Abstract: A method and apparatus for filling preforms with resin or slurry includes a tank for holding the slurry and an autoclave for holding the preforms. The tank and autoclave have a common vacuum system connected thereto, and the tank is disposed above the autoclave. This arrangement provides a compact casting system which utilizes a vacuum and gravity to transfer slurry from the tank to the preforms within the autoclave.

Abstract: A method of manufacturing a gas turbine part including a member having fluid transmission paths therein utilized as a cooling/heat insulating structure, includes the steps of: melting a metal under pressurization of an atmospheric gas; dissolving a gas in the molten metal; and solidifying the metal to thereby manufacture the member including a porous metal having thus created pores. The pores of the porous metal are arranged as a plurality of through pores and/or closed pores, each of which is formed in an substantially linear shape by controlling an angle of a solid-liquid interface in solidification with respect to a plane perpendicular to a traveling direction of the solid-liquid interface which is a determination factor of a pore growing direction.

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 injector particularly for a vacuum die-casting apparatus, comprising an injector body provided with at least one first opening for injecting/aspirating a protective gas and at least one second opening for loading molten material, which are arranged in order of operation. The injector body is further provided with a chamber for containing material and for the sliding of a piston for pushing the material into a die. The injector also comprises elements for cleaning and lubricating the external surface of the piston which are arranged in order of operation on a corresponding supporting element which is separate from the injector body.

Abstract: A process for producing a sputtering target from a silicon-based alloy with an aluminum content of 5-50 wt. %. The target material is produced by a casting technique in which the material is melted and vacuum-cast, such that the casting is carried out in a hollow cylindrical casting mold.

Abstract: The present invention relates to an apparatus for metal casting and can be used in producing castings with directional and single crystal structure. The apparatus comprises a vacuum chamber inside which there is disposed an induction melting furnace, a mold preheating furnace with a ceramic mold, and a water-cooled tank being shaped as a truncated cone having a bottom portion and an upper portion which is opened towards a heating zone. The heating zone and the cooling zone are separated by a baffle articulating in a horizontal plane and consisting of segments or sectors. The apparatus allows the production of high quality castings having the directional and single crystal structure including the large sized castings by both the method of radiation cooling and the method of liquid metal cooling.

Abstract: The present invention provides a die-casting method comprising the steps of evacuating a cavity 30 defined by dies of a die-casting machine to provide therein a vacuum of 100 millibar or less during a first period, injecting a reactive gas from a sleeve of the die-casting machine into the cavity 30 during a second period which has a partial overlap period with the first period and follows the overlap period, so as to increase the inner pressure of the cavity to atmospheric pressure or more, pouring a molten aluminum alloy M into the sleeve 40 while keeping the injection of the reactive gas, and subsequently moving a plunger 42 in the sleeve forward to forcibly inject the molten aluminum alloy from the sleeve into the cavity 30 while re-evacuating the cavity 30. The evacuation, reactive-gas injection and re-evacuation operations can be performed with respective overlap periods therebetween.

Abstract: A method of casting a metal article comprising the steps of forming a mold having a mold cavity with a height, a thinwall portion and a base wall portion. The thinwall portion may be less than 0.05 inches thick and free of gating. The method comprises the steps of: positioning the mold in a preheated furnace so that the furnace substantially surrounds the mold and so that a longitudinal axis of the long thin portion of the mold cavity is in an upright orientation; heating the mold in the furnace to a temperature between 1045° C. and 1055° C.; and drawing a vacuum in the furnace. The metal is heated until it is molten and is then poured at a temperature between 1560° land 1570° C. into the mold cavity. The vacuum is then broken and the mold cavity withdrawn from the furnace. The molten metal is allowed to solidify in the mold cavity so that it will solidify with a equiaxed grain structure.

Abstract: The target material for a sputtering target for depositing silicon layers in their nitride or oxide form by means of reactive cathode atomization, such as e.g. Si3N4 or SiO2 in the form of optical functional layers or in the form of thermal protective layers on glass substrates, is a cast silicon element, that has been solidified from the melt condition and which forms a parallelepiped, with a dopant, that has been mixed in with the melt, whereby the dopant is 1 wt % to 15 wt % aluminum, and whereby the casting mold preferably has a cavity which forms a parallelepiped.

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: A maraging steel for use as a mold steel is disclosed. In general, the use of maraging steels in molds is limited by the fact that the martensitic microstructure is not stable at temperatures above 480° C. The precipitate hardening maraging type steel according to the invention contains titanium, molybdenum, cobalt, chromium and nickel and has, in addition to high strength, good ductility, small thermal expansion coefficient and good thermal conductivity, a significantly better thermal stability than other maraging steels, which makes it suitable for use as a mold material particularly in pressure casting.

Abstract: A method of making a wrought aluminum alloy component comprises die casting the wrought aluminum alloy in a die cavity to produce a die cast component and isostatically pressing the die cast component to promote closure of internal voids therein.

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 cooled mold. The process preferably comprises a vacuum chamber, inductive heaters to bring two or more high melting point slugs to either a solid or thixotropic phase, and a plunger that accelerates one or more high melting point solid slugs into one or more thixotropic slugs and then into a mold. Prior to heating, preconditioning at least one of the slugs to form a non-dendritic microstructure simplifies processing. The semisolid microstructure solidifies as the completed forged assembly cools. Thixotropic forging of a multi-alloy assembly achieves optimized properties in specific locations of the final product.

Abstract: The invention relates to a process for producing shaped metal parts, in particular reduced-weight shaped parts made from metallic materials.

Abstract: Solid objects are made by means of a novel multi-step forming, debinding, sintering and infiltrating process, using a metal-ceramic composition. In this process, the mixture is held for a period of time to degas and settle the powdered material from a liquid binder. The packed geometry is then heated to above the melting temperature of the binder to remove the binder portion of the solid geometry. Upon removal of the binder the binder-free solid geometry is raised to a temperature where the metal pre-sinters together into a three-dimensional rigid matrix with interconnected porosity to form a solid precursor. The porous matrix includes the particulate ceramic material and a first metal, which are at least partially sintered. A molten second metal is then introduced to the fill the porous matrix and form an infiltrated matrix.

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 process for die-casting aluminum and aluminum alloys is such that the molten metal is introduced into a filling chamber and injected from the filling chamber into a mold cavity by a piston. The mold cavity is evacuated in advance, after which it is flooded with oxygen. After flooding with oxygen and before injecting the molten metal into it, the mold cavity is again evacuated. Finally, the molten metal is injected into the hollow mold cavity. The process enables die-cast parts to be produced with low tendency to forming pores and blisters.

Abstract: Spraycasting method involves directing an atomized metal or alloy spray at a collector disposed in a spray chamber and controlling temperature of the spray in flight in the spray chamber and of the atomized metal or alloy as it is deposited on the collector by a spray chamber pressure control technique that involves in-situ evacuation of the spray chamber during spray deposition to a maintain spray chamber gas partial pressure less than about 400 torr. Such low spray chamber gas partial pressure provides a higher temperature of the atomized spray in flight in the spray chamber and of the sprayed material as it is deposited on a collector in the spray chamber effective to reduce deposit porosity, reduce grain layering or banding, and provide a uniform grain through the thickness of the deposit.

Abstract: A method for preparing a mould lubricant for use in direct chill casting of reactive metals, including magnesium, magnesium alloys, aluminum, and aluminum alloys, proceeds through combining a casting lubricant and a gaseous oxidation-inhibiting agent in a vessel external from the mold under vacuum conditions. The casting lubricant is selected from a variety of casting oils and casting greases. The gaseous oxidation-inhibiting agent is selected from a variety of inert gases, including sulfur hexafluoride (SF6).

Abstract: A composite material having less than about 25 volume percent refractory particles in a metal matrix is concentrated to have about 37-45 volume percent refractory particles. The concentrating is accomplished by heating the composite material to melt the matrix, and then contacting the molten composite material to a porous element having an average pore size greater than that of the average particle size. A small pressure differential, on the order of about one atmosphere, is applied across the porous element, so that metal matrix material separates from the composite material and flows through the porous element. The particulate volume fraction in the composite material gradually increases. When the particulate volume fraction exceeds about 37 volume percent, the mass of composite material becomes semi-solid and freestanding. The resulting composite material may be further processed, as by forming to a useful shape or diluting with another matrix material.

Abstract: A method for forming a heat transfer apparatus wherein a conduit construct is formed between first and second construct ends and is disposed in a mold cavity with the first and second ends extending from the cavity, air is removed from the construct, body material in molten fluid form is provided in the cavity so as to cover the construct and the molten material is permitted to solidify. In addition, the invention includes a manganese/nickel barrier material which is placed on a conduit construct prior to introducing molten material into the cavity to reduce bubbles in the sink. The invention also includes a system for maintaining heat sink temperature despite fluctuating amount of heat generated by devices mounted to or adjacent a sink wherein the system includes a temperature sensor, a controller and a regulator, the controller controlling the regulator as a function of feedback signals received from the sensor.

Abstract: For the production of precision cast objects a gas change method is used. A melting crucible (1) and a casting mold (2) with at least partially porous walls are disposed in a gastight receptacle (5). The casting mold (2) with the mold cavity (3) is evacuated before the pouring-in process and subsequently flushed with a light gas, for example helium. After the mold cavity (3) is filled, the surface level (18) of the melt in the casting mold (2) is acted upon by a second heavy gas, for example argon, and subjected to excess pressure. A better degree of filling of the mold cavity (3) and an improved structure of the cast object results.

Abstract: An apparatus and method for die casting includes a multi-part, reusable die having at least two die sections defining a die cavity for receiving molten material to be cast. The die sections are moveable relative to one another. Each die section defines a portion of the die cavity and the die sections define the die cavity when positioned in engagement with one another. A melting unit of the apparatus melts the material, and a shot sleeve receives molten material from the melting unit and is in fluid communication with the die. A plunger unit urges material from the sleeve into the die. The apparatus further includes a reduced pressure means, e.g., a vacuum unit, coupled to at least the die for providing a reduced pressure to at least the die cavity. A sealing mechanism of the apparatus is coupled to the die.

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: After a cavity 2 of a die-casting mold 1 is evacuated to exclude gases, oxygen gas is blown into the cavity 2 until an internal pressure of the cavity exceeds the atmospheric pressure, and then a molten metal 5 is forcibly injected into the cavity 2. The cavity 2 is evacuated to a degree of vacuum less than 100 millibar through a suction nozzle 11. The oxygen gas is blown through a nozzle 14 into the cavity 2 so as to fill the cavity 2 with the oxygen gas at an internal pressure higher than the atmospheric pressure. When the molten metal 5 is injected into the cavity 2 clarified in this way, inclusion of gases is perfectly prohibited. As a result, obtained die-cast products are free from defects such as blowholes or porosity caused by inclusion of gases and so useful as functional members as well as structural members.

Abstract: A vacuum die casting system has three die casting machines connected to a single vacuum system, all of which is controlled by a programmable logic controller. The controller allows any two of the machines to be operatively connected to the vacuum system so that the casting operation of those two machines are performed under vacuum. The controller comprises six address relays, a sixteen channel input card, a processor, a sixteen channel output card, an interface and two high speed counter cards. The result is an efficient, reliable, and economical vacuum die casting system.

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: A mold having a supply tube in a lower portion and in which has been placed a fibrous preform, is placed in a container. A crucible filled with magnesium blocks is placed under the mold. The magnesium is heated and the mold is preheated under vacuum until the fusion of the magnesium starts. The tube is then introduced into the magnesium and a neutral gas circulation is set up in the container, under a vacuum insufficient to trigger the evaporation of magnesium. After its complete fusion, the magnesium is transferred into the mold by a rapid pressurization of the container. The mold is then cooled and the part removed from the mold.

Abstract: The apparatus includes a diecasting mold and evacuation elements for the controlled evacuation of a mold cavity. The evacuation elements includes a vacuum tank and a suction line interconnecting the vacuum tank and the diecasting mold. the suction line includes a first valve and a second valve which is coupled in parallel to the first valve. The valves are arranged so that a reference space is formed therebetween. The method for manufacturing die-castings includes evacuating a diecasting mold, filling the diecasting mold with casting material, removing the die-casting, forming a reference space in a portion of the suction line by closing the two valves which are coupled in parallel, measuring moisture, and pressure and temperature in the reference space, and controlling the apparatus in accordance with the measured values.

Abstract: A method for producing metal castings comprising the steps of: i) providing a conditioning furnace, having an inlet channel and an outlet channel, with pre-treated molten metal; and ii) reducing the height of molten metal in the outlet channel to a level (h.sub.1) lower than the level of the molten metal in the conditioning furnace (h.sub.0) such that the molten metal in the spout and in the outlet channel, at least partly, is brought back into the furnace body where it can be recharged with a nucleating and/or structure modifying agent, iii) adding further nucleating and/or structure agent to the molten metal when necessary, iv) mixing the melt in the furnace when necessary and v) after the stoppage, casting the melt with the desired content of structure modifying agent.

Abstract: A metal or alloy is melted in a vaccuum chamber disposed about an end of a shot sleeve. The opposite end of the shot sleeve is communicated to a die cavity between first and second dies which are disposed in ambient air atmosphere. The dies have one or more vacuum seals therebetween extending about the die cavity to isolate the die cavity from the ambient air atmosphere when the dies are closed. A vacuum thereby is provided in the die cavity through the shot sleeve when the vacuum chamber is evacuated despite the dies being disposed in ambient air atmosphere. The first and second dies are opened after the metal or alloy is die cast in the die cavity for ready removal of the cast component from the die cavity directly to the ambient air atmosphere and then to an optional quenchant medium proximate the dies.

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: Parts are diecast from a light metal alloy which in the molten state is fed under gravity into a casting chamber of a diecasting machine and whence forced by a plunger into a mould chamber which undergoes controlled evacuation in accordance with the position of a plunger. A parting compound is applied to at least one mold half and the application of a lubricant to the plunger. The light metal alloy consists of a primary alloy of invariable composition, with a limit placed on the proportions of Cu, Fe and Zn; the alloy undergoes smelting treatment, de-gassing and/or filtration before being introduced. The vacuum in the mould chamber is below 50 mbar when the molten alloy is introduced and the parting compound contains alkali halides and anti-corrosion additives.

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 removable mold. The process preferably comprises a vacuum chamber, an inductive heater to bring a high melting point multi-alloy slug to a thixotropic phase, a supercooled mold comprised of a low melting point alloy or metal, and a plunger that accelerates and injects the high melting point slug into the low melting point mold. As the formed part cools, the supercooled low melting point mold heats up to its melting point upon which separation from the formed part occurs. Supercooling of the removable mold permits the use of thixotropic methods for high melting point alloys. Thixotropic forging of a multi-alloy assembly tailors its mechanical properties to achieve optimized properties in specific locations of the final product.

Abstract: A method for producing light metal castings, in particular cylinder heads, cylinder blocks and/or crankcases for internal combustion engines, includes a sand mold which forms a mold cavity for the casting. The sand mold includes outer mold parts, at least one core and at least one feeder for forming a riser, wherein the mold is provided with an in-gate for receiving the metal melt and the metal melt is filled into the mold cavity under the effect of gravity. A cover core (5) is fitted onto the mold that is at least in partial regions designed to be impermeable to gas and which contains at least one feeder, and wherein immediately after the filling operation, the feeder filled with metal melt is admitted with a pressure via a pressurized gas.

Abstract: Metal matrix composite is made by assembling pre-forms of porous reinforcing material with an array of separator plates in a die in a pressure vessel, and infiltrating molten metal matrix material. Pre-evacuation followed by pressurisation when the molten metal matrix material is introduced into the die aids the infiltration. Re-introduction of gas during initial heating prior to melting speeds the heat-up process.

Abstract: The process serves to produce a directionally solidified casting (20) and uses an alloy located in a casting mold (12). The casting mold (12) is guided from a heating chamber (4) into a cooling chamber (5). The heating chamber (4) is here at a temperature above the liquidus temperature of the alloy, and the cooling chamber (5) is at a temperature below the solidus temperature of the alloy. The heating chamber (4) and the cooling chamber (5) are separated from one another by a baffle (3), aligned transversely to the guidance direction, having an opening (7) for the casting mold (12). When carrying out the process, a solidification front (19) is formed, beneath which the directionally solidified casting (20) is formed. The part of the casting mold (12) which is guided into the cooling chamber (5) is cooled with a flow of inert gas. As a result, castings (20) which are practically free of defects are achieved with high throughput times.

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: A system for die casting including a die having a die cavity. There is also a vacuum chamber and a device for creating a vacuum in the vacuum chamber. The die casting system further includes an injection device for introducing a fluidically based material, such as molten metal, into the die cavity from the vacuum chamber. The injection device is in fluidic communication with the die cavity and is at least partially disposed within the vacuum chamber. The die casting system also includes a device for providing the fluidically based material into the injection device. The providing device is separated from the injection device and is preferably disposed within the vacuum chamber. A method of die casting includes the step of providing, such as by pouring, fluidically based material into an injection device within the vacuum chamber. Then, there is the step of forcing the fluidically based material into the die cavity with the injection device.

Abstract: Methods for semisolid manufacturing of precision parts, turbine rotors for example, comprised of high melting point alloys are given. Generally, a semisolid/thixotropic process is operated under vacuum utilizing a removable mold. The process preferably comprises a vacuum chamber, an inductive heater to bring a high melting point alloy to a thixotropic phase, a supercooled mold comprised of a low melting point alloy or metal, and a plunger that accelerates and injects the high melting point alloy into the low melting point mold. As the formed part cools, the supercooled low melting point mold heats up to its melting point upon which separation from the formed part occurs. Supercooling of the removable mold permits the use of thixotropic methods for high melting point alloys.

Abstract: Metal is melted in an induction-heated crucible (13) on which a mold (10) with a downward-facing filling opening (26) is located in the melting position. After melting the metal, the crucible (13) and the mold (10) are jointly rotated about a horizontal axis (A--A) into a tilting position in which the molten material flows from the crucible (13) into the mold (10). In order to melt reactive metals, melting is done in a crucible (13) that is surrounded by a vacuum, this crucible being surrounded by an induction coil (15) outside of the vacuum. The mold (10) is located in a vacuum-sealed casting chamber (6) which is evacuated together with the crucible (13) prior to melting and casting is carried out by a joint tilting of the crucible (13), casting chamber (6) and mold (10) by at least 180 degrees while the vacuum is maintained.

Abstract: A method of lubricating a lubricant requiring portion of a die casting machine includes inserting a unitized lubricant element including flowable lubricant into a cylinder when an associated ram is retracted and advancing the ram against the lubricant element to squeeze the element against a partially closed end of the cylinder and force the lubricant to flow through a restricted passage to the portion to be lubricated. A metal injecting shot sleeve and plunger may act as the cylinder and ram for lubricant delivery prior to the introduction of molten casting metal where the die cavity is to be lubricated but provision of a separate cylinder and ram apparatus is preferred. Various forms of unitized lubricant elements with and without containers and examples of lubricant delivery apparatus are disclosed.

Abstract: The firing and/or casting kiln has a containment casing which internally forms a treatment chamber, a part holder which is movably mounted inside the treatment chamber, an opening for access to the treatment chamber, and a conditioning system for producing a vacuum and introducing inert gas into the treatment chamber.

Abstract: The apparatus comprises a vessel having an interior. A mold is disposed within the interior of the vessel. A casting material is contained in the interior of the vessel. The apparatus also comprises a mechanism for providing the casting material to the mold in a manner such that vapors of the casting material are prevented from communicating with the interior of the vessel. The providing mechanism is in communication with the vessel. The providing mechanism comprises an inner chamber within which the mold and casting material are contained in. The providing mechanism further comprises a mechanism for heating the inner chamber, such as heating coils. The heating mechanism is disposed within the interior of the vessel adjacent to the inner chamber. Preferably, the inner chamber has a tube extending therefrom having a filter element, disposed therein for catching vapors of the casting material.

Abstract: A method for casting oxidization-active metal under oxygen-free conditions wherein air is discharged from a melting chamber and a casting chamber while maintaining the condition of the melting chamber pressure P.sub.R >the casting chamber pressure P.sub.C and dry compressed inert gas is then introduced into the melting chamber, directionality is imparted to the atmosphere gas of the melting chamber under the condition of P.sub.R >P.sub.C for replacing and discharging the atmosphere in a mold of the casting chamber with inert gas and establishing a non-oxidizing atmosphere in the melting chamber and the casting chamber, and precision casting is thereafter conducted by melting a fusible casting material and pouring it into the mold in the casting chamber.

Abstract: A method for casting low specific gravity metal with ultra-fine features using high differential pressure wherein a melting chamber volume V.sub.1 and a casting chamber volume V.sub.2 are defined such that V.sub.1 <V.sub.2, fusible casting material is melted with a melting plate under an inert gas atmosphere, a high differential pressure is established between the melting chamber and the casting chamber by introducing compressed inert gas into the melting chamber simultaneously with pouring the melt into a mold of the casting chamber, and the high differential pressure is held until the cast melt solidifies.

Abstract: Method and apparatus are provided for casting titanium-aluminum alloys including generally 10 weight % or more Al in a reusable metallic mold or die in a manner that retards or avoids build-up of a deleterious aluminum layer on the mold or die cavity surfaces that adversely affects surface quality of castings solidified therein.

Abstract: Composites of materials in which the matrix material does not spontaneously or readily wet the disperse phase and in which the volume fraction of the disperse phase is less than that formed in a packed bed of dispersate particles can be made effectively by an indirect method of infiltrating a packed bed of dispersate particles, using pressure or other mechanical force as needed to overcome poor wetting and form an intermediate concentrated composite. The concentrated composite is then mixed with additional matrix-forming material to produce the finally desired composite. The technique is particularly valuable for composites with ceramic dispersates and metal or alloy matrixes.

Abstract: A method and apparatus capable of continuously discharging contaminated gas out of metal molds, the gas being generated prior to the casting step and including moisture. A gas vent valve is provided at a gas vent passage in communication with a mold cavity. A suction unit and a vacuum pump are selectively connected to the gas vent valve. After closure of the metal molds, the suction unit is connected to the gas vent valve to perform sucking interior of the mold cavity. By this suction, an external air is introduced into the metal molds through a pouring port of a shot sleeve. Thus, contaminated gas in the cavity is replaced with a clean air. During injection molding, the gas vent valve is connected to the vacuum pump for decompressing the mold cavity. Vapor explosion is avoidable since moisture content is removed from the mold cavity even if the molten metal is introduced into the cavity.

Abstract: Vacuum die casting machine including an improved siphon tube for transporting molten metal from a reservoir to a shot cylinder. The siphon tube defines a passageway having a first end portion which is adapted to communicate with a shot cylinder and a second end portion opposite the first end portion which defines a molten metal entry portion. The passageway tapers from the first end portion to the second end portion which reduces jetting in the shot cylinder. An associated method is also disclosed.