Abstract: Battery parts, such as battery terminals, and associated systems and methods for making same. In one embodiment, a battery part has a sealing region or sealing bead located on a lateral face of an acid ring for increasing resistance to leakage therepast as the battery container shrinks. Another embodiment includes a forming assembly for use with, for example, a battery part having a bifurcated acid ring with spaced apart lips. The forming assembly can include movable forming members that can be driven together to peen, crimp, flare or otherwise form the lips on the bifurcated acid ring.

Abstract: The present invention is aimed to provide a low-pressure casting apparatus which can prevent the molten metal that is a residue in a conduit from being oxidized. A conduit in the apparatus is connected to a lower part of a pressure chamber in which the molten metal is pressurized. Also, the end of the conduit is made so that it can communicate with a sprue for a mold.

Abstract: The invention relates to a method for the production of a cast component (10), in particular a die casting component, preferably made of an aluminum alloy, according to which the cast component (10) is at least partially subjected to a heat treatment following the molding process and the removal from the mold (12), wherein the heat treatment of the cast component (10) is begun within a period of up to 15 minutes after the removal from the mold (12). In addition, the invention relates to a device by which a cast component (10) is taken out of the mold (12) and transported into a heat treatment facility (28) by means of one and the same transport system (robot 24).

Abstract: According to one embodiment, a die is provided with a stationary die and a movable die. When the movable die is combined with the stationary die, a biscuit section, a product section in which a product is to be cast, a main runner configured to guide a molten metal from the biscuit section toward the product section, a main gate provided between the main runner and the product section, a sub-runner diverging from the main runner and extending along a side edge part of the product section, and a sub-gate provided between the sub-runner and the product section are formed between the stationary die and the movable die. The sub-gate is connected to the side edge part in an end portion of the product section. The sub-runner extends beyond the product section in a direction in which the side edge part extends.

Abstract: The present invention provides a cooling system for a low-pressure casting mold, in which a sprue is located at a side surface of a cylinder head to ensure a sufficient distance between a combustion chamber and the sprue so that a combustion chamber cooling system combined with water cooling and air cooling is provided in a lower mold, thus reducing cycle time. Moreover, the cooling system for a low-pressure casting mold in accordance with the present invention improves mechanical properties of a material used by reducing DAS and porosity.

Abstract: The inventive casting method consists in extruding a melt from a metal reservoir into the cavity of a shaped investment mold at a temperature above liquidus and a pressure enabling a maximum splash-free liquid metal flow and increasable along with the melt crystallization to a pressure sufficient for further filling the mold in proportion to the amount of cast shrinkage. The inventive device for carrying out said method comprises a metal reservoir arranged as a removable insert lined from the inside and provided with an annular flange, and a container which comprises the shaped investment mold and a hollow neck provided with a removable thimble. The flange is mounted in such a way that its inner diameter matches with the outer diameter of the thimble, wherein the inner diameter of the flange is smaller than the inner diameter of the insert.

Abstract: According to one embodiment, a die is provided with a stationary die and a movable die. When the movable die is combined with the stationary die, a biscuit section, a product section in which a product is to be cast, a main runner configured to guide a molten metal from the biscuit section toward the product section, a main gate provided between the main runner and the product section, a sub-runner diverging from the main runner and extending along a side edge part of the product section, and a sub-gate provided between the sub-runner and the product section are formed between the stationary die and the movable die. The sub-gate is connected to the side edge part in an end portion of the product section. The sub-runner extends beyond the product section in a direction in which the side edge part extends.

Abstract: A nucleated casting apparatus including an atomizing nozzle configured to produce a droplet spray of a metallic material, a mold configured to receive the droplet spray and form a preform therein, and a gas injector which can limit, and possibly prevent, overspray from accumulating on the mold. The gas injector can be configured to produce a gas flow which can impinge on the droplet spray to redirect at least a portion of the droplet spray away from a side wall of the mold. In various embodiments, the droplet spray may be directed by the atomizing nozzle in a generally downward direction and the gas flow may be directed in a generally upward direction such that the gas flow circumscribes the perimeter of the mold.

Abstract: A mold for casting primarily of SMC420, wherein a cavity forming portion comprising maraging steel, which has the toughness and the resistance to heat shock superior to those of SMC420, is provided in a vertical wall heading for a cavity surface from a molten metal inlet and a portion nearest to the molten metal inlet in the cavity surface, which are portions suffering relatively large heat shock in the contact with a molten metal. Also provided is a method for providing the cavity forming portion, which comprises filling a concave portion of the mold with a molten metal prepared by melting a welding rod by arc welding, in other words, carrying out an overlaying welding, and then cooling and solidifying the molten metal.

Abstract: A metallic, ferriferous permanent mold, especially a permanent steel mold, is provided that can be impinged upon with a liquid or flowable aluminum material, a layer for protecting the permanent form and for obtaining an optimum cast result being producible by means of a mold release agent. The invention also relates to a mold release agent for producing said layer and to a method for producing said layer.

Abstract: Disclosed is a metal casting system, an engineered mold for use therewith, a process for utilizing the system and mold, and articles having a clean, oxide-free sand casting of molten metals that have been produced under an inert environment. This is especially advantageous for making automotive and airplane parts from the manufacture of lightweight metals, and more especially for the production of magnesium parts in order to reduce weight while maintaining properties found in other lightweight metals. Currently, sand cast articles are being used for automotive, aerospace and semiconductor parts and other industrial applications.

Abstract: The invention relates to steel for hot tooling, the composition of said steel being made up of the following weight percentages: 0.30%=C=0.39%, 4.00%=Cr=6.00%, traces=Si=0.50%, traces=Mn=0.80%, traces=W=1.45%, traces=Co=2.75%, 0.80%=Ni=2.80%, 1.50%=Mo=2.60% with 1.50%=Mo+0.65W=3.20%, 0.55%=V=0.80%, with 0.65=K=0.65, where K=K2?K1 and K2=0.75×(Ni 0.60), K1=1.43×(V0.40)+0.63×[(Mo+0.65W) 1.20], traces=Al=0.080%, traces=S=0.0040%, traces=P=0.0200%, traces=Ti=0.05%, traces=Zr=0.05%, traces=Nb=0.08%, traces=N=0.040%, 10P+As+5Sb+4Sn=0.21%, traces=O=30 ppm, the remainder being iron and inevitable impurities. The invention also relates to a part produced from said steel, to the method for the production thereof, and to the use of the same.

Abstract: A system for producing cast components from molten metal. One form of the present invention includes a system for the precision pouring of molten metal within a casting mold.

Abstract: An apparatus for casting metals by a nucleated casting technique to create a preform, the apparatus including a mold having a base and a side wall where the base can be moved relative to the side wall to withdraw the preform as it is being created. In various circumstances, portions of a droplet spray created by an atomizing nozzle, i.e., overspray, may accumulate on a top surface of the side wall and prevent or inhibit the preform from being moved relative to the side wall. The atomizing nozzle can be oriented such that the droplet spray passes over the top of the side wall to remelt and remove at least a portion of the overspray that has accumulated thereon. The mold can be rotated such that the overspray formed on a region of or on the entire perimeter of the top surface can pass through the droplet spray and can be removed from the side wall.

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: 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: An impermeable ceramic mold is disposed within a steel die and used in a process for pressure casting of elevated melting temperature alloys and pressure infiltration casting of elevated melting temperature alloys having wear resistant particles, included therewith. The ceramic mold provides an insulation layer between the molten metal and the steel die, and prevents welding between the molten metal and the die. The alloy steel die encloses the ceramic mold and provides the strength needed to resist the pressures generated during pressure infiltration casting.

Abstract: When casting e.g. aluminium alloy in a mould (2), that may be one of a string of moulds extending at right angles to the plane of the drawing, the pressure used for filling the mould (2) against gravity by a pressurizing device (4) is controlled according to a predetermined pressure/time programme having previously been read into a control unit (22), e.g. a digital computer, at least one of a number of sensors sensing pressure (8), levels (9,10) and full level (11) being used to supply inputs to the control unit (22). Sensors are chosen according to need for each particular casting programme.

Abstract: Method and apparatus for investment casting wherein a ceramic investment mold is disposed in a chamber and communicates with a melt reservoir connected to the mold and having a reservoir volume for holding enough melt to fill the mold. The melt pour cup reservoir is communicated to the mold via an inverted loop feed gate so that the melt is fed from a lower region of the reservoir through the inverted loop feed gate to the mold upon gas pressurization of the melt in the reservoir. The loop feed gate is configured to have a loop region above the melt level in the reservoir so as to prevent melt flow from the reservoir to the more mold cavities in the absence of pressurization. While residing in the reservoir, oxides and other inclusion-forming particles in the melt can float to the upper surface of the melt, whereby the melt fed from the lower region of the reservoir to the mold via the inverted loop melt feed gate includes reduced amount of inclusion-forming particles.

Abstract: In metallic material injection molding machines, the connection between the injection nozzle and the sprue bushing has tended to leak metallic material. To overcome this problem, the nozzle has been modified to have a projecting portion or spigot that extends into a mating portion of the sprue bushing to form a seal between the respective portion walls. The nozzle and sprue bushing can move axially with respect to one another without loss of sealing whereas with the prior designs any separation between confronting annular surfaces on the sprue bushing and the nozzle would result in a loss of sealing and leakage.

Abstract: A metal mold for manufacturing amorphous alloy. A metal mold is composed of a lower mold having a portion for fusing metal material and a cavity portion, and an upper mold working with the lower mold which presses molten metal in the portion for fusing metal material and pours the molten metal into the cavity portion to mold. And, surface roughness of a part of or all of an inner surface of the metal mold is arranged to be more than 12S in JIS indication.

Abstract: A method of making jewelry in which liquid gold is shaped into the desired hollow configuration using centrifugal/gyroscopic motion. The gold is liquidified either before application to a mold or melted after it is deposited into the mold. A centrifugal force is applied to the mold to press the gold against the interior walls of the mold and the gold is allowed to solidify. Once solid, in the preferred embodiment, the gold is “hardened” using a pulse of air pressure applied to the interior of the mold.

Abstract: A metal mold for manufacturing amorphous alloy. A metal mold is composed of a lower mold having a portion for fusing metal material and a cavity portion, and an upper mold working with the lower mold which presses molten metal in the portion for fusing metal material and pours the molten metal into the cavity portion to mold. And, surface roughness of a part of or all of an inner surface of the metal mold is arranged to be more than 12 S in JIS indication.

Abstract: A gas permeable ceramic investment mold is disposed in a casting chamber and filled with melt to be solidified via a mold melt inlet, such as for example a mold pour cup adapted to receive the melt from a melting crucible in the casting chamber. After the melt is cast into the hot investment mold in the vacuum casting chamber, a pressure cap is positioned in sealing engagement with the mold melt inlet, and gas pressure is introduced through the pressure cap to provide selective or local gas pressure on the melt in the mold without pressure cracking or other damage to the relatively fragile investment mold, while the casting chamber is maintained under relative vacuum or a different pressure from that in the mold.

Abstract: A porous composite forming material is held in a cavity of a casting mold, and molten light alloy is poured into the cavity of the casting mold through a gate. Then a gas pressure is applied to the cavity in the casting mold with the cavity closed, thereby impregnating the pores of the porous composite forming material with the molten light alloy and forming a composite portion formed of a composite material of the light alloy and the composite forming material.

Abstract: A ceramic investment mold is disposed in a casting chamber and communicates with a pour cup melt reservoir connected to the mold and having a reservoir volume for holding enough melt to fill the mold. The melt pour cup reservoir is communicated to the mold via an inverted loop feed gate so that the melt is fed from a lower region of the reservoir through the inverted loop feed gate to the mold upon gas pressurization of the reservoir. The loop feed gate is configured to have a loop region above the melt level in the reservoir so as to prevent melt flow from the reservoir to the more mold cavities in the absence of reservoir pressurization. While residing in the pour cup reservoir, oxides and other inclusion-forming particles in the melt can float to the upper surface of the melt, whereby the melt fed from the lower region of the reservoir to the mold via the inverted loop melt feed gate includes reduced amount of inclusion-forming particles.

Abstract: Electronic parts such as an inductor of improved connectivity between magnetic and conductive materials made by sintering the magnetic material under a condition where no accumulation is developed, by forming a hollow-core of a shape different from an external shape of said conductive material through said magnetic material to be molded by an extrusion-molding means while inserting said magnetic material into said hollow-core, or by providing an erasable means to be removed by a heat treatment in said conductive material and conducting extrusion molding so as to embed said conductive material into said magnetic material, said erasable means being removed during a sintering treatment to form a space between said conductive material and said magnetic material, and a method for making same.

Abstract: The apparatus comprises a vessel having an interior. A mold is disposed within the interior of the vessel. A casting material is contained in the interior of the vessel. The apparatus also comprises a mechanism for providing the casting material to the mold in a manner such that vapors of the casting material are prevented from communicating with the interior of the vessel. The providing mechanism is in communication with the vessel. The providing mechanism comprises an inner chamber within which the mold and casting material are contained in. The providing mechanism further comprises a mechanism for heating the inner chamber, such as heating coils. The heating mechanism is disposed within the interior of the vessel adjacent to the inner chamber. Preferably, the inner chamber has a tube extending therefrom having a filter element, disposed therein for catching vapors of the casting material.

Abstract: Metal is cast by melting it in a crucible over a hole too small to enable gravity to make the molten metal pass through the hole and with a diameter to length ratio greater than one, after which increased pressure is applied to the metal to drive it through the hole into a mold.

Abstract: The apparatus for casting comprises a pressure vessel and a device for pressurizing the vessel. The pressurizing device is in fluidic connection with the vessel. The apparatus is also comprised of a chamber disposed in the pressure vessel within which material is melted. There is a mold adapted to contain a preform disposed in the vessel and in fluidic connection with the chamber by a passage such that melted material in the chamber can be forced down into the mold through the passage as the pressurizing device pressurizes the vessel. A heating device is disposed in the vessel. There is also a device for directionally solidifying the material in the mold. Additionally, there is a method comprising the steps of loading the pressure vessel by disposing a material within the chamber whereby the material is in fluidic connection with the mold adapted to contain a preform through the passage. The passage has a filter disposed therein.

Abstract: A pressure molding method and apparatus uses a mold with a casting cavity and a pouring gate through which a molten metal is fed into the casting cavity. After feeding a molten metal into the mold through the pouring gate to fill the casting cavity and pouring gate, a cap member is placed on the mold to bring its open end into contact with a dead head of the molten metal in the pouring gate of the mold so as to form an air-tightly sealed chamber between the cap member and dead head of the molten metal. Pressure is supplied into the sealed chamber to force the molten metal in the mold through the dead head.

Abstract: A porous preform is placed in a nonporous mold chamber of a pressure vessel. A material is placed in a crucible of the pressure vessel. The pressure vessel is evacuated through a snorkel fluidically connected to the mold chamber and extending therefrom out of the pressure vessel. The material in the crucible is melted. The crucible is placed in fluidic communication with the mold chamber such that the melted material fluidically seals the inside of the mold chamber and the snorkel from the interior of the pressure vessel to fluidically isolate the mold chamber from the interior of the pressure vessel so that a pressure differential exists therebetween.

Abstract: Metal is cast by melting it in a crucible over a hole too small to enable gravity to make the molten metal pass through the hole, after which increased pressure is applied to the metal to drive it through the hole into a mold.

Abstract: A porous preform is placed within a permanent, nonporous, thin walled mold chamber. The mold chamber is disposed within a pressure vessel. A material is placed in a crucible of the pressure vessel. The pressure vessel is evacuated through a snorkel fluidically connected to the mold chamber. There is means for cooling the snorkel in thermal communication with the snorkel. The material is melted within the crucible. The crucible is placed in fluidic communication with the mold chamber such that the melted material seals the inside of the mold chamber from the pressure vessel to isolate a vacuum within the mold chamber.

Abstract: The apparatus for casting comprises a pressure vessel and a device for evacuating and pressurizing the vessel. The evacuating and pressurizing device is in fluidic connection with the vessel. The apparatus is also comprised of a chamber disposed in the pressure vessel within which material is melted. There is a mold with a passage such that the melted material in the chamber can be forced down into the mold through the passage as the pressurizing device pressurize the vessel. The passage contains a filter such that the melted material is prevented from entering the interior of the mold prior to pressurization. Additionally, the apparatus is comprised of a device for heating material in the chamber and the mold such that material is melted in the chamber and stays melted as it is forced down into mold while the pressurizing device pressurizes the vessel. The heating device is disposed in the vessel.

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: The invention is a pressure rig for repetitive casting of metal. The pressure rig performs like a piston for feeding molten metal into a mold. Pressure is applied to an expandable rubber diaphragm 22 which expands like a balloon to force the metal into the mold. A ceramic cavity 26 which holds molten metal is lined with blanket-type insulating material 11, 15, necessitating only a relining for subsequent use and eliminating the lengthy cavity preparation inherent in previous rigs. In addition, the expandable rubber diaphragm 22 is protected by the insulating material 14 thereby decreasing its vulnerability to heat damage. As a result of the improved design the like expectancy of the pressure rig contemplated by the present invention if more than doubled. Moreover, the improved heat protection has allowed the casting of brass and other alloys with higher melting temperatures than possible in conventional pressure rigs.

Abstract: A method and apparatus 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 casting-by-squeezing mold having a base, mold halves, and enclosing cheeks. One of the mold halves is movably mounted on the base so that the two mold halves can be driven apart and brought together to form a complete mold. The internal surfaces of the base, mold halves and cheeks form a cavity. One of the mold halves has projections which divide it into three chambers. The first, lower chamber is a metal receiving chamber; the second, side chamber is a feeding chamber; the third, central chamber is a molding chamber. A variable-volume cavity is provided, which communicates with the metal receiving chamber so that the level of the metal in the receiving chamber can be adjusted to a predetermined level.

Abstract: A method of charging molten metal into a vertical die casting machine, wherein molten metal is introduced into a lower sleeve in which a lower plunger is slidably received, to store therein a mass of molten metal having a surface level not higher than the bottom of a molten metal inlet to a mold cavity. Next, an upper plunger is lowered to a predetermined position, raising the lower plunger to urge the molten metal upwardly and move it into the mold cavity. The upper plunger can then be moved to apply pressure to the molten metal. The method ensures smooth charging of molten metal and casting of a product free of casting defects.

Abstract: The invention relates to an apparatus for pressure die casting of metals and alloys involving the action of increased gas pressure on the solidifying melt. In this apparatus, the gas is pressurized automatically during the stroke of the press and pressurized gas at elevated pressure is applied to molten metal in the die cavity immediately after the closing of the die. For this purpose, the apparatus comprises a hydraulic press including a cylinder and a piston slidably mounted therein, which piston divides the cylinder into a first and second chamber. The first chamber is in communication with a source of pressurized liquid and the second chamber is in communication with a gas retaining cavity disposed in the piston rod of the piston. A press plate and die having at least one die cavity is rigidly mounted on the piston rod. The cavity of the die is connected by means of corresponding valves to a supply reservoir with gas under low pressure.

Abstract: A casting furnace includes upper and lower chambers, separated by a wall having a pouring path extending therethrough. A crucible is positioned in the upper chamber and a mold is positioned in the lower chamber, both in alignment with the pouring path. A body of casting metal is placed in the crucible and is melted from the top down by an electric arc generated in the upper chamber, the bottom portion of the body of casting metal blocking the pouring path until the casting metal has become molten. Thereafter, the molten casting metal falls by gravity through the pouring path, and into the mold. The arrangement is such that the molten metal requires nothing but the force of gravity to enter the mold cavity.

Abstract: A method and apparatus for making dental castings wherein the crucible is supported on a platform having a central opening positioned beneath the crucible opening over the mold cavity of the investment, which, in turn, is supported on a platform having a central opening. The upper platform is lowered against the investment so that a single sealed vessel comprising the crucible and investment cavity is formed. Air is then admitted to the crucible and investment cavity at a point beneath the crucible opening so that both the investment and crucible may be purged, an arc is formed in the crucible thereby melting the casting material, and air under pressure is admitted to the top of a crucible thereby causing the molten casting material to flow into the investment cavity.

Abstract: A casting machine including a control circuit which automatically controls ts operation. The casting machine includes a casting chamber which supports an alloy filled open-ended container whose open end faces the sprue hole of an investment casting ring. The control circuit couples a vacuum to the casting chamber while maintaining the casting chamber in its initial upright position. After a first timing interval, the chamber is inverted and the vacuum is decoupled from the casting chamber, and compressed air is applied to the casting chamber. After a second subsequent time interval the casting chamber is automatically returned to its initial upright position, the action of which causes the casting chamber to be automatically vented to the atmosphere.

Abstract: In metallic material injection molding machines, the connection between the injection nozzle and the sprue bushing has tended to leak metallic material. To overcome this problem, the nozzle has been modified to have a projecting portion or spigot that extends into a mating portion of the sprue bushing to form a seal between the respective portion walls. The nozzle and sprue bushing can move axially with respect to one another without loss of sealing whereas with the prior designs any separation between confronting annular surfaces on the sprue bushing and the nozzle would result in a loss of sealing and leakage.