0110097A1 (en) * 1982-11-26 1984-06-13 Toyota Jidosha Kabushiki Kaisha Method and apparatus for manufacturing composite material using pressure chamber and casting chamber
GB2156720A (en) * 1984-04-07 1985-10-16 Gkn Technology Ltd Squeeze-cast composite article
GB2187533A (en) * 1985-02-07 1987-09-09 Metal Leve Sa Method of attaching a ceramic insert to an alloy piston
GB2196623A (en) * 1986-10-16 1988-05-05 Nabeya Iron & Tool Works Fluid-permeable article and method for producing the same
WO1991016159A1 (en) * 1990-04-12 1991-10-31 Alcan Deutschland Gmbh Composite casting process
GB2247636A (en) * 1990-08-03 1992-03-11 Atomic Energy Authority Uk The manufacture of composite materials
GB2254814A (en) * 1991-04-18 1992-10-21 Gkn Sankey Ltd Reinforced light metal article and method for its production
GB2284238A (en) * 1993-11-25 1995-05-31 Gkn Sankey Ltd A brake disc and method for its production

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GB1533512A (en) * 1976-09-01 1978-11-29 Mahle Gmbh Pistons
US4318438A (en) * 1977-09-27 1982-03-09 Honda Giken Kogyo Kabushiki Kaisha Method for casting a fiber-reinforced composite article
GB2079653A (en) * 1980-07-07 1982-01-27 Teves Gmbh Alfred A composite casting
EP0110097A1 (en) * 1982-11-26 1984-06-13 Toyota Jidosha Kabushiki Kaisha Method and apparatus for manufacturing composite material using pressure chamber and casting chamber
GB2156720A (en) * 1984-04-07 1985-10-16 Gkn Technology Ltd Squeeze-cast composite article
GB2187533A (en) * 1985-02-07 1987-09-09 Metal Leve Sa Method of attaching a ceramic insert to an alloy piston
GB2196623A (en) * 1986-10-16 1988-05-05 Nabeya Iron & Tool Works Fluid-permeable article and method for producing the same
WO1991016159A1 (en) * 1990-04-12 1991-10-31 Alcan Deutschland Gmbh Composite casting process
GB2247636A (en) * 1990-08-03 1992-03-11 Atomic Energy Authority Uk The manufacture of composite materials
GB2254814A (en) * 1991-04-18 1992-10-21 Gkn Sankey Ltd Reinforced light metal article and method for its production
GB2284238A (en) * 1993-11-25 1995-05-31 Gkn Sankey Ltd A brake disc and method for its production

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2010344A2 (en) * 2006-03-30 2009-01-07 Z F Group North American Operations, Inc. Method of making a multilayered duplex material article
EP2010344A4 (en) * 2006-03-30 2009-04-15 Z F Group North American Opera Method of making a multilayered duplex material article
WO2014096274A2 (en) * 2012-12-21 2014-06-26 Jaguar Land Rover Limited Sleeve member and method of casting
WO2014096274A3 (en) * 2012-12-21 2015-02-19 Jaguar Land Rover Limited A method of forming a component comprising a sleeve member formed from a metal matrix composite
CN105008068A (en) * 2012-12-21 2015-10-28 捷豹路虎有限公司 Sleeve member and method of casting
JP2016507379A (en) * 2012-12-21 2016-03-10 ジャガー・ランド・ローバー・リミテッドJaguar Land Rover Limited Sleeve member and casting method
GB2538017A (en) * 2012-12-21 2016-11-02 Jaguar Land Rover Ltd Sleeve member and method of casting
GB2538017B (en) * 2012-12-21 2017-05-03 Jaguar Land Rover Ltd Automotive, aerospace or vessel component

Also Published As

Publication number Publication date
GB9514934D0 (en) 1995-09-20
GB9414660D0 (en) 1994-09-07
GB2291370B (en) 1997-11-12
DE19526363A1 (en) 1996-01-25

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Effective date: 19990720