Dynamic systems and methods for manufacturing lightweight metal alloy articles
OwnerKassem ALHUSSEIN, Dustin GRACE +2inventors
InventorsKassem ALHUSSEIN, Dustin GRACE, David LAI, Cagkan YILDIZ
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Abstract
Disclosed herein are systems and methods for providing lightweight alloy articles, for example, magnesium alloy battery enclosures for electric vehicles. In some embodiments, a magnesium alloy can progress through a production line configured to chip a magnesium alloy ingot, mix the chipped alloy with additional alloying elements, and melt and mold the alloy to form a magnesium alloy metal article. The article can then be finished, coated, and joined to another magnesium article and/or to a dissimilar metal to create the magnesium alloy article.
Claims26
A magnesium alloy article production line, comprising:
- a metal breakdown apparatus configured to chip a magnesium alloy ingot into magnesium alloy pieces;
- a solid particle mixing apparatus configured to mix the magnesium alloy pieces with one or more powdered alloying materials to provide a mixture comprising a target magnesium alloy composition;
- a metal forming apparatus configured to melt the mixture into a molten magnesium alloy and urge the molten magnesium alloy into a mold to form a molded magnesium alloy article;
- a metal finishing apparatus configured to machine the molded magnesium alloy article to create a finished magnesium alloy article;
- a first coating apparatus configured to coat the finished magnesium alloy article with a first coating;
- and
- a second coating apparatus configured to coat the finished magnesium alloy article with a second coating, the second coating being different from the first coating.
A method of manufacturing a magnesium alloy article, the method comprising:
- chipping a magnesium alloy ingot into magnesium alloy pieces;
- mixing the magnesium alloy pieces with one or more powdered alloying materials to provide a mixture comprising a target magnesium alloy composition;
- melting the mixture comprising the target magnesium alloy composition into a molten magnesium alloy;
- molding the molten magnesium alloy in a mold to form a molded magnesium alloy article;
- machining the molded magnesium alloy article to create a finished magnesium alloy article;
- coating at least a portion of the finished magnesium alloy article with a first coating;
- and
- coating at least a portion of the finished magnesium alloy article with a second coating, the second coating being different from the first coating.
Dependencies are inferred from the claim text.