Abstract: A method of die casting spheroidal graphite cast iron able to prevent formation of chill crystals to allow the crystallization of fine spheroidal graphite and simultaneously prevent the formation of internal defects, including the steps of preparing a die formed with a heat insulation layer at inside walls of a cavity, filling molten metal having a composition of the spheroidal graphite cast iron through a runner into the cavity, closing the runner so as to seal the cavity right before the molten metal in the cavity starts to solidify, and allowing the molten metal to solidify by the action of the inside pressure caused by crystallization of the spheroidal graphite in the sealed cavity.

Abstract: Provided herein is a method for refining primary silicon present in a hypereutectic aluminum silicon alloy. The method contemplates the controlled application of pressure to refine the primary silicon during the casting of articles. The application of pressure decreases the primary silicon particle size to improve the machinability and wear resistance of the final cast articles.

Abstract: An apparatus and method for enhanced gravity casting wherein a portion of the mold is maintained in pressure contact with molten metal as it solidifies to allow the mold surface to follow the contraction of the solidifying metal. A further feature of the invention is the use of an air clearance between mold parts that is sufficient to allow air to escape but insufficient to allow molten metal to flow therepast.

Abstract: A pound or number sign shaped (#-shaped) die cast sub-frame includes first and second horizontal members and first and second vertical members. The sub-frame has four arm mounting portions provided at four corners thereof, respectively. The arm mounting portion is a die cast part obtained near a communication portion of a runner formed in a die casting machine. Generally triangular bulged portions are formed at junction portions where the first horizontal member meets the first and second vertical members. Each junction portion has increased width. The junction portion is a die cast obtained within a cavity of increased width of the die casting machine. The bulged portion is pierced to provide a hole. The bulged portion having the hole formed therein is to be mounted to a small vehicle component.

Abstract: A closed system and method that includes a source of pressurizeable molten lead connected to a mold having a mold cavity therein with the mold maintainable at sufficiently low temperature so that a charge of molten lead located in the mold cavity solidifies to thereby form a solidified casting in the mold cavity. A housing having a runner, is maintainable at sufficiently high temperature to maintain the molten lead in a molten state so that the mold cavity can be refilled with a fresh charge molten lead when a solidified casting is removed therefrom without introducing air to the closed system. A shut-off valve, having an open position to allow a charge of molten lead to flow into the mold cavity and a closed position to prevent molten lead from flowing out of the runner as the molten lead in mold cavity solidifies with the shut-off valve configurable to intensify the pressure of the lead in the mold cavity.

Abstract: The newly proposed cast aluminum alloy product has the composition consisting of 6.5-8.0% Si, 0.25-0.45% Mg, 0.08-0.40% Fe, 0.001-0.01% Ca, P less than 0.001%, 0.02-0.1% Ti, 0.001-0.01% B, optionally one or two of 0.05-0.3% Cr and 0.05-0.2% Mn, and the balance being Al except inevitable impurities. It has the metallurgical structure that an ?-Al phase in a surface layer is of average grain size different by 50 ?m or less from an ?-Al phase in an inner part, and that a maximum size of eutectic Si particles is 400 ?m or smaller. It is manufactured by injecting a molten aluminum alloy into metal dies at an injection speed of 0.05-0.25 m/second, and then cooling the injected alloy at a cooling speed of 20° C./or higher in a temperature range between liquidus and solidus curves in a state charged with a pressure of 30 MPa or higher. Since the cast product is good of ductility, it is used as a member for coupling another member therewith by calking or the like.

Abstract: An apparatus and method for pressure casting a battery part wherein an extendible piston includes sidewalls for shutting off the supply of molten lead and an impact surface that extends in a side-to-side condition to form an end surface of a battery part cavity so that when the extendible piston is brought into an intensifying condition the extendible piston shuts off further supply of molten metal while a heat source maintains the lead in a molten state as the impact surface of the piston forms a side-to-side mold cavity surface to complete the mold cavity surface thereby eliminating unevenness in the surface of the finished battery part by generating a force with the extendible piston which is sufficient to form a battery part so that upon removal from the mold the batter part is substantially free of tears and cracks as well as surface irregularities.

Abstract: An iron based alloy material for a thixocasting process and a method for casting the material which extends the service life of dies by inhibiting solidification contraction, and in which casting defects such as size variations and cracks can be inhibited. The material comprises 1.6 wt %?C?2.5 wt % and 3.0 wt %<Si?5.5 wt %, and a carbon equivalent (the value of CE) defined as “C(wt %)+?Si(wt %)” of 2.9 to 3.5. This material is made to be in a half-melted state with 35 to 50 wt % of a solid phase to be cast under a pressure load.

Abstract: A high pressure die casting method including providing first and second accumulator assemblies, wherein the first accumulator assembly provides pressurized fluid toad die assembly while the second accumulator assembly provides pressurized fluid to remaining portions of the die casting machine. A barrel insert loader inserts cylinder barrels into the die assembly, and then the dies are closed to permit molten aluminum to be injected therein and thereby form the cast engine block. The dies include side gates and sub-gates through which molten aluminum is introduced into the mold. The dies are opened, and the cast engine is removed from the dies by operation of a robot arm, and a die spraying assembly is inserted between the open dies and sequentially sprays the dies, to clean and cool the dies in preparation for a subsequent casting operation.

Abstract: It is necessary for the stroke of squeeze pin to be controlled so as to reach a defined target stroke position or zone during each shot operation of a die-casting machine. To achieve such control of squeeze pin, controlled variables T, Q or P are set in a trial molding process. The setting operation of the controlled variable is executed in a short time automatically. In case of adopting flow rate Q supplied to the squeeze cylinder as a controlled variable, the initial setting value Q1 is defined as 50% with conversion of opening degree of a flow control valve. Then, if the stroke of the pin is out of target, flow rate Q2 is set, which is defined as 75% corresponding to a intermediate value between the maximum degree of opening 100% and 50% at Q1. In a similar way, flow rates Q3, Q4, Q5 are set, namely, each Q3, Q4, Q5 is defined as the intermediate value between controlled variables set in consecutive two shots ahead. In case of Q5 the detected stroke of the squeeze pin is within the target stroke zone.

Abstract: Method and apparatus for making a cast product shape using a die casting method wherein a molten metallic material is introduced into a shot sleeve having an end that is closed by a movable closure member. The molten metallic material is forced by movement of a plunger in the shot sleeve to the closed end of the shot sleeve where the plunger maintains pressure on the metallic material until it is at least partially solidified in the shot sleeve in the form of a cast product having a outer peripheral shape corresponding to the inner peripheral shape of the shot sleeve. The end of the shot sleeve then is opened by relative movement of the closure member and the shot sleeve, and the plunger is moved further to eject the product shape from the open end of the shot sleeve.

Abstract: Methods and materials for preparing investment molds useful in pressure infiltration casting of near net-shape metal or metal matrix composite (MMC) components. One embodiment of the invention includes disposing a slurry of an appropriately sized refractory material and a vehicle around a preform or fugitive pattern, removing the bulk of the vehicle, then curing/drying the refractory material to create an investment mold of the invention. Subsequently, pressure infiltration casting with a molten infiltrant using the investment mold permits infiltration of the mold cavity and/or preform without infiltration of the investment mold. As a result, the investment mold readily is removed to provide the near net-shape metal or MMC component. In other embodiments of the invention, a non-fugitive pattern is used, typically with a modified refractory cement of the invention.

Abstract: An apparatus for producing toe caps for safety shoes and the like made of aluminum, aluminum alloys and light alloys in general, comprising a bottom die and a top die which can be associated with respective platens and can be mated so as to form at least one impression. The apparatus further comprises at least one male plug that can be inserted in the impression in order to form the shape of the part being formed and is suitable to act as a flow control element for the duct for introducing the liquid metal in the impression.

Abstract: An apparatus and method for pressure casting a battery part wherein an extendible piston includes sidewalls for shutting off the supply of molten lead and an impact surface that extends in a side-to-side condition to form an end surface of a battery part cavity so that when the extendible piston is brought into an intensifying condition the extendible piston shuts off further supply of molten metal while a heat source maintains the lead in a molten state as the impact surface of the piston forms a side-to-side mold cavity surface to complete the mold cavity surface thereby eliminating unevenness in the surface of the finished battery part by generating a force with the extendible piston which is sufficient to form a battery part so that upon removal from the mold the batter part is substantially free of tears and cracks as well as surface irregularities.

Abstract: In order to impregnate a porous workpiece with a liquid impregnating agent, the pre-manufactured workpiece is arranged in an injection mould or diecasting mould and the liquid impregnating agent is introduced into the mould with the aid of a commercially available injection moulding or diecast moulding apparatus. To limit the need for post impregnation cleaning and/or shaping, the mould cavity is configured to closely fit the shape of the pre-manufactured workpiece. The impregnating agent may be a natural or synthetic lubricant, a plastic or, more commonly, a molten metal or metal alloy.

Abstract: An apparatus and method for pressure casting a battery part wherein at least one of the mold members forming the surfaces of an internal battery part cavity are displaced with respect to one another to reduce the volume of the mold cavity formed between the two parts to thereby intensify the pressure sufficiently high pressure so as to inhibit the formation of cracks and tears in a cast part.

Abstract: An impermeable ceramic mold is disposed within a steel die and used in a process for pressure casting of elevated melting temperature alloys and pressure infiltration casting of elevated melting temperature alloys having wear resistant particles, included therewith. The ceramic mold provides an insulation layer between the molten metal and the steel die, and prevents welding between the molten metal and the die. The alloy steel die encloses the ceramic mold and provides the strength needed to resist the pressures generated during pressure infiltration casting.

Abstract: Molten metallic material is cast into a mold that is made with a barrier to reduce gas permeability through a mold wall that forms on its innermost side a mold surface for contacting the molten metallic material. The molten metallic material is gravity cast into the mold residing in a furnace in a casting chamber under a first pressure, such as subambient pressure. Then, a gaseous pressure is provided in the casting chamber higher than the first pressure rapidly enough to reduce or eliminate the presence of localized voids in the casting solidified in the mold.

Abstract: A manufacturing process for casting amorphous metallic parts separates the filling and quenching steps of the casting process in time. The mold is heated to an elevated casting temperature at which the metallic alloy has high fluidity. The alloy fills the mold at the casting temperature, thereby enabling the alloy to effectively fill the spaces of the mold. The mold and the alloy are then quenched together, the quenching occurring before the onset of crystallization in the alloy. With this process, compared to conventional techniques, amorphous metallic parts with higher aspect ratios can be prepared.

Abstract: The invention relates to a method for producing a composite structure in which a foamed metal core (1) is surrounded with a metal body (3). Said method comprises the following steps: a) producing a foamed metal core (1) with an essentially closed surface; b) introducing the foamed metal core (1) into a pressure diecasting mould; c) filling said pressure diecasting mould at a first casting pressure (p1); d) reducing said first casting pressure (p1) before the pressure diecasting mould has been filled; e) filling the pressure diecasting mould entirely, the first casting pressure (p1) being reduced to zero or almost zero; and f) applying a second casting pressure (p2) and maintaining this for a predetermined holding period.

Abstract: A closed system and method that includes a source of pressurizeable molten lead connected to a mold having a mold cavity therein with the mold maintainable at sufficiently low temperature so that a charge of molten lead located in the mold cavity solidifies to thereby form a solidified casting in the mold cavity. A housing having a runner, is maintainable at sufficiently high temperature to maintain the molten lead in a molten state so that the mold cavity can be refilled with a fresh charge molten lead when a solidified casting is removed therefrom without introducing air to the closed system. A shut-off valve, having an open position to allow a charge of molten lead to flow into the mold cavity and a closed position to prevent molten lead from flowing out of the runner as the molten lead in mold cavity solidifies with the shut-off valve configurable to intensify the pressure of the lead in the mold cavity.

Abstract: An apparatus and method for pressure casting a plurality of battery terminal wherein the molten lead is prevented from entering the mold cavities until molten lead is present by the inlets of all the mold cavities with the inlets to the molds simultaneously opened to allow molten lead therein and simultaneously closed with the volume of each of the mold cavities in each of the mold cavities is quickly reduced to thereby cause the molten lead solidifies under the reduced volume and high pressure produces a battery terminal that is substantially free of both tears and cracks.

Abstract: Precision castings, such as brake calipers and other parts requiring a fine finish and having complex internal geometries, can be produced by casting a shot of a semi-solid thixotropic metal alloy about a core, preferably a hot-chamber die-cast core, having a lower melting point than the solid-to-semi-solid transition temperature of the thixotropic alloy. Then, after the shot solidifies to form a casting with a captured core, the core is melted from the casting in a liquid bath, in an air furnace, or during other heat treatment of the part. The process dramatically reduces or even eliminates machining requirements for cast metal parts because the inner surface of the casting is of extremely low porosity and meets stringent tolerance requirements and because the melt-away core can be formed with protrusions that prevent mechanical removal of the core from the casting and that form undercuts, threads, bores, etc. in the casting.

Abstract: A process for producing an aluminum alloy semi-molten billet for use as a transporation unit, including the steps of: producing an aluminum alloy having a composition consisting essentially of, in weight %, 0.5 or less Cu, 5.0 to 10.0 Si, 0.2 to 0.7 Mg, 0.35 or less Zn, 0.55 or less Fe, 0.5 or less Mn, 0.005 to 0.5 Ti, and the balance aluminum; introducing working strain into a melt of the aluminum alloy by means of molding flask-assisted cold forging at a distortion rate of 10 to 40%, at a working introduction velocity of 10 mm or less per second, and at a temperature of 200° C. or lower; and, thereafter heat-treating such a strain introduced melt at temperatures in a range of 576 to 585° C.

Abstract: An apparatus and method for pressure casting a battery part wherein at least one of the mold members forming the surfaces of an internal battery part cavity are displaced with respect to one another to reduce the volume of the mold cavity formed between the two parts to thereby intensify the pressure sufficiently high pressure so as to inhibit the formation of cracks and tears in a cast part.

Abstract: An apparatus and method for pressure casting a battery part wherein the state of molten lead is monitored so that when the molten lead enters a liquid-to-solid transformation stage, the volume of the mold available for the lead to solidify therein is quickly reduced through a volume contraction step to thereby cause the molten lead to flow into the remaining volume at the same time one maintains pressure on the molten lead. As the molten lead solidifies under the reduced volume and high pressure it produces a battery part that is substantially free of both tears and cracks. In an alternate method, the lead is allowed to solidify and at least a portion of the lead is mechanically deformed through a volume contraction step to cause cracks or tears in the battery part to be eliminated thereby providing a battery part free of cracks or tears.

Abstract: The present invention is to manufacture a lightweight high-strength member having desired mechanical properties such as a suspension part of an automobile. The present invention is a method of manufacturing a lightweight high-strength member such as a suspension part of an automobile, and has the steps of pouring the molten metal of an aluminum alloy containing, by weight, 4.0% to 10.5% Si and 0.3% to 1.3% Cu into a mold to cast a preform, and hot-forging the preform by the use of a forging die to form a final formed product.

Abstract: An impermeable ceramic mold is disposed within a steel die and used in a process for pressure casting of elevated melting temperature alloys and pressure infiltration casting of elevated melting temperature alloys having wear resistant particles, included therewith. The ceramic mold provides an insulation layer between the molten metal and the steel die, and prevents welding between the molten metal and the die. The alloy steel die encloses the ceramic mold and provides the strength needed to resist the pressures generated during pressure infiltration casting.

Abstract: The invention relates to a camshaft made of cast steel having an inner cavity with a cylindrical inner shape, especially a profiled cylindrical inner shape produced rationally according to a lost-foam casting method known per se. A steel camshaft thus produced exhibits a long service life and can withstand extremely high hertzian surface pressures on its bearing surfaces without any damages.

Abstract: A metal mold for manufacturing amorphous alloy. A metal mold is composed of a lower mold having a portion for fusing metal material and a cavity portion, and an upper mold working with the lower mold which presses molten metal in the portion for fusing metal material and pours the molten metal into the cavity portion to mold. And, surface roughness of a part of or all of an inner surface of the metal mold is arranged to be more than 12S in JIS indication.

Abstract: A process and an apparatus for producing metallic glass which are capable of producing a bulk amorphous alloy of desired shape, in particular, a bulk amorphous alloy of desired final shape are provided. In the present invention, the molten metal at a temperature above the melting point is selectively cooled at a rate higher than the critical cooling rate, and the product comprises single amorphous phase which is free from the crystalline phase formed by the development of crystal nuclei through nonuniform nucleation. The present invention is capable of producing the bulk amorphous alloy which is free from casting defects such as cold shuts and which has excellent strength properties in a simple process at a high reproducibility.

Abstract: An apparatus and method for pressure casting a battery part wherein the state of molten lead is monitored so that when the molten lead enters a liquid-to-solid transformation stage, the volume of the mold available for the lead to solidify therein is quickly reduced through a volume contraction step to thereby cause the molten lead to flow into the remaining volume at the same time one maintains pressure on the molten lead. As the molten lead solidifies under the reduced volume and high pressure it produces a battery part that is substantially free of both tears and cracks. In an alternate method, the lead is allowed to solidify and at least a portion of the lead is mechanically deformed through a volume contraction step to cause cracks or tears in the battery part to be eliminated thereby providing a battery part free of cracks or tears.

Abstract: A metal material is placed on a lower mold of a press metal mold which has an upper mold and the lower mold not having engagement portions. The metal material is fused by a high energy heat source, and obtained molten metal over a melting point is pressed with the press metal mold and transformed into a predetermined configuration. The molten metal is cooled at a rate over a critical cooling rate simultaneously with or after the transformation, and the molded product of amorphous metal in predetermined configuration is obtained.

Abstract: An apparatus and method for pressure casting a battery part wherein the state of molten lead is monitored so that when the molten lead enters a liquid-to-solid transformation stage, the volume of the mold available for the lead to solidify therein is quickly reduced through a volume contraction step to thereby cause the molten lead to flow into the remaining volume at the same time one maintains pressure on the molten lead. As the molten lead solidifies under the reduced volume and high pressure it produces a battery part that is substantially free of both tears and cracks. In an alternate method, the lead is allowed to solidify and at least a portion of the lead is mechanically deformed through a volume contraction step to cause cracks or tears in the battery part to be eliminated thereby providing a battery part free of cracks or tears.

Abstract: Disclosed are economical methods and apparatus for high throughput pressure infiltration casting. Methods of the invention use a mold vessel as an evacuation chamber along with an evacuation cap to produce superior quality near-net shape finished cast parts with low porosity. Other methods of the invention use an improved heat transfer technique for directionally solidifying molten infiltrant at an increased rate to increase further the throughput of the pressure infiltration casting cycle. The invention also provides apparatus for practicing methods for high throughput pressure infiltration casting. One embodiment of an apparatus of the invention is a removable evacuation cap, often used in conjunction with a fill tube. Another apparatus embodiment is an evacuation cap coupled to a mold vessel which is used as an evacuation chamber.

Abstract: A fan according to the present invention can be monolithically molded out of a metal with a low energy in combination with a structure of a metal mold, in which gate arrangement and/or distribution of dimensions of vanes is devised in injecting a low melting-point metal such as magnesium, wherein not only production but also reproducing such as recycling are facilitated, and also a metalwave of the fan can be produced in consideration of the global atmosphere preservation.

Abstract: An apparatus and method for pressure casting a battery part wherein the state of molten lead is monitored so that when the molten lead enters a liquid-to-solid transformation stage, the volume of the mold available for the lead to solidify therein is quickly reduced through a volume contraction step to thereby cause the molten lead to flow into the remaining volume at the same time one maintains pressure on the molten lead. As the molten lead solidifies under the reduced volume and high pressure it produces a battery part that is substantially free of both tears and cracks. In an alternate method, the lead is allowed to solidify and at least a portion of the lead is mechanically deformed through a volume contraction step to cause cracks or tears in the battery part to be eliminated thereby providing a battery part free of cracks or tears.

Abstract: In the case of uphill low pressure casting of metals, particularly light metal, a casting mold is connected by its gate, via a riser to a melting container and the melt contained therein is displaced under pressure through the riser into the mold. For increasing the casting capacity while maintaining a high quality of the casting, most of the melt volume necessary for filling the mold is displaced into the latter at the maximum casting speed, then the melting column in the riser is sheared and a residual volume remaining between the shearing point and the gate is displaced into the mold with a negative speed gradient. An apparatus for performing the above process is includes a tubular portion provided between the riser and the gate, the tubular portion forming a residual volume, an opening being formed between the riser and the tubular portion.

Abstract: A method of high throughput pressure casting involving the steps of providing a mold vessel containing an infiltrant and a mold cavity; evacuating the mold cavity, and heating the infiltrant to form a molten infiltrant which isolates a reduced pressure in the mold cavity; transferring the mold vessel containing the molten infiltrant to a pressure vessel; applying pressure to the molten infiltrant to move it into the mold cavity; and cooling the molten infiltrant in the mold cavity to solidify the molten infiltrant. The mold cavity may contain a preform to produce a metal matrix composite.

Abstract: In a method for injection molding of metallic mixtures, a metallic substance with a high melting point is mixed with a metallic substance having a lower melting point that serves in part as a binder material, and the mixture may be blended to form a homogenous feedstock for injection molding, or the mixture may be introduced directly into an injection molding apparatus.

Abstract: When pouring casting cavities in casting moulds having after-feeding reservoirs, tubular lances are introduced, firstly with their point at a short distance from the after-feeding reservoir, after which the lances are pressurized from a pressure chamber and by means of a member with an inclined surface pressed downwardly through the last short distance to the after-feeding reservoir so as to pressurize the latter. With this arrangement it is possible to pressurize the after-feeding reservoirs without the need of equipping the casting moulds with complicated extra equipment and without risk of the molten metal being pressurized unnecessarily.

Abstract: A process for manufacturing a heat sink, in which a plate-shaped base portion is formed by the diecasting method integrally with the one-end portions of a plurality of fins arrayed at a constant pitch and in parallel with each other.

Abstract: An apparatus and method for pressure casting a battery part wherein the state of molten lead is monitored so that when the molten lead enters a liquid-to-solid transformation stage, the volume of the mold available for the lead to solidify therein is quickly reduced through a volume contraction step to thereby cause the molten lead to flow into the remaining volume at the same time one maintains pressure on the molten lead. As the molten lead solidifies under the reduced volume and high pressure it produces a battery part that is substantially free of both tears and cracks. In an alternate method, the lead is allowed to solidify and at least a portion of the lead is mechanically deformed through a volume contraction step to cause cracks or tears in the battery part to be eliminated thereby providing a battery part free of cracks or tears.

Abstract: A mold cavity in a mold vessel is evacuated. A charge of molten infiltrant is transported into the mold vessel while the vacuum is maintained in the mold cavity. Pressure is applied to the molten infiltrant to move the molten infiltrant from the mold vessel into the mold cavity. The molten infiltrant is cooled in the mold cavity to solidify the infiltrant. A fill tube can be used to transport the infiltrant to the mold vessel.

Abstract: Molten material is elevated into a mold cavity and subsequently pressure is brought to bear on the molten material in the mold cavity substantially immediately to solidify the molten material under pressure. The molten material is tapped from a reservoir of molten material below the surface of the molten material to minimize exposure to air of the molten material and transferred to the mold cavity without a downward flow or a pouring of the tapped molten material.

Abstract: A gas permeable ceramic investment mold is disposed in a casting chamber and filled with melt to be solidified via a mold melt inlet, such as for example a mold pour cup adapted to receive the melt from a melting crucible in the casting chamber. After the melt is cast into the hot investment mold in the vacuum casting chamber, a pressure cap is positioned in sealing engagement with the mold melt inlet, and gas pressure is introduced through the pressure cap to provide selective or local gas pressure on the melt in the mold without pressure cracking or other damage to the relatively fragile investment mold, while the casting chamber is maintained under relative vacuum or a different pressure from that in the mold.

Abstract: A porous composite forming material is held in a cavity of a casting mold, and molten light alloy is poured into the cavity of the casting mold through a gate. Then a gas pressure is applied to the cavity in the casting mold with the cavity closed, thereby impregnating the pores of the porous composite forming material with the molten light alloy and forming a composite portion formed of a composite material of the light alloy and the composite forming material.

Abstract: A zinc alloy melt-out core comprises from 0.75% to 3% Cu, from 0% to 0.3% Ni, from 0% to 0.5% Al, and balance Zn. The zinc alloy melt-out core is used in pressure casting processes for producing an aluminum article having a hollow. The zinc alloy core has a shape-imparting outer surface. In the pressure casting process, the zinc alloy core preserves a space corresponding to the hollow. The zinc alloy core has improved hot strength and thus maintains its integrity during the pressure casting process, inhibiting seepage of the core material into the aluminum cast article. Preferred zinc alloy melt-out cores further comprise an outer coating of insulating material selected from the group consisting of mica, graphite, ceramics and combinations thereof.

Abstract: A method of casting hypereutectic aluminum-silicon alloys in an evaporable foam casting process with the application of pressure during the solidification of the alloy. A pattern is formed from a polymeric material having a configuration of an article to be cast. The pattern is supported in an outer mold and unbounded sand surrounds the pattern and fills the cavities within the pattern. The pattern is contacted with a molten hypereutectic aluminum-silicon alloy containing 16% to 30% silicon and having less than 0.8% copper. The molten alloy decomposes the foam pattern with the vapors of decomposition being entrapped within the interstices of the sand. While the alloy is in the molten state, gas pressure is applied to the alloy in the magnitude of 5 to 12 atmospheres to produce a cast alloy having less than 0.03% porosity and a high cycle fatigue strength greater than 13 KSI.

Abstract: A mold vessel having a mold cavity is heated and evacuated. A charge of molten infiltrant is provided into the mold vessel from a source not in vacuum communication with the mold vessel while a reduced pressure is maintained in the mold cavity. Pressure is applied to the molten infiltrant to move it into the mold cavity. The molten infiltrant in the mold cavity is cooled to solidify the molten infiltrant. The mold cavity may contain a preform to produce a metal matrix composite.