Abstract: Disclosed is, according to an aspect, a metal-molded article, including: (i) a body molded in association with a mold assembly, and (ii) a hollow insert embedded, at least in part, in the body. The body has a light-metal alloy that was injected, under pressure, into the mold assembly.

Abstract: A method of applying a physical barrier to suppress thermal decomposition near a surface of a thermoelectric material including applying a continuous metal foil to a predetermined portion of the surface of the thermoelectric material, physically binding the continuous metal foil to the surface of the thermoelectric material using a binding member, and heating in a predetermined atmosphere the applied and physically bound continuous metal foil and the thermoelectric material to a sufficient temperature in order to promote bonding between the continuous metal foil and the surface of the thermoelectric material. The continuous metal foil forms a physical barrier to enclose a predetermined portion of the surface. Thermal decomposition is suppressed at the surface of the thermoelectric material enclosed by the physical barrier when the thermoelectric element is in operation.

Abstract: Methods for manufacturing components capable of transporting a liquid including providing a mold, placing at least one core made from a core material into the mold, injecting a component material into the mold about the core to produce a green component, heating the green component to burn out the core and produce a brown component, and sintering the brown component to produce a finished component capable of transporting a liquid wherein the finished component is from about 95% to about 99% dense.

Abstract: A cold-chamber die-casting apparatus and method for making a die-cast part with an open space within the geometry of the part. The apparatus includes an injection shaft which receives molten material for casting the part. The molten material is pushed with a plunger through a gate and into a tool cavity corresponding to the part. The gate is disposed at an end of the injection shaft and adjacent the tool cavity at a position that corresponds to the open space of the part and is inside the geometry of the part.

Abstract: A injection-molding process injects a semi-solid slurry with a solids content ranging from approximately 60% to 85% into a mold at a velocity sufficient to completely fill the mold. The slurry is injected under laminar or turbulent flow conditions and produces a molded article that has a low internal porosity.

Abstract: An insert for a die casting assembly. The insert comprises a cast iron insert having a first end, a second end and a body disposed between the first end and the second end, the body having a pour aperture in communication with a pour hole of a shot sleeve. The insert is removeably positioned within a groove of the shot sleeve wherein the molten material that is dispensed from the pour hole and into the pour aperture initially contacts the cast iron insert when the molten material flows into the cast iron insert such that the cast iron insert withstands heat erosion effects applied by the molten material to provide a smooth path for the plunger as the plunger reciprocates within a sleeve bore of the shot sleeve and pushes the molten material into a mold cavity.

Abstract: Disclosed is a process having an operation. The operation includes near-liquidus rheomolding of a molten light-metal alloy being injectable, under pressure, into a mold.

Abstract: A vehicle wheel includes a hub, a plurality of spokes and a rim. The plurality of spokes radially extend from the hub. The rim is carried at outer ends of the plurality of spokes and circumscribe the wheel. At least the plurality of spokes is injection molded of a magnesium alloy.

Abstract: A metal alloy is heated to a molten state and then poured into a shallow shot chamber defined by a shot sleeve and a shot piston of a vertical die cast press. A homogenizing member having L-shape arms projecting outwardly from a vertical shaft is inserted into the molten metal, and the shaft and arms are simultaneously rotated and orbited by a six axes robot for moving more solidified semi-solid metal cooled by the shot sleeve and shot piston into a more liquified semi-solid metal within a central portion of the shot chamber to form a homogenizing slurry. The force required to move the homogenizing member is used to determine the solid fraction of the slurry and to stop the homogenizing process after a predetermined force is detected. A hydraulic cylinder actuates the piston to transfer the semi-solid slurry upwardly from the shot chamber into a die cavity.

Abstract: A positioning plate of this invention comprises an outer side plate of a torus shape having an outer side plate hole formed eccentrically of the outer circumference, and an inner side plate of a torus shape having such an inner side plate hole eccentrically of the outer circumference that a leading end portion is fitted. The outer side plate is fitted in a stationary die hole, and the inner side plate is fitted in the outer side plate hole of the outer side plate.

Abstract: A supply apparatus supplies a semi-solid metal to a molding apparatus having an injection sleeve formed with an opening portion and a plunger provided progressively/regressively at an inner portion of the injection sleeve. The supply apparatus includes a crucible in a shape of a cylinder containing a semi-solid metal, a carry arm for grabbing to move the crucible, and a control apparatus for controlling the carry arm. The control apparatus inserts a front end portion of a gutter mounted to the crucible into the opening portion of the injection sleeve by a predetermined angle to inject the semi-solid metal to a side of a direction of advancing the plunger more than at a position formed with the opening portion at inside of the injection sleeve.

Abstract: Jewelry and methods of making jewelry containing a precious metal-base alloy component in bulk-solidified amorphous phase are provided.

Abstract: A heat-resistant magnesium alloy is for casting, and includes Ca in an amount of from 1 to 15% by mass, Al in a summed amount of from 4 to 25% by mass with the amount of Ca, and the balance being Mg and inevitable impurities when the entirety is taken as 100% by mass. The heat-resistant magnesium alloy is not only inexpensive, but also effects an advantage that cracks are inhibited from occurring when being cast. For example, a process for producing heat-resistant magnesium alloy cast product includes the step of pressure pouring an alloy molten metal, which has a target composition around Mg-3% Ca-3% Al-from 0.2 to 0.3% Mn, into a cavity of metallic die, which is preheated to a die temperature of from 130 to 140° C. in advance. The process makes it possible to produce die-cast products, which are free from cast cracks.

Abstract: Discontinuous diamond particulate containing metal matrix composites of high thermal conductivity and methods for producing these composites are provided. The manufacturing method includes producing a thin reaction formed and diffusion bonded functionally graded interactive SiC surface layer on diamond particles. The interactive surface converted SiC coated diamond particles are then disposed into a mold and between the particles and permitted to rapidly solidify under pressure. The surface conversion interactive SiC coating on the diamond particles achieves minimal interface thermal resistance with the metal matrix which translates into good mechanical strength and stiffness of the composites and facilitates near theoretical thermal conductivity levels to be attained in the composite. Secondary working of the diamond metal composite can be performed for producing thin sheet product.

Abstract: A flexible nozzle for injection molded solder and a method of utilizing a flexible nozzle for injection molded solder applications. In order to be able to efficiently carry out the injection molded soldering process, there is utilized a compliant or flexible solder-dispensing nozzle structure, which is particularly advantageously adapted to be utilized with circular or round molds. In this connection, the tip of the nozzle, which provides for the discharge of the solder, provides a series of small holes or apertures for extruding the solder under pressure from at least one solder reservoir. In one embodiment, there may be employed a single solder reservoir with which there communicates a plurality of discharge apertures or holes for extruding the solder so as to fill suitable cavities or recesses formed in a facing surface of a mold for injection molded solder.

Abstract: Disclosed is: (i) a metal molding system, (ii) a metal molding system including a combining chamber, (iii) a metal molding system including a first injection-type extruder and a second injection-type extruder, (iv) a metal molding system including a first injection-type extruder being co-operable with a second injection-type extruder, (v) a mold of a metal molding system, and (vi) a method of a metal molding system.

Abstract: A flexible die case system for forming a variety of face plates used in telecommunications equipment without having to replace the mold base is provided. The system includes a main insert for forming a first portion of the face plate and a sub-insert for forming a second portion of the face plate. The second portion includes the minor variations that might be required to accommodate minor variations in face plate requirements. For example, the second portion can be used to change the number, size and location of apertures used for light emitting diodes, as well as the number, size and location of ports used to make connections to the electronics carried by or associated with the face plate.

Abstract: A sprue apparatus for use in a molding apparatus for connecting the melt duct of a molding machine nozzle with a runner system of a molding apparatus. The sprue apparatus includes a plurality of thermal regulators that regulate a plurality of thermal zones that segment the length of the sprue apparatus for the purpose of localized temperature control in support of a molding process. The plurality of zones may be thermally regulated such as to enable a substantially leak-free junction between the machine nozzle and the molding apparatus. The sprue apparatus may include an isolating coupler that substantially isolates a heated sprue bushing from carriage force. The invention has been found particularly useful when injecting metal alloys such as magnesium based alloys when in the thixotropic state.

Abstract: A backing plate comprises a front side configured to engage a friction material, a rear side opposite the front side, a first edge, a second edge generally opposing the first edge, and at least one channel disposed between the front side and the rear side and extending from the first edge toward the second edge. The rear side is configured to engage a caliper assembly. The backing plate is configured to achieve a resonant frequency that attenuates vibration.

Abstract: A mechanical apparatus and method for the casting of metal components is disclosed. The apparatus includes a gooseneck having dual plungers for drawing molten metal from a crucible of hot metal and for forcing the drawn molten metal through the system, a hot runner assembly having a thermal valve developed in time and positioned adjacent the mold cavity, and a machine nozzle positioned between the gooseneck and the hot runner assembly. The dual plunger is fitted with a shot plunger and a shutoff plunger which work in conjunction to allow for molten metal to be drawn into the gooseneck but to stop its passage into the gooseneck when the metal is forced through the system into the die. Both temperature and flow rate are carefully monitored and controlled. Two embodiments of the gooseneck are provided in which the positions of the shot plunger and the shutoff plunger are altered and in which the molten metal is drawn into the gooseneck at different locations.

Abstract: Disclosed a method of a metallic-molding-material runner system for filling a metallic-molding material into a mold cavity of a mold, the metallic-molding material includes a metallic component, the method including: substantially equilibrating flow of the metallic-molding material through a collection of branches from a molding system into the mold by; (i) receiving the metallic-molding material from the molding system through an input being defined by a conduit assembly, the conduit assembly including the collection of branches each being configured to pass the metallic-molding material from the input over to outputs of the collection of branches; (ii) conveying the metallic-molding material from the input through the collection of branches of the conduit assembly over to the outputs; (iii) forming plugs in the outputs; and (iv) chronological blowing out the plugs from the outputs into the mold cavity of the mold.

Abstract: Techniques for forming cast parts for medical devices suitable for contact with internal regions of patients are described herein. Such parts can be small in scale (e.g., having a major axis less than 0.3 inches, and/or a minor axis less than about 0.08 inches), and can be formed from metals that have a high melting point and high reactivity with environmental components or mold surfaces, such as stainless steel and titanium alloys. Such techniques can include injecting molten metal into the sprue of a mold tree such that the side runners are backfilled after the molten metal impacts a closed end of the sprue. Side runners can be oriented in particular directions and positions to promote backfilling. As well, flask temperatures and the use of surfactants can also promote cast part formation, hindering the formation of surface defects.

Abstract: The present invention relates to a die casting machine. A molten metal (melted liquid) is supplied into a evacuated casting space that is formed by a combination of a movable mold and a fixed mold. The molten metal is first moved in a horizontal direction along a molten metal injection pipe and is then injected into a chamber located at the bottom of the casting space. Thereafter, the molten metal is moved in a vertical direction by means of a follower plunger and is then inserted into the casting space. Therefore, since occurrence of a turbulent flow of the molten metal injected into a mold is prevented, a product of a high quality with no minute bubbles can be obtained.

Abstract: A method and apparatus for the casting of metal components is disclosed. The apparatus includes a gooseneck for drawing molten metal from a crucible of hot metal and for forcing the drawn molten metal through the system, a hot runner assembly having a hot runner tip positioned adjacent the mold cavity, and a machine nozzle inserted between the gooseneck and the hot runner assembly. The gooseneck is fitted with a one-way check valve to allow for molten metal to be drawn into the plunger but to stop its passage out of the gooseneck when the metal is forced through the system into the die. A thermal valve is formed within the hot runner tip to provide a metal blockage from the molten metal which prevents the back-flow of molten metal back into the hot runner assembly. Both temperature and flow rate are carefully monitored and controlled.

Abstract: Disclosed is (i) a molding-material handling component of a metal molding system, (ii) a metal molding system having a molding-material handling component, and/or (iii) a method, and (iv) a hot runner having a molding-material handling component.

Abstract: Disclosed is: (i) a cap for servicing a molding-system valve, and (ii) a method of a cap for servicing a molding-system valve, amongst other things.

Abstract: The present invention provides a pressure casting method of a magnesium alloy. In the method, a molten magnesium alloy is cooled to form a partially molten state containing a solid-phase, and the partially molten state is further cooled to form a solid-phase granularly crystallized solid material. The solid material is partially-melted and pressure cast into a mold by a molding machine. A ratio of primary crystals in said solid material is set to 55 to 65%. The solid material is partially-melted in a solid-phase and liquid-phase coexisting state at a selected heating temperature so that a semi-solid having thixotropic properties and having the size of a main solid phase of 50 to 250 ?m and a solid-phase ratio of 30 to 70% is formed. The semi-solid is pressure cast into a mold through a nozzle while maintaining the semi-solid state to form metal products having a ratio of primary crystals of 20 to 50%.

Abstract: A SOD (slurry-on-demand) casting method and charge is provided for casting a low-solid-fraction, namely 10 to 30% solid-fraction, alloy.

Abstract: A method and an apparatus for manufacturing an aluminum die-cast product are provided, wherein an occurrence of shrinkage cavity is eliminated or reduced to a very small amount, and a sound and high-quality aluminum die-cast product having no casting defect can be produced. The method for manufacturing an aluminum die-cast product by performing die casting while a part, in which a casting defect tends to occur due to solidification shrinkage of a melt, which has been pressure-filled in a mold, during a solidification process, is pressurized with a local pressurization pin includes the steps of allowing the local pressurization pin to follow the movement of a solidification interface based on a solidification interface movement speed, which is calculated in advance, of the melt and keeping pushing the local pressurization pin in until the solidification is completed.

Abstract: Method for inductive heating of a material located in a channel, the material having a melting range between a solidus temperature and a liquidus temperature. The method includes providing an internal inductive heating assembly in the material in the channel, and supplying a signal to the assembly to generate a magnetic flux in at least one of the assembly and material. The magnetic flux generates inductive heating of the assembly and/or the material and a physical agitation which lowers the solidus temperature of the material to a reduced solidus temperature.

Abstract: A vent assembly (453) for a high pressure die casting system comprising a pair of opposed chill blocks (450, 452) having corresponding chill surfaces defining a continuous vent chamber therebetween, each of the chill surfaces comprising a plurality of adjoining chill faces (62, 136, 162, 163, 170) extending the length of the vent chamber, each chill face having a corresponding chill face on the paired chill block defining a section of the vent chamber, the plane of each chill face being oriented at an angle to an adjoining chill face on the corresponding block. Preferably the chill face on a chill block is substantially equidistant from the chill face of the corresponding chill block defining the respective section of the vent chamber.

Abstract: To insert a cylindrical metallic raw material into a melting cylinder provided in a heating holding cylinder of a metal molding apparatus and to efficiently semi-melt or completely melt the cylindrical metallic raw material, a clearance between an inner circumferential surface of the melting cylinder and an outer circumferential surface of the cylindrical metallic raw material is limited to a range in which the clearance does not exceed 1.0 mm with respect to the inner diameter of the melting cylinder and the diameter of the metallic raw material during thermal expansion and the insertion of the metallic raw material in a non-thermal expansion state into the thermally expanding melting cylinder is possible, from a linear expansion coefficient of a metallic raw material and a linear expansion coefficient of a material of the melting cylinder.

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: Disclosed, amongst other things, is: (i) a seal of a metal molding system; (ii) a runner system of a metal molding system including a seal; (iii) a barrel assembly of a metal molding system including a seal; (iv) a metal molding system including a seal; and (v) a method of configuring a seal of a metal molding system, amongst other things.

Abstract: Disclosed is: (i) a method of a molding system, (ii) a controller of a molding system, (iii) an article of manufacture of a controller of a molding system, (iv) a network-transmittable signal of a controller of a molding system, and/or (v) a molding system having a controller, amongst other things.

Abstract: Disclosed is: (i) a metal-molding-system valve, (ii) a metal-molding system having a metal-molding-system valve, and (iii) a method of a metal-molding-system valve.

Abstract: In an injection mold including at least two mold sections which are movable relative to one another for opening and closing the injection mold and an electronic counter with an actuator and a sensor element supplying, influenced by the actuator, a signal indicative of the number of closings of the injection mold, the sensor element is disposed in a first housing and the electronic counter is disposed outside the first housing and connected to the sensor element via an electrical communication line.

Abstract: A method and apparatus is disclosed for the preparation of a semi-solid material in a mixing sleeve of a casting apparatus, the semi-solid material formed from a molten material after a mixing and a cooling thereof in the mixing sleeve wherein a handling of the semi-solid material is minimized.

Abstract: A metal alloy is heated to a molten state, and a grain refiner may be added. The molten alloy is poured into a shallow chamber of a shot sleeve of a vertical die cast press and on top of a shot piston. The shot sleeve is transferred to an injection station while the molten alloy cools to a semi-solid slurry with a globular, generally non-dendritic micro structure. An inner portion of the shallow slurry is injected upwardly by the piston through a gate opening into a die cavity while an outer more solid portion of the slurry is entrapped in an annular recess. After the slurry solidifies, the shot piston retracts, and the shot sleeve is transferred to a position where the residual biscuit is removed. The shot piston may have internal grooves to provide a large heat transfer area for cooling water to absorb heat from the molten alloy.

Abstract: A die casting machine 100 to fill by injecting molten metal into a die cavity 24 includes a variable displacement pump 16 driven by a servo motor 17 for discharging hydraulic fluid from a hydraulic fluid tank 40, an injection cylinder 11 with a slidable piston 12 assembled therein, hydraulic fluid pipes a and c for supplying hydraulic fluid discharged by the variable displacement pump 16 to the injection cylinder 11, hydraulic fluid pipes d, e1, g and a logic valve 14 connected to hydraulic fluid pipe c for supplying hydraulic fluid ejected from the injection cylinder 11 to hydraulic fluid pipe c with the piston 12 slid by the hydraulic fluid supplied to the injection cylinder 11.

Abstract: An injection molding apparatus includes a melt furnace and a metal supply system located in the melt furnace. The metal supply system includes a pump. The injection molding apparatus also includes a first metal inlet from the melt furnace to the metal supply system and a vertical injection mechanism adapted to inject liquid metal into a die system. The injection molding apparatus also includes a second metal inlet from the metal supply system to the vertical injection mechanism.

Abstract: A movable die is fastened to a stationary die, a relationship between a contact force of an injection nozzle to an injection hole of the stationary die and a closeness is investigated, the injection nozzle is brought into press contact with the injection hole of the stationary die by a contact force achieving a predetermined closeness, and a lubricant is coated by a predetermined pressure. At this occasion, one end portion of a cavity is opened or air is exhausted from the end portion as necessary. The lubricant is coated as mist by being mixed with a compressed gas. Further, the lubricant is coated by maintaining constant a pressure difference between a pressure applied to the lubricant and an inner pressure of the cavity and a pressure difference between a pressure of the compressed gas and the inner pressure of the cavity.

Abstract: An apparatus for producing a shaped part has a shot sleeve. A melt can be fed into the shot sleeve. The melt can be forced into a die by means of an injection plunger. The apparatus is provided with a drive unit for actuating the plunger rod. Moreover, the apparatus has an oscillation generator, by means of which the plunger rod can be set in longitudinal oscillations. The plunger rod is moveably connected to the drive unit.

Abstract: A cast aluminum base frame of a movable guide for a timing chain in an internal combustion engine is produced by a die in which the parting lines are located so that the shoe-engaging surface of the base frame and the pivot shaft-receiving hole are each formed by a continuous surface of the die, without oppositely pitched drafts.

Abstract: The present invention provides a manufacturing method of high precision titanium compressor wheel in which by removing pads attached on an entire surface entirely as a machining allowance in manufacturing process, dimensional accuracy at the time of manufacturing is intensified, and correction work of dynamic balance (rotation balance) is simplified or omitted so as to improve yield of products and suppress boosting of manufacturing cost. The outer peripheral face of a front cast boss portion of a cast titanium product is fixed with a chuck of lathe. A plurality of receiving plates projecting from the lathe are positioned between respective cast blades and front ends thereof are pressed against a disc-like large-diameter front end face formed on a rear half portion of a cast core portion. With a large-diameter front end face of the cast core portion and the outer peripheral face of the front cast boss portion as reference plane, the cast titanium product is held by the chuck and receiving plates and rotated.

Abstract: Made up of a step of preparing a map expressing a correlation between solid phase percentage and viscosity of a slurry-form semi-solid metal (27) for a given metal composition; a step of setting a target viscosity corresponding to a target solid phase percentage using this map; a viscosity measuring step of measuring the viscosity of a semi-solid metal in a vessel (13) while cooling it; and a step of carrying out cooling until this viscosity reaches the target viscosity, by these steps being carried out in from the preparation of the map expressing the correlation between solid phase percentage and viscosity of the semi-solid metal to the end of cooling of the semi-solid metal the solid phase percentage of the semi-solid metal is made to match the target solid phase percentage.

Abstract: A shot tube for the introduction of molten metal into a die cavity has a casing with a first end, a second end and a bore extending through the casing. The first end is adapted to be connected to the die cavity and a sleeve protrudes from the second end of the casing. The sleeve has a pour opening for the introduction of molten metal. A hard lubricious coating may also be applied to the interior surface of the shot tube to reduce sticking of cooled metal within the shot tube. A method for producing the shot tube described above is also disclosed.

Abstract: An injection-molding process for molding a metal alloy into a near net shape article that is characterized in that the processing temperature of the alloy at injection is approaching the liquidus, preferably having a maximum solids content of %, whereby a net-shape molded article can be produced that has a homogeneous, fine equi-axed structure without directional dendrites, and a minimum of entrapped porosity. Advantageously, the resulting solid article has optimal mechanical properties without the expected porosity and solidification shrinkage attributed to castings made from super-heated melts.

Abstract: The invention provides die casting systems and methods. A die casting system has two body portions, each having a die insert. A die-insert rack that holds the die inserts thereon and is used for positioning the die inserts between the two body portions is also provided. The rack includes a die-insert-ejection system for pushing the die inserts into the respective body portions. Each body portion may include a plurality of cooling inserts connected in parallel between inlet and outlet channels of a corresponding body portion. One body portion may include a plurality of alignment blocks protruding therefrom, while the other body portion may have a plurality of recesses for respectively receiving the alignment blocks. Each recess may have adjustable sidewalls for adjusting alignment between the body portions.

Abstract: A multi metal base thermal resistance alloy and a mold with the multi metal base thermal resistance alloy layer are provided. The weight percent of each element in this alloy is less than 45%. The structure of the alloy is an amorphous structure and the phonon thermal conductivity of the amorphous structure is intrinsically low. Therefore, the alloy is a metal material with low thermal conductivity coefficient and high thermal stability, which can increase the heat retaining property of the die casting mold, enhance the forming yield and stability of a metal sheet with a low fusion point, and is suitable to be used as a thermal-resistance coating material on die casting molds.