Reinforced aluminum metal composite carrier

Abstract

The present invention is generally directed towards a carrier of a motor vehicle. The carrier is formed of a first portion and the second portion. The first portion is made of aluminum having ceramic particles reinforcing the aluminum matrix. The second portion is made of unreinforced aluminum metal or metal alloy. Preferably the second portion is present in form of discrete pockets in the first portion and is adapted to be machined or welded.

What is claimed is:  
     
         1 . A carrier for supporting a gearset adaptable to transfer torque from the engine to the wheels in a motor vehicle, the carrier comprising: 
 a first portion formed of an aluminum matrix, wherein the aluminum matrix is reinforced by ceramic particles, such that the ceramic particles are in the range of 10% to 50% of volume of the first portion; and    a second portion formed of unreinforced aluminum metal, wherein the second portion is integral with the first portion;    wherein the second portion is adapted to attach the carrier to a support structure.    
     
     
         2 . The carrier of  claim 1 , wherein the ceramic particles are preferably 20% of the volume of the first portion.  
     
     
         3 . The carrier of  claim 1 , wherein the ceramic particles are selected from a group consisting of silicon carbide or aluminum oxide.  
     
     
         4 . The carrier of  claim 1 , wherein the ceramic particles have a particle size in the range of 4 microns to 30 microns.  
     
     
         5 . The carrier of  claim 4 , wherein the particle size is preferably in the range of 7 microns to 20 microns.  
     
     
         6 . The carrier of  claim 1 , wherein the first portion forms 80% to 97% by weight of the carrier and the second portion forms 20% to 3% by weight of the carrier.  
     
     
         7 . The carrier of  claim 1 , wherein the first portion has yield strength in the range of 20 ksi to 52 ksi.  
     
     
         8 . The carrier of  claim 7 , wherein the first portion has the yield strength of not less than 42 ksi.  
     
     
         9 . The carrier of  claim 1 , wherein the first portion has an elastic modulus in the range of 13.2 Msi to 16.5 Msi.  
     
     
         10 . The carrier of  claim 9 , wherein the elastic modulus is not less than 14.3 Msi.  
     
     
         11 . The carrier of  claim 11 , wherein the first portion has a thermal expansion coefficient in the range of 6.5 ppm/F to 11.2 ppm/F  
     
     
         12 . The carrier of  claim 11 , wherein the thermal expansion coefficient is not more than 9.7 ppm/F  
     
     
         13 . The carrier of  claim 1 , wherein the first portion is attached to a cover adaptable to prevent leaking of a lubricant from the carrier.  
     
     
         14 . The carrier of  claim 1 , wherein the second portion is formed as discrete pockets in the first portion.  
     
     
         15 . A method of forming a carrier to support a gearset such that the carrier is adaptable to transfer torque from the engine to the wheels in a motor vehicle, the method comprising the steps of: 
 mixing a predetermined amount of ceramic particles into molten aluminum to form a reinforced aluminum matrix wherein the reinforced aluminum matrix defines a first portion in the carrier;    providing an insert of substantially pure aluminum in a casting mold wherein the inserts define a second portion in the carrier; and    casting the reinforced aluminum matrix in the casting mold to form the first portion and the second portion such that the first portion and the second portion are integral with each other.    
     
     
         16 . The method of  claim 15 , further comprising selecting the ceramic particles from a group consisting of silicon carbide or aluminum oxide.  
     
     
         17 . The method of  claim 15 , further comprising selecting a predetermined amount of ceramic particles in the range of 10% to 50% of the volume of the first portion.  
     
     
         18 . The method of  claim 15 , where selecting the predetermined amount of ceramic particles in the 20% of the volume of the first portion.  
     
     
         19 . A method of forming a carrier to support a gearset such that the carrier is adaptable to transfer torque from the engine to the wheels in a motor vehicle, the method comprising the steps of: 
 providing a pre-determined amount of ceramic particles;    sintering the pre-determined amount of ceramic particles to form a first portion;    inserting the first portion in a casting mold wherein the molding die is adaptable to form the carrier;    providing voids in the areas where the first portion does not fill the casting mold; and    adding molten aluminum to the casting mold such that the molten aluminum fills the voids and forms the second portion of the carrier.    
     
     
         20 . The method of  claim 19 , further comprising selecting the ceramic particles from a group consisting of silicon carbide or aluminum oxide.  
     
     
         21 . The method of  claim 19 , further comprising selecting a predetermined amount of ceramic particles in the range of 10% to 50% of the volume of the first portion.  
     
     
         22 . The method of  claim 19 , where selecting the predetermined amount of ceramic particles in the 20% of the volume of the first portion.