Abstract: A composite material includes a porous substrate covered by thermoplastic foil. The porous substrate has a top side, a bottom side, and a plurality of gaps connecting the top side with the bottom side. The thermoplastic foil covers the top side and the bottom side, and fills the gaps. A method for preparing the composite material includes the steps of preparing a porous substrate having a top side, a bottom side, and a plurality of gaps connecting the top side with the bottom side. A top foil is placed on the top side and a bottom foil is placed on the bottom side, and a force is then applied to the top foil at a predetermined temperature, thereby filling the gaps with the top foil or the bottom foil.

Abstract: A method of making a molding tool includes: preparing an imprinting master having a surface relief pattern; applying a curable material on a flexible film; embossing the curable material on the flexible film using the imprinting master so as to transfer the surface relief pattern to the curable material; curing the embossed curable material so as to form a patterned-and-cured material; attaching and conforming the flexible film to a non-planar surface of a model; forming a thin metal film over the patterned-and-cured material; electroforming a metal layer over the thin metal film so as to form a molding tool of the metal layer; and removing the molding tool from the thin metal film.

Abstract: This invention discloses a method of selective plastic insert molding on metal component and its product. A metal joint component is bonded with a metal component. After which, the joint component is submerged in plastic so that the molded plastic can be secured on the metal component firmly. Hence, a desired plastic structure can be formed on the metal component. This invention can shorten the manufacturing process and reduce the cost. In addition, it solves the traditional bonding problem between the plastic and the metal component as well as the problem concerning processing time and high cost.

Abstract: An apparatus for producing a thixotropic metallic melt by simultaneously controlledly cooling and stirring the melt to form solid particles of a first phase suspended in a residual liquid second phase. Vigorous stirring of the metallic melt results in the formation of degenerate dendritic particles having substantially spheroidal shapes. The metallic melt is stirred to rapidly and efficiently circulate the forming semi-solid slurry. Circulation of the forming semi-solid slurry results in a substantially uniform temperature throughout. Through precision stirring and cooling, a semi-solid slurry is formed having a first solid phase of about 70–80 wt. % suspended in a second liquid phase.

Abstract: A method and apparatus to improve the atomization of liquid and the efficiency of depositing liquid particles onto target objects, or to coat the target object with a thin film of liquid, to reduce the risk of high-voltage electrical shock, and to reduce the weight of an electrostatic spray system has been developed by inducing electrostatic charges onto the atomized liquid particles sprayed from a grounded metal nozzle.

Abstract: A container system including a vessel for holding a thixotropic semi-solid aluminum alloy slurry during its processing as a billet and an ejection system for cleanly discharging the processed thixotropic semi-solid aluminum billet. The crucible is preferably formed from a chemically and thermally stable material (such as graphite or a ceramic). The crucible defines a mixing volume. The crucible ejection mechanism may include a movable bottom portion mounted on a piston or may include a solenoid coil for inducing an electromotive force in the electrically conducting billet for urging it from the crucible. During processing, a molten aluminum alloy precursor is transferred into the crucible and vigorously stirred and controlledly cooled to form a thixotropic semi-solid billet. Once the billet is formed, the ejection mechanism is activated to discharge the billet from the crucible. The billet is discharged onto a shot sleeve and immediately placed in a mold and molded into a desired form.

Abstract: A numerical procedure for simulating the behavior of incompressible, viscous fluid in a casting/molding process. The method is based on classical fluid dynamic equations and uses control volume-finite element and numerical techniques to solve the momentum and energy equations to obtain solution for the variable parameters. The method incorporates five additional modules which simulate fluid flow in the shot sleeve, heat transfer between the die and the heat transfer fluid, die cooling by lubricant, formation of mend line. These additional simulation modules produce realistic boundary conditions, and replace many of the assumptions that would have to be made, to solve the governing equations. These added improvements ensure a faster convergence of the numerical solution and a more realistic simulation of the die casting process.

Abstract: A method and apparatus for stirring a molten thixotropic aluminum alloy comprising a first solid particulate phase suspended in a second liquid phase so as to maintain its thixotropic character by degenerating forming dendritic particles into spheroidal particles while simultaneously equilibrating the melt temperature by quickly transferring heat between the melt and its surroundings. The melt is stirred by a magnetomotive force field generated by a stacked stator assembly. The stacked stator assembly includes a stator ring adapted to generate a linear/longitudinal magnetic field positioned between two stator rings adapted to generate a rotational magnetic field. The stacked stator rings generate a substantially spiral magnetomotive mixing force and define a substantially cylindrical mixing region therein.

Abstract: A die-casting method and a device for use in the die-casting method are disclosed. The casting material, which can be liquid metal, semi-solid metal or metal-matrix composite, in the shot chamber of a die-casting machine is driven to flow with high shear rate to mix homogeneously by the electromotive force induced with at least one low-frequency shifting electromagnetic field. The temperature and the microstructure of the casting material near the shot chamber are further controlled and perturbed by at least one high-frequency electromagnetic field to minimize the temperature difference or the growth of dendritic microstructure. To ensure the efficiency of the electromagnetic fields, the shot chamber is made of non-magnetic material and its wall thickness is less than three times the penetration depth of the electromagnetic fields. The shot chamber is surrounded by at least one solenoid coil, a conducting shield and at least one electric motor stator.

Abstract: An apparatus for producing a thixotropic metallic melt by simultaneously controlledly cooling and stirring the melt to form solid particles of a first phase suspended in a residual liquid second phase. Vigorous stirring of the metallic melt results in the formation of degenerate dendritic particles having substantially spheroidal shapes. The metallic melt is stirred to rapidly and efficiently circulate the forming semi-solid slurry. Circulation of the forming semi-solid slurry results in a substantially uniform temperature throughout. Through precision stirring and cooling, a semi-solid slurry is formed having a first solid phase of about 70-80 wt. % suspended in a second liquid phase.

Abstract: A container system including a vessel for holding a thixotropic semi-solid aluminum alloy slurry during its processing as a billet and an ejection system for cleanly discharging the processed thixotropic semi-solid aluminum billet. The crucible is preferably formed from a chemically and thermally stable material (such as graphite or a ceramic). The crucible defines a mixing volume. The crucible ejection mechanism may include a movable bottom portion mounted on a piston or may include a solenoid coil for inducing an electromotive force in the electrically conducting billet for urging it from the crucible. During processing, a molten aluminum alloy precursor is transferred into the crucible and vigorously stirred and controlledly cooled to form a thixotropic semi-solid billet. Once the billet is formed, the ejection mechanism is activated to discharge the billet from the crucible. The billet is discharged onto a shot sleeve and immediately placed in a mold and molded into a desired form.

Abstract: An apparatus for producing a thixotropic metallic melt by simultaneously controlledly cooling and stirring the melt to form solid particles of a first phase suspended in a residual liquid second phase. Vigorous stirring of the metallic melt results in the formation of degenerate dendritic particles having substantially spheroidal shapes. The metallic melt is stirred to rapidly and efficiently circulate the forming semi-solid slurry. Circulation of the forming semi-solid slurry results in a substantially uniform temperature throughout. Through precision stirring and cooling, a semi-solid slurry is formed having a first solid phase of about 70-80 wt. % suspended in a second liquid phase.

Abstract: A container system including a vessel for holding a thixotropic semi-solid aluminum alloy slurry during its processing as a billet and an ejection system for cleanly discharging the processed thixotropic semi-solid aluminum billet. The crucible is preferably formed from a chemically and thermally stable material (such as graphite or a ceramic). The crucible defines a mixing volume. The crucible ejection mechanism may include a movable bottom portion mounted on a piston or may include a solenoid coil for inducing an electromotive force in the electrically conducting billet for urging it from the crucible. During processing, a molten aluminum alloy precursor is transferred into the crucible and vigorously stirred and controlledly cooled to form a thixotropic semi-solid billet. Once the billet is formed, the ejection mechanism is activated to discharge the billet from the crucible. The billet is discharged onto a shot sleeve and immediately placed in a mold and molded into a desired form.

Abstract: A method of producing on-demand, semi-solid material for a casting process includes the steps of first heating a metal alloy until it reaches a molten state and maintaining that molten state within a desired temperature range. The next step is to ladle out a portion of the molten alloy and transfer it into a processing vessel. In one arrangement the vessel is configured with its own cooling arrangement so as to begin the solidification process for the molten alloy. In another embodiment, a thermal jacket is used to facilitate the cooling of the vessel and accordingly the cooling of the molten alloy. The next step is to apply an electromagnetic field to the molten alloy in order to create a stirring action which results in a desired flow pattern of the molten alloy within the vessel. The electromagnetic stirring begins as soon as the molten alloy is placed in the vessel and continues while the cooling continues in order to create a slurry billet of the desired metallurgical composition.

Abstract: An apparatus for producing a metallic slurry material for use in semi-solid forming of a shaped part. The apparatus is generally comprised of a forming vessel and a thermal jacket. The forming vessel defines an inner volume for containing the metallic slurry material and has an outer surface. The thermal jacket has an inner surface disposed in thermal communication with the outer surface of the forming vessel to effectuate heat transfer therebetween. At least one of the forming vessel and the thermal jacket defines a number of grooves to limit the rate of heat transfer adjacent the grooves. In one embodiment, the forming vessel defines a plurality of axially-offset grooves extending about the entire periphery of the outer surface of the forming vessel. In another embodiment, a stator is disposed about the thermal jacket to impart an electromagnetic stirring force to the metallic slurry material contained within the forming vessel.

Abstract: An apparatus for producing a metallic slurry material for use in semi-solid forming of a shaped part. The apparatus is generally comprised of a forming vessel and a thermal jacket. The forming vessel defines an inner volume for containing the metallic slurry material and has an outer surface. The thermal jacket has an inner surface disposed in thermal communication with the outer surface of the forming vessel to effectuate heat transfer therebetween. At least one of the forming vessel and the thermal jacket defines a number of grooves to limit the rate of heat transfer adjacent the grooves. In one embodiment, the forming vessel defines a plurality of axially-offset grooves extending about the entire periphery of the outer surface of the forming vessel. In another embodiment, a stator is disposed about the thermal jacket to impart an electromagnetic stirring force to the metallic slurry material contained within the forming vessel.

Abstract: A die-casting method and a device for use in the die-casting method are disclosed. The casting material, which can be liquid metal, semi-solid metal or metal-matrix composite, in the shot chamber of a die-casting machine is driven to flow with high shear rate to mix homogeneously by the electromotive force induced with at least one low-frequency shifting electromagnetic field. The temperature and the microstructure of the casting material near the shot chamber are further controlled and perturbed by at least one high-frequency electromagnetic field to minimize the temperature difference or the growth of dendritic microstructure. To ensure the efficiency of the electromagnetic fields, the shot chamber is made of non-magnetic material and its wall thickness is less than three times the penetration depth of the electromagnetic fields. The shot chamber is surrounded by at least one solenoid coil, a conducting shield and at least one electric motor stator.

Abstract: A method and apparatus to improve the atomization of liquid and the efficiency of depositing liquid particles onto target objects, or to coat the target object with a thin film of liquid, to reduce the risk of high-voltage electrical shock, and to reduce the weight of an electrostatic spray system has been developed by inducing electrostatic charges onto the atomized liquid particles sprayed from a grounded metal nozzle.

Abstract: A method and apparatus for stirring a molten thixotropic aluminum alloy comprising a first solid particulate phase suspended in a second liquid phase so as to maintain its thixotropic character by degenerating forming dendritic particles into spheroidal particles while simultaneously equilibrating the melt temperature by quickly transferring heat between the melt and its surroundings. The melt is stirred by a magnetomotive force field generated by a stacked stator assembly. The stacked stator assembly includes a stator ring adapted to generate a linear/longitudinal magnetic field positioned between two stator rings adapted to generate a rotational magnetic field. The stacked stator rings generate a substantially spiral magnetomotive mixing force and define a substantially cylindrical mixing region therein.

Abstract: The present invention provides a method for solving the Navier-Stokes equation of viscous, incompressible laminar flows with moving free surfaces in complex domains. The method uses fixed mesh control volume-finite element techniques to track the flow. A gauss point velocity vector is defined as the average of its nodal counterpart, such that the gauss point velocity vector is constant over the element. The gauss point velocity vector is then inserted into the continuity constraint to form the Poisson pressure equation for solving the pressure field. The solution to the Poisson pressure equation is unique, the common checker-board problem is therefore eliminated. The corrected pressure field is substituted into the momentum equations, so that the resulting velocity field satisfies the continuity equation. Since velocity and pressure are evaluated at the same order, the global mass conservation can be evaluated to machine round-off tolerances.