A process of fabricating a shield, a process of preparing a component, and an erosion shield are disclosed. The process of fabricating the shield includes forming a near-net shape shield. The near-net shape shield includes a nickel-based layer and an erosion-resistant alloy layer. The nickel-based layer is configured to facilitate secure attachment of the near-net shaped to a component. The process of preparing the component includes securing a near-net shape shield to a substrate of a component.

A process of fabricating a shield, a process of preparing a component, and an erosion shield are disclosed. The process of fabricating the shield includes forming a near-net shape shield. The near-net shape shield includes a nickel-based layer and an erosion-resistant alloy layer. The nickel-based layer is configured to facilitate secure attachment of the near-net shaped to a component. The process of preparing the component includes securing a near-net shape shield to a substrate of a component.

A die cast component includes an insert element with a plurality of form-fitting elements which are designed for the form-fitting connection of the insert element with a casting material. A ratio of a component wall thickness to a wall thickness of the insert element is a maximum of 4.

A die cast component includes an insert element with a plurality of form-fitting elements which are designed for the form-fitting connection of the insert element with a casting material. A ratio of a component wall thickness to a wall thickness of the insert element is a maximum of 4.

A contact layer is formed by a deposition method on an inner surface of a first metal element by a centrifuging process, and preferably includes an inner layer of copper alloy and an outer layer of tin alloy. Such a contact layer is used in an articulation joint including a first metal element having a surface provided with the contact layer, and a second metal element with a second surface. The first and second elements are relatively movable such that first and second surfaces slide against each other.

A process of forming an erosion, oxidation, and wear resistant shot chamber, either a gooseneck or a shot sleeve, is provided. The process utilizes a self-healing erosive wear resistant coating on a liner of refractory metal to serve as the working surfaces of a shot chamber. Such a shot chamber is expected to have an improved service life for die casting of corrosive metals and alloys, including hot chamber die casting of aluminum alloys. An improved hot dipping process using stirring in the motel metal bath is also disclosed.

A wear-resistant component includes a substrate formed from a metal, defining a bore, and having a bore surface. The substrate includes a first region having a first microstructure adjacent the bore surface and a first average particle size. The substrate also includes a second region having a second microstructure adjacent the first microstructure and a second average particle size. The first average particle size is larger than the second average particle size. A system and a method of forming the wear-resistant coating are also described.

A mold is used to form a solder joint to join the distal end of the guidewire to a wire coil. The mold has a cavity that can have different configurations so that the solder joint can be any of bullet shaped, micro-J shaped, cone shaped, truncated cone shaped, or have a textured surface.

Presented are lithium-metal electrodes for electrochemical devices, systems and methods for manufacturing lithium-metal foils, and vehicle battery packs containing battery cells with lithium-metal anodes. A method of melt spinning lithium-metal foils includes melting lithium (Li) metal stock in an actively heated vessel to form molten Li metal. Using pressurized gas, the molten Li metal is ejected through a slotted nozzle at the base of the vessel. The ejected molten Li metal is directly impinged onto an actively cooled and spinning quench wheel or a carrier sheet that is fed across a support roller underneath the vessel. The molten Li metal is cooled and solidified on the spinning wheel/carrier sheet to form a Li-metal foil. The carrier sheet may be a polymeric carrier film or a copper current collector foil. An optional protective film may be applied onto an exposed surface of the Li-metal foil opposite the carrier sheet.

Presented are lithium-metal electrodes for electrochemical devices, systems and methods for manufacturing lithium-metal foils, and vehicle battery packs containing battery cells with lithium-metal anodes. A method of melt spinning lithium-metal foils includes melting lithium (Li) metal stock in an actively heated vessel to form molten Li metal. Using pressurized gas, the molten Li metal is ejected through a slotted nozzle at the base of the vessel. The ejected molten Li metal is directly impinged onto an actively cooled and spinning quench wheel or a carrier sheet that is fed across a support roller underneath the vessel. The molten Li metal is cooled and solidified on the spinning wheel/carrier sheet to form a Li-metal foil. The carrier sheet may be a polymeric carrier film or a copper current collector foil. An optional protective film may be applied onto an exposed surface of the Li-metal foil opposite the carrier sheet.