Abstract: Methods for replacing an impingement site of a shot sleeve with an erosion resistant material, for manufacturing a shot sleeve for high pressure die casting of Aluminum Silicon alloys having an erosion resistant material at an impingement site, and for manufacturing a shot sleeve for high pressure die casting of aluminum silicon alloys containing 0.40% max Fe, having an erosion resistant material at an impingement site are disclosed. The shot sleeve assembly includes a shot sleeve including a pouring hole and a, impingement site. In certain embodiments a bushing assembly is implemented. The impingement site or bushing assembly includes a refractory metal tube constructed of erosion resistant material.

Abstract: A slide for the high pressure die casting of at least one closed deck engine block having at least one cylinder is disclosed. The slide includes a tool steel portion with reliefs for forming a water jacket surrounding each cylinder. At least one expendable core is located in each relief, the expendable core having an inner surface and an outer surface with an aperture extending therethrough. The outer surface and inner surface of the expendable core is coextensive with an inner surface and outer surface of the tool steel portion. A method for high pressure die casting a closed deck engine block using the disclosed slide and expendable cores is also disclosed. The expendable cores are separable from the reliefs in the slide, and form bridges or supports across a water jacket to add stiffness and rigidity to the cast engine cylinders.

Abstract: Methods for replacing an impingement site of a shot sleeve with an erosion resistant material, for manufacturing a shot sleeve for high pressure die casting of Aluminum Silicon alloys having an erosion resistant material at an impingement site, and for manufacturing a shot sleeve for high pressure die casting of aluminum silicon alloys containing 0.40% max Fe, having an erosion resistant material at an impingement site are disclosed. The shot sleeve assembly includes a shot sleeve including a pouring hole and a, impingement site. In certain embodiments a bushing assembly is implemented. The impingement site or bushing assembly includes a refractory metal tube constructed of erosion resistant material.

Abstract: A slide for the high pressure die casting of at least one closed deck engine block having at least one cylinder is disclosed. The slide includes a tool steel portion with reliefs for forming a water jacket surrounding each cylinder. At least one expendable salt core is located in each relief, the salt core having an inner surface and an outer surface with an aperture extending therethrough. The outer surface and inner surface of the salt core is coextensive with an inner surface and outer surface of the tool steel portion. A method for high pressure die casting a closed deck engine block using the disclosed slide and expendable salt cores is also disclosed. The expendable salt cores are separable from the reliefs in the slide, and form bridges or supports across a water jacket to add stiffness and rigidity to the cast engine cylinders.

Abstract: A shot sleeve assembly for use in the high pressure die casting of aluminum silicon alloys containing 0.40% maximum Fe is also disclosed. The shot sleeve assembly includes a shot sleeve including a pouring hole and a bushing assembly. The bushing assembly includes a refractory metal tube constructed of erosion resistant material surrounded by a bushing of conventional tool steel. The tube includes an opening and an impingement site located opposite the opening. The bushing includes an opening aligned with the opening of the tube, and an end plate. The bushing assembly is readily removed and inserted into the shot sleeve such that the openings of the bushing assembly align with the pouring hole of the shot sleeve. A method of replacing an impingement site of a shot sleeve with an erosion resistant material is also disclosed.

Abstract: A hypereutectic aluminum silicon high pressure die cast alloys is disclosed herein having 16% to 23% by weight silicon, 0.01% to 1.5% by weight iron, 0.01% to 0.6% by weight manganese, 0.01% to 1.3% by weight magnesium, 0.05% to 0.20% by weight strontium and the balance aluminum. The iron constituency may me modified to 0.01% to 0.7% by weight iron, or 0.01% to 0.2% by weight iron. The manganese constituency may be modified to 0.01% to 0.5% by weight manganese. The strontium constituency may be modified to 0.05% to 0.1% by weight strontium. The exhibits an elongation of at least 2%, an average ultimate tensile strength of greater than 250 MPa, and yield strength of greater than 200 MPa. The microstructure has a volume fraction of primary silicon at greater than 10% and a volume fraction of modified aluminum-silicon eutectic at 45% to 90%.

Abstract: A method and alloys for low pressure permanent mold casting without a coating are disclosed. The method includes preparing a permanent mold casting die that is devoid of die coating or lubrication along the die surface, preparing a permanent mold casting alloy, pushing the alloy into the die under low pressure, cooling the permanent mold casting, and removing the casting from the die. One alloy has 4.5-11.5% by weight silicon; 0.45% by weight maximum iron; 0.20-0.40% by weight manganese; 0.045-0.110% by weight strontium; 0.05-5.0% by weight copper; 0.01-0.70% by weight magnesium; and the balance aluminum. Another alloy has 4.2-5.0% by weight copper; 0.005-0.45% by weight iron; 0.20-0.50% by weight manganese; 0.15-0.35% by weight magnesium; 0.045-0.110% by weight strontium; 0.50% by weight maximum nickel; 0.10% by weight maximum silicon; 0.15-0.30% by weight titanium; 0.05% by weight maximum tin; 0.10% by weight maximum zinc; and the balance aluminum.

Abstract: A slide for the high pressure die casting of at least one closed deck engine block having at least one cylinder is disclosed. The slide includes a tool steel portion with reliefs for forming a water jacket surrounding each cylinder. At least one expendable salt core is located in each relief, the salt core having an inner surface and an outer surface with an aperture extending therethrough. The outer surface and inner surface of the salt core is coextensive with an inner surface and outer surface of the tool steel portion. A method for high pressure die casting a closed deck engine block using the disclosed slide and expendable salt cores is also disclosed. The expendable salt cores are separable from the reliefs in the slide, and form bridges or supports across a water jacket to add stiffness and rigidity to the cast engine cylinders.

Abstract: A method and alloys for low pressure permanent mold casting without a coating are disclosed. The method includes preparing a permanent mold casting die that is devoid of die coating or lubrication along the die surface, preparing a permanent mold casting alloy, pushing the alloy into the die under low pressure, cooling the permanent mold casting, and removing the casting from the die. One alloy has 4.5-11.5% by weight silicon; 0.45% by weight maximum iron; 0.20-0.40% by weight manganese; 0.45-0.110% by weight strontium; 0.05-5.0% by weight copper; 0.01-0.70% by weight magnesium; and the balance aluminum. Another alloy has 4.2-5.0% by weight copper; 0.005-0.45% by weight iron; 0.20-0.50% by weight manganese; 0.15-0.35% by weight magnesium; 0.045-0.110% by weight strontium; 0.50% by weight maximum nickel; 0.10% by weight maximum silicon; 0.15-0.30% by weight titanium; 0.05% by weight maximum tin; 0.10% by weight maximum zinc; and the balance aluminum.

Abstract: A hypereutectic aluminum silicon high pressure die cast alloys is disclosed herein having 16% to 23% by weight silicon, 0.01% to 1.5% by weight iron, 0.01% to 0.6% by weight manganese, 0.01% to 1.3% by weight magnesium, 0.05% to 0.20% by weight strontium and the balance aluminum. The iron constituency may me modified to 0.01% to 0.7% by weight iron, or 0.01% to 0.2% by weight iron. The manganese constituency may be modified to 0.01% to 0.5% by weight manganese. The strontium constituency may be modified to 0.05% to 0.1% by weight strontium. The exhibits an elongation of at least 2%, an average ultimate tensile strength of greater than 250 MPa, and yield strength of greater than 200 MPa. The microstructure has a volume fraction of primary silicon at greater than 10% and a volume fraction of modified aluminum-silicon eutectic at 45% to 90%.

Abstract: An improved shot sleeve for high pressure die casting of low-iron aluminum silicon alloys and a method of making the shot sleeve, the shot sleeve includes a top portion including a pouring hole and a bottom portion including an impingement site on an inner surface of the bottom portion opposite the pouring hole. The impingement site is constructed of an erosion resistant material. The erosion resistant material is selected from: titanium, tungsten, molybdenum, ruthenium, tantalum, niobium, chromium, vanadium, zirconium, hafnium, boron or a secondary, tertiary or quaternary alloy formed from combination thereof. An erosion resistant insert located at an impingement site of a shot sleeve may accomplish the construction. The insert may be introduced into an internal surface of a conventional shot sleeve or replace a bottom portion of a conventional shot sleeve.

Abstract: An improved shot sleeve for high pressure die casting of low-iron aluminum silicon alloys and a method of making the shot sleeve, the shot sleeve includes a top portion including a pouring hole and a bottom portion including an impingement site on an inner surface of the bottom portion opposite the pouring hole. The impingement site is constructed of an erosion resistant material. The erosion resistant material is selected from: titanium, tungsten, molybdenum, ruthenium, tantalum, niobium, chromium, vanadium, zirconium, hafnium, boron or a secondary, tertiary or quaternary alloy formed from combination thereof. An erosion resistant insert located at an impingement site of a shot sleeve may accomplish the construction. The insert may be introduced into an internal surface of a conventional shot sleeve or replace a bottom portion of a conventional shot sleeve.

Abstract: A hypereutectic aluminum-silicon alloy is disclosed herein containing 18-20% by weight silicon, 0.03-0.20% by weight strontium and the balance aluminum, and alternatively with 3.0-6.0% by weight nickel. The alloy is substantially free of copper and manganese, but for any impurities that may exist. The alloy may also be substantially free of iron, but up to 1.2% by weight iron is permitted in certain embodiments. A more narrow strontium content of 0.05-0.10% by weight, may be used and the alloy may further include 0.3-1.2% by weight magnesium. In some embodiments 0.1-2.0% by weight nickel may be substituted with 0.1-2.0% by weight cobalt. The alloy of the present invention is preferably die cast resulting in castings that have a highly refined primary silicon microstructure with a modified eutectic structure and are highly ductile, but avoid soldering to the die casting dies.

Abstract: An improved shot sleeve for high pressure die casting of low-iron Aluminum Silicon alloys and a method of making the shot sleeve, the shot sleeve includes a top portion including a pouring hole and a bottom portion including an impingement site on an inner surface of the bottom portion opposite the pouring hole. The impingement site is constructed of an erosion resistant material. The erosion resistant material is selected from: titanium, tungsten, molybdenum, ruthenium, tantalum, niobium, chromium, vanadium, zirconiwn, hafnium or a secondary, tertiary or quaternary alloy formed from combination thereof. An erosion resistant insert located at an impingement site of a shot sleeve may accomplish the construction. The insert may be introduced into an internal surface of a conventional shot sleeve or replace a bottom portion of a conventional shot sleeve.

Abstract: An improved shot sleeve for high pressure die casting of low-iron Aluminum Silicon alloys and a method of making the shot sleeve, the shot sleeve includes a top portion including a pouring hole and a bottom portion including an impingement site on an inner surface of the bottom portion opposite the pouring hole. The impingement site is constructed of an erosion resistant material. The erosion resistant material is selected from: titanium, tungsten, molybdenum, ruthenium, tantalum, niobium, chromium vanadium, zirconium, hafnium or a secondary, tertiary or quaternary alloy formed from combination thereof. An erosion resistant insert located at an impingement site of a shot sleeve may accomplish the construction. The insert may be introduced into an internal surface of a conventional shot sleeve or replace a bottom portion of a conventional shot sleeve.

Abstract: A nickel containing hypereutectic aluminum-silicon sand cast alloy is disclosed herein containing 18-20% by weight silicon, 0.3-1.2% by weight magnesium, 3.0-6.0% by weight nickel, 0.6% by weight maximum iron, 0.4% by weight maximum copper, 0.6% by weight maximum manganese, 0.1% maximum zinc and balance aluminum. The alloy may have a more narrow nickel content of 4.5%-6.0% by weight, and up to 2% by weight cobalt. The alloy may be substantially free from iron, copper and manganese. The alloy of the present invention is preferably sand cast, and most preferably lost foam cast with a pressure of 10 ATM to produce engine parts with high thermal properties that are easily machined.

Abstract: A method for manufacturing a connecting rod for an engine contemplates creating a rough connecting rod from high carbon steel. The rough connecting rod is normalized to provide strength and toughness characteristics to the core of the connecting rod for functional operation. A first, second or both ends of the connecting rod are selectively induction hardened to create a durable martensitic structure in those ends. The connecting rod is then cracked and ground to form a final connecting rod for use in internal combustion engines.

Abstract: An aluminum silicon die cast alloy having a very low iron content and relatively high strontium content that prevents soldering to dies into die casting process. The alloys of the present invention also have a modified eutectic silicon and modified iron morphology, when iron is present, resulting in low microporosity and high impact properties. The alloy comprises 6-22% by weight silicon, 0.05 to 0.20% by weight strontium and the balance aluminum. Preferably, the alloy of the present invention contains in weight percent: 6-20% silicon, 0.05-0.10% strontium, 0.40% maximum iron and most preferably 0.20% maximum iron, 4.5% maximum copper, 0.50% maximum manganese, 0.60% maximum magnesium, 3.0% maximum zinc, balance aluminum. On cooling from the solution temperature, the strontium serves to modify the eutectic silicon structure as well as create an iron phase morphology change if iron is present, facilitating feeding through the aluminum interdendritic matrix.

Abstract: An aluminum-silicon lost foam casting alloy having reduced microporosity and a method for casting the same is herein disclosed. A preferred lost foam cast alloy consists essentially of 6 to 12% by weight silicon and preferably 9.0 to 9.5% by weight silicon, 0.035-0.30% strontium, 0.40% maximum iron, 0.45% maximum copper, 0.49% maximum manganese, 0.60% maximum magnesium, 3.0% maximum zinc, and the balance aluminum. Most preferably, the lost foam alloy is free from iron, titanium and boron. However, such elements may exist at trace levels. Most preferably, the alloy is lost foam cast with the process that applies at least 10 atmospheres of pressure during solidification. However, the range may be 5 to 60 atmospheres. The strontium addition is greater than 0.005% by weight and most preferably greater than 0.05% by weight.

Abstract: Provided herein is a method for refining primary silicon present in a hypereutectic aluminum silicon alloy. The method contemplates the controlled application of pressure to refine the primary silicon during the casting of articles. The application of pressure decreases the primary silicon particle size to improve the machinability and wear resistance of the final cast articles.