Extruded Material Pattern Grooves for Cast Bonding
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Solution Overview
Problem
The existing methods for manufacturing vehicle chassis parts using high-pressure casting and extruded materials often result in decreased bonding strength due to bubble defects, leading to reduced strength and impact characteristics of vehicles.
Innovation Solution
A method is introduced where a pattern is formed on the outer surface of an extruded material, which is then inserted into a mold and overlapped with a cast material. The molten metal is injected into the mold, filling the pattern grooves and enhancing the bonding strength between the extruded and cast materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is used to connect extruded material and cast material, then the required rigidity of chassis part is satisfied, but bonding strength decreases due to bubble defects
Solution Approach 1:
The patent combines the extruded material and cast material through direct integrally formed bonding without welding, eliminating the harmful bubble defects that occur in welded areas. The pattern portion on the extruded material surface creates mechanical interlocking with the cast material, achieving both high strength and reliability in the bonding interface.
Solution Approach 2:
The pattern portion is formed on the outer surface of the extruded material before the casting process. This preliminary surface preparation creates grooves and irregularities that enhance mechanical interlocking with the molten metal, ensuring strong and reliable bonding before the actual casting occurs.
2Manufacturing precision
If high vacuum method is applied to minimize bubbles in welded area, then bubble defects are reduced, but bonding strength still decreases due to chronic bubble problem in cast product
Solution Approach 1:
The patent extracts or eliminates the welding process entirely from the manufacturing method. By replacing welding with direct integrally formed bonding through pattern portions, the source of bubble defects in welded areas is removed, and the chronic bubble problem in cast products no longer affects bonding strength.
Solution Approach 2:
The pattern portion is formed on the extruded material surface before casting, creating a surface structure that promotes strong bonding without requiring welding. This preliminary surface preparation ensures that the bonding interface is free from bubble defects while maintaining high bonding strength.
3Strength
If extruded material is inserted into mold for integrally formed bonding, then bonding strength increases, but risk of molten metal scattering increases
Solution Approach 1:
The pattern portion is formed on the extruded material surface before insertion into the mold. This preliminary surface preparation creates a controlled interface that guides the molten metal flow into the grooves, enhancing bonding strength while preventing uncontrolled scattering of molten metal during the casting process.
4Strength
If pattern portion is formed on extruded material surface, then bonding strength between extruded and cast material increases, but manufacturing process complexity increases
Solution Approach 1:
The pattern portion is formed on the extruded material surface as a preliminary step before casting. This surface preparation creates mechanical interlocking features that significantly enhance bonding strength between the extruded and cast materials, providing a simple yet effective solution to the bonding strength problem.
Data Source
AI summary
A method of manufacturing a vehicle chassis part capable of increasing bonding strength between a cast material and an extruded material forming the chassis part is proposed. The method includes: forming a pattern portion for bonding to a cast material on an outer surface of an extruded material; inserting and fixing the extruded material into which the pattern portion is formed, in a mold for molding the cast material; and injecting molten metal for molding the cast material into the mold to form the cast material. A portion of the cast material overlaps the pattern portion of the extruded material to be formed integrally therewith.