Abstract: A fiber reinforced porous preform is positioned within a die cavity defined by upper and lower die members, and the lower die member defines at least one gate opening in the center portion of a water cooled shot sleeve which receives a vertically moveable shot piston. The area of the gate opening is small relative to the area of the shot sleeve, and the lower die member defines an annular recess above the inner surface of the shot sleeve for entrapping a shell of pre-solidified metal. Air vent slots extend outwardly between the shot sleeve and lower die member and are closed by the shell of pre-solidified metal. In one embodiment, the shot sleeve and shot piston are non-circular or oval in cross-section; and the lower die member has a plurality of longitudinally space gate openings.

Abstract: A metal alloy is heated to a molten state and is poured into a shot sleeve of a vertical die cast press and on top of a shot piston. The shot sleeve is transferred to an injection station while the molten alloy is cooled to a semi-solid slurry and a globular, generally non-dendritic microstructure. A retractable cooling pin is temporarily inserted into a center portion of the slurry while in the shot sleeve to obtain optimum cooling. A center portion of the slurry is injected upwardly by the piston through a gate opening into a die cavity while an outer more solid portion of the slurry is entrapped in an annular recess. After the slurry solidifies, the shot piston retracts, and the shot sleeve is transferred to a position where the residual biscuit is removed. Another shot sleeve filled with the molten allow is transferred, and the process is repeated.

Abstract: A fiber reinforced porous preform is positioned within a die cavity defined by upper and lower die members, and the lower die member defines at least one gate opening in the center portion of a water cooled shot sleeve which receives a vertically moveable shot piston. The area of the gate opening is small relative to the area of the shot sleeve, and the lower die member defines an annular recess above the inner surface of the shot sleeve for entrapping a shell of pre-solidified metal. Air vent slots extend outwardly between the shot sleeve and lower die member and are closed by the shell of pre-solidified metal. In one embodiment, the shot sleeve and shot piston are non-circular or oval in cross-section; and the lower die member has a plurality of longitudinally space gate openings.

Abstract: A metal alloy is heated to a molten state, and a grain refiner may be added. The refined molten alloy is poured into a large diameter shot sleeve of a vertical die cast press and on top of a shot piston. The shot sleeve is transferred to an injection station while the molten alloy cools to a semi-solid slurry with approximately fifty percent solids and a globular, generally non-dendritic microstructure. A center portion of the slurry is injected upwardly by the piston through a gate opening into a die cavity while an outer more solid portion of the slurry is entrapped in an annular recess. After the slurry solidifies, the shot piston retracts, and the shot sleeve is transferred to a position where the residual biscuit is removed. A second shot sleeve filled with the molten alloy is transferred to the metal transfer station, and the process is repeated.

Abstract: A fiber reinforced porous preform is positioned within a die cavity defined by upper and lower die members, and the lower die member defines at least one gate opening in the center portion of a water cooled shot sleeve which receives a vertically moveable shot piston. The area of the gate opening is small relative to the area of the shot sleeve, and the lower die member defines an annular recess above the inner surface of the shot sleeve for entrapping a shell of pre-solidified metal. Air vent slots extend outwardly between the shot sleeve and lower die member and are closed by the shell of pre-solidified metal. In one embodiment, the shot sleeve and shot piston are non-circular or oval in cross-section; and the lower die member has a plurality of longitudinally space gate openings.

Abstract: A metal alloy is heated to a molten state, and a grain refiner may be added. The refined molten alloy is poured into a large diameter shot sleeve of a vertical die cast press and on top of a shot piston. The shot sleeve is transferred to an injection station while the molten alloy cools to a semi-solid slurry with approximately fifty percent solids and a globular, generally non-dendritic microstructure. A center portion of the slurry is injected upwardly by the piston through a gate opening into a die cavity while an outer more solid portion of the slurry is entrapped in an annular recess. After the slurry solidifies, the shot piston retracts, and the shot sleeve is transferred to a position where the residual biscuit is removed. A second shot sleeve filled with the molten alloy is transferred to the metal transfer station, and the process is repeated.

Abstract: A metal alloy is heated to a molten state and is poured into a shot sleeve of a vertical die cast press and on top of a shot piston. The shot sleeve is transferred to an injection station while the molten alloy is cooled to a semi-solid slurry and a globular, generally non-dendritic microstructure. A retractable cooling pin is temporarily inserted into a center portion of the slurry while in the shot sleeve to obtain optimum cooling. A center portion of the slurry is injected upwardly by the piston through a gate opening into a die cavity while an outer more solid portion of the slurry is entrapped in an annular recess. After the slurry solidifies, the shot piston retracts, and the shot sleeve is transferred to a position where the residual biscuit is removed. Another shot sleeve filled with the molten allow is transferred, and the process is repeated.

Abstract: A metal alloy is heated to a molten state, and a grain refiner may be added. The refined molten alloy is poured into a large diameter shot sleeve of a vertical die cast press and on top of a shot piston. The shot sleeve is transferred to an injection station while the molten alloy cools to a semi-solid slurry with approximately fifty percent solids and a globular, generally non-dendritic microstructure. A center portion of the slurry is injected upwardly by the piston through a gate opening into a die cavity while an outer more solid portion of the slurry is entrapped in an annular recess. After the slurry solidifies, the shot piston retracts, and the shot sleeve is transferred to a position where the residual biscuit is removed. A second shot sleeve filled with the molten alloy is transferred to the metal transfer station, and the process is repeated.

Abstract: A fiber reinforced porous preform is positioned within a die cavity defined by upper and lower die members, and the lower die member defines at least one gate opening in the center portion of a water cooled shot sleeve which receives a vertically moveable shot piston. The area of the gate opening is small relative to the area of the shot sleeve, and the lower die member defines an annular recess above the inner surface of the shot sleeve for entrapping a shell of pre-solidified metal. Air vent slots extend outwardly between the shot sleeve and lower die member and are closed by the shell of pre-solidified metal. In one embodiment, the shot sleeve and shot piston are non-circular or oval in cross-section; and the lower die member has a plurality of longitudinally space gate openings.

Abstract: A fiber reinforced porous preform is positioned within a die cavity defined by upper and lower die members, and the lower die member defines a gate opening in the center portion of a water cooled shot sleeve which receives a vertically moveable shot piston. The area of the gate opening is small relative to the area of the shot sleeve, and the lower die member defines an annular recess above the inner surface of the shot sleeve for entrapping a shell of pre-solidified metal. Air vent slots extend outwardly between the shot sleeve and lower die member and are closed by the shell of pre-solidified metal. The structure prevents pre-solidified metal and air from entering the die cavity.

Abstract: A vertical frame supports a rotary indexing table which carries a pair of vertical shot sleeves each having a shot piston with a depending shot piston rod. The shot sleeves are alternately indexed between a metal receiving station and a metal transfer station where a mold is supported above the table by a gate plate mounted on the frame. A hydraulic ejection cylinder and a substantially larger hydraulic shot cylinder are supported by the frame under the metal receiving and transfer stations, respectively, and laterally sliding couplings alternately connect the shot piston rods to the hydraulic cylinders when the table is indexed 180.degree.. Each shot piston and the gate plate form a biscuit which is retracted into the shot sleeve at the transfer station by the shot cylinder and is ejected at the receiving station by the ejection cylinder after the table and shot sleeves are indexed.

Abstract: A vertical die casting press includes a frame supporting a stationary lower horizontal platen which supports a base plate attached to a lower mold. An upper horizontal platen is supported for vertical movement between vertical columns by corner lift cylinders mounted on the lower platen, and the upper platen encloses hydraulic cylinders for actuating blades for releasably locking the upper platen to teeth on the vertical columns at a selected height. The upper platen carries a relatively movable intermediate platen which supports a base plate attached to an upper mold. After the upper platen is locked to the columns, a hydraulic load cell or cylinder within the upper platen clamps the intermediate platen and upper mold to the lower mold and lower platen.

Abstract: An ingot having a predetermined amount of electrolytic copper and a small percentage of boron copper alloy is rapidly heated to about 2,100.degree. F. in a clay graphite crucible by induction coils surrounding the crucible. The crucible and the entire amount of molten copper are automatically transferred to a cavity defined within a shot cylinder above a vertically movable shot piston of a vertical die casting press. A shuttle moves a lower end ring mold and a stack of connected rotor laminations into a position above the shot cylinder, and the press moves an upper end ring mold downwardly to clamp the stack between the molds and against the cylinder. The molten copper is rapidly injected upwardly through gates within the lower mold and into end ring cavities within the molds and also through connecting aligned bar slots within the stack of laminations with a shot pressure of about 2250 psi.