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.

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.