US 12,331,383 B2
Magnesium alloy housing for an electric vehicle drive unit
Qigui Wang, Rochester Hills, MI (US); and Lokesh Choudhary, Bangalore (IN)
Assigned to GM GLOBAL TECHNOLOGY OPERATIONS LLC, Detroit, MI (US)
Filed by GM Global Technology Operations LLC, Detroit, MI (US)
Filed on Dec. 9, 2021, as Appl. No. 17/546,363.
Prior Publication US 2023/0183842 A1, Jun. 15, 2023
Int. Cl. F16H 57/032 (2012.01); C22C 23/00 (2006.01)
CPC C22C 23/00 (2013.01) [F16H 57/032 (2013.01)] 20 Claims
OG exemplary drawing
 
1. A magnesium (Mg) alloy housing for a drive unit of an electric vehicle (EV) having a drive shaft connected to an electric motor, the Mg alloy housing comprising:
a body comprising a Mg alloy, the body arranged to house the drive unit of the EV; and
a cylindrical hub disposed on the body, the hub having a bore formed therethrough and arranged to couple the drive shaft of the electric motor to the drive unit, the hub comprising a first Mg portion having a first inner surface and a second Mg portion having a second inner surface, the hub comprising an aluminum (Al) alloy insert having a first outerface and a second outerface, the Al alloy insert being casted between the first and second Mg portions such that the first inner surface aligns with the first outerface to define a first interface and such that the second inner surface aligns with the second outerface to define a second interface, the Al alloy insert having a flange formed adjacent the first outerface, the flange arranged to be loaded with a compressive stress and to transfer the compressive stress to the first interface to offset tensile stress during use, thereby minimizing fatigue and cracking thereon, and wherein each of the first and second outerfaces comprises a zinc (Zn) coating thereon for metallurgical bonding with the Mg alloy at the first and second interfaces.