Abstract: An apparatus and method are provided that increase yield and reduce cycle time. In particular, a gate plate for a die casting machine is configured to lessen the waste produced during die casting, resulting in greater yield. Further, the gate plate is configured with tapered sides to produce a draft, leading to less friction during the gate break/pull back sequence. This draft reduces the amount of unpressurized dwell time and subsequently the cycle time for producing the cast part.

Abstract: A method of making a cast product, includes heating an alloy to a temperature between about 1210 and 1470° F. so that the alloy is in a liquid state, injecting the alloy into a vertical die casting machine cavity, injecting the alloy into a mold having a gated configuration, wherein the injecting further comprises a shot velocity between 3-8 inches per second and a pressure between 5,000 and 14,000 psi, cooling the alloy in the mold, and forming the cast product, wherein the cast product is selected from a group consisting of suspension components, knuckles, control arms, transmission input housings, bed plates, swash plates, air conditioning compressor pistons, engine valve bodies, engine bed plates, transmission valve bodies, master cylinders, brake calipers, ABS braking components, shock mounts, engine bedplates, engine valve bodies and pump housings.

Abstract: To cast a part, an injectable form of an aluminum-copper (206) alloy is generated and the aluminum-copper (206) alloy is injected into a mold. This mold corresponds to the part. In addition, the aluminum-copper (206) alloy is solidified to generate the part and the part is ejected from the mold.

Abstract: An apparatus and method are provided that increase yield and reduce cycle time. In particular, a gate plate for a die casting machine is configured to lessen the waste produced during die casting, resulting in greater yield. Further, the gate plate is configured with tapered sides to produce a draft, leading to less friction during the gate break/pull back sequence. This draft reduces the amount of unpressurized dwell time and subsequently the cycle time for producing the cast part.

Abstract: An embodiment of the presently claimed invention includes an in-situ slurry formation apparatus mounted to die casting machines to convert liquid metal to semi-solid metal (SSM). Thus, there is no need to modify existing machines or change the cell layout to accommodate more space than would otherwise be necessary. These machines also need not be replaced with machines specially designed for SSM. Further, a method for converting molten metal to semi-solid metal includes coupling a conduit to a die casting machine, wherein the conduit comprises an inlet, an outlet and a body disposed between the inlet and the outlet, regulating the conduit's temperature, surrounding the conduit with a housing, inserting molten metal at the inlet, cooling the molten metal to semi-solid metal in the body, and expelling semi-solid metal from the outlet.

Abstract: A method of making a cast product, includes heating an alloy to a temperature between about 1210 and 1470° F. so that the alloy is in a liquid state, injecting the alloy into a vertical die casting machine cavity, injecting the alloy into a mold having a gated configuration, wherein the injecting further comprises a shot velocity between 3-8 inches per second and a pressure between 5,000 and 14,000 psi, cooling the alloy in the mold, and forming the cast product, wherein the cast product is selected from a group consisting of suspension components, knuckles, control arms, transmission input housings, bed plates, swash plates, air conditioning compressor pistons, engine valve bodies, engine bed plates, transmission valve bodies, master cylinders, brake calipers, ABS braking components, shock mounts, engine bedplates, engine valve bodies and pump housings.

Abstract: A method for the refining of primary aluminum in hypoeutectic alloys by mixing a titanium based grain refiner into a solid/semi-solid hypoeutectic slurry is described. The method provides control of the morphology, size, and distribution of primary Al in a hypoeutectic Al—Si casting by mixing a hypoeutectic Al—Si liquid with titanium boron alloys. The invention enables grain refining techniques for SSM casting of hypoeutectic Al—Si alloys.

Abstract: The method and apparatus of the present invention utilizes a computer and at least one pressure transducer for monitoring vacuum parameters in the operation of a die casting machine. A profile of the vacuum measurements are generated as a function of time and are graphically displayed on a shot monitor. The computer is optionally programmed with operator defined traces for comparison with acquired data profiles to segregate parts based on the comparison values.

Abstract: A method for the refining of primary silicon in hypereutectic alloys by mixing at least two hypereutectic alloys into a solid/semi-solid hypereutectic slurry is described. The method provides control of the morphology, size, and distribution of primary Si in a hypereutectic Al—Si casting by mixing a hypereutectic Al—Si liquid with solid hypereutectic Al—Si particles. The invention enables SSM processing of hypereutectic Al—Si alloys.

Abstract: A method for the refining of primary aluminum in hypoeutectic alloys by mixing at least two hypoeutectic alloys into a solid/semi-solid hypoeutectic slurry is described. The method provides control of the morphology, size, and distribution of primary Al in a hypoeutectic Al—Si casting by mixing a hypoeutectic Al—Si liquid with solid hypoeutectic Al—Si particles to impart desirable mechanical properties. The invention enables SSM molding of hypoeutiectic alloys without the need for secondary processing steps associated with other rheocasting processes.

Abstract: To cast a part, an injectable form of an aluminum-copper (206) alloy is generated and the aluminum-copper (206) alloy is injected into a mold. This mold corresponds to the part. In addition, the aluminum-copper (206) alloy is solidified to generate the part and the part is ejected from the mold.

Abstract: The method and apparatus of the present invention utilizes a computer and at least one pressure transducer for monitoring vacuum parameters in the operation of a die casting machine. A profile of the vacuum measurements are generated as a function of time and are graphically displayed on a shot monitor. The computer is optionally programmed with operator defined traces for comparison with acquired data profiles to segregate parts based on the comparison values.

Abstract: A method of semi-solid metal casting without the need for retrofitting of conventional casting equipment is provided. A method of direct-feed casting of semi-solid metals is also provided.

Abstract: A method for the refining of primary aluminum in hypoeutectic alloys by mixing at least two hypoeutectic alloys into a solid/semi-solid hypoeutectic slurry is described. The method provides control of the morphology, size, and distribution of primary Al in a hypoeutectic Al—Si casting by mixing a hypoeutectic Al—Si liquid with solid hypoeutectic Al—Si particles to impart desirable mechanical properties. The invention enables SSM molding of hypoeutiectic alloys without the need for secondary processing steps associated with other rheocasting processes.

Abstract: A method and product for semi-solid metal casting without the need for retrofitting of conventional casting equipment is provided. A semi solid method is used with a vertical indexing casting machine in which an indexing time can be used as the time to allow the metal that is heated to one temperature to cool to a second temperature before casting. The resulting product from the semi-solid metal casting method with the vertical indexing casting machine is also provided.

Abstract: A method for the refining of primary aluminum in hypoeutectic alloys by mixing a titanium based grain refiner into a solid/semi-solid hypoeutectic slurry is described. The method provides control of the morphology, size, and distribution of primary Al in a hypoeutectic Al-Si casting by mixing a hypoeutectic Al-Si liquid with titanium boron alloys. The invention enables grain refining techniques for SSM casting of hypoeutectic Al-Si alloys.

Abstract: A method for the refining of primary silicon in hypereutectic alloys by mixing at least two hypereutectic alloys into a solid/semi-solid hypereutectic slurry is described. The method provides control of the morphology, size, and distribution of primary Si in a hypereutectic Al—Si casting by mixing a hypereutectic Al—Si liquid with solid hypereutectic Al—Si particles. The invention enables SSM processing of hypereutectic Al—Si alloys.

Abstract: A method for the refining of primary aluminum in hypoeutectic alloys by mixing at least two hypoeutectic alloys into a solid/semi-solid hypoeutectic slurry is described. The method provides control of the morphology, size, and distribution of primary Al in a hypoeutectic Al—Si casting by mixing a hypoeutectic Al—Si liquid with solid hypoeutectic Al—Si particles to impart desirable mechanical properties. The invention enables SSM molding of hypoeutiectic alloys without the need for secondary processing steps associated with other rheocasting processes.