Abstract: A method of repairing a leak path formed through a casting defect in a die-cast part includes inserting a plug into threads of a bore formed in the die-cast part. A leak path is formed from the bore through the casting defect. The head of the plug may be sheared off, leaving a remaining length of the plug within the bore. The remaining length of the plug within the bore is pilot drilled to leave a shell of donor material around a wall of the bore. A mechanical bit is then operated within the bore and through the shell of donor material to generate plasticized local material along an inner surface of the bore. The plasticized local material flows into the casting defect to seal the leak path and produces a clean, sealed hole that is ready for tapping.

Abstract: A method of repairing a casting defect in a die-cast part includes operating a mechanical bit within a void space formed in a die-cast part to generate plasticized local material along an inner surface of the void space to close one or more casting defects in a vicinity of the void space. The void space may be a hole bored in the part, or a channel or passage formed in the part. The casting defect may be a porosity formed in the part. A tool for repairing a casting defect in a die-cast part includes a bit operable by a drill. The bit includes a shank and an elongated body extending in an axial direction from the shank. The body is configured to generate plasticized local material along a surface defining a void space in a die-cast part. The plasticized local material closes a casting defect formed in the part, and plasticized material may flow into the casting defect.

Abstract: A method of repairing a leak path formed through a casting defect in a die-cast part includes inserting a plug into threads of a bore formed in the die-cast part. A leak path is formed from the bore through the casting defect. The head of the plug may be sheared off, leaving a remaining length of the plug within the bore. The remaining length of the plug within the bore is pilot drilled to leave a shell of donor material around a wall of the bore. A mechanical bit is then operated within the bore and through the shell of donor material to generate plasticized local material along an inner surface of the bore. The plasticized local material flows into the casting defect to seal the leak path and produces a clean, sealed hole that is ready for tapping.

Abstract: A disc brake rotor for a vehicle is provided. The disc brake rotor includes a hat and a friction ring extending circumferentially from the hat. The disc brake rotor is formed of a cast hypereutectic aluminum alloy. The hypereutectic aluminum alloy includes: 14.00 to 25.00 wt. % of silicon; 4.90 to 8.00 wt. % of copper; 0.05 to 0.90 wt. % of nickel; 0.50 to 1.50 wt. % of magnesium; 0.05 to 1.20 wt. % of iron; 0.05 to 1.00 wt. % of manganese; 0.05 to 1.00 wt. % of zinc; 0.05 to 1.20 wt. % of titanium; 0.05 to 1.20 wt. % of zirconium; 0.05 to 1.20 wt. % of vanadium; 0.001 to 0.10 wt. % of phosphorous; and the balance aluminum. The alloy may also include other trace elements such as chromium, lead, and tin in an amount not exceeding 0.20 wt. %. The disc brake rotor may be formed by a high pressure, semi-solid die casting process including rheocasting.