An exemplary method for making a metal matrix composite vehicle component includes: using a mold including male and female die portions having mold surfaces and a plurality of spacers; heating the mold to a casting temperature; placing a ceramic preform on the plurality of spacers, the ceramic preform being spaced apart from at least one of the mold surfaces by the spacers; closing the mold to form a mold cavity between the mold surfaces of the male and female die portions, the ceramic preform being disposed within the mold cavity; providing molten metal into the mold cavity; and pressurizing the molten metal to a casting pressure for a casting duration to infiltrate the ceramic preform thereby forming the metal matrix composite vehicle component.

An exemplary method for making a metal matrix composite vehicle component includes: using a mold including male and female die portions having mold surfaces and a plurality of spacers; heating the mold to a casting temperature; placing a ceramic preform on the plurality of spacers, the ceramic preform being spaced apart from at least one of the mold surfaces by the spacers; closing the mold to form a mold cavity between the mold surfaces of the male and female die portions, the ceramic preform being disposed within the mold cavity; providing molten metal into the mold cavity; and pressurizing the molten metal to a casting pressure for a casting duration to infiltrate the ceramic preform thereby forming the metal matrix composite vehicle component.

An inner door panel (30) for a vehicle side door that includes an integrated side impact beam (70) formed as part of the door in a die casting process. The inner door panel (30) includes an outer frame having a top rail (38), a bottom rail (40), an inner side rail (42) and an outer side rail (44) defining a central opening (34). The impact beam (70) includes a main beam portion (72), a first end support portion (74) and a second end support portion (78). The first end support portion is formed to the side rail (42) and the second end support portion (78) is formed to the outer side rail (44), where the main beam portion (72) extends across the opening (34).

An inner door panel (30) for a vehicle side door that includes an integrated side impact beam (70) formed as part of the door in a die casting process. The inner door panel (30) includes an outer frame having a top rail (38), a bottom rail (40), an inner side rail (42) and an outer side rail (44) defining a central opening (34). The impact beam (70) includes a main beam portion (72), a first end support portion (74) and a second end support portion (78). The first end support portion is formed to the side rail (42) and the second end support portion (78) is formed to the outer side rail (44), where the main beam portion (72) extends across the opening (34).

The present disclosure relates to a mold improved to tune the position of an insert pin for forming a hole in a molded article. The mold includes a core forming a cavity corresponding to a molded article, a forming plate accommodating the core, and an insert pin configured to penetrate the forming plate and the core in a first direction to form a hole in the molded article inside the cavity and be movable along the first direction.

The present disclosure relates to a mold improved to tune the position of an insert pin for forming a hole in a molded article. The mold includes a core forming a cavity corresponding to a molded article, a forming plate accommodating the core, and an insert pin configured to penetrate the forming plate and the core in a first direction to form a hole in the molded article inside the cavity and be movable along the first direction.

The present disclosure relates to a process of machining a metal middle frame, which includes the following steps of: obtaining a sheet material and cutting the sheet material into a linear profile; performing a finish machining to the linear profile; bending the linear profile after the finish machining, obtaining a metal border frame with an R angle; welding the metal border frame; and placing the metal border frame after the welding in a die-casting mold, providing a die-casting metal liquid, thereby obtaining a die-cast middle plate connected to the metal border frame, so as to form the metal middle frame.

An exemplary method for making a metal matrix composite vehicle component includes: using a mold including male and female die portions having mold surfaces and a plurality of spacers; heating the mold to a casting temperature; placing a ceramic preform on the plurality of spacers, the ceramic preform being spaced apart from at least one of the mold surfaces by the spacers; closing the mold to form a mold cavity between the mold surfaces of the male and female die portions, the ceramic preform being disposed within the mold cavity; providing molten metal into the mold cavity; and pressurizing the molten metal to a casting pressure for a casting duration to infiltrate the ceramic preform thereby forming the metal matrix composite vehicle component.

An exemplary method for making a metal matrix composite vehicle component includes: using a mold including male and female die portions having mold surfaces and a plurality of spacers; heating the mold to a casting temperature; placing a ceramic preform on the plurality of spacers, the ceramic preform being spaced apart from at least one of the mold surfaces by the spacers; closing the mold to form a mold cavity between the mold surfaces of the male and female die portions, the ceramic preform being disposed within the mold cavity; providing molten metal into the mold cavity; and pressurizing the molten metal to a casting pressure for a casting duration to infiltrate the ceramic preform thereby forming the metal matrix composite vehicle component.

Composite parts (100) and methods of making the same are disclosed. A composite part may include an internal insert component (124) made of a first material. The internal insert component may be provided with surface features such as mechanical surface features or material surface features, on at least a portion of its surface. The composite part may further include an external part component (136) that is cast around at least a portion of the internal insert component, and is made of a second material different from the first material. The surface features of the internal insert component may help establish a bond within the composite part between the internal insert component and the external part component.