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Leak repair method

a leakage repair and leak technology, applied in the field of leakage repair methods, can solve the problems of casting aluminum wheels manufactured, market-wide porosity in materials, and detrimental to the performance of wheels,

Inactive Publication Date: 2005-12-22
JACOBS TERRY LANE
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0007] The invention involves repairing cast aluminum wheels that leak air due to porosity. A roller burnishing tool is used to deep roll the surface of the wheel such that the porosity becomes sealed and the wheel no longer leaks air. The wheel can be used in service and does not have to be discarded. By roller burnishing the surface of the wheel under controlled operating parameters, the plastic deformation of the surface and subsurface layers cause the material to flow and the porosity formed during the casting process to close. This effectively seals the wheel's surface permanently for the life of the wheel.

Problems solved by technology

Cast aluminum wheels manufactured for the automotive market and other markets frequently have porosity in the material.
This porosity is detrimental to the performance of the wheel and can be large enough to allow air to pass through the wheel.
A tire mounted to such a wheel would not be capable of sustaining air pressure as the air would leak out through the porosity of the wheel.
They are undesirable.
Unfortunately, most of the cost to produce the wheel has already been spent by the time the wheel is tested for leaking.
So, a wheel which has been determined to be a leaker and subsequently scraped or melted back down results in a significant loss to the manufacturer.
High scrap rates due to leakers can have a dramatic impact on the cost of manufacturing cast aluminum wheels.
Even with these efforts, porosity cannot be completely eliminated.
As a result, some leakers will always remain.

Method used

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Embodiment Construction

[0009] The invention involves using a roller burnishing tool to deep roll the surface of a cast aluminum wheel such that the porosity becomes sealed and the wheel no longer leaks air. Deep rolling is a method of roller burnishing where the parameters of the burnishing process are tightly controlled. Particularly, the parameters of applied force, feed rate, roller material properties, and roller geometry are required to be specified and validated. Unfortunately, past commercially available burnishing tools were not capable of maintaining tight control of the operational parameters to the degree necessary. Deep rolling produces cold work and plastic deformation in the surface of the wheel due to the Hertzian contact stress induced by the action of the roller under an applied load. This plastic deformation effectively closes the porosity in the near surface layers in the wheel material. The residual compressive stresses and cold work induced by the deep rolling process also acts to kee...

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Abstract

The present invention is a novel method for the repair of cast aluminum wheels that leak air due to porosity caused during the casting process. It involves deep roller burnishing the surface of the wheel under controlled operating parameters to effectively seal the porosity so that the wheel no longer leaks air.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS [0001] Not Applicable STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT [0002] Not Applicable REFERENCE TO SEQUENCE LISTING, A TABLE, OR COMPUTER PROGRAM LISTING COMPACT DISK APPENDIX [0003] Not Applicable BACKROUND OF THE INVENTION [0004] Cast aluminum wheels manufactured for the automotive market and other markets frequently have porosity in the material. This porosity is created during the molding or casting process during manufacture of the wheel. As the aluminum freezes from its liquid or molten state in the mold, the aluminum material contracts. This contraction occurs not only at the surface but throughout the interior of the wheel as well. The contracting interior material can develop openings or holes called porosity while accommodating the geometry constraints and cooling rates governing the shape of the wheel in the mold. This porosity is detrimental to the performance of the wheel and can be large enough to allow air ...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): B21C37/30B23P6/00B23P9/02B60B3/00
CPCB23P6/00B23P9/02Y10T29/49748B60B3/06Y10T29/47B60B3/02
Inventor JACOBS, TERRY LANE
Owner JACOBS TERRY LANE
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