Abstract: A process for the casting of metals and their alloys includes the steps of providing at least a mold equipped with a plurality of cooling nozzles, making a layer of coolant permeable materials covering the nozzles and maintaining the materials at desired temperatures, delivering a molten metal into the mold, supplying predetermined amount of coolant to each nozzles to contact the casting at desired rate, time, and duration to achieve an acceptable level of progressive solidification from the distal end of the casting towards the riser until the casting has reached desired temperatures.

Abstract: A process for high integrity castings of metals and their alloys includes the steps of providing at least a sand mold at desired elevated temperatures, delivering a molten metal into the mold, and supplying a predetermined amount of coolant to contact the surfaces of the casting at desired rates, times, and durations to achieve an acceptable level of progressive solidification from the distal end of the casting towards the riser until the casting has reached desired temperatures.

Abstract: Components made of a metal matrix composite and methods for the manufacture thereof. The metal matrix composite contains TiB2 particles, Al3Ti particles, and particles of an intermetallic compound of aluminum and at least one rare earth element dispersed in an aluminum matrix. Methods include casting a first melt to produce an ingot, remelting the ingot to form a second melt, forming a powder from the second melt using an atomization process, and fabricating a component utilizing the powder in an additive manufacturing process. The ingot and the powder include an aluminum matrix that contains dispersions of TiB2 particles and Al3Ti particles.

Abstract: A method for accelerating the creep age forming of a metallic component is provided. The method includes the steps of applying static loading and ultrasound vibrations to the local regions on a metallic component during the creep age forming process. The transmission of ultrasound in the component enhances the mobility of dislocations and atoms and thus accelerates the creep deformation in the component.

Abstract: A process of reducing internal defects or enhancing mechanical properties in local regions in a solidified casting utilizes the combination effect of compression, high-intensity ultrasound, and heat on improving the local microstructure. The casting is brought to predetermined temperatures where plastic deformation in the local regions of the casting is produced under controlled conditions to close voids, breakup oxide films, and refine solidification structure.

Abstract: A process of forming an erosion, oxidation, and wear resistant shot chamber, either a gooseneck or a shot sleeve, is provided. The process utilizes a shrink fitting process for forming a one-piece shot chamber having a liner bonded to the bulk portion of the shot chamber. Channels of predetermined shape and layout are built on the tubular external surface of the liner for facilitating thermal management of the shot chamber during die casting operations.

Abstract: A process of reducing internal defects or enhancing mechanical properties in local regions in a casting utilizes the combined effect of compression, high-intensity ultrasound, heat, and feeding using extra material on improving the local microstructure. A modified version of the process can be used for accelerating the creep age forming process.

Abstract: A process of forming an erosion, oxidation, and wear resistant shot chamber, either a gooseneck or a shot sleeve, is provided. The process utilizes a self-healing erosive wear resistant coating on a liner of refractory metal to serve as the working surfaces of a shot chamber. Such a shot chamber is expected to have an improved service life for die casting of corrosive metals and alloys, including hot chamber die casting of aluminum alloys. An improved hot dipping process using stirring in the molten metal bath is also disclosed.

Abstract: A method of forming high quality metallurgical bonds in a composite casting is provided. The bonding technology includes the step of introducing a liquid material to contact the solid components placed in a mold cavity, applying an external field to generate stifling near the solid/liquid interface to wash off bubbles and oxide particles that prevent the liquid material from reacting to the solid component, and causing progressive solidification from the surfaces of the solid component to the liquid to drive away bubbles in the mushy zone near the bonding region. High quality metallurgical bonds are formed within the composite casting after the liquid solidifies. The resultant large composite casting has minimal defects, such as pores and oxides, at the interfaces between the solidified material and the solid objects.

Abstract: Lubricant compositions and methods of producing die-cast products by applying such a lubricant composition to a working surface of a die prior to casting a product from a molten metal injected into the die. The composition serves as lubricant between the die and resulting product, and contains at least one active component that reacts with an oxide of the metal to remove a layer of the oxide that forms on a surface of the melt during the die casting process.

Abstract: A method of producing flakes containing nanostructures from a part made of a material. The method includes subjecting the part made of the material to peening by shots driven by ultrasonic energy for a period of time, wherein nano structures form on the surface of the part and, subsequently, damage to the part caused by continued peening of the part by the shots driven by ultrasonic energy results in separation of flakes containing nanostructures from the part made of the material. Nanocrystalline flakes containing fractured surfaces, microcracks, nanograins and nanolamellae. Sensors comprising nanocrystalline flakes containing fractured surfaces, microcracks, nanograins and nanolamellae.

Abstract: Components made of a metal matrix composite and methods for the manufacture thereof. The metal matrix composite contains TiB2 particles, Al3Ti particles, and particles of an intermetallic compound of aluminum and at least one rare earth element dispersed in an aluminum matrix. Methods include casting a first melt to produce an ingot, remelting the ingot to form a second melt, forming a powder from the second melt using an atomization process, and fabricating a component utilizing the powder in an additive manufacturing process. The ingot and the powder include an aluminum matrix that contains dispersions of TiB2 particles and Al3Ti particles.

Abstract: A process of forming a low cost, erosion, oxidation, and wear resistant composite liner or insert that can be installed into a shot chamber in a die casting machine is provided. The process utilizes a self-healing erosive wear resistant coating on a liner of refractory metal to serve as the working surfaces of a shot chamber. The refractory liner is bonded to a low cost material so that the liner can be made extremely thin. Such a composite liner is expected to have an improved service life for die casting of corrosive metals and alloys.

Abstract: An acoustic rotary liquid processor coupled with high-intensity ultrasonic vibration, rotary stiffing, gas purging, and melt surface stabilizing is described. The processor can be used for the synthesis of particulate reinforced composite materials, scavenging dissolved gases in molten materials, and preparation of a slurry containing a small fraction of non-dendritic solid particles for semi-solid material processing.

Abstract: A method and apparatus for producing semi-solid material castings from its liquid state in a shot chamber of a die casting machine where the liquid material is poured into a shot chamber and rapidly cooled from its liquid state to temperatures below its liquidus. High-intensity ultrasonic vibration is coupled to the plunger, shot plate, or sprue-spreader while the cast material is injected by the plunger to fill the die cavity. The combined action of rapid cooling from the shot chamber, vigorous pushing by the plunger, and radiation of ultrasonic vibration on the cast material in the shot chamber directly turns the initial liquid material directly into a semi-solid slurry by breaking up dendrites and making these dendritic fragments globular. The slurry is then injected into the die cavity to form a casting.

Abstract: A process for the casting of metals and their alloys includes the steps of providing at least a mold equipped with a plurality of cooling nozzles, making a layer of coolant permeable materials covering the nozzles and maintaining the materials at desired temperatures, delivering a molten metal into the mold, supplying predetermined amount of coolant to each nozzles to contact the casting at desired rate, time, and duration to achieve an acceptable level of progressive solidification from the distal end of the casting towards the riser until the casting has reached desired temperatures.

Abstract: Methods for manufacturing components that include casting a first melt to produce an ingot, remelting the ingot to form a second melt, forming a powder from the second melt using an atomization process, and fabricating a component utilizing the powder in an additive manufacturing process. The ingot and the powder include an aluminum matrix that contains dispersions of TiB2 particles and Al3Ti particles and the component is a metal matrix composite having an aluminum matrix that contains dispersions of TiB2 particles and Al3Ti particles. Optionally, the metal matrix composite may include particles of an intermetallic compound of aluminum and at least one alloying element.

Abstract: A process of reducing internal defects or enhancing mechanical properties in local regions in a casting utilizes the combined effect of compression, high-intensity ultrasound, heat, and feeding using extra material on improving the local microstructure. A modified version of the process can be used for accelerating the creep age forming process.

Abstract: A method and apparatus for producing solid alloy components from its liquid state are provided. The molten alloy is rapidly cooled using a chill to temperatures below the thermosolutal transition temperature of the alloy. Finite-amplitude acoustic vibration is applied on the chill to shake off dendrites that form on the chill surface, to stir the slurry containing the fragments of dendrites, and to shake off slurry material that sticks on the surface of the chill as the chill is separating from the slurry. The slurry is then immediately poured into a chamber of a forming machine or a mold cavity shaped into solid components.

Abstract: Methods of ultrasound assisted 3D printing and welding involve the use of an ultrasonic sonotrode placed in on top of the solidified layer in the vicinity of a melt pool. The sonotrode, pressed against the solidified materials at the edge of the melt pool, is synchronized with the heat source such that it travels side-by-side with the melt pool to transmit ultrasonic vibrations to the solidifying melt pool, reducing hot tearing and porosity formation, and to consolidate the solidified materials under the sonotrode. The methods of the present invention are capable of making a large variety of commercially important alloys 3D printable and weldable.