Abstract: An apparatus and method for pressure casting a battery part wherein an extendible piston includes sidewalls for shutting off the supply of molten lead and an impact surface that extends in a side-to-side condition to form an end surface of a battery part cavity so that when the extendible piston is brought into an intensifying condition the extendible piston shuts off further supply of molten metal while a heat source maintains the lead in a molten state as the impact surface of the piston forms a side-to-side mold cavity surface to complete the mold cavity surface thereby eliminating unevenness in the surface of the finished battery part by generating a force with the extendible piston which is sufficient to form a battery part so that upon removal from the mold the batter part is substantially free of tears and cracks as well as surface irregularities.

Abstract: An apparatus and method for pressure casting a battery part wherein an extendible piston includes sidewalls for shutting off the supply of molten lead and an impact surface that extends in a side-to-side condition to form an end surface of a battery part cavity so that when the extendible piston is brought into an intensifying condition the extendible piston shuts off further supply of molten metal while a heat source maintains the lead in a molten state as the impact surface of the piston forms a side-to-side mold cavity surface to complete the mold cavity surface thereby eliminating unevenness in the surface of the finished battery part by generating a force with the extendible piston which is sufficient to form a battery part so that upon removal from the mold the batter part is substantially free of tears and cracks as well as surface irregularities.

Abstract: A pound or number sign shaped (#-shaped) die cast sub-frame includes first and second horizontal members and first and second vertical members. The sub-frame has four arm mounting portions provided at four corners thereof, respectively. The arm mounting portion is a die cast part obtained near a communication portion of a runner formed in a die casting machine. Generally triangular bulged portions are formed at junction portions where the first horizontal member meets the first and second vertical members. Each junction portion has increased width. The junction portion is a die cast obtained within a cavity of increased width of the die casting machine. The bulged portion is pierced to provide a hole. The bulged portion having the hole formed therein is to be mounted to a small vehicle component.

Abstract: A disk rotor is produced using pre-forms. A manufacturing device 10 includes lower mold 11 and upper mold 12. The lower mold 11 includes support block 13, main body part of the lower mold 14, inclined pins 15, core elements 16 and slider 17. In securing and supporting pre-forms 4A, 5A, a cylinder 18 is actuated to cause upward movement of the support block 13 and the main body part of the lower mold 14, during which movement, core elements 16 and slider 17 are slid relatively outwards along inclined pins 15. In this state, the pre-forms 4A, 5A are guided to preset sites. The support block 13 and the main body part of the lower mold 14 are then moved downwards, during which movement, core elements 16 and slider 17 are slid relatively inwards along the inclined pins 15. In this state, the pre-forms 4A, 5A are supported and secured stably to define a cavity.

Abstract: An apparatus and method for pressure casting a battery part wherein at least one of the mold members forming the surfaces of an internal battery part cavity are displaced with respect to one another to reduce the volume of the mold cavity formed between the two parts to thereby intensify the pressure sufficiently high pressure so as to inhibit the formation of cracks and tears in a cast part.

Abstract: A process and an apparatus for producing metallic glass which are capable of producing a bulk amorphous alloy of desired shape, in particular, a bulk amorphous alloy of desired final shape are provided. In the present invention, the molten metal at a temperature above the melting point is selectively cooled at a rate higher than the critical cooling rate, and the product comprises single amorphous phase which is free from the crystalline phase formed by the development of crystal nuclei through nonuniform nucleation. The present invention is capable of producing the bulk amorphous alloy which is free from casting defects such as cold shuts and which has excellent strength properties in a simple process at a high reproducibility.

Abstract: A casting method and apparatus using a resin core wherein a portion of a wall of the resin core that receives a greater heat and/or load than other portions of the wall of the resin core, is increased in thickness. As a result, even if the resin core receives more heat and/or load in places, a local deformation or breakage of the resin core is effectively prevented.

Abstract: A rotor core (12) of a squirrel-cage rotor of an induction motor is housed in a recess (14) of a mold (18) of a conductor casting apparatus (10). A composite cylinder device (68) is fixed on the upper side of the mold (18) or on the side remoter from the pouring gate thereof, and the rotor core 12 is held in a predetermined position in the recess 14 by one piston (70). The other piston (72) locally pressurizes a molten metal that fills an end-connector ring cavity (66) defined between the rotor core (12) and the recess (14) on the side remoter from the pouring gate.

Abstract: The present invention is to provide a semi-molten metal molding apparatus with a die including a die hole and a cavity, and a punch movable into the die hole, in which the die hole is opened downwardly, and the punch is set below the die hole in such a manner that it is movable into the die hole. According to the present invention, the cavity is filled with a part of the material which has no oxide film or has an oxide film smaller in thickness.

Abstract: A process and an apparatus for manufacturing a cast product in which the cavity 2c is defined by a top die 1, a bottom die 2 and a slidable die insert 11 relative to the top die 1 and a pressure is applied to the die insert 11 by a hydraulic cylinder 13 before casting, injecting a molten metal 6 at a pressure higher than that on the die insert 11 to cause the die insert 11 to move rearward, whereby the molten metal 6 is additionally filled in the cavity 2c by an amount corresponding to the shrinkage due to pressurization, and a pressure on the molten metal 6 within the cavity 2c is maintained through the die insert 11 even after the molten metal 6 in the gate 2b has been solidified and the injection pressure has: not been transmitted anymore.

Abstract: A piston is formed with a rib which is formed on a base portion and is formed with through holes which is formed in such manner that the core is in contact with a projection portions of a holding die.

Abstract: A die-casting machine is described which includes at least one cylinder/piston assembly. Each assembly has main, ejector and core pistons and cylinders. The main cylinder is stationary and holds a piston which reciprocates to bring the molds together for metal injection or apart for releasing a die casting. A portion of the interior of the main piston constitutes an ejector cylinder having an ejector piston and a portion of the interior of the ejector piston constitutes a core cylinder having a core piston. The present invention is more compact and less complex than conventional die-casting machines.

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: The stepped core pin has a shank to be fitted in a pin holding bore formed in a wall of a casting mold and a forming portion having a diameter smaller than that of the shank which is projected from the inner surface of the casting mold defining a mold cavity into the mold cavity. A front portion of the shank is reduced to form a neck portion and a molten metal stopping portion is formed between the neck portion and the forming portion. The diameter of the molten metal stopping portion, which is slightly smaller than that of the shank excluding the neck portion, is determined so that a clearance through which the molten metal is unable to leak into the pin holding bore is formed between the outer circumference of the pin holding bore and the inner circumference of the molten metal stopping portion. This clearance effectively combines the length of the forming portion with the length of the neck, thereby reducing stress and fatigue to the projected forming portion.

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 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: 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: 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 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 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.