Abstract: Methods for making a tribological bearing wear surface for a compressor component are provided. Such methods involve semi-solid metal casting, where an admixture of solid lubricant particles and a metal alloy material is heated to melt the metal alloy material, while the lubricant particles remain in a solid phase. The alloy material and solid lubricant have substantially different densities. The metal alloy material may be a copper, iron, or aluminum alloy, for example. The method further comprises mixing and cooling the admixture to form a semi-solid slurry admixture. Next, the method comprises introducing the semi-solid slurry admixture into a die. Finally, the semi-solid slurry admixture in the die is solidified to form a solid component having the solid lubricant particles homogenously distributed within a metal alloy material matrix, thus forming a metal matrix composite. Compressor components made from such methods are also provided.

Abstract: Methods for making a tribological bearing wear surface for a compressor component are provided. Such methods involve semi-solid metal casting, where an admixture of solid lubricant particles and a metal alloy material is heated to melt the metal alloy material, while the lubricant particles remain in a solid phase. The alloy material and solid lubricant have substantially different densities. The metal alloy material may be a copper, iron, or aluminum alloy, for example. The method further comprises mixing and cooling the admixture to form a semi-solid slurry admixture. Next, the method comprises introducing the semi-solid slurry admixture into a die. Finally, the semi-solid slurry admixture in the die is solidified to form a solid component having the solid lubricant particles homogenously distributed within a metal alloy material matrix, thus forming a metal matrix composite. Compressor components made from such methods are also provided.

Abstract: A die casting system includes a vessel defining a reservoir with a controlled heater and an agitator for maintaining the bath of semi-solid metal in a homogeneous isothermal state, a transfer system capable of transferring a known quantity of metal in its semi-solid state to a mold cavity in a die casting machine, the transfer system including a heated suction tube, a vacuum source for vacuum ladling semi-solid metal from the bath to a die, and a plunger tip providing a path for free air flow to allow evacuation of the suction tube during casting and a metal replacement system for replacing the known quantity of transferred metal with a similar amount of liquid metal so that a stable homogeneous isothermal bath of semi-solid metal is controllably maintained to be available for die casting operations.

Abstract: A die casting system includes a vessel defining a reservoir with a controlled heater and an agitator for maintaining the bath of semi-solid metal in a homogeneous isothermal state, a transfer system capable of transferring a known quantity of metal in its semi-solid state to a mold cavity in a die casting machine, the transfer system including a heated suction tube, a vacuum source for vacuum ladling semi-solid metal from the bath to a die, and a plunger tip providing a path for free air flow to allow evacuation of the suction tube during casting and a metal replacement system for replacing the known quantity of transferred metal with a similar amount of liquid metal so that a stable homogeneous isothermal bath of semi-solid metal is controllably maintained to be available for die casting operations.

Abstract: A die casting system includes a vessel defining a reservoir with a controlled heater and an agitator for maintaining the bath of semi-solid metal in a homogeneous isothermal state, a transfer system capable of transferring a known quantity of metal in its semi-solid state to a mold cavity in a die casting machine, the transfer system including a heated suction tube, a vacuum source for vacuum ladling semi-solid metal from the bath to a die, and a plunger tip providing a path for free air flow to allow evacuation of the suction tube during casting and a metal replacement system for replacing the known quantity of transferred metal with a similar amount of liquid metal so that a stable homogeneous isothermal bath of semi-solid metal is controllably maintained to be available for die casting operations.

Abstract: An apparatus and process is provided for producing semi-solid material and directly casting the semi-solid material into a component wherein the semi-solid material is formed from a molten material and the molten material is introduced into a container. Semi-solid is produced therefrom by agitating, shearing, and thermally controlling the molten material. The semi-solid material is maintained in a substantially isothermal state within the container by appropriate thermal control and thorough three-dimensional mixing. Extending from the container is a means for removing the semi-solid material from the container, including a temperature control mechanism to control the temperature of the semi-solid material within the removing means.

Abstract: An apparatus and process is provided for producing a semi-solid material suitable for directly casting into a component wherein the semi-solid material is formed from a molten material and the molten material is introduced into a container. Semi-solid is produced therefrom by agitating, shearing, and thermally controlling the molten material. The semi-solid material is maintained in a substantially isothermal state within the container by appropriate thermal control and thorough three dimensional mixing. Extending from the container is a means for removing the semi-solid material from the container, including a temperature control mechanism to control the temperature of the semi-solid material within the removing means.

Abstract: An apparatus and process is provided for producing semi-solid material and directly casting the semi-solid material into a component wherein the semi-solid material is formed from a molten material and the molten material is introduced into a container. Semi-solid is produced therefrom by agitating, shearing, and thermally controlling the molten material. The semi-solid material is maintained in a substantially isothermal state within the container by appropriate thermal control and thorough three-dimensional mixing. Extending from the container is a means for removing the semi-solid material from the container, including a temperature control mechanism to control the temperature of the semi-solid material within the removing means.