Abstract: A die casting method for use with semi-solid metal billets allows the removal of air from portions of the billet as it is compressed and deformed to flow into a cavity of a die. The die is formed in a manner that captures other potential defects and impurities in portions of the finished die cast product that can easily be removed subsequent to the completion of the die casting operation. The air is removed through passages formed in a generally cylindrical rod that extends through a second surface of the die to allow the air to flow from pockets formed by a concavity of the billet and through the air conduit to the atmosphere.

Abstract: An injection molding machine (10) comprises an injection molding tool (14) having a mold cavity, in which a molded part can be produced by overmolding a mold core of metal inserted into the mold cavity using an injection molding material, and a melting tool (18) by means of which the mold core overmolded with the injection molding material can be melted out, wherein the melting tool (18) comprises at least one current-carrying element (28) by which eddy currents can be generated in the material of the mold core.

Abstract: By blocking an angular extent of an annular skimming trap used for semi-solid injection, a notable reduction in lenticular defects and porosity are observed. The blocking can be performed by a ring having dimensions to completely occlude a prior art annular skimming trap throughout the angular extent, and providing complete and/or partial flow across the ring throughout the rest of the angular extent. Preferably an outlet to the ring trap includes a chamfered edge and/or a deflector for encouraging flow of the contaminated semi-solid material into the trap.

Abstract: An injection sleeve or shot sleeve for a die-casting machine includes an elongated plunger passage and a container supporting portion configured to support an elongated container containing a charge of semi-solid metal alloy. The charge can be axially aligned with the plunger passage, and an interior surface of the container can be axially aligned with an interior surface of the plunger passage.

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 semi-solid metal alloy injection feed system for reduced inclusion injection moulding comprises a substantially closed injection chamber for containing a billet of semi-solid metal alloy, and thrusting the billet through the injection chamber into a mould, wherein the injection chamber has a first section defined by a wall with an inner contour for mating with a bearing surface for reciprocating motion of the bearing surface within the first section, along a center axis of the injection chamber; and the injection chamber has an outlet in fluid communication with the mould, the outlet provided at an opening in the injection chamber that is offset with respect to the center axis, and is disposed at an angle of 90° to 125° from the center axis. There is no neck or throttling between the chamber and the outlet. A butt end trap is preferably formed that requires inclusions that are principally on a bottom side of the injector to travel a relatively long ways to enter the outlet.

Abstract: This invention discloses a molten metal supply system that can supply molten metal to a downstream process at a constant pressure and molten metal flow rate. The molten metal supply system includes a molten metal supply source, a plurality of injectors, and a plurality of check valves.

Abstract: Provided is an electric die casting machine capable of achieving high injection speed and high boost pressure. An injection unit (100) is provided with an electric servomotor (104) for injection in a first stage, a ball screw mechanism (110) (motion converting mechanism in the first stage) for converting rotational motion of the electric servomotor for injection in the first stage into rectilinear motion of a linear motion body (106), electric servomotors (111 and 112) for injection in a second stage, mounted on the linear motion body, a crank mechanism (113 and 116) (motion converting mechanism in the second stage) for converting rotational motion of the electric motor servomotor for injection in the second stage into rectilinear motion of an injection plunger (118), and a control unit (400) for controlling driving of each electric servomotor for injection.

Abstract: Leakage of molten metal material from between a cylinder body having a tight-fitting liner and a nozzle member of an injection apparatus is prevented through the interaction of the nozzle member and a coupling ring with the liner.

Abstract: A device for melting, storing, and feeding a metal material is provided which can store a large amount of molten metal material corresponding to molding cycles with a compact configuration, using barrels to melt bar-shaped metal materials and a tank-and-barrel storage unit to store the molten metal material. The storage unit for the molten metal material is composed of an upper storage tank and a lower material temperature control barrel having a smaller diameter, the barrel being perpendicularly arranged under and in communication with the bottom center of the tank. The melting barrels for bar-shaped metal materials are made of barrel bodies having an inside diameter and a length appropriate to accommodate the bar-shaped metal materials. A more than one melting barrel is vertically arranged in parallel on a lid member of the storage tank, with their bottom openings facing the inside of the storage tank.

Abstract: A process for forming an article includes locating a container containing a charge of semi-solid metal alloy in a passage in front of a plunger arranged to travel relative to the passage to force the charge of semi-solid metal alloy into a desired shape, and displacing the charge of semi-solid metal alloy from the container and forming it into the desired shape by causing relative travel between the plunger and the passage. The plunger can push a displaceable closure member to displace the closure member and the charge of semi-solid metal alloy along an interior volume of the container from a first opening proximal the plunger and closed by the closure member towards a second opening remote from the first opening.

Abstract: There is provided a method for melting a material rod in a material melting and holding apparatus of a metal molding apparatus where the material melting and holding apparatus provided for the metal molding apparatus includes a furnace body of a melting and holding furnace, and a melting cylinder for a material rod and a material supply cylinder for directly supplying the material rod into the furnace body provided in parallel with each other on the furnace body, upon startup of molding, the material rod is melted using the melting cylinder prior to supplying the molten material from the melting cylinder into the melting and holding furnace, and the material rod subsequently supplied from the material supply cylinder to a bottom portion of the furnace body is submerged and melted by the molten material, thereby maintaining the submersion melting in the melting and holding furnace after the startup of molding.

Abstract: By pouring, by means of pressure, melted liquid of magnesium or magnesium alloy into a hollow portion which is formed using a casting mold, a valve body where a channel groove for hydraulic oil for use in a speed change operation of the automatic transmission is formed. In the above, the channel grove for the hydraulic oil is formed due to a convex portion which is formed on the mold so as to project into the hollow portion. As the magnesium has small heat capacity, variation of the temperature of the mold during the cooling and heating cycle can be suppressed. Moreover, as the magnesium melted liquid has no reactivity with respect to the casting mold, the convex portion is not deteriorated. This allows employment of a mold having a thinner convex portion formed thereon, and therefore formation of a valve body having a narrower channel groove.

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: In a die-casting mold used in a casting method, a fixed insert includes a recessed cavity portion, and a fixed mold body is arranged to hold the fixed insert. The fixed insert includes a first insert and a second insert. The first insert is held with the fixed mold body. The second insert is fitted and held within a recess formed on the first insert. The size of the second insert is minimized so as to just surround the recessed cavity portion.

Abstract: Disclosed is a metal molding system, including a metal molding conduit assembly having a conduit passageway configured to pass a volume of molten metal located downstream of a passageway blockage formable in the conduit passageway. Also disclosed is a mold for forming an article from a molten metallic, including a mold body configured to cooperate with a metal molding conduit assembly, including a conduit passageway configured to pass a volume of molten metal into a mold cavity defined by the mold body, the volume of molten metal located downstream of a passageway blockage.

Abstract: A method of and an apparatus for high pressure die casting are disclosed. The method uses a die casting apparatus which comprises a group of three plungers for casting metal. The two of which, injection plunger 1 and assistant plunger 3, are used to reduce metal loading time and reduce entrapped gases in die casting during a fast injection stage. By moving into injection sleeve 2, the assistant plunger separates the mold cavity 11 from the space defined by assistant plunger 3, injection sleeve 2, and injection plunger 1. The flow power device for moving said assistant plunger 3 is mounded on a back plate 8. A third plunger, the intensification plunger 12, is used to squeeze casting as soon as the injection plunger advances to a position in which the runner is separated from the closed space.

Abstract: A method for removing a casted part, for use in a die casting machine comprises the steps of setting a position in which a chuck performs an operation to grasp a casted part attached to a movable mold as a position from which the casted part is to be removed, and setting a relative positional relationship between a handle portion which is a part of the casted part attached to the movable mold to be grasped by the chuck and a movable die plate. The method further comprises the step of advancing the chuck between the movable mold and the fixed mold and positioning the chuck at the position from which the casted part is to be removed, in parallel with the movement of the movable die plate.

Abstract: A release agent spray method and apparatus for a die casting machine. As a movable die plate is moved in a die closing direction, a spray head is moved in a perpendicular direction to a spray position. The movable die plate is stopped when it has reached a position at which the distance between the spray head and a die cavity surface of a movable die and the distance between the spray head and die cavity surface of a fixed die both become equal to a spray distance. A release agent is sprayed from the spray head onto the cavity surfaces of the movable die and the fixed die.

Abstract: A die-casting die having a plurality of laterally movable slides is provided with a plurality of hydraulic cylinders located and carried internally within the die and connected with the plurality of slides to move the slides between cavity-open and cavity-closed positions.

Abstract: A method for operating an automated reciprocator for applying lubricant in a die casting system. As a reciprocator is moved between two die halves and a fluid is applied to the dies with the reciprocator, a safety bar is moved ahead of the reciprocator. Any objects in the path of the reciprocator are detected by contact with the safety bar. If the safety bar contacts an object as the reciprocator is moving down, a sensor signals a control system and the reciprocator is stopped.

Abstract: A rheo-casting container for containing a charge of semi-solid metal alloy includes an elongate body defining a side wall of the container, a mouth at a first end of the body, an opening at a second end of the body, and a closure member to close the opening. The closure member is configured to be displaceable along an interior volume of the body from the second end towards the first end to display a charge of semi-solid metal alloy contained in the container. The closure member is of a metal alloy the same as or similar to the semi-solid metal alloy for which the container is to be used and has a melting point which is not less than the temperature at which the metal alloy is to be introduced into the container.

Abstract: Disclosed, according to an aspect of the present invention, is a molding system that includes a mechanical fuse assembly configured to (i) abut a conduit connection, and (ii) permit movement of a conduit connection.

Abstract: Disclosed is a metal molding process, including passing, through a conduit passageway, a volume of molten metal located downstream of a passageway blockage formable in the conduit passageway. Also disclosed is a molded article having a body made by a metal molding process, including passing, through a conduit passageway, a volume of molten metal located downstream of a passageway blockage formable in the conduit passageway.

Abstract: A die-casting machine using an electric servo motor as a driving source for injecting/filling molten metal into a cavity of a mold through an injection sleeve. The molten metal in the injection sleeve is injected/filled into the cavity by an injection member. During the course between the stage when the molten metal has not reached a gate of the mold yet and the stage when the molten metal begins to pass the gate of the mold, the speed of the injection member is controlled to be accelerated in a smooth speed characteristic curve which does not have a broken-line characteristic. Thus, rising to a high injection speed can be attained rapidly and smoothly.

Abstract: A mold clamping apparatus for a die casting machine is provided. The apparatus can include a base, a fixed die plate standing fixedly on an end of an injection side of the base and defining a cavity therein, and a moving die plate arranged so as to proceed and retract on the base facing the fixed die plate and defining a cavity therein. A first versatile main mold can be disposed in the cavity of the fixed die plate and adapted to receive an insert die. Further, a second versatile main mold can be disposed in the cavity of the moving die plate and adapted to receive an insert die.

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

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: Method of operating metal molding system configured to handle mold, system including injection unit having: output port; and machine nozzle defining conduit passageway, nozzle including: egress end, ingress end, conduit passageway for receiving molten metal; and mechanical valve received in passageway, valve positioned between egress end and ingress end, and valve operable in opened and closed positions. Method includes: processing volume of molten metal; placing valve in closed position, so that prior to application of injection pressure by unit, volume of molten metal is located; (i) downstream of valve, and (ii) between egress end and valve; and placing valve in opened position, so that volume of molten metal is injected, in response to application of injection pressure into, at least in part, mold cavity; and actuating valve to closed position, so that another volume of molten metal is located: (i) downstream of valve, and (ii) between egress end and valve.

Abstract: The preferred embodiment of the present invention is a die casting apparatus and method evidencing increased apparatus output including the ability of using multiple die tools. The invention includes an indexing assembly removably engaged with at least one die block assembly for transporting between four stations, including an injection station, a cooling station, an ejection station, and a recovery station. The injection station includes a frame, a clamp assembly attached to the frame for clamping and releasing the die block assembly, a shot sleeve assembly engaged with the die block assembly for receiving molten material, such as metal, from a furnace means and injecting the molten material into the die block assembly, and a shot cylinder releasably coupled with the shot sleeve assembly for controlling the injection of molten material.

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: 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: According to one embodiment, a die includes a stationary die, and a movable die. A fin section provided between a runner section and a product section is extended from one end part to the other end part of the product section in a direction intersecting a stream direction of molten metal, and includes a fin central section opposed to a biscuit section in the stream direction of the molten metal, and a fin side section on a side of the fin central section. The fin side section includes a fin thick part formed thicker than a thickness of the fin central section. The fin thick part is extended to a boundary between the fin section and the product section. The product section includes a product thick part connected to the fin thick part in a region opposed to the fin thick part.

Abstract: A method of forming a material includes the steps of: vibrating a molten material at an ultrasonic frequency while cooling the material to a semi-solid state to form non-dendritic grains therein; forming the semi-solid material into a desired shape; and cooling the material to a solid state. The method makes semi-solid castings directly from molten materials (usually a metal), produces grain size usually in the range of smaller than 50 ?m, and can be easily retrofitted into existing conventional forming machine.

Abstract: A diecast machine comprises: a sleeve extending in a vertical direction; a plunger moving upward in the vertical direction inside the sleeve; a mold disposed above an upper side of the sleeve; and a metal material heater configured to heat a metal material disposed on the plunger and melting the metal material.

Abstract: A method of the surface treatment of a mold for casting, which comprises subjecting a cavity surface of a fixed mold made by the use of a SCM420 material to first shot peening, a sulfurizing-nitriding treatment and second shot peening. The resulting cavity surface of the fixed mold exhibits a high hardness of 700 or higher in terms of Vickers hardness due to the presence of a sulfurized and nitrided layer, and further has a compression residual stress of more than 1200 Mpa and a largest height, which is a surface roughness value defined by JIS standard, of 8 ?m or less.

Abstract: A diecasting process and a diecasting device to shorten the cycle times. The closing of the mold and the filling of molten metal into a casting chamber (4) are performed simultaneously.

Abstract: The preferred embodiment of the present invention is a die casting apparatus and method evidencing increased apparatus output including the ability of using multiple die tools. The invention includes an indexing assembly removably engaged with at least one die block assembly for transporting between four stations, including an injection station, a cooling station, an ejection station, and a recovery station. The injection station includes a frame, a clamp assembly attached to the frame for clamping and releasing the die block assembly, a shot sleeve assembly engaged with the die block assembly for receiving molten material, such as metal, from a furnace means and injecting the molten material into the die block assembly, and a shot cylinder releasably coupled with the shot sleeve assembly for controlling the injection of molten material.

Abstract: The preferred embodiment of the present invention is a die casting apparatus and method evidencing increased apparatus output including the ability of using multiple die tools. The invention includes an indexing assembly removably engaged with at least one die block assembly for transporting between four stations, including an injection station, a cooling station, an ejection station, and a recovery station. The injection station includes a frame, a clamp assembly attached to the frame for clamping and releasing the die block assembly, a shot sleeve assembly engaged with the die block assembly for receiving molten material, such as metal, from a furnace means and injecting the molten material into the die block assembly, and a shot cylinder releasably coupled with the shot sleeve assembly for controlling the injection of molten material.

Abstract: A multi-piece piston (1) is disclosed, for fixing to the high pressure side end (3) of a piston rod (5) running axially in a casting cylinder (7) of a cold chamber casting machine. The piston comprises a piston crown (9) forming a piston front face (13) on the high pressure side and a piston body (15) in the form of a bush connected to the piston crown (9) on the low pressure side. The piston body (15) can be connected to the piston crown (9) by means of fixing screws (23) to form a module. Complementary bayonet locking means (25, 27) are provided, for axial fixing of the piston (1) to the end (3) of the piston rod (5), on the piston crown (9) and the end (3).

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: An apparatus and method are provided that increase yield and reduce cycle time. In particular, a gate plate for a die casting machine is configured to lessen the waste produced during die casting, resulting in greater yield. Further, the gate plate is configured with tapered sides to produce a draft, leading to less friction during the gate break/pull back sequence. This draft reduces the amount of unpressurized dwell time and subsequently the cycle time for producing the cast part.

Abstract: A method for operating an automated reciprocator for applying lubricant in a die casting system. As a reciprocator is moved between two die halves and a fluid is applied to the dies with the reciprocator, a safety bar is moved ahead of the reciprocator. Any objects in the path of the reciprocator are detected by contact with the safety bar. If the safety bar contacts an object as the reciprocator is moving down, a sensor signals a control system and the reciprocator is stopped.

Abstract: A forming method wherein a billet (31, 66, 77, 87, 107, 128, 136, 144, 153, 77B, 77C) comprising a metal-based composite material (27) prepared by mixing an aluminum alloy (22) and a ceramic (15) is subjected to pressure forming to manufacture a formed article, which comprises carrying out the pressure forming by the use of different compression ratios for different portions of the formed article, wherein a compression ratio means the ratio of the height of a billet before the pressure forming to height of the billet after the pressure forming. The above forming method allows the manufacture of a formed article having different volume contents 8Vf) of the ceramic for different portions thereof.

Abstract: The object of the present invention is a piston for cold chamber die-casting machines comprising a body and at least one sealing band mounted around said body, wherein said body and said band are provided with coupling means suitable for concurrently obtaining both an angular locking and an axial locking of the band to the piston body.

Abstract: An injection-molding device is for manufacturing V-engine blocks, in particular an injection-molding machine with a fixed and moving mold half, wherein the moving mold frame contains sliders and ejectors, along with center sleeve sliders angularly arranged relative to each other and a supporting plate for locking the center sleeve slider. Therefore, the force is introduced perpendicular via the center sleeve sliders, and absorbed via the supporting plate or moving identification plate. The moving mold half is secured on a mounting frame.

Abstract: A method of forming a material includes the steps of: vibrating a molten material at an ultrasonic frequency while cooling the material to a semi-solid state to form non-dendritic grains therein; forming the semi-solid material into a desired shape; and cooling the material to a solid state. The method makes semi-solid castings directly from molten materials (usually a metal), produces grain size usually in the range of smaller than 50 ?m, and can be easily retrofitted into existing conventional forming machine.

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: 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: A casting chamber (1) of a die casting machine, includes an inlet (2) and a casting plunger which is arranged so as to be movable along the longitudinal axis of the casting chamber (1). The casting chamber (1) is composed of an inner tube (3) which is coated with a thermally insulating layer and is shrunk into a steel jacket (5).