A metal workpiece, such as a wheel, and a method of providing an enhanced corrosion resistant surface coating on an exposed surface of a metal or alloy substrate (such as magnesium). A corrosion resistance basecoat is formed, including generating an oxide layer, and applying a first primer coating onto at least a portion of the oxide layer. The method may further include identifying highest corrosion prone areas on the substrate and designing a support rack that avoids contact with these corrosion prone areas. The method also includes forming a topcoat over at least a portion of the basecoat, by applying a second primer coating onto at least a portion of the first primer coating and depositing a sputtered metallic film onto the second primer coating using a physical vapor deposition technique. A clear coat layer may be applied over the metallic film.

Hub bearing assembly for a vehicle wheel, the assembly having an axial tubular appendage capable of being inserted into a central hole of a wheel of the vehicle, and wherein the tubular appendage has a radially outer surface of substantially cylindrical shape; a collar of cylindrical shape being mounted on the tubular appendage so as to cover a second centring section of the radially outer cylindrical surface, and having an insert of metallic material and an inner coating layer which at least partially covers the insert and is formed on the insert by galvanizing.

Hub bearing assembly for a vehicle wheel, the assembly having an axial tubular appendage capable of being inserted into a central hole of a wheel of the vehicle, and wherein the tubular appendage has a radially outer surface of substantially cylindrical shape; a collar of cylindrical shape being mounted on the tubular appendage so as to cover a second centring section of the radially outer cylindrical surface, and having an insert of metallic material and an inner coating layer which at least partially covers the insert and is formed on the insert by galvanizing.

In one aspect, a method for forging a vehicle wheel with three-dimensional features may include steps of utilizing toe-clamps and center collets to reduce chatter marks and the effects of vibrations and harmonics; employing a parametric CNC program which allows for feed rates and spindle RPM speeds that are specific to the process of the vehicle wheel design; utilizing end-mills, bull-nose end-mills, ball-mills, chamfer tools, V-tools, custom rivet tools, and other commonly used CNC milling tools to machine the sides of the spokes on the wheels; utilizing a coolant to operate the CNC machine; providing a tool to make the three-dimensional features on the wheel; cleaning the wheel to remove coolant and debris remaining on the wheel; and painting selected areas of the wheel.

A system and a method of forming a wear surface of a wheel of a rail vehicle include depositing one or more alloy powders onto a main body of the wheel, and plasma transfer arc welding the one or more powders to form one or more alloy layers secured to the main body.

This invention is related to a lightweight process of manufacturing a bicycle's rim and a rim structure manufactured thereby. A rim frame comprising an inner frame, a cladding part, and a support part between the inner frame and the cladding part. The inner frame and the support part are milled to form plural through holes uniformly distributed thereon. The areas occupied by the through holes is 35% to 85% of a total surface of the inner frame and the support part. Moreover, a proper distance is formed between the adjacent through holes in the process, and a carbon fiber layer covers the outer surface of the rim frame. Therefore, the weight of the bicycle's rim is decreased, and the carbon fiber layer can stably attach on the rim frame to increase the structural strength of the rim.