Abstract: The wear resistant insert is an annular ring of austenitic iron alloy. It has a peripheral surface which conforms to the exterior of the piston into which it is to be cast. A plurality of frangible tabs project outward from the periphery. When casting a piston, the insert is supported on a ledge in a die cavity. A predetermined amount of aluminum alloy is poured into the die cavity and the cavity is closed by a punch. The punch applies a force on the solidifying alloy. As the aluminum alloy shrinks during solidification, the pressure severs the frangible tabs allowing the insert to shift.

Abstract: This invention relates to an improved method of manufacturing a heater nozzle for an injection molding system. The heater nozzle has a helical heating element which is cast into an outer portion around an inner liner through which the melt flows. The outer portion is formed of a conductive material such as a beryllium copper alloy and the inner liner is formed of a durable corrosion resistant material such as stainless steel to provide an excellent combination of these characteristics. The heater nozzle is made by positioning the heating element around a pre-heated solid threaded liner in a mold and pressure casting the beryllium copper outer portion around them. The elongated liner is very accurately located in the mold by having the lower end received in a seat in the mold and the upper end received in an aperture through the plunger as it closes.

Abstract: The present invention relates to a die-casting method in which a molten metal is injected through a runner (31) into a die cavity (30) for casting an article and the injected metal is squeezed also from a squeezing passage (17) by a squeeze plunger (36). The squeeze passage is communicated with the die cavity (30) at a portion thereof where the die cavity is communicated with the runner (31). The invention is characterized in that, on squeezing, the molten metal is displaced from the squeeze passage (17) while forming a divergent flow, to thereby assure that squeezing operations are carried out always at a stable squeezing pressure.

Abstract: A method of charging molten metal into a vertical die casting machine, wherein molten metal is introduced into a lower sleeve in which a lower plunger is slidably received, to store therein a mass of molten metal having a surface level not higher than the bottom of a molten metal inlet to a mold cavity. Next, an upper plunger is lowered to a predetermined position, raising the lower plunger to urge the molten metal upwardly and move it into the mold cavity. The upper plunger can then be moved to apply pressure to the molten metal. The method ensures smooth charging of molten metal and casting of a product free of casting defects.

Abstract: A die-casting method in which a molten metal is injected into a die cavity 30 through a runner 31 and the molten metal in the die cavity is pressurized and squeezed also through a squeeze passage 17 which is communicated with the die cavity 30 at a point other than the point of connection of the runner with the die cavity. The timing of commencement of the squeeze effected through the squeeze passage 17, squeezing pressure and the amount of molten metal squeezed out of the squeeze passage 17 into the die cavity 30 are suitably determined so that the formation of cavities or voids which adversely affect the strength and gas-tightness of die-cast product is remarkably decreased to assure a reliable manufacture of voidless die-cast products without substantial fluctuation of quality.

Abstract: A modified die casting process and machine utilizes a shaped and contained charge of molten metal which is formed and moved proximate the gate runner while the die halves are open. The charge is formed between the shot piston and an ejector side plunger which includes a slave driver rod projecting to engage the shot piston. By confining and compacting the charge, a charge more homogeneous and of uniform temperature is provided. When the die halves close, the shot piston further advances moving the plunger against a stop, retracting the slave driver rod and filling the cavity at the desired flow rate. The cavity is provided with one or more impact absorbing devices positioned in recesses on the parting plane of the die.

Abstract: A method for joining a member to a diecast article using an apparatus comprising dies, an injection sleeve communicating with a cavity of the dies and a plunger tip slidably arranged in the injection sleeve for filling the cavity of the dies with the molten metal previously poured in the injection sleeve. According to the invention, the plunger tip is formed with an insert aperture for receiving the member to be joined such that a portion of the member extending beyond an upper surface of the plunger tip is exposed in the molten metal when it is poured in the injection sleeve, thereby sufficiently transmitting the heat of the molten metal to the portion of the member to obtain a metallurgical bond at a boundary between the member and the diecast article.

Abstract: The invention provides a piston formed by casting a metal piston body under pressure around an insert, the body being made of aluminium or aluminium alloy and the insert being made of a porous layer having a thickness 20 to 50 times the pore diameter and completely filled with the piston body metal which projects from the body into the pores of the insert.

Abstract: Disclosed in this specification is a method for casting, in which a shaped body of an inorganic fiber material is fixedly secured on a chill member, then the chill member together with the shaped body of inorganic fiber is incorporated in a predetermined part of a cast article through a fiber-reinforced composite layer to be brought about at the time of casting under high pressure solidification casting techniques.

Abstract: A process for producing fiber-reinforced magnesium alloy materials with improved mechanical properties which includes the steps of placing a shaped article of silicon carbide whiskers or silica type, alumina type or silica-alumina type fibers in a casting mold, and pouring into the mold a molten matrix of a magnesium alloy at a temperature lower than 800.degree. C. The shaped article is impregnated with the molten matrix by means of a high pressure coagulation casting method while maintaining the original configuration of the shaped article to form a composite. A magnesium-silicon compound and/or a magnesium-aluminum compound are precipitated in the matrix at the filling and composite-forming step by reaction between the surface fibers of the shaped article and the molten matrix. The whiskers or fibers may be covered by a film of copper, nickel or silver to vary the amount of the precipitated compounds.

Abstract: A fiber-reinforced light alloy cast article for use in various mechanical parts such as, for example, a connecting rod, a rocker arm, and so forth in an internal combustion engine. The composite light alloy cast article includes therein a portion filled with a shaped body made of an inorganic fiber material of high elasticity and high mechanical strength, and another portion filled with a shaped body of inorganic fibers having low elasticity and high hardness and having an appropriate bulk density suited for required purposes, the fiber-shaped bodies being filled in the required portions of the composite light alloy cast article by high pressure solidification casting.

Abstract: The invention relates to the manufacture of aluminum alloy blanks containing a large quantity of silicon and designed for extrusion by impact.It consists in applying the method of casting with oriented cooling in the main patent to a hypereutectic silicon aluminum alloy which has previously been refined with phosphorus.An even distribution of the remarkably fine primary silicon crystals is obtained in this way.The invention is particularly applicable to the manufacture of linings for heat engines made of aluminum alloys.

Abstract: A method and apparatus for fabricating reinforcing bands for strengthening arts to be subjected to high centrifugal stresses. The reinforcing bands are made of coiled wire with a high modulus of elasticity and with a matrix of light metal or light-metal alloy. The coil, hoop or blank so formed is compacted in a direction parallel to its axis under high pressure and heat by an annular metal ram in a mold or die consisting of a bottom member, an inner ring, and an outer ring which are constructed so that the blank or coil does not undergo any radial stresses.

Abstract: An improved method of and apparatus for pressure casting metal are disclosed. The method is generally known in the art as "squeeze casting". The present method provides for casting articles under forging pressures in a die to predetermined dimensions regardless of varying amounts of excess of poured molten metal, by the inclusion of a retractable charge-quantity compensator positioned adjacent the casting cavity to form on the cast article an extension which may vary in volume from article to article. The extension is later removed. The charge-quantity compensator may be in the form of a piston in a cylinder with hydraulic fluid behind the piston connected to a hydraulic source. The piston, which may be normally biased toward the die cavity but yieldable away therefrom is fixed in position when the punch die has advanced to a predetermined position at which the quantity of casting material in the die cavity is appropriate for the article being formed. Full casting pressure is then applied.

Abstract: A system for the die stamping of a fluid comprises a male die member which s forced into a die cavity to compress and spread the fluid material therein. A piston in this die member is advanced after the die member is arrested by a shoulder of the female die member to compress gas ahead of this piston and increase the pressure at selected locations along the face of the male member at which cavities are provided to communicate this gas pressure to the fluid.

Abstract: A biskeletal composite is created by forming a skeletal host body of reaction bonded silicon nitride, heating an infiltrant material, and applying pressure to such infiltrant to thereby force such infiltrant into the void volume of the porous host body. In one aspect of the method, the application of pressure is done rapidly to impart desirable characteristics to the composite.

Abstract: The preparation of three dimensional skeletal structures using the step of deforming rounded beads to form a mold or matrix is described. A filler material is introduced and then rigidified to form the skeletal structure. The deformable beads are composed of materials which deform upon compression or expansion due to pressure from adjacent beads and included, for instance, metals, waxes, salts, polymers, and ceramic compositions in their plasticly deformable states. The filler material which rigidifies to form the skeletal structure can be composed of solidifiable materials such as metals, polymers, or ceramic compositions. The solid material volume of the skeletal structure so formed upon removal of the beads is between about two percent (2%) to twenty percent (20%) of a corresponding volume of a non-skeletal solid material.

Abstract: The invention concerns an improved injection device for molding machines with a cooling chamber for casting of non-ferrous metals and alloys. It is characterized by a two-part piston, one part of which slides freely and coaxially inside the other, forming a chamber in which a gas, neutral with respect to the metal to be cast, is compressed by the forward movement of the piston by virtue of a stop-pin, then liberated and expanded at the end of injection in a container of liquid metal where it causes a balancing force effect and improves the filling of the mold.This device makes it possible to eliminate the "ramroddings" which occur in single-piston machines at the end of injection and to obtain cast products which are free of defects.

Abstract: The present invention relates to a method of manufacturing a metal-impregnated body in which a porous body is immersed under sub-atmospheric pressure in a molten alloy for impregnation with said alloy or a porous body is immersed under elevated pressures produced by various gases, the pressure then being reduced to normal level, after which the porous body is introduced together with a molten alloy into a metal mold, in which said molten alloy is impregnated into said porous body. The porous body is then separated from said molten alloy.

Abstract: Seamless tubular products made of metal, particularly steel, by the apparatus and method are manufactured by casting molten metal into a round, downwardly converging mold cavity having a coaxial removable cooled core of substantially uniform diameter throughout and which is less than the cavity's minimum diameter, the metal solidifying initially where it contacts the cavity wall and the core with solidification proceeding upwardly with incidental possible formation of pipe in the upper portion of the casting. Prior to the resulting casting cooling below a forging temperature, the core is removed and replaced by a mandrel having a flaring portion and which is pressed into the casting under pressure forging the casting radially outwardly and upwardly against the mold cavity wall with consequent closing and welding of any pipe.