Abstract: A pattern of an aluminum alloy article made from a foam of an organic substance. The pattern is immersed in a mold of dry sand containing no binder. The mold is filled with molten aluminum alloy from a feeder zone and the alloy is allowed to solidify, thereby creating at least one critical zone in which solidification takes place last. Before the solidified fraction of metal exceeds 40% by weight, an isostatic gas pressure is applied to the mold. The aluminum alloy has a solidification range higher than 30.degree. C. and a ratio R of the distance between the feeder zone and at least one critical zone to half the means thickness of the article over this distance is greater than 10. The isostatic gas pressure being applied is between 0.1 and 0.5 MPa.

Abstract: A permanent mold for mold-casting reactive metals and metal alloys (FIG. 1) includes a multiple of radially disposed, plate-like segments 3, 3', 3", . . . which enclose the workpiece 12 and are preferably made of cooled metallic material and which form together the permanent mold including a top inlet opening 14 and a bottom opening 15 for withdrawing the working piece; in order to close the withdrawal opening 15, a closing plate 9 is provided which is composed of a multiple of ring segments 13, 13', 13", . . . and the permanent mold 5 is enclosed by a magnetic coil 6 so as to generate an electromagnetic field.

Abstract: Controlled-pressure casting of molten metals using a die with an extractable punch and a fixed die, includes positioning and stopping the punch within the die so as to define a casting cavity with a volume greater that that of the part to be obtained. A metered amount of liquid metal is then poured into the casting cavity through a duct which leads into the cavity, and the punch is moved to close inside the die so as to create a pressure suitable for distributing the metal throughout the cavity. A high-pressure compression is then exerted on the metal contained in the cavity and, maintained until the molten metal solidifies, the punch is partially removed from the die, with separation of the punch from the formed part, before finally removing the punch from the die and extracting the part from the die.

Abstract: A method and apparatus for controlling a casting process for obtaining a cast product from a cast substance injected into a die cavity of a pair of casting dies by a fluid-operated injecting plunger and pressurized by a fluid operated squeezing plunger after the completion of an injecting process. Actual movement of the squeezing plunger is controlled to copy a desired curve with respect to a desired movement of the squeezing plunger versus an elapse of time from the start of the actual movement of the squeezing plunger.

Abstract: An improvement to the process for the lost-foam casting of metal articles. According to the process, the casting takes place under a controlled pressure which initially increases at a rate between 0.003 and 0.3 MPa for a first period of at most 5 seconds from the begining of the rise in pressure. The pressure then increases during a second period at a rate higher than the rate of increase during the first period, until the maximum desired pressure is attained.

Abstract: A casting is formed, by compression casting, in a mold having a casting cavity which is formed by at least an outer mold die and a sand core. After feeding a molten metal into the casting cavity through a pouring gate, a compressive pressure, maintained at a lower extreme of approximately 2.5 atmospheres, is applied to the molten metal through the pouring gate in an early stage of solidification of the molten metal. The compressive pressure is varied, either gradually or quickly, to an upper extreme of approximately 10 atmospheres as the solidifcation of the molten metal progresses past an early stage of solidification, and is at this time applied to the solidifying molten metal through the sand core.

Abstract: A method for manufacturing a ceramic reinforced piston and a molding machine therefor. A composite product composed of a cast product made of aluminum alloy or the like and shaped inorganic short fiber, particles or the like is obtained so that mechanical strength, wear resistance, heat resistance and the like of such composite product can be increased. Furthermore, mass production of such composite products becomes possible. A suitable amount of ceramic particles or a shaped inorganic short fiber is introduced in a casting mold, a molten metal such as an aluminum alloy and the like is then poured in the casting mold, and an upper punch is suitably pushed down on the molten metal to pressurize such molten metal in the casting mold. Push rams are additionally introduced laterally into the mold before or during the pouring of the molten metal to compensate for any shortage of molten metal and assure the metal penetrates the particles of fiber. The metal solidifies under pressure.

Abstract: The invention concerns a method for moulding objects by feeding at least one consistent material into a mould where it solidifies prior to closing the inlet or opening of each runner of a cavity by means of at least one closing device, the gate feeding face of the runner of the cavity in question is closed, and then the molten material contained in the runner is expelled from the mould.

Abstract: A manufacturing method for a defect-free cast product comprises the steps of forming a cavity surrounded by a plurality of dies, charging molten conductive material into the cavity, and applying pressure to the conductive material by pressure means. In the method, additional pressure is selectively applied to the portion of the conductive material which may suffer shrinkage cavities due to delay in solidification, by utilizing the pressure applied by the pressure means and by relatively moving a portion of the dies with respect to the conductive material when the conductive material solidifies and shrinks, whereby shrinkage cavities are prevented. Accordingly, with a cast rotor core obtained by this method, it is possible to prevent shrinkage cavities from occurring in the conductive material and it is also possible to improve the efficiency and torque characteristics of the motor, thereby achieving reductions in the size and weight of the motor.

Abstract: A mold casting process comprises, after pouring of a molten metal into a mold, rapidly cooling that surface layer of a cast product which is in contact with a mold, and releasing the resulting product from the mold when the surface layer thereof has been converted into a shell-like solidified layer. Such process is used for casting a mechanical part blank and apparatus for carrying out the process is provided.

Abstract: An improvement in the lost foam casting process in which a foam pattern of a part to be cast is immersed in a dry sand mold and the mold is filled with molten metal in order to burn the pattern. According to the improvement, after filling but before the solidified fraction of metal exceeds 40% by weight, an isostatic gas pressure which increases at a predetermined and substantially constant rate to a predetermined maximum value is applied to the mold and maintained at the maximum value until solidification occurs. The rate of increase of pressure is determined as a function of the granulometry of the sand and depth of immersion of the pattern, to cause due to a temporary lag in pressure transmittal through the sand, a rapid and temporary overpressure of the molten metal relative to the sand at the sand/metal interface. The overpressure reaches a maximum value of 0.001 to 0.030 MPa at the beginning of the pressure application and declines as the applied pressure further increases.

Abstract: A method and an apparatus for forming a battery terminal bushing from a molten lead alloy in order to substantially eliminate the porosity in the material of the finished bushing. This method and apparatus includes the heating of the lead alloy until molten, pouring the molten alloy into a mold cavity, forcing a punch centrally and longitudinally through the center of the mold cavity not only to remove the core from the center of the material which will form the bushing, but also to simultaneously force the remaining alloy within the mold cavity campactly against the inner surface of the mold cavity, withdrawing the punch and ejecting the finished bushing of high density and a polished exterior surface, substantially free of air pores within the bushing material.

Abstract: This invention provides a die casting method comprising the steps of that a pulverized insulation agent is coated to form a porous insulation layer on the interior surface of die cavity when a casting products are made by utilizing a die casting machine, wherein a molten metal is filled into the cavity with a slow pace thereon, a high pressure is applied upon the molten metal mechanically so as to crush and make thin the porous insulation layer pressed by the high pressurization upon the molten metal, simultaneously the molten metal sinks into and passes through the porous insulation layer to reach at the interior surface of the cavity wherein the molten metal is rapidly solidified to produce a final casting products according to the temperature drop due to the direct contact with the interior surface of the cavity.

Abstract: A metal casting process for producing melt-out metal cores and the like made of metal alloys with low melting temperatures achieves a casting with uniform density, high quality finish and a fine grain structure. The process and apparatus do not require the pre-pressurization of a charging cylinder and permit closed dies to be used. The apparatus comprises a molten metal alloy tank, a cylinder in the tank having at its base a connection to a passageway leading through the tank to a die located outside the tank. A valve is provided in the passageway, located in the tank having a first position where the passageway to the die is open and a second position where the passageway to the die is closed. In the second position, a valve port provides a connection from the cylinder to the molten metal alloy in the tank.

Abstract: An organic foam pattern of the article to be cast is immersed in a dry sand mold containing no binder, the mold is filled with molten aluminum or aluminum alloy which replaces the foam and gradually solidifies, and an increasing isostatic gas pressure is simultaneously applied to the mold and to the aluminum or aluminum alloy after filling of the mold is complete. The isostatic gas pressure rises to a maximum value higher than 1.5 MPa and up to 10 MPa, and results in cast articles having improved mechanical characteristics and, in particular, better resistance to fatigue.

Abstract: A method of bonding a component in a piston, involves the steps of coating the component surfaces to be bonded with an oxidation-resistant particulate material, preheating the coated component, placing the preheated component in a casting die and then casting an aluminum alloy around the component. The casting technique may comprise squeeze-casting.

Abstract: A framework template of non-reinforcing material is provided containing, distributed therein and bonded to the building constituents thereof, a reinforcing material such as particles, fibers or whiskers of high tenacity nitrides, carbides, borides, oxides and the like, this distribution being arranged according to some given pattern of orientation and packing density. The template is placed in a mould which is then filled with molten metal which solidifies by cooling. During casting, the constituents of the template may be destroyed by the heat, or they may dissolve in the metal, or they can remain embedded therein.

Abstract: An improved valve mechanism for casting metal alloys with low melting temperatures provides two valves in a single assembly inside an alloy tank. The valves being in the tank reduces the formation of oxides which can occur in air and tends to reduce leaks. The apparatus comprises a tank adapted to contain molten metal alloys, a cylinder in the tank having at its base a connection to an injection passageway which leads through the tank to a die located outside the tank. A piston reciprocates in the tank which allows molten metal alloy to be drawn into the cylinder and forced through the passageway to the die. A control system for the piston controls accurately the speed of the piston in the cylinder when the molten metal alloy is fed to the die.

Abstract: A porous body is formed around an element which has the shape of the desired cavity and the body is heated to a temperature such that the element melts and infiltrates the porous body at least in the immediate vicinity of the resulting cavity. The article may then, for example, be incorporated into a piston for an internal combustion engine so as to form a cavity in the crown region thereof.

Abstract: A process for producing metal parts in accordance with the principle of squeeze or forge casting wherein a permanent mold (2) is provided having a mold cavity, a seal (4) is placed on an upper edge flange (5) of the mold surrounding the cavity opening (6), liquid metal (9) is introduced into the cavity, an upper die (3) is inserted (7) into the cavity such that the level of the liquid metal is raised until the higher-level cavity created by the seal (4) is filled, the metal is at least partially solidified, and the final shape of the part is produced by pressing (9) in the upper die, with deformation and spreading of the seal. The result is a completely dense workpiece of excellent dimensional stability which has the texture of a forged part and is correspondingly of very high strength.

Abstract: Porous material of metal is held in a die and molten aluminum alloy is introduced into the die to surround the porous material. Thus, high-pressure squeeze casting is accomplished under an applied pressure of not lower than 400 Kg/cm.sup.2 to form an aluminum alloy casting stock with the porous material cast therein. The casting stock is heated to and maintained at 450.degree. to 550.degree. C. for 1 to 10 hours, and an intermetallic compound layer of aluminum and the metal of the porous material is thereby formed on the boundary between the porous material and the aluminum alloy.

Abstract: A metal casting process for producing melt-out metal cores and the like made of metal alloys with low melting temperatures achieves a casting with uniform density, high quality finish and a fine grain structure. The process and apparatus do not require the pre-pressurization of a charging cylinder and permit closed dies to be used. The apparatus comprises a molten metal alloy tank, a cylinder in the tank having at its base a connection to a passageway leading through the tank to a die located outside the tank. A valve is provided in the passageway, located in the tank having a first position where the passageway to the die is open and a second position where the passageway to the die is closed. In the second position, a valve port provides a connection from the cylinder to the molten metal alloy in the tank.

Abstract: A method for casting a rocker arm made of light alloy for use in an overhead cam shaft type valve operating mechanism of an internal combustion engine, which rocker arm includes a thick-walled bearing section to be fitted on a rocker arm shaft and is integrally provided with a wear-resistive piece having a protrusion on its rear surface and adapted to abut a cam. After molten metal has been injected under pressure into a metallic mold for the rocker arm, a secondary pressurizing force directed in the direction of an imaginary center axis of a rocker arm shaft is exerted by means of a pressurizing rod. In the metallic mold for the rocker arm, a sprue is provided close to the position where the wear-resistive piece is disposed with respect to the position where the bearing section is formed, and the direction of the sprue is directed towards the position where the wear-resistive place is disposed.

Abstract: A die cast, heat treated shaped aluminum silicon alloy article consisting essentially of, based on an alloy weight, from 13 to 25 wt % silicon, from 2 to 6 wt % copper, up to 1 wt % magnesium, balance aluminum, said heat treated alloy being formed by the process comprising: subjecting said alloy while in molten condition to a primary pressure die casting at a casting pressure of from about 450 to about 500 kg/cm.sup.2 to form a primary pressure die cast product; removing the primary casting pressure from said primary pressure die cast product; prior to the time said aluminum silicon alloy completely solidifies, subjecting said primary pressure die cast alloy to a secondary pressure die casting so as to reduce the volume thereof from about 1.5% to about 3%; heating the thus treated product to a temperature of from about 460.degree. C. to about 520.degree. C. for a period of time of from about 2 to about 10 hours; and rapidly quenching said product to produce said article.

Abstract: A method of and a system for operating a squeeze plunger in a die cast machine. When the fill-up of molten metal in a cavity is completed by an injection plunger, the moving speed of the injection plunger is rapidly decreased. When the speed at this time becomes lower than a preset value, a preset delay time is measured. After a lapse of this delay time, the squeeze plunger is operated to press a molding material in the cavity, so that plastic flows are caused in the molding material.

Abstract: A method of producing a fiber reinforced metal composition is characterized by a unique and successful pressure exerting program for consolidating a fiber assembly fabricated into a desired configuration and a molten metal matrix. The program is generally constituted a first step in which relatively low pressure is exerted on the molten metal for consolidation of the fiber assembly and the molten metal and a second step in which pressure is instantly increased to a maximum pressure for solidification of the metal matrix.

Abstract: A method for controlling implements by means of a hydraulic pressure. A hydraulic pressure is fed from an accumulator to a first hydraulic circuit, after the operating pressure has been once lowered any arbitrary operating pressure or variation of the operating pressure is detected in the course of restoration to an initial set pressure, and a second hydraulic circuit is triggered by a detection signal based on this detection.

Abstract: A secondary pressurization casting method, in which molten metal is injected into and filled in a cavity of a mold and then a secondary pressurizing force is exerted upon the filled molten metal by making a secondary pressurization pin advance within a through-hole formed in the wall of the mold. After commencement of filling of the molten metal in the cavity, the secondary pressurization pin placed at an initial set position is once retreated, and subsequently it is made to advance to pressurize the molten metal. A casting fin produced around the outer circumference of the tip end of the secondary pressurization pin during the period when the molten metal is being injected and filled, is integrated with the molten metal entered into the through-hole as a result of the retreat of the secondary pressurization pin, and subsequently it is pushed into the cavity by the secondary pressurization pin.

Abstract: A die casting apparatus comprising a secondary pressing cylinder mounted on one mold, a sequence valve, a control valve and a reducing valve, the valves being interposed between a switching valve and the secondary pressing cylinder. Operating timing of the secondary pressing cylinder is changed by the sequence valve, the moving speed of the pressing plunger is adjusted by the flow control valve, and the pressing force of the pressing plunger is varied by the reducing valve. The operation of secondary pressing is adjusted by the sequence valve and the flow control valve.

Abstract: In a method of feeding a molten metal in metal molds through a casting sleeve to cast a predetermined article, a hollow thin-plate body is provided to at least an inner wall surface portion of the casting sleeve near the molds.

Abstract: A method for making small lead objects such as bullets. Lead is melted and while in a molten state is pumped through a metering device that regulates the amount fed into a die where it solidifies. Force is immediately applied to the still-soft lead to form the hard bullet.

Abstract: A die casting process and apparatus is described for forming a metal casting having a bore therethrough surrounded by dense, nonporous metal. During solidification, a plunger core is driven through the metal to substantially form the bore. The plunger core comprises a metal-penetrating conical tip that laterally displaces metal in response to plunger core advance to densify the metal about the bore. The plunger core tip is received into a correspondingly shaped recess so that only a thin metal flash is formed therebetween, which flash is readily removed by punching to complete the bore.

Abstract: A metal die casting apparatus preferably comprises a plunger core and a stationary core adapted to form recesses in the casting and to densify the metal to reduce shrink porosity. The cores are located at opposite sides of a die cavity and the plunger core is moveable in the direction of the stationary core to penetrate the metal while in a partially solidified, extrudable state. The cores are suitably shaped to displace metal laterally as the plunger core advances. The apparatus is particularly suited for forming a casting comprising an enlarged region intended to define a bore completely therethrough and surrounded by dense, nonporous metal.

Abstract: In this method for manufacturing an aluminum alloy, a porous preform is manufactured from a mixture of a finely divided oxide of a metallic element which has a weaker tendency to form oxide than does aluminum, and an additional substance substantially more finely divided than that metallic oxide. Then an aluminum alloy containing a substantial quantity of silicon is permeated in the molten state through the porous preform. This causes the metallic oxide to be reduced by a thermite reaction, to leave the metal which it included as alloyed with the aluminum alloy. At this time, the silicon in the aluminum alloy does not tend to crystallize out upon the particles of the metallic oxide, which would interfere with such a reduction reaction by forming crystalline silicon shells around such metallic oxide particles and would lead to a poor final product, because instead the silicon tends to crystallize out upon the particles of the additional substance.

Abstract: A process for casting a cylinder block blank made of light alloy provided with a cylinder barrel reinforced around its cylinder bore with a reinforcing tubular body and a crankcase provided continuous to the cylinder bore, which includes placing the reinforcing tubular body in a first cavity formed for shaping a cylinder barrel at the lower portion of a mold which is formed at its upper portion with a second cavity for shaping a crankcase communicating with the first cavity, and pouring a light alloy molten metal from the lower portion of the first cavity into the first and second cavities while simultaneously venting gas from the first and second cavities.

Abstract: A piston of a light alloy matrix material having a cavity for containing heat insulating air immediately below its head or a cavity for passing cooling oil inside the grooved side wall is manufactured by preforming a precursory member having the shape of the cavity from an extractable material which remains in solid state at room temperature and is convertible into a fluid, gas or liquid when heated at a temperature below the melting point of the matrix metal. The precursory member is disposed in place in a pressure casting mold having a cavity corresponding to the shape of the piston, and covered with a porous member stable to the molten matrix metal. A head member of heat resisting metal material to constitute at least a portion of the piston head may be disposed on the mold cavity bottom. Molten matrix metal is then cast into the mold cavity and a pressure is applied thereto to form a piston-shaped casting having precursory member and porous member embedded therein.

Abstract: A squeeze formed aluminium alloy article, such as a piston, is formed with a re-entrant cavity (14) with reinforced edges by locating an isostatically compacted salt core (10) and annular alumina-silicate fibre pad (11) in the mould cavity of the squeeze forming press prior to introduction of the molten metal therein. The core (10) is subsequently dissolved from the squeeze formed article to provide a reinforced corresponding shape to the article which does not require subsequent machining.

Abstract: A process is described for producing fiber-reinforced light-metal castings in which a loose fiber tangle is placed in a casting mold and is saturated with molten light-metal under low pressure. Subsequently, the excess of molten light-metal is squeezed off while the fiber tangle is compressed. The outflow of the molten light-metal is then stopped with the molten light-metal being solidified under high pressure. The process is especially suitable for utilizing the solution-spun inorganic fiber tangles that up to now had not been especially suitable for the reinforcing of light-metals.

Abstract: A method of producing a fiber-reinforced composite material comprising the steps of arranging a fiber shaped article in a cavity of a casting mold; pouring a molten metal acting as a matrix into the cavity and subjecting the molten metal to primary pressure; holding the molten metal under pressure for a predetermined period of time; and subjecting the molten metal, at least in proximity of one end of the fiber shaped article, to secondary pressure with a high hydrostatic pressure after the predetermined period of time has passed, to fill the molted metal into the fiber shaped article and integrate them.

Abstract: A method of producing a fiber-reinforced composite material in which a fiber body is mounted on mounting surfaces in a mold cavity, which mounting surfaces are in fluid communication with the outside of the mold through air relief passages. A molten matrix metal is poured into the mold cavity and then subjected to a high hydrostatic pressure so as to be filled into the fiber body while expelling the air from the fiber body to the outside of the mold through the air relief passages. The molten metal is thereafter filled into the air relief passages and solidifies immediately to seal the mold cavity from the ambient atmosphere whereby the molten matrix in the mold cavity is rapidly solidified under high pressure to form a fiber-reinforced composite material of high quality with inclusion of substantially reduced voids or cavities.

Abstract: The reinforcement of the crown of a piston of aluminum or aluminum alloy for an internal combustion engine comprises the preparation of a reinforcement member (10, 13) which is provided with apertures (11, 14), or reentrants. The reinforcement member is placed in a crown-forming part (18) of a piston die in a squeeze casting apparatus and the piston is squeeze cast. The molten metal penetrates the apertures, or enters the reentrants, and these are so shaped that when the molten metal has solidified, keys are formed which connect securely the reinforcement member to the aluminum or aluminum alloy. Further reinforcement members can then be readily brazed or welded to the first reinforcement member.

Abstract: A squeeze casting press has a movable top die part (11) and movable side die parts (13). When these parts are in a die-forming position, the side die parts (13) are locked against movement by respective locking wedges (25) to prevent these die parts separating under the squeeze casting pressure. The provision of movable die side parts allows easy access to the cast article (which may be a piston for an engine or a compressor). It also allows easy location in the die of reinforcements or inserts to be cast into the article.

Abstract: A composite material containing dispersed particles is manufactured by disposing within a mold a porous shaped article of ceramic particles, then pouring a molten metal into the mold, compressing the contents of the mold, subsequently allowing the molten metal to solidify, and subjecting the resultant solidified composite to a plasticizing treatment.

Abstract: A process is provided for the production of fibre-reinforced light-metal castings by die casting. A fibre moulding is introduced into an auxiliary mould and the auxiliary mould is heated to an optimum temperature above the melting point of the light metal. The auxiliary mould is then inserted with positive fit into a die casting mould corresponding to the outer contour of the auxiliary mould and filled with light metal under pressure. The fibre moulding can optionally be stabilized by means of a temporary organic binder which decomposes when the auxiliary mould is heated.

Abstract: A method for forming metal base composite use a retainer made of water soluble salt with a high melting point. Molten metal and a reinforcement are compounded in the retainer and then solidified. After solidification the retainer is dissolved away by water.

Abstract: A squeeze formed aluminum alloy article, such as a piston, is formed with a re-entrant cavity (14) by locating an isostatically compacted salt core (10) in the mould cavity of the squeeze forming press prior to introduction of the molten metal therein. The core (14) is subsequently dissolved from the squeeze formed article to provide a corresponding shape to the article which does not require subsequent machining.

Abstract: A method for injecting molten metal in a vertical diecasting machine. In order to efficiently produce high quality castings, a molten metal is injected into a mold cavity with the upper part of the mold cavity communicating with the atmosphere, the mold cavity is occluded before the completion of the injection, and then the molten metal is pressurized to suppress the trapping of air or gases in the casting.

Abstract: A method for producing a fiber reinforced composite body, wherein a shaped body of inorganic fiber or a sintered body of metal or ceramic material is placed in a metal mold, and a melt of a metal alloy as a matrix is caused to be penetrated or impregnated into the shaped body by a high pressure solidification casting method so that the matrix may perfectly fill in the voids or pores of the shaped body and solidify to be a desired composite body.

Abstract: A die-casting apparatus having a runner 31 through which molten metal is injected into a die cavity for die-casting an article, a squeeze passage 17 communicating with the die cavity 30 at a portion other than the portion where the runner 31 is communicated with the die cavity 30, and a squeeze plunger 36 snugly and slidably disposed in the squeeze passage 17 and adapted to commence, before the runner 30 is closed by solidification of metal therein, to forcibly displace the molten metal from the squeeze passage 17 back into the die cavity to effect a squeeze on the molten metal in the die cavity 30. The stroke of the squeeze plunger 36 is greater than one half of the length L of the squeeze passage 17. The cross-sectional area S and the length L of the squeeze passage are given by:S.gtoreq.0.35L.sup.

Abstract: A method of producing a composite material from porous reinforcing material and molten matrix metal. First the porous reinforcing material is heated up to a temperature substantially above melting point of the matrix metal. Then the molten matrix metal is infiltrated into the porous structure of the reinforcing material under a substantial pressure. Then the combination of the reinforcing material and the matrix metal infiltrated thereinto is cooled down to a temperature below the melting point of the matrix metal, while maintaining the abovementioned substantial pressure. Optionally, the reinforcing material may be charged into a case; and, again optionally, the case may have one opening only, and a vacant space may be left between another part of the case and the reinforcing material charged in the case, with the reinforcing material interrupting communication between the opening and the vacant space. The case can be made of stainless steel, or of a refractory material such as porous brick.