Abstract: A plunger for strengthening spoke root R angle cooling. A plunger main body is step-shaped and provided with a blind hole, and vent holes are uniformly distributed around the blind hole; an annular groove is formed in the plunger main body, and connects the blind hole with the vent holes; air outlet pipes are inserted into the blind hole, the distance between the air outlet pipes and the bottom of the blind hole is 1-1.5 times the radius of the blind hole, an annular air pipe connects the air inlet pipe with the air outlet pipes and distributes cooling air entering from an air inlet pipe to each air outlet pipe, and the diameter of the air inlet pipe is not smaller than two times that of the air outlet pipe.

Abstract: An electrode for the projection welding of a weld nut to a workpiece has an electrode welding head with parts including a replaceable welding interface disc fitted therein. The electrode can be disassembled so that the conductive electrode interface within the welding head may be replaced when it becomes worn.

Abstract: A method of casting valve seat inserts comprises pouring molten metal into a gating system of a mold plate stack wherein mold plates are located between top and bottom molds wherein the gating system includes a casting header, down-sprue, horizontal sprue, up-sprues, runners, and gates in fluid communication with mold cavities configured to form the valve seat inserts. The method includes filling the mold cavities with the molten metal, and controlling solidification of the molten metal in the mold cavities by means of an outer thermal barrier which retards heat transfer in mold plate material between the mold cavities and an outer periphery of the mold plate stack. An inner thermal barrier can be used to further control solidification of the molten metal. Valve seat inserts produced using the thermal jacket molds can exhibit an improved microhardness distribution which provides improved machining and higher yield.

Abstract: A process for producing a coupler knuckle and an improved coupler knuckle design are provided. The process produces a coupler knuckle by constructing a mold having the shape of the coupler knuckle. The mold is coated with a material that is resistant to melting at the molten melt temperatures of the molten metal used to form the knuckle. With the mold coated, the cavities in the mold interior are filled by placing an inert material therein. The molten metal used for forming the knuckle contacts the mold and consumes it, while the coating serves to provide a shape for the knuckle.

Abstract: A mold for casting a titanium-containing article includes calcium aluminate and silicon carbide, and the silicon carbide is graded in the mold such that it is in different portions of the mold in different amounts, with the highest concentration of silicon carbide being located between a bulk of the mold and a surface of the mold that opens to a mold cavity.

Abstract: A suction pressure casting method uses a casting device that includes a holding furnace for accumulating molten metal, a metal mold and a core forming a cavity, a molten-metal pressurizing tank that supplies a pressurizing gas, and a suction and exhaust tank for sucking and exhausting the inside of the cavity. A preset decompression pattern of a casting process is compared with a measured pressure pattern of the cavity and the core that is measured during actual casting. A corrected decompression pattern is calculated based on a difference therebetween. The preset decompression pattern at the time of the next casting is then corrected by using the corrected decompression pattern.

Abstract: A system and method for continuous casting. The system includes a melt chamber, a withdrawal chamber, and a secondary chamber therebetween. The melt chamber can maintain a melting pressure and the withdrawal chamber can attain atmospheric pressure. The secondary chamber can include regions that can be adjusted to different pressures. During continuous casting operations, the first region adjacent to the melt chamber can be adjusted to a pressure that is at least slightly greater than the melting pressure; the pressure in subsequent regions can be sequentially decreased and then sequentially increased. The pressure in the final region can be at least slightly greater than atmospheric pressure. The differential pressures can form a dynamic airlock between the melt chamber and the withdrawal chamber, which can prevent infiltration of the melt chamber by non-inert gas in the atmosphere, and thus can prevent contamination of reactive materials in the melt chamber.

Abstract: A mold transfer assembly includes a transfer housing providing an interior defined by one or more sidewalls and a top. The transfer housing is sized to receive and encapsulate a mold as the mold is moved between a furnace and a thermal heat sink. An arm is coupled to the transfer housing to move the transfer housing and the mold encapsulated within the transfer housing between the furnace and a thermal heat sink. The transfer housing exhibits one or more thermal properties to control a thermal profile of the mold.

Abstract: A core for use in casting an internal cooling circuit within a gas turbine engine component includes an additively manufactured skeleton core portion manufactured of a refractory metal, a surround core portion that at least partially encapsulates the additively manufactured skeleton core portion, the surround core portion manufactured of a ceramic material, a surround core portion that at least partially encapsulates the additively manufactured skeleton core portion, the surround core portion manufactured of a ceramic material and a cooling hole shape that extends from the additively manufactured skeleton core portion through the surround core portion, the cooling hole shape operable to form a cooling hole.

Abstract: A method of controlling molten metal flow and an electromagnetic brake system for a metal-making process, including: a first magnetic core arrangement having a first and second long sides with Nc teeth, and arranged to be mounted to opposite longitudinal sides of an upper portion of a mould, a first set of coils, each being wound around a respective tooth of the first magnetic core arrangement, and Np power converters, with Np being an integer that is at least two and Nc is an integer that is at least four and evenly divisible with Np, wherein each power converter is configured to feed a DC current to its respective group of 2Nc/Np series-connected coils.

Abstract: An insert part for a cast piston of an internal combustion engine may include a powder, such as a sintered powder material, containing at least iron or alloys thereof, and having a capacity for being infiltrated. The powder may contain particles having different grain sizes, and up to 4% by volume of the powder may include particles having a diameter smaller than 75 ?m.

Abstract: An investment mold includes a mold cavity and a refractory investment wall that bounds at least a portion of the mold cavity. At least a portion of the refractory investment wall includes a plurality of fugitive beads. The fugitive beads can be sacrificed to provide voids that control the strength of the refractory investment wall such that the wall fractures at the voids during investment casting to alleviate stress on a solidified metal cast in the mold cavity.

Abstract: Various embodiments provide apparatus and methods for melting materials and for containing the molten materials within melt zone during melting. Exemplary apparatus may include a vessel configured to receive a material for melting therein; a load induction coil positioned adjacent to the vessel to melt the material therein; and a containment induction coil positioned in line with the load induction coil. The material in the vessel can be heated by operating the load induction coil at a first RF frequency to form a molten material. The containment induction coil can be operated at a second RF frequency to contain the molten material within the load induction coil. Once the desired temperature is achieved and maintained for the molten material, operation of the containment induction coil can be stopped and the molten material can be ejected from the vessel into a mold through an ejection path.

Abstract: A casting mold of a casting assembly is openable in first and second release directions different from each other. The casting mold has a first base plate transverse to the first release direction and an opposite second base plate. First mold parts on first base plate and second mold parts on second base plate define first and second casting cavities. First and second lateral parts are arranged between first and second base plates. A third mold part on the first lateral part defines the first casting cavity. A fourth mold part on the second lateral part defines the second casting cavity. A fifth mold part on first base plate defines the first and second casting cavities. The first and second lateral parts are movable in second release direction. The first mold parts are moveably supported on guides of first base plate extending in second release direction.

Abstract: A die casting plunger tip includes a hollow outer portion and a hollow inner portion. The outer portion has a first closed end. The inner portion has a second partially closed end. The inner portion is disposed within the outer portion and the second partially closed end is adjacent the first closed end of the outer portion in an axial direction. A plurality of connectors connects the outer portion and the inner portion. A plenum is formed between the outer portion and the inner portion.

Abstract: A die casting plunger tip assembly includes a first portion having a closed end defining an outer face and a tip cover disposed on the outer face of the closed end. The tip cover includes a support structure extending from an inner surface of the tip cover toward the closed end. The support structure is positioned in contact with the outer face of the closed end and a cavity is formed between the outer face of the closed end and the tip cover.

Abstract: A system and method for continuous casting. The system includes a melt chamber, a withdrawal chamber, and a secondary chamber therebetween. The melt chamber can maintain a melting pressure and the withdrawal chamber can attain atmospheric pressure. The secondary chamber can include regions that can be adjusted to different pressures. During continuous casting operations, the first region adjacent to the melt chamber can be adjusted to a pressure that is at least slightly greater than the melting pressure; the pressure in subsequent regions can be sequentially decreased and then sequentially increased. The pressure in the final region can be at least slightly greater than atmospheric pressure. The differential pressures can form a dynamic airlock between the melt chamber and the withdrawal chamber, which can prevent infiltration of the melt chamber by non-inert gas in the atmosphere, and thus can prevent contamination of reactive materials in the melt chamber.

Abstract: A bonding method of a die bonder with a single conveyance lane and a single bonding head, or a plurality of conveyance lanes and a plurality of bonding heads includes the steps of generating a classification map of class dies with different electric properties on the wafer, which are classified in accordance with a plurality of grades, picking up the die from the wafer, bonding the die onto a substrate or the die using a bonding head, conveying a class substrate corresponding to the class die on the conveyance lane in a unit of the class substrate, and further bonding the class die to the corresponding class substrate based on the classification map.

Abstract: A shot sleeve for use in a die cast assembly has a shot sleeve body extending along an axis and having a bore for receiving a plunger. An insert is secured at a shot end of the shot sleeve body. A die cast assembly is also disclosed.

Abstract: A bonding structure enabling fast and reliable methods to fabricate a substantially homogeneous bondline with reduced dependency of a thickness limitation is disclosed. Also, this system creates a bondline targeted for performance in power electronics. This system is highly adaptable as various structures and fabrication options may be implemented. This enables diverse fabrication selection and creates less dependency on outside conditions. The disclosed system is at least applicable to wafer-to-wafer, die-to-wafer, die-to-substrate, or die-to-die bonding.