Abstract: A high pressure die casting (HPDC) system for casting ultra-large single-piece castings for vehicles. The HPDC system includes a clear feeding path from at least one ingate to a predetermined thicker section of a mold cavity, a last to solidify ingate having an equivalent or larger feeding modulus than the highest feeding modulus of the other ingates, and thermal management elements. The clear feeding path, last to solidify ingate, and thermal management elements ensure sufficient supplemental molten metal flow to the thicker portion of the mold cavity to accommodate for shrinkage of the thicker portion of an ultra large casting during the casting and solidification process.

Abstract: Methods of manufacturing a honeycomb structure comprise the step of providing a honeycomb body having a multiplicity of cells extending therethrough between opposing end faces. The cells are defined by intersecting porous walls. The methods further include the steps of applying an after-applied skin layer on the honeycomb body and chamfering an edge of the after-applied skin. The chamfering step is performed on a wet after-applied skin layer.

Abstract: The present invention provides methods for manufacturing a honeycomb filter having an after-applied skin with chamfered edges formed on the face-ends of the honeycomb filter structure. Apparatus for the manufacture of these honeycomb structures having after-applied skin with chamfered edges are also provided.