Abstract: Systems, methods, and apparatus for multifunctional battery packaging and insulation are disclosed. In one or more embodiments, a battery pack comprises a plurality of battery cells. The battery pack further comprises a block comprising a plurality of recesses formed within the block. In one or more embodiments, each of the recesses respectively houses one of the battery cells within the block. In at least one embodiment, the block comprises a low density ceramic fiber reinforced foam that is porous such that a gas or liquid may pass through the block to cool the battery pack. In one or more embodiments, at least a portion of the block is covered with a ceramic matrix composite (CMC) material comprising a ceramic slurry composite pre-impregnated (prepreg) with fibers. In some embodiments, the CMC material is cured via kiln firing the block.

Abstract: A casting device includes a bore formation core and a water jacket formation core. When a cavity is formed, gas existing in a space between both cores is suctioned through a flow path formed in the bore formation core under operation of a suctioning device. When the bore formation core is viewed from a side, this flow path exists above a virtual axial line that passes a center of the bore formation core and extends along a longitudinal direction of the bore formation core.

Abstract: Various embodiments include methods for densifying a melt infiltrated ceramic matrix composite (CMC) article, and a densified melt infiltrated CMC article formed thereby. Particular embodiments include a method including: providing a porous CMC preform within a first region of a casting apparatus; providing a molten densifier within a pressure head area of a second region of the casting apparatus, the first and second regions being operably connected and the molten densifier including at least one source of silicon; and applying a first pressure to the molten densifier within the pressure head, thereby infiltrating voids within the porous CMC preform with the molten densifier and forming a densified melt infiltrated CMC article.

Abstract: The present invention aims for obtaining a fuel rail for gasoline direct injection which can be used for the direct injection at a high fuel pressure of 50 MPa or more by increasing the thickness at the portion near the branch hole and using the material having high thickness for the metal seal portion while keeping the weight light and keeping the cost low. A fuel rail for gasoline direct injection made of steel and used at a fuel pressure of 50 MPa or more, the fuel rail having: a plurality of block members 2; and a pipe member 1 which connects an interval between the block members, wherein the block members 2 have: a branch hole 3 which communicates with the pipe member 1; and a metal seal portion 6 to which an injector is connected, and the hardness of the block members 2 is higher than the hardness of the pipe member 1.

Abstract: A lightweight, selectively degradable composite material is disclosed. The composite material comprises a compacted powder mixture of a first powder, the first powder comprising first metal particles comprising Mg, Al, Mn, or Zn, or an alloy of any of the above, or a combination of any of the above, having a first particle oxidation potential, a second powder, the second powder comprising low-density ceramic, glass, cermet, intermetallic, metal, polymer, or inorganic compound second particles, and a third metal powder, the third metal powder comprising third metal particles having an oxidation potential that is different than the first particle oxidation potential. The compacted powder mixture has a microstructure comprising a matrix comprising the first metal particles, the second particles and third particles dispersed within the matrix, the third particles comprising a network of third particles extending throughout the matrix, the composite material having a density of about 3.5 g/cm3 or less.

Abstract: A powder metal bearing support insert for casting into an engine component includes a pair of holes formed by interdigitated slots during a powder metal compaction process. Since they are formed by interdigitated slots, this pair of holes may receive the cast material therein during the casting step. Among other things, the cast material in these holes may be drilled or machined using tools graded to work the material of the casting in contrast to the material of the insert.

Abstract: A method for forming a product having cast-in components provides an insulating barrier of solidified sand formed next to the insider diameter of the cast-in component. The center of the solidified sand is hollow. Before pouring the molten metal into the primary runner/riser system that feeds the portion of the mold that will create the actual part, the molten material is poured into the hollow portion of the solidified sand through a separate runner/riser system. This molten metal provides the energy necessary to heat the cast-in part to an acceptable temperature. The temperature can be controlled by the shape, thickness and material of the insulating member. This controlled time/temperature profile enables the creation of a final cast product that demonstrates good quality properties at the cast/insert interface. The method of the disclosed inventive concept has the added benefit of not altering the resulting part itself.

Abstract: This piston includes a piston main body made of aluminum or an aluminum alloy, used in an internal combustion and a modified layer formed on a surface of a strength reinforced portion of the piston main body, having a surface made of aluminum oxide by plasma oxidation, to which compressive residual stress is applied.

Abstract: A manufacturing method of golf strike pad includes the following steps of shaping an embryonic form of the golf strike pad, solidifying the embryonic form of the golf strike pad, heating the solidified embryonic form of the golf strike pad, positioning the heated embryonic form of the golf strike pad in a mold, casting the melted aluminum-magnesium alloy into the mold, taking the blank of the golf strike pad from the mold and grinding the blank of the golf strike pad for finishing the manufacturing method.

Abstract: A method of removing voids from a casting is disclosed including the steps of introducing molten metal into a die, providing an impact surface and dropping the die containing the molten metal at least once from a predetermined height to strike the impact surface. A device for removing voids from a casting includes a base, a drive means operably coupled to at least one cam, and a guide configured to receive a die, wherein the at least one cam is positioned on the base to contact a die placed on the guide, and wherein rotation of the at least one cam is operable to raise and subsequently release the die to strike a surface of the base, and wherein the guide maintains the die in a stable orientation relative to a horizontal axis of the base.

Abstract: The present invention relates to a metal matrix composite (MMC). The MMC includes a preform formed from a composition having ceramic particles and ceramic fibers and defining a plurality of voids. The metal matrix composite also includes a support element, such as a metal, disposed within the voids of the preform. The MMC has a wear surface defined by both the preform and the support element.

Abstract: Embodiments of the present invention provide apparatus for forming a component from a solidified fluid medium. The apparatus comprises a body defining a cavity into which the fluid medium may be introduced, the cavity optionally being shaped to define a shape of the component, and a carrier for supporting one or more elements to be embedded in the component. The carrier is arranged to be introduced into the cavity to support the one or more elements within the cavity while the fluid medium is introduced into the cavity. Embodiments of the invention are useful in a range of fabrication technologies including casting of metals and injection molding operations.

Abstract: Provided are an indium target capable of achieving a high deposition rate while suppressing the occurrence of arcing, and a method for manufacturing the indium target. In the process of solidification at the time of melting and casting an indium ingot, ultrasonic vibration is applied to molten indium liquid which is at least in a state immediately before solidification, and thereby, coarsening of the grain size is suppressed. Thus, an indium target is provided An indium target in which an overall average grain size is 10 mm or less; for the grains observed from a cross-section parallel to a thickness direction, a ratio of an average grain size in a direction parallel to the thickness direction with respect to an average grain size in a direction perpendicular to the thickness direction is 0.7 to 1.1; and pores with a pore size of 50 ?m or greater exists at a density of 1 pore/cm3 or less.

Abstract: A metal matrix ceramic composite is completely formed by permeating at least part of a matrix metal into an array of ceramic granules by squeeze-casting, and the volume percentage of the ceramic granules may be adjusted within a range of 10%-80% of the metal matrix ceramic composite according to the usage requirements. The metal matrix ceramic composites not only retain high performance of anti-penetration, but also have the strong toughness of the metal; in addition, this composite has features of low density, resistance against ordinary mechanical cutting and flame cutting, and inhibition of crack propagation and the like. The composite has broad application prospects in the protection of such important security facilities as safes, automatic teller machines and vault gates.

Abstract: A connection structure that includes a region where at least a Cu—Sn intermetallic compound, a M-Sn intermetallic compound and a Cu-M-Sn intermetallic compound (where M is Ni and/or Mn) exist in a cross-section of a connecting part when the cross-section of the connecting part is analyzed with a WDX. Further, the connection structure is configured so that when the cross-section of the connecting part is evenly divided into ten sections in a vertical direction and a lateral direction, respectively, to form 100 segmentalized squares in total, a ratio of the number of squares in which two or more kinds of intermetallic compounds having different constituent elements exist to the number of all the squares, except for squares in which only a Sn-based metal component exists, is 70% or more.

Abstract: Disclosed is a brake disc manufactured from heterogeneous materials and a method for manufacturing the brake disc. The brake disc includes a friction part in which a connection hole is formed in a center, protrusions and recesses are alternately repeated along a circumference of the connection hole, the recess has a shape curved in an opposite direction of the connection hole. The brake disc also includes a hat part that is made of material different from that of the friction part, and has insertion grooves formed along an outer circumference so as to allow the protrusions to be inserted. Particularly, heat radiation holes are formed along the circumference of the connection hole at predetermined distance by connecting insertion parts of the protrusions to the insertion grooves of the hat part with a predetermined gap from an inner surface of the friction part. Also provided is a brake disc manufactured from heterogeneous materials having excellent durability.

Abstract: A method of making a turbomachine part, wherein the method can include machining a blank into a base having blades extending therefrom, the blades defining a channel therebetween. The method can also include forming a bridge constructed from refractory material in the channel between the blades, and forming a cover on the tops of the blades and over the channel, such that the base, the blades, and the cover form a single substantially homogenous turbomachine part once the bridge is removed.

Abstract: System and method of producing multi-layered aluminum alloy products are disclosed. A multi-layered aluminum alloy product may be formed by first heating a first aluminum alloy to a first temperature where the first temperature is at least about 5° C. lower than the eutectic temperature of the first aluminum alloy, second heating a second aluminum alloy to a second temperature where the second temperature is at least about 5° C. higher than the liquidus temperature of the second aluminum alloy, and coupling the second aluminum alloy to the first aluminum alloy to produce a multi-layered aluminum alloy product.

Abstract: A composite ballistic armor or other composite component may be formed by encapsulating one or more ceramic elements in a casting shell and introducing molten base metal into the casting shell, such that the molten base metal encapsulates the one or more ceramic elements to form the composite component. Prior to the pouring process, the ceramic elements are pre-heated to, or near, the melting point temperature or pouring temperature of the encapsulating metal. Additionally, the cooling rate following the metal pour may be less than a predetermined rate for a predetermined period of time. The encapsulating metal may comprise, for example, a steel alloy, such as 4140 or 8630 AISI, a stainless steel alloy, or FeMnAl.

Abstract: A cast component having localized areas of improved physical properties is disclosed. The component may initially be produced having a void portion in a predetermined area requiring improved physical properties. A second molten material may be added to the void portion such that it chemically bonds to the void portion. The component may then be finished such to a final shape with a localized area of improved physical properties.

Abstract: A method for forming a rotor assembly including a cast rotor frame includes positioning a preheated rotor core defining a plurality of passages in a mold cavity such that the mold cavity and the rotor core define the rotor frame including a plurality of conductor bars defined by the plurality of passages in fluid communication with first and second end portions of the mold cavity. Molten metal is quiescently introduced into the mold cavity through an ingate and simultaneously flowed through the plurality of passages prior to filling at least one of the first and second end portions of the mold cavity to form the cast rotor frame. Entrained air and impurities may be displaced from the passages by the flow of molten metal and vented or entrapped by a biscuit. The rotor frame and conductor bars thus formed may be characterized by high conductivity, negligible porosity, and minimal oxides.

Abstract: A rotor for an induction motor and a method of preparing same. The method includes making a squirrel-cage rotor made up of a cage and a laminate stack by forming a mold around the stack, heating the stack and introducing a molten metal into the mold such that the molten metal substantially fills a space defined in the stack that corresponds to the cage. In one form, the space includes slots or related channels formed in the stack that upon filling with the molten metal become longitudinal bars that form electric current loops with end rings of the cage. By heating the stack and maintaining it at a temperature high enough to keep the molten metal in a substantially molten state at least long enough for it to flow through the slots of the stack, premature freezing of the molten metal is avoided. In addition, by providing low pressure to the molten metal in conjunction with the elevated temperature in the stack, flow is promoted to ensure a substantially porosity-free, fully dense squirrel-cage for the rotor.

Abstract: A casting machine system includes a first casting machine and a separate second casting machine, wherein the first casting machine is a metal-casting machine and the second casting machine is a plastic-casting machine, or the first casting machine is a plastic-casting machine and the second casting machine is a metal-casting machine. An associated process produces hybrid metal/plastic articles. The casting machine includes a transfer device for transferring a precursor product, produced by a first casting process in the first casting machine, to the second casting machine, in which a hybrid metal/plastic component is formed from the precursor product by a second casting process, and a temperature-regulating device for regulating the temperature of the precursor product in a controllable manner after its removal from the first casting machine, and before starting the second casting process.

Abstract: A brake disc is disclosed which includes a friction unit having a coupling aperture formed at a center thereof, insert protrusions and depressions which are provided in a sawtooth formation at predetermined intervals along a circumference of the coupling aperture, wherein chamfers are formed at a predetermined angle on one or more of the upper and lower surfaces of the insert protrusions, and first locking parts locked into upper or lower spaces of the depressions. A hat unit, formed of a material different from that of the friction unit, coupled to the coupling aperture of the friction unit, and including insert recesses formed along a circumference thereof so that the insert protrusions are fitted therein, and second locking parts formed at predetermined intervals in the insert recesses so that they are inserted into the depressions and engage with the first locking parts, and to a method of producing the same.

Abstract: A procedure for centrifugally casting a shorted structure around induction motor rotors is described. The method is commonly applied to a plurality of rotors disposed and arranged for rotational balance and supported on a suitable support, or optionally, on a plurality of supports arranged in layered fashion about a common rotational axis. The method comprises forming a wax representation of the shorted structure around a lamination stack; mounting a plurality of such lamination stacks in a mounting fixture and-attaching a suitable gating and runner system; forming an investment by coating the structure with refractory followed by melting out the wax; casting molten metal into the investment while it is rotating and aligning the mold to allow the centrifugal force generated to promote mold filling; and, continuing to rotate the investment until solidification is substantially complete.

Abstract: A method of forming a coated article is disclosed. The method involves heating a magnesium alloy component, positioning the component in a mold such that a gap exists between component outer surfaces and mold inner surfaces, and heating a magnesium-containing alloy material above its melting temperature, which is lower than that of the component. The material is formed from magnesium alloyed with i) the component element, but at a higher concentration, ii) at least one element that is different than the component element, or iii) the component element and at least one other element. The method further includes introducing the material into the gap, thereby covering at least the outer surfaces of the component, and cooling the material to form a substantially evenly distributed solidified coating on the outer surfaces of the component. The coating has a higher wear and/or corrosion resistance than that of the magnesium alloy component.

Abstract: A cast component having localized areas of improved physical properties is disclosed. The component may initially be produced having a void portion in a predetermined area requiring improved physical properties. A second molten material may be added to the void portion such that it chemically bonds to the void portion. The component may then be finished such to a final shape with a localized area of improved physical properties.

Abstract: In a cylinder block manufacturing method, first and second dies and a liner support are provided to form a liner overcast configuration. The first and second dies are positioned with respect to the liner support and a dummy cylinder liner made of an aluminum alloy such that the first die contacts a pressing section of a first axial end of the liner support and a first axially facing end of the dummy cylinder liner, and the second die contacts a second axial end of the liner support and a second axially facing end of the dummy cylinder liner. The first and second dies are preheated to a prescribed temperature with the dummy cylinder liner positioned on the liner support by injecting molten aluminum alloy into a cylinder block molding cavity to form a dummy cylinder block with the dummy cylinder liner casted in the dummy cylinder block.

Abstract: Disclosed are a bonded product, and a manufacturing method and manufacturing device therefor. To obtain a bonded product formed of a solidified material of a molten metal which has been poured into a forming mold with a workpiece, all or part of which is already held therein, or formed of a semi-solidified slurry which is contained in the forming mold together with the workpiece, the semi-solidified slurry or the molten metal is relatively made to flow on the end faces of the workpiece while friction sufficient to break the passive state existing at the surface of the molten metal or the semi-solidified slurry is generated between the workpiece and the semi-solidified slurry or the molten metal.

Abstract: A method including positioning an insert in a vertical mold including a first mold portion and a second mold portion; and casting a material including a metal around at least a portion of the insert.

Abstract: A method is described for producing a stratified composite material, with a melt of a layer material being cast progressively in a forward feed direction onto a strip-like metal carrier which is heated to a treatment temperature required for the bonding with the layer material and is cooled below the melting temperature after the casting via the metal carrier. In order to provide advantageous casting conditions it is proposed that the metal carrier is heated continuously with a temperature profile prior to the casting of the melt of the layer material in the forward feed direction, which temperature profile decreases towards lower temperatures from a maximum temperature below the treatment temperature in the region of a surface layer receiving the melt towards a core layer of the metal carrier, and that the metal carrier is heated in a surface layer by the melt to the treatment temperature upon casting of the melt which is overheated for this purpose.

Abstract: A method is described for producing a stratified composite material, with a layer of sinterable solids particles being applied to a strip-like metal carrier and being sintered with liquid phase by the supply of heat continuously in the forward feed direction. In order to provide simplified production conditions it is proposed that the metal carrier is heated continuously in the forward feed direction with a temperature profile which decreases towards lower temperatures from a maximum temperature above the melting temperature of the solids particles in the region of a surface layer receiving the particle layer towards a core layer of the metal carrier, and that the particle layer is sintered at least in a layer resting on the metal carrier by a heat transmission from the heated metal carrier.

Abstract: This invention relates generally to a method for repairing a casting, and more specifically to a method of repairing a casting by pouring melted filler material into a damaged portion of the original casting. Damaged cast metal components, such as a cylinder head of an internal combustion engine are repaired by preheating the component to a first preheat temperature. The damaged area of the casting is then heated to a higher temperature using a torch and melted filler material is poured into the casting. The torch is used to maintain the temperature of the melted material for thirty seconds to two minutes. The temperature of the filler material is then cooled using compressed air.

Abstract: A method for the manufacture of a three-dimensional object includes the steps of forming a mixture that contains a binder and a least one of aluminum or a first aluminum-base alloy into a green composite, removing the binder from said green composite, forming a porous perform structure, reacting the aluminum or first aluminum base alloy with nitrogen to form a rigid and continuous skeleton and infiltrating the porous structure with molten aluminum or second aluminum base alloy to form the three-dimensional object with near theoretical density. The green composite may be formed by an additive process such as computer aided rapid prototyping, for example, selective laser sintering. The method facilitates the rapid manufacture of aluminum components by an inexpensive technique that provides high dimensional stability and high density.

Abstract: A method for preparing engine block cylinder bore liners is disclosed, the method including preconditioning of the cylinder bore liners for use in sand casting of engine cylinder blocks, wherein an efficiency of the preconditioning process is maximized, a metal pour temperature is minimized, and material properties of the casting are optimized.

Abstract: A method for the manufacture of a three-dimensional object includes the steps of forming a mixture that contains a binder and a least one of aluminum or a first aluminum-base alloy into a green composite, removing the binder from said green composite, forming a porous preform structure, reacting the aluminum or first aluminum base alloy with nitrogen to form a rigid skeleton and infiltrating the porous structure with molten aluminum or second aluminum base alloy to form the three-dimensional object with near theoretical density. The green composite may be formed by an additive process such as computer aided rapid prototyping, for example selective laser sintering. The method facilitates the rapid manufacture of aluminum components by an inexpensive technique that provides high dimensional stability and high density.

Abstract: A process for the injection of an electric motor rotor, said rotor comprising: a lamination stack (10) having a central axial bore (11) and a plurality of axial channels (12); and a cage (30) of aluminum, which is formed by an upper end ring (31) and a lower end ring (32), which are interconnected by a plurality of bars (33) molten in the axial channels (12).

Abstract: A sink compound laminate molding process having a copper material in thickness of 0.1-0.8 mm placed at the bottom of the molding cavity with the bottom of the copper laminate fully bound to the bottom of the molding cavity, the copper being heated up to 300-600° C., and molten aluminum being filled into the molding cavity using a gravity casing process to create diffusion bonding to the interface between the copper and aluminum materials, molten aluminum being cooled and cured to avail an integrated compound laminate in a given profile of heterogeneous copper and aluminum.

Abstract: A method for the manufacture of a three-dimensional object includes the steps of forming a mixture that contains a binder and a least one of aluminum or a first aluminum-base alloy into a green composite, removing the binder from said green composite forming a porous preform structure and infiltrating the porous structure with a molten second aluminum base alloy to form the three-dimensional object with near theoretical density. The green composite may be formed by an additive process such as computer aided rapid prototyping, for example selective laser sintering. The method facilitates the rapid manufacture of aluminum components by an inexpensive technique that provides high dimensional stability and high density.

Abstract: The present invention provides a method and apparatus for die-casting copper and other metals that are cost-effective and practical for production use in die-casting, for example, copper motor rotors. In motor rotors, the incorporation of die-cast copper for conductor bars and end rings in place of aluminum is known to result in improvements in motor energy efficiency. Previous attempts to die-cast copper motor rotors in a commercially feasible manner have failed because copper's high melting point places too great a stress on the die material, resulting in cracking and fracturing of the molds. High temperature die materials such as nickel, tungsten and molybdenum based alloys with a high melting point are employed, and a die casting apparatus is provided to pre-heat the molds prior to injection of the molten copper. Pre-heating and high operating temperatures provide extended die life.

Abstract: A process for producing a tube target for cathode sputtering plants, in which the tube target is formed from a metallic inner tube (target holder) made of a first material with a first melting point of Ts1≧900 K and a metallic outer tube (target) that concentrically surrounds the inner tube and that is made of a second material with a second melting point of Ts2≦800 K. The inside diameter of the outer tube and the outside diameter of the inner tube are proportioned in such a way that the two tubes fit together tightly and are mechanically firmly joined. The outer tube is formed by casting the second material in a molten state in a heated, vertical, cylindrical permanent mold, which has a heated mandrel that constitutes the inner tube.

Abstract: A method and apparatus for molding wind chimes reduces the likelihood that a glass insert will fracture when they are placed in a mold and the mold is charged with molten metal. The casting temperature of the molten metal is adjusted to compensate for the surface area of the glass insert that is contacted by the molten metal. The glass insert are annealed prior to molding. A flexible mold is utilized. The tolerances of the glass insert are carefully controlled. The molded wind chime is carefully cooled.

Abstract: The present invention provides a method and apparatus for die-casting copper and other metals that are cost-effective and practical for production use in die-casting, for example, copper motor rotors. In motor rotors, the incorporation of die-cast copper for conductor bars and end rings in place of aluminum is known to result in improvements in motor energy efficiency. Previous attempts to die-cast copper motor rotors in a commercially feasible manner have failed because copper's high melting point places too great a stress on the die material, resulting in cracking and fracturing of the molds. High temperature die materials such as nickel, tungsten and molybdenum based alloys with a high melting point are employed, and a die casting apparatus is provided to pre-heat the molds prior to injection of the molten copper. Pre-heating and high operating temperatures provide extended die life.

Abstract: A ceramic-metal composite that is tough and stiff has been prepared and is comprised of an inert ceramic (e.g., alumina) embedded and dispersed in a matrix comprised of a metal (e.g., aluminum), a reactive ceramic (e.g., boron carbide) and a reactive ceramic-metal reaction product (e.g., AlB2, Al4BC, Al3B48C2, AlB12, Al4C3, AlB24C4 or mixtures thereof) wherein grains of the inert ceramic have an average grain size greater than or equal to the average grain size of grains of the reactive ceramic. The ceramic-metal composite may be prepared by forming a mixture comprised of an inert ceramic powder (e.g., alumina) and a reactive ceramic powder (e.g., boron carbide), the inert ceramic powder having an average particle size equal to or greater than the average particle size of the reactive ceramic powder, forming the mixture into a porous body and consolidating the porous body in the presence of a metal (e.g., aluminum) to form the ceramic-metal composite.

Abstract: The cylinder head for internal combustion engines is produced by pouring liquid cylinder head material, especially aluminum, into a cylinder head mold containing a mold core having stepped sections in the region of the valve seat ring and the valve guide. The valve seat rings and valve guides are produced from a conventional material based on steel or copper by pressing and sintering in such a way that they have an open pore volume of 5 to 15%, a valve seat and/or a valve guide are laid on the stepped sections of the mold core, whereafter liquid aluminum is poured into the preheated mold and the mold core is removed in the conventional way after the molten aluminum has solidified.

Abstract: The aim is to improve the strength of an intermetallic bond between engine component made from an aluminium alloy and a reinforcing element made from austenitic cast iron. For that purpose, the reinforcing element is annealed in a decarbonising atmosphere before the known prior art alfin process is carried out, in order to obtain an alfin layer largely free of graphite scales.

Abstract: A mold with a cylindrical sidewall, is provided. A shell is positioned around the sidewall. The shell is heated to between 500 and 1,000 F. Molten iron alloy between 2550 and 2650.degree. F. is poured into the mold. The resulting composite brake drum is cooled and cleaned. The method of casting includes positioning a brake drum shell around a mold defining a cavity interior of the shell, heating the shell, pouring molten iron alloy into the mold to fill the cavity and cooling and cleaning the composite brake drum.

Abstract: An aluminum-based composite member having an increased strength of bond between an aluminum-based body and a cast iron material portion which is incorporated into the aluminum-based body by casting is provided by an improved process. The following steps are employed in the process: a step of removing an oxide film on the surface of the cast iron material portion and activating such surface; a step of forming a protecting plated-layer having a thickness a in a range of 0.8 .mu.m.ltoreq.a.ltoreq.5 .mu.

Abstract: Methods for semisolid manufacturing of precision parts, turbine rotors for example, comprised of a plurality of high melting point alloys are given. Generally, a semisolid/thixotropic process is operated under vacuum utilizing a heated mold. The process preferably comprises a vacuum chamber, inductive heaters to bring two or more high melting point slugs to a either a solid or thixotropic phase, and a plunger that accelerates and injects a high melting point slug into the heated mold containing one or more solid or thixotropic slugs. The semisolid solution is eliminated as the completed forged assembly cools. Thixotropic forging of a multi-alloy assembly tailors its mechanical properties to achieve optimized properties in specific locations of the final product.

Abstract: In carrying out a cast-in process, a cast-in insert member is placed into a cast forming cavity in a casting mold, and a casting is conducted. The cast-in insert member has a barrier layer on its non-deposited surface for inhibiting the deposition of a molten metal. During casting, a portion of a molten metal is introduced to a heating chamber on the side of the barrier layer to come into contact with the barrier layer. Thus, the cast-in insert member can be heated not only from the side of its deposited surface, but also from the side of its non-deposited surface, thereby providing an enhanced strength of deposition of the cast-in insert member.