Patent Publication Number: US-11655844-B2

Title: Multi-material boss and method of making the same

Description:
RELATED APPLICATIONS 
     The application claims the benefit of priority under 35 U.S.C. 119(a) to Chinese Patent Application No. 202021416654.X, filed on Jul. 17, 2020, the entire contents of which is hereby incorporated by reference in its entirety. 
     TECHNICAL FIELD 
     Exemplary embodiments described herein relate generally to the field of mechanical fasteners and, more particularly, to multi-material bosses and methods of making the same. 
     BACKGROUND 
     Thin-walled metal enclosures, such as those used for electric and electronic appliances and equipment housings, having bosses on an interior thereof, are often manufactured in high volumes by die casting. Die casting is a manufacturing process that produces non-ferrous metal or alloy parts via reusable molds or dies. Typically, the die casting process involves the use of a furnace, metal, die casting machine, and die, whereby the die casting machine injects molten metal, such as aluminum or zinc, at high pressure and velocity, into the die, producing geometrically complex parts, both economically and effectively. There are two main types of die casting machines, hot chamber machines, for low melting temperature metals such as zinc, and cold chamber machines, for high melting temperature metals, such as aluminum. 
     Notwithstanding, generally, comparable metal or alloy die cast parts are not as dense and not as strong as forged parts being manufactured by the application of thermal and mechanical energy to billets and ingots, whereby materials of the billets and ingots deform, resulting in metallurgical recrystalisation and grain refinement. The difference is compounded when consideration is given to bosses and the formation thereof. 
     Bosses generally aid in the assembly of enclosures, acting as mounting points of the enclosures or other components. Screw bosses provide a channel for a screw for assembly. Despite screws being a reliable and inexpensive method of mechanical fastening, mounting point fastening failure often occurs due to wear-and-tear caused by multiple assembly, disassembly, and reassembly procedures. Generally, fastening failure and/or decreased fastening effectiveness results, due to chipping or cracking caused by tensile stresses that can be induced under high pressure or cross threading, among other factors. 
     One technique developed for decreasing and/or mitigating fastening failure and decreased fastening effectiveness is to replace bosses with a more durable and harder material threaded inserts or bushings. However, such inserts and bushings are associated with increased costs due to the pre-threaded parts and additional costs for adhesives required for securing the threaded insert or bushing in place so it doesn&#39;t back out. 
     SUMMARY 
     Accordingly, there is a need for a solution to the above mentioned problems that will provide various advantages. Such solutions are described herein. In one exemplary embodiment, a multi-material boss, configured for fastening of a fastener thereto, being a feature of a die cast part, is provided. The multi-material boss comprises a boss cylinder, an augmenting cylinder, and a filler metal layer. The boss cylinder is preferably made of the same material as the die cast part having a first liquidus temperature and a first hardness, and has a first interior defined by a first cylindrical shaped wall, and a first base. The augmenting cylinder is made of an augmenting material having a second liquidus temperature and a second hardness, is fixedly secured in the first interior of the boss cylinder, and has a second interior defined by a second cylindrical shaped wall, a base rim, and a second opening. The second liquidus temperature is higher than the first liquidus temperature and the second hardness is greater than the first hardness. The filler metal layer is made of a material having a third liquidus temperature lower than that of the first and second liquidus temperatures, at least partially compressed between the base rim of the augmenting cylinder and first base of the interior of the boss cylinder. The fastener is fastened to the multi-material boss via the second opening of the augmenting cylinder having the higher liquidus temperature and greater hardness. 
     In some embodiments, the feature of the die cast part comprises a protruding feature extending from a surface thereof. In some embodiments, the die cast part further comprises at least a strengthening member, configured for providing strength and stability to the protruding feature of the multi-material boss. In some embodiments, the strengthening member comprises a spacer between the protruding feature of the multi-material boss and a surface of the die cast part. In some embodiments, the shape of the spacer comprises at least one of straight lines, curves, or any combination of the foregoing. 
     In some embodiments, the features of the die cast part comprise at least one of a protruding feature encompassing the multi-material boss, extending from an outer perimeter wall surface of the die cast part, a protruding feature encompassing the multi-material boss, extending from an inner perimeter wall surface or corner to a base of the die cast part, or any combination of the foregoing. 
     In some embodiments, the multi-material boss further comprises a conical depression, configured for recessing a head of a fastener. 
     In some embodiments, the die cast part is made of an aluminum alloy material and the augmenting cylinder is made of at least one of a stainless steel, iron, aluminum silicon alloy, copper, copper alloy, aluminum magnesium alloy material, having a second hardness greater than the first hardness of the boss cylinder. 
     In some embodiments, the die cast part is made of at least one of an aluminum alloy, zinc alloy, magnesium, zinc-aluminum alloy, copper, tin or lead material, or any combination of the foregoing. 
     In some embodiments, the second cylindrical shaped wall comprises threads, configured for fastening by a screw fastener. 
     In another exemplary embodiment, a method of forming a multi-material boss, configured for fastening of a fastener thereto, being a feature of a die cast part, is provided. The method generally comprises the steps of providing a boss cylinder and providing an augmenting cylinder, and bonding the augmenting cylinder within the boss cylinder. The method preferably comprises providing a boss cylinder, made of a same material as the die cast part having a first liquidus temperature and a first hardness. Next, the method comprises determining whether the boss cylinder comprises a first interior defined by a first cylindrical shaped wall, a first base and a receivable opening. If not, drilling a first interior of the boss cylinder at a central axis thereof, defining a first cylindrical shaped wall, a first base, and a receivable opening. If yes, the method comprises providing an augmenting cylinder, made of an augmenting material having a second liquidus temperature and a second hardness, wherein the second liquidus temperature is higher than the first liquidus temperature and the second hardness is greater than the first hardness, having a multi-functional interior defined by a working cylindrical shaped wall, a working base rim, and a multi-functional opening. Next, the method comprises providing a filler metal, made of a material having a third liquidus temperature lower than that of the first and second liquidus temperatures, in the first interior of the boss cylinder via the receivable opening. The method further comprises press-inserting the augmenting cylinder into the boss cylinder via the receivable opening. Next, the method comprises bonding the augmenting cylinder to the boss cylinder via brazing, at least spreading and adhering the filler metal between the working base rim of the augmenting cylinder and first base of the first interior of the boss cylinder forming a filler metal layer, whereby expanding air and gasses are vented through the multi-functional interior of the augmenting cylinder. The method continues with cooling the augmenting cylinder and boss cylinder. Next, the method comprises drilling the multi-functional interior of the augmenting cylinder at the multi-functional opening, forming an intermediary interior, defining an intermediary cylindrical shaped wall, a base rim, and an intermediary opening. The method comprises tapping the intermediary interior of the augmenting cylinder at the intermediary opening, forming a second interior, defining a second cylindrical shaped wall, a base rim, and a second opening. The method comprises countersinking the second interior of the augmenting cylinder at the second opening, enlarging a top portion of the second opening forming a conical depression, configured for recessing a head of a fastener, whereby the fastener is fastened to the multi-material boss via the second opening of the augmenting cylinder having the higher liquidus temperature and greater mechanical properties hardness. 
     In some embodiments of the method, the feature of the die cast part comprises a protruding feature extending from a surface thereof. In some embodiments of the method, the die cast part further comprises at least a strengthening member, configured for providing strength and stability to the protruding feature of the multi-material boss. In some embodiments of the method, the strengthening member comprises a spacer between the protruding feature of the multi-material boss and surface of the die cast part. In some embodiments of the method, the shape of the spacer comprises at least one of straight lines, curves, or any combination of the foregoing. 
     In some embodiments of the method, the features of the die cast part comprises at least one of a protruding feature encompassing the multi-material boss, extending from an outer perimeter wall surface of the die cast part, a protruding feature encompassing the multi-material boss, extending from an inner perimeter wall surface or corner to a base of the die cast part, or any combination of the foregoing. 
     In some embodiments of the method, the die cast part is made of an aluminum alloy material and the augmenting cylinder is made of at least one of a stainless steel, iron, aluminum silicon alloy, copper, copper alloy, aluminum magnesium alloy material, having a second mechanical properties hardness greater than the first hardness of the boss cylinder. 
     In some embodiments of the method, the die cast part is made of at least one of an aluminum alloy, zinc alloy, magnesium, zinc-aluminum alloy, copper, tin or lead material, or any combination of the foregoing. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Unless specified otherwise, the accompanying drawings illustrate aspects of the innovative subject matter described herein. Referring to the drawings, wherein like reference numerals indicate similar parts, features or steps throughout the several views, several examples of heat exchanger systems incorporating aspects of the presently disclosed principles are illustrated by way of example, and not by way of limitation. 
         FIG.  1 A  is a schematic interior view of a multi-material boss, according to an exemplary embodiment; 
         FIG.  1 B  is a schematic view of the multi-material boss of  FIG.  1 A , according to an exemplary embodiment; 
         FIG.  1 C  is a schematic top view of the multi-material boss of  FIG.  1 A , according to an exemplary embodiment; 
         FIG.  1 D  is a schematic perspective interior view of the multi-material boss of  FIG.  1 A , according to an exemplary embodiment; 
         FIG.  2 A  is a schematic top view of the multi-material boss of  FIG.  1 A  with line A-A, according to an exemplary embodiment; 
         FIG.  2 B  is a schematic cross-sectional view of the multi-material boss of  FIG.  1 A  along line A-A of  FIG.  2 A , according to an exemplary embodiment; 
         FIG.  2 C  is a schematic detailed cross-sectional view of the multi-material boss of  FIG.  1 A  along line A-A of  FIG.  2 A , according to an exemplary embodiment; 
         FIG.  3    is a flow chart illustrating a manufacturing method of the multi-material boss of  FIG.  1 A , according to an exemplary embodiment; 
         FIG.  4    is a schematic detailed cross-sectional view of the multi-material boss of  FIG.  1 A , following Step ( 1100 ) of the manufacturing method of  FIG.  3   , according to an exemplary embodiment; 
         FIG.  5    is a schematic detailed cross-sectional view of the multi-material boss having a filler material layer therein of  FIG.  1 A , following Step ( 1100 ) of the manufacturing method of  FIG.  3   , according to an exemplary embodiment; 
         FIG.  6 A  is a schematic interior view of the multi-material boss of  FIG.  1 A , following Step ( 1300 ) of the manufacturing method of  FIG.  3   , according to an exemplary embodiment; 
         FIG.  6 B  is a schematic top view of the multi-material boss of  FIG.  6 A , following Step ( 1300 ) of the manufacturing method of  FIG.  3   , according to an exemplary embodiment; 
         FIG.  6 C  is a schematic detailed cross-sectional view of the multi-material boss of  FIG.  6 A , during Step ( 1400 ) of the manufacturing method of  FIG.  3   , according to an exemplary embodiment; 
         FIG.  6 D  is a schematic detailed cross-sectional view of the multi-material boss of  FIG.  6 A , following Step ( 1500 ) of the manufacturing method of  FIG.  3   , according to an exemplary embodiment; 
         FIG.  7 A  is a schematic interior view of the multi-material boss of  FIG.  1 A , following Step ( 1600 ) of the manufacturing method of  FIG.  3   , according to an exemplary embodiment; 
         FIG.  7 B  is a schematic top view of the multi-material boss of  FIG.  7 A , following Step ( 1600 ) of the manufacturing method of  FIG.  3   , according to an exemplary embodiment; 
         FIG.  8 A  is a schematic interior view of the multi-material boss of  FIG.  1 A , following Step ( 1900 ) of the manufacturing method of  FIG.  3   , according to an exemplary embodiment; 
         FIG.  8 B  is a schematic top view of the multi-material boss of  FIG.  8 A , following Step ( 1900 ) of the manufacturing method of  FIG.  3   , according to an exemplary embodiment; and 
         FIG.  8 C  is a schematic detailed cross-sectional view of the multi-material boss having a filler material layer therein of  FIG.  8 A , following Step ( 1900 ) of the manufacturing method of  FIG.  3   , according to an exemplary embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     As used herein, the term “liquidus temperature” is the temperature above which, a material is liquid, and below which, the material begins to freeze. The term “hardness” refers to the mechanical property of hardness, the measure of a material&#39;s resistance to localized plastic deformation induced by mechanical indentation of abrasion. 
     The following describes various principles related to fastening systems by way of reference to specific examples of die cast parts and features thereof, including specific arrangements and examples of multi-material bosses, and fasteners embodying innovative concepts. More particularly, but not exclusively, such innovative principles are described in relation to selected examples of multi-material bosses and fasteners, and well-known functions or constructions are not described in detail for purposes of succinctness and clarity. Nonetheless, one or more of the disclosed principles can be incorporated in various other embodiments of multi-material bosses, and fasteners to achieve any of a variety of desired outcomes, characteristics, and/or performance criteria. 
     Thus, multi-material bosses, and fasteners having attributes that are different from those specific examples discussed herein can embody one or more of the innovative principles, and can be used in applications not described herein in detail. Accordingly, embodiments of multi-material bosses, and fasteners not described herein in detail also fall within the scope of this disclosure, as will be appreciated by those of ordinary skill in the relevant art following a review of this disclosure. 
     Exemplary embodiments as disclosed herein are directed to bosses aiding in the assembly of enclosures, acting as mounting points of the enclosures or other components. Bosses may be configured within an electric or electronics appliance or equipment system that includes thin-walled enclosures. Some other illustrative examples include enclosures used in the machinery, vehicle, appliance, toy, sporting goods, office equipment, and heat sink industries. 
     In one embodiment, a multi-material boss, configured for fastening of a fastener thereto, being a feature of a die cast part, comprising a boss cylinder, an augmenting cylinder, and a filler metal layer is provided. The boss cylinder is made of the same material as the die cast part having a first hardness, and has a first interior. The augmenting cylinder is made of an augmenting material having a second hardness, is fixedly secured in the first interior of the boss cylinder, and has a second interior defined by a second cylindrical shaped wall, a base rim, and a second opening. The second hardness is greater than the first hardness. The fastener is fastened to the multi-material boss via the second opening of the augmenting cylinder having the higher liquidus temperature and greater hardness. 
       FIG.  1 A  is a schematic interior view of a multi-material boss, according to an exemplary embodiment.  FIG.  1 B  is a schematic view of the multi-material boss of  FIG.  1 A , according to an exemplary embodiment.  FIG.  1 C  is a schematic top view of the multi-material boss of  FIG.  1 A , according to an exemplary embodiment.  FIG.  1 D  is a schematic perspective interior view of the multi-material boss of  FIG.  1 A , according to an exemplary embodiment.  FIG.  2 A  is a schematic top view of the multi-material boss of  FIG.  1 A  with line A-A, according to an exemplary embodiment.  FIG.  2 B  is a schematic cross-sectional view of the multi-material boss of  FIG.  1 A  along line A-A of  FIG.  2 A , according to an exemplary embodiment.  FIG.  2 C  is a schematic detailed cross-sectional view of the multi-material boss of  FIG.  1 A  along line A-A of  FIG.  2 A , according to an exemplary embodiment. Referring to  FIGS.  1 A to  2 C , in one embodiment, a multi-material boss  100 , configured for fastening of a fastener (not shown) thereto, being a feature of a die cast part  190 , is provided. The multi-material boss  100  comprises a boss cylinder  170 , an augmenting cylinder  160 , and a filler metal layer (FML) (see  FIG.  2 C ). The boss cylinder  170  is made of the same material as the die cast part  190 , and has a first liquidus temperature and a first hardness, having a first interior  172  defined by a first cylindrical shaped wall  175 , and a first base  179 . The augmenting cylinder  160 , fixedly secured in the first interior  172  of the boss cylinder  170 , preferably aligning flush therewith, is made of an augmenting material having a second liquidus temperature and a second hardness, and has a second interior  162  defined by a second cylindrical shaped wall  165 , a base rim  166 , and a second opening  120 . The second liquidus temperature is higher than the first liquidus temperature and the second hardness is greater than the first hardness. The filler metal layer (FML) is made of a material having a third liquidus temperature lower than that of the first and second liquidus temperatures, at least partially compressed between the base rim  166  of the augmenting cylinder  160  and first base  179  of the interior of the boss cylinder  170 . The fastener is fastened to the multi-material boss  100  via the second opening  120  of the augmenting cylinder  160  having the higher liquidus temperature and greater hardness. 
     In some embodiments, the second cylindrical shaped wall  165  comprises threads (See  FIG.  2 C ), configured for fastening by a screw fastener. In some embodiments, the number of multi-material bosses  100  is two or greater. 
     In some embodiments, the feature of the die cast part  190  comprises a protruding feature extending from a surface  191  thereof. In some embodiments, the die cast part  190  further comprises at least a strengthening member  185 , configured for providing strength and stability to the protruding feature of the multi-material boss  100 . In some embodiments, the strengthening member  185  comprises a spacer between the protruding feature of the multi-material boss  100  and surface  191  of the die cast part  190 . In some embodiments, the shape of the spacer comprises at least one of straight lines, curves, or any combination of the foregoing. In some embodiments, the shape of the spacer is quadrilateral. 
     In some embodiments, the feature of the die cast part comprises at least one of a protruding feature encompassing the multi-material boss  100 , extending from an outer perimeter wall surface of the die cast part, a protruding feature encompassing the multi-material boss  100 , extending from an inner perimeter wall surface or corner to a base of the die cast part, or any combination of the foregoing. 
     In the various embodiments, the strengthening member  185  comprises a spacer between the protruding feature of the multi-material boss  100  and surface  191  of the die cast part  190 ; however, the embodiments are not limited thereto. Those having ordinary skill in the relevant art may readily appreciate that the feature of the die cast part  190  may also comprise at least one of a gusset extending from an outer sidewall of the multi-material boss to a base of the die cast part, a rib extending from an outer sidewall of the multi-material boss to a wall of the die cast part, or any combination of the foregoing. 
     In some embodiments, the multi-material boss  100  further comprises a conical depression  168 , configured for recessing a head of a fastener. 
     In some embodiments, the die cast part  190  is made of an aluminum alloy material and the augmenting cylinder  160  is made of at least one of a stainless steel, iron, aluminum silicon alloy, copper, copper alloy, aluminum magnesium alloy material, having a second hardness greater than the first hardness of the boss cylinder  170 . 
     In the various embodiments, the die cast part  190  is made of an aluminum alloy material; however, the embodiments are not limited thereto. Those having ordinary skill in the relevant art may readily appreciate that the die cast part  190  may also be made of alternative materials suitably known in the art. As an example, in some embodiments, the die cast part  190  is made of at least one of a zinc alloy, magnesium, zinc-aluminum alloy, copper, tin or lead material, or any combination of the foregoing. 
     In the various embodiments, the augmenting cylinder  160  is made of at least one of a stainless steel, iron, aluminum silicon alloy, copper, copper alloy, and aluminum magnesium alloy material; however, the embodiments are not limited thereto. Those having ordinary skill in the relevant art may readily appreciate that the augmenting cylinder  160  may be made of at least one of a stainless steel, iron, aluminum silicon alloy, copper, copper alloy, aluminum magnesium alloy material. As long as the second hardness of the augmenting cylinder  160  is greater than the first hardness of the boss cylinder  170 . 
       FIG.  3    is a flow chart illustrating a manufacturing method of the multi-material boss of  FIG.  1 A , according to an exemplary embodiment.  FIG.  4    is a schematic detailed cross-sectional view of the multi-material boss of  FIG.  1 A , following Step ( 1100 ) of the manufacturing method of  FIG.  3   , according to an exemplary embodiment.  FIG.  5    is a schematic detailed cross-sectional view of the multi-material boss having a filler material layer therein of  FIG.  1 A , following Step ( 1100 ) of the manufacturing method of  FIG.  3   , according to an exemplary embodiment. Referring to  FIGS.  3  to  5   , and referring to  FIGS.  1 A to  2 C , in an exemplary embodiment, a method of forming a multi-material boss  100 , configured for fastening of a fastener thereto, being a feature of a die cast part  190 , is provided. The method  1000  generally comprises the steps of providing a boss cylinder  170  and providing an augmenting cylinder  160 , and bonding the augmenting cylinder  160  within the boss cylinder  170 . Step ( 1100 ) comprises providing a boss cylinder  170 , made of a same material as the die cast part  190  having a first liquidus temperature and a first hardness. Next, in Step ( 1200 ), determining whether the boss cylinder  170  comprises a first interior  172  defined by a first cylindrical shaped wall  175 , a first base  179  and a receivable opening  110 . If no, performing Step ( 1250 ). If yes, performing Step ( 1300 ). Step ( 1250 ) comprises drilling a first interior  172  of the boss cylinder  170  at a central axis thereof, defining a first cylindrical shaped wall  175 , a first base  179 , and a receivable opening  110 . 
       FIG.  6 A  is a schematic interior view of the multi-material boss of  FIG.  1 A , following Step ( 1300 ) of the manufacturing method of  FIG.  3   , according to an exemplary embodiment and  FIG.  6 B  is a schematic top view of the multi-material boss of  FIG.  6 A , following Step ( 1300 ) of the manufacturing method of  FIG.  3   , according to an exemplary embodiment.  FIG.  6 C  is a schematic detailed cross-sectional view of the multi-material boss of  FIG.  6 A , during Step ( 1400 ) of the manufacturing method of  FIG.  3   , according to an exemplary embodiment.  FIG.  6 D  is a schematic detailed cross-sectional view of the multi-material boss of  FIG.  6 A , following Step ( 1500 ) of the manufacturing method of  FIG.  3   , according to an exemplary embodiment. Referring to  FIGS.  6 A and  6 D , and referring to  FIGS.  1 A to  3   , Step ( 1300 ) comprises providing an augmenting cylinder  160   a , made of an augmenting material having a second liquidus temperature and a second hardness, wherein the second liquidus temperature is higher than the first liquidus temperature and the second hardness is greater than the first hardness, having a multi-functional through hole  162   a  defined by a working cylindrical shaped wall  165   a , a working base rim  166   a , and a multi-functional opening  120   a . Following, in Step ( 1300 ), a filler metal FML, made of a material having a third liquidus temperature lower than that of the first and second liquidus temperatures, is provided in the first interior  172  of the boss cylinder  170  via the receivable opening  110 . Step ( 1400 ) comprises press-inserting the augmenting cylinder  160   a  into the boss cylinder  170  via the receivable opening  110 . In some embodiments, before the augmenting cylinder  160   a  is press-inserted into the boss cylinder  170  via the receivable opening  110  the mating surfaces thereof, respectively, are cleaned and free of grease, dirt or foreign matter by methods known to those having ordinary skill in the relevant art. Also, when mated, the augmenting cylinder  160   a  and boss cylinder  170  are not strained to ensure uniform pressure distribution across the entire bond areas for optimum bonding. Next, in Step ( 1500 ), the augmenting cylinder  160   a  is bonded to the boss cylinder  170  via brazing or soldering, at least spreading and adhering the filler metal between the working base rim  166   a  of the augmenting cylinder  160   a  and first base  179  of the first interior  172  of the boss cylinder  170  forming a filler metal layer (FML), whereby expanding air and gasses are vented through through hole  162   a  of the augmenting cylinder  160   a.    
     Those having ordinary skill in the relevant art may readily appreciate that any suitably brazing or soldering filler metal known in the relevant art may be used to bond the augmenting cylinder  160   a  to the boss cylinder  170 , such as copper, nickel, silver and aluminum/zinc alloys or lead/tin alloys, as examples. As long as the third liquidus temperature is lower than that of the first and second liquidus temperatures and suitable wetting, capillary action, spreading and adhesion is allowed to occur. 
       FIG.  7 A  is a schematic interior view of the multi-material boss of  FIG.  1 A , following Step ( 1600 ) of the manufacturing method of  FIG.  3   , according to an exemplary embodiment and  FIG.  7 B  is a schematic top view of the multi-material boss of  FIG.  7 A , following Step ( 1600 ) of the manufacturing method of  FIG.  3   , according to an exemplary embodiment. Referring to  FIGS.  5 A and  5 B , and referring to  FIGS.  1 A to  48   , in Step ( 1600 ), cooling the augmenting cylinder  160   a  and boss cylinder  170  is performed. Next, in Step ( 1700 ), drilling the multi-functional through hole  162   a  of the augmenting cylinder  160   a  at the multi-functional opening  120   a , forming an intermediary interior  162   b , defining an intermediary cylindrical shaped wall  165   b , an intermediary base rim  166 , and an intermediary opening  120   b  is performed. Following, in Step ( 1800 ), tapping the intermediary interior  162   b  of the augmenting cylinder  160   b  at the intermediary opening  120   b , forming a second interior  162 , defining a second cylindrical shaped wall  165 , a base rim  166 , and a second opening  120  is performed. 
       FIG.  8 A  is a schematic interior view of the multi-material boss of  FIG.  1 A , following Step ( 1900 ) of the manufacturing method of  FIG.  3   , according to an exemplary embodiment.  FIG.  8 B  is a schematic top view of the multi-material boss of  FIG.  8 A , following Step ( 1900 ) of the manufacturing method of  FIG.  3   , according to an exemplary embodiment.  FIG.  8 C  is a schematic detailed cross-sectional view of the multi-material boss having a filler material layer (FML) therein of  FIG.  8 A , following Step ( 1900 ) of the manufacturing method of  FIG.  3   , according to an exemplary embodiment. Referring to  FIGS.  8 A to  8 C , and referring to  FIGS.  1 A to  7 B , Step ( 1900 ) comprises countersinking the second interior  162   b  of the augmenting cylinder  160   b  at the second opening  120   b , enlarging a top portion of the second opening  120   b  forming a conical depression  168 , configured for recessing a head of a fastener, whereby the fastener is fastened to the multi-material boss  100  via the second opening  120  of the augmenting cylinder  160  having the higher liquidus temperature and greater hardness. 
     Those having skilled in the relevant art may readily appreciate that additional ‘Steps’ may be added to the manufacturing method in order to incorporate additional features into the finished multi-material boss and the embodiments are not limited thereto. Also, the ‘Steps’ may be altered depending upon different requirements. 
     In some embodiments of the method, the feature of the die cast part  190  comprises a protruding feature extending from a surface  191  thereof. In some embodiments of the method, the die cast part  190  further comprises at least a strengthening member  185 , configured for providing strength and stability to the protruding feature of the multi-material boss  100 . In some embodiments of the method, the at least a strengthening member  185  comprises a spacer between the protruding feature of the multi-material boss  100  and surface  191  of the die cast part  190 . In some embodiments of the method, the shape of the spacer comprises at least one of straight lines, curves, or any combination of the foregoing. In some embodiments of the method, the shape of the spacer is quadrilateral. 
     In some embodiments of the method, the feature of the die cast part comprises at least one of a protruding feature encompassing the multi-material boss  100 , extending from an outer perimeter wall surface  191  of the die cast part, a protruding feature encompassing the multi-material boss  100 , extending from an inner perimeter wall surface or corner to a base of the die cast part, or any combination of the foregoing. 
     In some embodiments of the method, the strengthening member  185 , comprises a spacer  185  between the protruding feature of the multi-material boss  100  and surface  191  of the die cast part  190 ; however, the embodiments are not limited thereto. Those having ordinary skill in the relevant art may readily appreciate that the feature of the die cast part  190  may also comprise at least one of a gusset extending from an outer sidewall of the multi-material boss to a base of the die cast part, a rib extending from an outer sidewall of the multi-material boss to a wall of the die cast part, or any combination of the foregoing. 
     In some embodiments of the method, the die cast part  190  is made of an aluminum alloy material and the augmenting cylinder  160  is made of at least one of a stainless steel, iron, aluminum silicon alloy, copper, copper alloy, aluminum magnesium alloy material, having a second hardness greater than the first hardness of the boss cylinder  170 . 
     In some embodiments of the method, the die cast part  190  is made of an aluminum alloy material; however, the embodiments are not limited thereto. Those having ordinary skill in the relevant art may readily appreciate that the die cast part  190  may also be made of alternative materials suitably known in the art. As an example, in some embodiments of the method, the die cast part  190  is made of at least one of a zinc alloy, magnesium, zinc-aluminum alloy, copper, tin or lead material, or any combination of the foregoing. 
     In some embodiments of the method, the augmenting cylinder  160  is made of at least one of a stainless steel, iron, aluminum silicon alloy, copper, copper alloy, and aluminum magnesium alloy material; however, the embodiments are not limited thereto. Those having ordinary skill in the relevant art may readily appreciate that the augmenting cylinder  160  may be made of at least one of a stainless steel, iron, aluminum silicon alloy, copper, copper alloy, aluminum magnesium alloy material. As long as the second liquidus temperature and second hardness of the augmenting cylinder  160  is higher and greater than the first liquidus temperature and first hardness of the boss cylinder  170 , respectively. 
     In some embodiments of the method, the number of the multi-material bosses  100  is two or greater. 
     Bosses generally aid in the assembly of enclosures, acting as mounting points of the enclosures or other components. Screw bosses provide a channel for a screw for assembly. Despite screws being a reliable and inexpensive method of mechanical fastening, mounting point fastening failure often occurs due to wear-and-tear caused by multiple assembly, disassembly, and reassembly procedures. Generally, chipping or cracking caused by tensile stresses that can be induced under high pressure or cross threading, and the like, may result in fastening failure and/or decreased fastening effectiveness. 
     One technique developed for decreasing and/or mitigating fastening failure and decreased fastening effectiveness is to replace bosses with a more durable and harder material threaded insert or bushing. However, costs would be increased due to the pre-threaded part and additional costs for adhesives required for securing the threaded insert or bushing in place so it doesn&#39;t back out would also need to be incurred. 
     In the exemplary embodiments, a multi-material boss  100 , configured for fastening of a fastener (not shown) thereto, being a feature of a die cast part  190 , comprising a boss cylinder  170 , an augmenting cylinder  160 , and a filler metal layer FML is provided. The boss cylinder  170  is made of a same material as the die cast part  190  having a first liquidus temperature and a first hardness, and has a first interior  172  defined by a first cylindrical shaped wall  175 , and a first base  179 . The augmenting cylinder  160  is made of an augmenting material having a second liquidus temperature and a second hardness, is fixedly secured in the boss cylinder  170 , and has a second interior  162  defined by a second cylindrical shaped wall  165 , a base rim  166 , and a second opening  120 . The second liquidus temperature is higher than the first liquidus temperature and the second hardness is greater than the first hardness. The fastener is fastened to the multi-material boss  100  via the second opening  120  of the augmenting cylinder  160  having the higher liquidus temperature and greater hardness. 
     Thus, costs are not increased due to requirement of pre-threaded parts and additional costs for adhesives required for securing threaded inserts or bushings in place so it doesn&#39;t back out are also not incurred, whereby costs for pre-threaded parts are higher than costs for non-threaded parts. Furthermore, due to the multi-functional through hole  162   a , the press-insertion Step ( 1400 ) is facilitated, as air is conveniently exhausted through the multi-functional through hole  162   a  and does not get entrapped between the bottoms of the augmenting cylinder  160   a  and boss cylinder  170 . Additionally, due to the multi-functional through hole  162   a , expanding air and gasses due to the brazing or soldering process is conveniently vented, mitigating ejection of the augmenting cylinder  160   a  and allowing the filler metal to evenly wet, spread and adhere to the surfaces of the augmenting cylinder  160   a  and the boss cylinder  170 , facilitating capillary action for solid bonding. Also, due to the multi-functional through hole  162   a  already being provided in the augmenting cylinder  160   a , additional processes for drilling venting holes are eliminated. Additionally, due to the multi-functional through hole  162   a , concern is not required for sharp corners or blind holes causing flux entrapment, as proper venting is conveniently provided. 
     The presently disclosed inventive concepts are not intended to be limited to the embodiments shown herein, but are to be accorded their full scope consistent with the principles underlying the disclosed concepts herein. Directions and references to an element, such as “up,” “down,”, “upper,” “lower,” “horizontal,” “vertical,” “left,” “right,” and the like, do not imply absolute relationships, positions, and/or orientations. Terms of an element, such as “first” and “second” are not literal, but, distinguishing terms. As used herein, terms “comprises” or “comprising” encompass the notions of “including” and “having” and specify the presence of elements, operations, and/or groups or combinations thereof and do not imply preclusion of the presence or addition of one or more other elements, operations and/or groups or combinations thereof. Sequence of operations do not imply absoluteness unless specifically so stated. Reference to an element in the singular, such as by use of the article “a” or “an”, is not intended to mean “one and only one” unless specifically so stated, but rather “one or more”. As used herein, “and/or” means “and” or “or”, as well as “and” and “or.” As used herein, ranges and subranges mean all ranges including whole and/or fractional values therein and language which defines or modifies ranges and subranges, such as “at least,” “greater than,” “less than,” “no more than,” and the like, mean subranges and/or an upper or lower limit. All structural and functional equivalents to the elements of the various embodiments described throughout the disclosure that are known or later come to be known to those of ordinary skill in the relevant art are intended to be encompassed by the features described and claimed herein. Moreover, nothing disclosed herein is intended to be dedicated to the public regardless of whether such disclosure may ultimately explicitly be recited in the claims. No element or concept disclosed herein or hereafter presented shall be construed under the provisions of 35 USC 112f unless the element or concept is expressly recited using the phrase “means for” or “step for”. 
     In view of the many possible embodiments to which the disclosed principles can be applied, we reserve the right to claim any and all combinations of features and acts described herein, including the right to claim all that comes within the scope and spirit of the foregoing description, as well as the combinations recited, literally and equivalently, in the following claims and any claims presented anytime throughout prosecution of this application or any application claiming benefit of or priority from this application.