Cast-in boss for feature attachment on steel casting

Abstract

A fastening system and method adapted for use on materials having poor machining characteristics, which provides an attachment feature for a component or an assembly. The attachment feature includes a mount having a boss defining a boss recess and a fastening surface. A first fastener is affixed to the fastening surface. A second fastener is received through an auxiliary feature and engages the first fastener to affix the auxiliary feature to the component. The boss recess may accommodate a portion of the second fastener.

What is claimed is:  
     
         1 . An exhaust manifold for mounting an auxiliary feature, the exhaust manifold comprising: 
 a manifold body having an exterior surface and an interior surface;    a mount extending from said exterior surface, said mount including a boss defining a boss recess and a fastening surface;    a first fastener affixed to said fastening surface and including a fastener opening, said fastener opening aligned with said boss recess and adapted to receive a second fastener for affixing the auxiliary feature.    
     
     
         2 . The exhaust manifold of  claim 1 , further comprising a weld affixing said first fastener to said fastening surface.  
     
     
         3 . The exhaust manifold of  claim 1 , wherein said boss is generally conical in shape.  
     
     
         4 . The exhaust manifold of  claim 3 , wherein said boss recess is an annular bore through said boss.  
     
     
         5 . The exhaust manifold of  claim 1 , wherein said boss includes two outwardly extending legs.  
     
     
         6 . The exhaust manifold of  claim 5 , wherein said boss recess includes a gap between said two outwardly extending legs.  
     
     
         7 . The exhaust manifold of  claim 1 , wherein said boss includes steel.  
     
     
         8 . A fastening system comprising: 
 a component having a mount, said mount including a boss defining a boss recess and a fastening surface;    a first fastener affixed to said fastening surface and including a fastener opening aligned with said boss recess;    an auxiliary feature having an aperture adapted for mounting to said component; and    a second fastener received through said aperture and engaging said first fastener, whereby said auxiliary feature is affixed to said component.    
     
     
         9 . The fastening system of  claim 8 , further comprising a weld affixing said first fastener to said fastening surface.  
     
     
         10 . The fastening system of  claim 8 , wherein said boss is generally conical in shape.  
     
     
         11 . The fastening system of  claim 10 , wherein said boss recess includes an annular bore through said boss.  
     
     
         12 . The fastening system of  claim 8 , wherein said boss includes two outwardly extending legs.  
     
     
         13 . The fastening system of  claim 12 , wherein said boss recess includes a gap between said two outwardly extending legs.  
     
     
         14 . The fastening system of  claim 8 , wherein said boss includes steel.  
     
     
         15 . A method for creating an attachment feature on the exterior surface of an engine manifold, the method comprising the steps of: 
 a) forming a boss on said exterior surface of said engine manifold;    b) forming a boss recess through said boss;    c) forming a fastener surface on said boss;    d) providing a first fastener having a opening;    e) positioning said opening coaxially with said boss recess; and    f) affixing said first fastener to said fastener surface.    
     
     
         16 . The method of  claim 15 , further comprising the step of mounting an auxiliary feature to said first fastener using a second fastener.  
     
     
         17 . The method of  claim 15 , further comprising the step of machining the fastener surface.  
     
     
         18 . The method of  claim 15 , wherein said steps forming of said boss, boss recess and said fastening surface is performed when manufacturing the engine manifold.  
     
     
         19 . The method of  claim 15 , wherein said step of affixing said first fastener to said fastener surface includes welding.  
     
     
         20 . A method for mounting an auxiliary feature on an exterior surface of a component, the method comprising the steps of: 
 a) providing a mount on said exterior surface of the component, said mount including: 
 i) a boss defining a boss recess and a fastening surface;  
 ii) a first fastener having an opening aligned with said boss recess, said first fastener affixed to said fastening surface; and  
   b) mounting the auxiliary feature to the component with a second fastener disposed through the auxiliary feature and engaging said first fastener.    
     
     
         21 . The method of  claim 20 , further comprising the step of machining the fastener surface.