Abstract: A aluminum base alloy containing boron and manufacturing method thereof, said alloy exhibiting good mechanical properties (such as high-temperature strength and creep strength) over a long period of time and also having a neutron absorbing capacity owing to boron present therein in the form of a compound without segregation. The alloy contains 0.5–10 mass % of boron with an isotopic element satisfying a relation of 10B/(10B +11B)?30%. said boron being present in the form of a boron compound which is 300 ?m or below in size. The alloy is obtained by melting at a temperature in excess of 950° C. and cast at a temperature in the range of 800° C. to 950° C., in such a way that the molten metal is kept for 60–180° seconds until it cools from 950° C. to the casting temperature.

Abstract: The invention relates to a method for the weight-accurate filling of ingot molds in a non-iron casting machine, e.g. a copper anode casting machine or a zinc anode casting machine, which is configured in the form of casting wheels that are use for production in a fully mechanized casting operation and are provided with the ingot molds. The aim of the invention is to obtain the desired precise-weight quality of a piece and exact plane parallelism of the bordering surfaces thereof. Said aim is achieved by carrying out the following steps: first, a liquid metal is introduced into an intermediate trough (4, 4?) at a regulated mass flow rate, the continuous dynamic weight increase being simultaneously determined; second, liquid metal is fed into a dosing trough (4, 4?) which is located on each side of the intermediate trough (4, 4?) by alternately tilting the intermediate trough (4, 4?) on one side followed by the other.

Abstract: An injection system of a die casting machine giving the necessary casting pressure without adjusting the accumulator side, provided with an injection cylinder including an injection piston linked with the injection plunger and a booster piston arranged behind the injection piston, an accumulator for supplying a pressurized liquid of a predetermined pressure, a liquid pressure circuit for supplying the pressurized liquid from the accumulator to the injection cylinder, driving the injection piston, then driving the booster piston, a control valve for controlling a flow rate of the pressurized liquid discharged from the front side of the injection piston of the injection cylinder so as to control a flow rate of the injection piston, and controlling the pressure of the pressurized liquid at the front side of the injection piston by the timing of closing the control valve to determine the final value of the casting pressure.

Abstract: A die casting machine obtain to obtain a suitable reduced pressure and reliably prevent the entry of molten metal into a valve when reducing the pressure in a cavity and injecting and filling it with a molten metal for casting, provided with the valve for opening and closing an exhaust path, a position detector for detecting an open/closed state of the exhaust path by the valve, an injection apparatus, a position detector for detecting the position of the injection plunger, and a control apparatus for controlling the injection. The control apparatus outputs a control instruction for making it close the exhaust path to the valve when the detected position of the injection plunger reaches a valve closing position set before the speed switching position and stops the drive of the injection plunger when not detecting completion of closure of the exhaust path when the injection plunger reaches the speed switching position.

Abstract: A vacuum die casting apparatus includes a casting cavity (10), which is evacuatable via a vacuum valve (26). A liquid casting material is pressable into the casting cavity by a piston (14) actuated by an actuator (17). A filling level sensor (20) detects a predetermined filling level of the casting material in the casting cavity. A control device (34) is connected to the filling level sensor for controlling the vacuum valve, and a position sensor (32) is connected to the control device (34) for detecting movement of the piston (14). The control device generates a closing signal for the vacuum valve (26) when the piston, after reaching the position (s1) at which the filling level sensor (20) indicates a predetermined filling level of the casting cavity (10) with casting material has been reached, is displaced in a predetermined manner.

Abstract: A casting apparatus has a melting pot (4) in which pieces of metal (8) to be melted is placed. A RF induction heater coil (10) is disposed in association with the melting pot (4) to heat the metal pieces (8). An inverter (18) supplies the coil (10) with high-frequency power to melt the metal pieces (8) in the melting pot (4), and the resulting molten metal is poured into a die (6). A control unit (36), after all of the metal pieces (8) having various sizes and shapes are melted, causes the operation of the inverter (18) to continue for a first time period and, after that, to suspend the operation of the inverter (18) for a second time period so that the heating can be stopped. After that, the control unit (36) causes the inverter (18) to resume its operation to heat the melted metal (8) in the melting pot (4) until the molten metal (8) assumes a predetermined state and, a third predetermined time after that, operates a melting pot driver (9) to cause the molten metal (8) to be poured into the die (6).

Abstract: A casting apparatus for pouring molten metal into molds comprises a vessel having a molten metal-receiving chamber generally extending between a filling end and a pouring end. The vessel includes a nozzle disposed in a bottom surface of the chamber proximate to the pouring end. A stopper cooperates with the nozzle to control a downward gravity flow of molten metal through the nozzle. A first support pivotably supports the vessel to provide a horizontal tilt axis substantially coincident with the nozzle. A second support is connected to the vessel at a point away from the tilt axis and has a drive for controlling a pivot position of the vessel. A tilt angle controller detects a level of molten metal within the chamber and engages the drive to maintain the level at a predetermined level.

Abstract: A casting apparatus for pouring molten metal into molds comprises a vessel having a molten metal-receiving chamber generally extending between a filling end and a pouring end. The vessel includes a nozzle disposed in a bottom surface of the chamber proximate to the pouring end. A stopper cooperates with the nozzle to control a downward gravity flow of molten metal through the nozzle. A first support pivotably supports the vessel to provide a horizontal tilt axis substantially coincident with the nozzle. A second support is connected to the vessel at a point away from the tilt axis and has a drive for controlling a pivot position of the vessel. A tilt angle controller detects a level of molten metal within the chamber and engages the drive to maintain the level at a predetermined level. A horizontal support rail slidably supports the vessel to provide a horizontal movement perpendicular to the tilt axis.

Abstract: A method (300) and a system (100) for controlling a casting process are described herein. The system (100) generally includes a die casting device (110) and a measuring device (120). The die casting device (110) includes a mold (130) configured to produce molded parts (140). The measuring device (120) may determine a position of the mold (130) within the die casting device (110) in a casting cycle. The measuring device (120) may determine an incremental increase in weight of molded parts (140) associated with the casting cycle. Based on the incremental increase in weight of molded parts (140), the measuring device (120) may provide a notification in response to a trigger event. The measuring device (120) may also reset the die casting device (110) for another casting cycle based on the incremental increase in weight of molded parts (140).

Abstract: A method for sizing an overflow chamber (46) in a mold (32) for the die casting of metals is disclosed. The method includes the steps of simulating a pressure of molten metal (30) in a main cavity (42) of the mold (32) and calculating the volume of the overflow chamber (46) from parameters yielded by the pressure simulation. A mold (32) defining overflow chambers (46) is also disclosed.

Abstract: The invention relates to a method according to which a metal (13) is re-shaped by a primary forming process. The aim of the invention is to improve such a method so that heat can be relatively easily added to the part and so that the addition can be varied as regards space and time. To this end, a voltage is applied to parts of the primary forming device between which the metal is disposed during the insertion process and/or during the primary forming process and/or during a subsequent treatment in the primary form after the primary forming process so that a closed circuit is produced and heat energy is supplied to the metal by the closed circuit.

Abstract: The invention concerns an apparatus 1 for carrying out a melting and casting operation in the fine casting art comprising a melting crucible 2 for receiving melting charge, a heating device 3 for heating the melting charge in the melting crucible 2, and a pyrometer 8 for ascertaining the temperature of the melting charge. In order to improve the quality of the products manufactured with such an operation the invention provides that the apparatus 1 is provided with a control device 4 for controlling the melting and casting operation in dependence on the ascertained melting charge temperature, wherein the control device 4 has a database 16 with a plurality of selectable, respectively melting charge material-specific parameter sets PS1, PS2, PS3 each with one or more parameters for configuring the pyrometer 8.

Abstract: A mold of a casting machine is filled to make a cast article. The method includes providing a molten metal to a casting chamber in fluid communication with the mold, the casting chamber having a supply conduit for introducing a gas into the casting chamber, and the casting chamber having an evacuation conduit for delivering the molten metal from the casting chamber to the mold. The method also includes controlling the filling of the mold during a first time interval by delivering the molten metal from the casting chamber to the mold at a first rate. The method further includes controlling the filling of the mold during a second time interval by delivering the molten metal from the casting chamber to the mold at a second rate. The filling of the mold decelerates from the first rate to the second rate and the second rate does not exceed the first rate.

Abstract: A casting apparatus has a melting pot (4) in which pieces of metal (8) to be melted is placed. A RF induction heater coil (10) is disposed in association with the melting pot (4) to heat the metal pieces (8). An inverter (18) supplies the coil (10) with high-frequency power to melt the metal pieces (8) in the melting pot (4), and the resulting molten metal is poured into a die (6). A control unit (36), after all of the metal pieces (8) having various sizes and shapes are melted, causes the operation of the inverter (18) to continue for a first time period and, after that, to suspend the operation of the inverter (18) for a second time period so that the heating can be stopped. After that, the control unit (36) causes the inverter (18) to resume its operation to heat the melted metal (8) in the melting pot (4) until the molten metal (8) assumes a predetermined state and, a third predetermined time after that, operates a melting pot driver (9) to cause the molten metal (8) to be poured into the die (6).

Abstract: A method is described of operating a hot-chamber pressure diecasting machine and a pressure diecasting machine suitable for the implementation of this method, by which a prefilling of the casting system can be carried out before the actual mold filling operation. During this prefilling operation, the air present in the casting system after each shot when the casting plunger is withdrawn, is pressed out during this prefilling operation through the mold which is still open during this time period. This amount of air therefore no longer has to escape during the subsequent mold filling operation. The mold filling operation and the pressing-in operation can therefore be implemented more effectively and within a shorter period of time.

Abstract: A method (300) and a system (100) for controlling a casting process are described herein. The system (100) generally includes a die casting device (110) and a measuring device (120). The die casting device (110) includes a mold (130) configured to produce molded parts (140). The measuring device (120) may determine a position of the mold (130) within the die casting device (110) in a casting cycle. The measuring device (120) may determine an incremental increase in weight of molded parts (140) associated with the casting cycle. Based on the incremental increase in weight of molded parts (140), the measuring device (120) may provide a notification in response to a trigger event. The measuring device (120) may also reset the die casting device (110) for another casting cycle based on the incremental increase in weight of molded parts (140).

Abstract: A molten metal supply system (90) includes a plurality of injectors (100) each having an injector housing (102) and a reciprocating piston (104). A molten metal supply source (132) is in fluid communication with the housing (102) of each of the injectors (100). The piston (104) is movable through a first stroke allowing molten metal (134) to be received into the housing (102) from the molten metal supply source (132), and a second stroke for displacing the molten metal (134) from the housing (102). A pressurized gas supply source (144) is in fluid communication with the housing (102) of each of the injectors (100) through respective gas control valves (146). The molten metal supply system (90) is in fluid communication with an outlet manifold (140) having a plurality of outlet dies (404), which may be used to form continuous metal articles including rods, bars, ingots, and continuous plate.

Abstract: The present invention relates to a method for casting ferrous or heavy metal articles in vertically parted sand moulds of a mould string plant through an inlet below or aside the mould cavity, by filling the moulds with molten metal by counter-gravity delivery using a source of pressure. The pressure is varied during the filling procedure to steer the flow speed and impact on the mould of the molten metal upon complete filling of the mould cavity is reduced.

Abstract: A process for producing pistons for a reciprocating internal combustion engine by casting, the process including the steps of determining for at least a first piston of a casting process batch, a volume Vactual formed by a surface of the piston that faces a combustion chamber of the engine, comparing the volume Vactual with a desired nominal volume Vnominal, and, based on this comparison, fixing a compression height KH so that its deviation from a set point ensures that, subsequently Vactual=Vnominal within tolerance limits.

Abstract: In a method for manufacturing a mold of a metal hot-runner injection molding machine, a temperature gradient of metal disposed in a nozzle between a heating device of the nozzle and a tip of the nozzle is measured. Then, an area in the nozzle is selected based on the measurement of the temperature gradient such that the metal in the nozzle upon a mold opening has a temperature at which a solidified condition of the metal can be stably maintained, where the temperature is close to a melting temperature of the metal. A gate cut portion is determined in the area.

Abstract: A method for controlling a molten metal pouring operation is disclosed which works in the presence of unusual pouring conditions such as typically encountered in aluminum casting and utilizes a laser type sensor, for example a triangulation based light section device, to monitor differences between a reference surface and the molten metal in a mold.

Abstract: An auger pump for pumping molten magnesium and its alloys from a furnace to a die casting machine, ingot mould, DC caster or the like is disclosed. The pump is comprised of a linearly aligned upper and lower portion. The upper portion is comprised of a housing which is attached to the furnace lid. An inverter duty electric motor is attached to the top of the housing and is controlled by a PLC. The auger shaft runs longitudinally between each portion and is supported in position by guide bearings located in the upper portion. The lower portion comprises a tubular casing which contains a gas inlet aperture and an feeder inlet aperture for drawing the molten magnesium into the pump. The outlet of the pump, a connector, is attached to a heated transfer tube, which conveys the molten magnesium to the mould.

Abstract: Apparatus for pouring of molten metal from a vessel onto the gating system of a mold includes a shield assembly that diverts any abnormal flow of molten metal occurring between normal flow of molten metal onto the gating system when molds are indexed for pouring. The shield assembly protects sensitive components of the mold, such as the gating and casting patterns in a lost foam casting process, from abnormal flow of molten metal.

Abstract: In a control method of the injection molding in accordance with the invention, in the process of injecting molding a low-melting-point alloy, an upper limit Qmax and a control lower limit CQmin of a quantity of material detained in a cylinder 12 are set to eliminate an excess or a shortage of the quantity of material detained in the cylinder 12. A material in a quantity greater than shot weight Qout is fed continuously into the cylinder until the upper limit is reached, while the material in a quantity less than the shot weight is fed into the cylinder until the lower limit is reached, thereby automatically maintaining the quantity of material detained in the cylinder within the range between the upper and lower limits. Accordingly, the down time due to the instability of metering in a molding machine can be reduced, and manpower for adjustment of conditions is not required, thereby making it possible to curtail the cost.

Abstract: A method for producing a cast article comprising the steps of: (a)providing a casting apparatus having a mold, a casting chamber containing a molten metal under pressure and a fluid under pressure, the casting apparatus having a first supply port for supplying the molten metal to the casting chamber and a second supply port for supplying the fluid to the casting chamber; (b) supplying the molten metal to the first supply port; (c) supplying the fluid to the second supply port; (d) determining the amount of the molten metal in the casting chamber as a variable V1; (e) determining the amount of the fluid in the casting chamber as a variable V2; (f) determining the amount of humidity in the casting chamber as a variable V3; (g) determining the amount of the fluid entering the casting chamber as a variable V4; (h) determining the pressure of the fluid in the casting chamber as a variable V5; (i) determining the amount of the molten metal needed to produce a cast article in the mold as a variable V6; (j) determini

Abstract: A process for continuously casting a thin metal strip controls has jets directed at casting rollers using sensor feedback. Sensor feedback can be taken directly from the rollers, or can be determined indirectly by sensing a condition of the thin metal strip. Surface conditions are controlled over a longitudinal extent of the rollers through locally controlled gas jets. The feedback control of the roller surfaces provides a more uniform casting surface and a more consistent output from the casting surface.

Abstract: A device for molding objects includes a mold having a molding space enclosed therein and adapted to be filled by a fluid mold material intended to solidify therein. The fluid mold material is injected under pressure into the molding space and solidifies under this high pressure. A chamber receives the mold and is filled with a medium. The medium filling the chamber and surrounding the mold is pressurized. The pressurized medium acts upon the mold from all directions with at least the same pressure magnitude as the pressure of the mold material within the mold. Therefore, the mold is isostatically balanced by the forces acting upon the mold by the mold material and the medium.

Abstract: A method for process monitoring during diecasting or thixotropic molding of metals in a diecasting or thixotropic molding installation which contains a casting chamber, a casting piston and a mould with a mold cavity. The method includes measuring temporal development of molding pressure p(t), determining time-related speed of the casting piston v(t); calculating energy E(t) supplied by the casting piston as a function of process time t, and calculating total energy Etot supplied by the casting piston during the diecasting or thixotropic molding process based on time-related development of the moulding pressure p(t) and the casting piston speed v(t), and using the total energy Etot as a parameter for monitoring the diecasting or thixotropic molding process.

Abstract: A continuous caster is controlled by a method anticipating the liquidus temperature in the mold of the caster to prevent premature solidification. The temperature in the tundish is measured and based upon the tundish temperature and the resistance time of the molten metal in the tundish, an equivalent liquidus temperature window is defined and the speed of the continuous caster is controlled to maintain this window of operation of the tundish.

Abstract: A feeding sensor for die caster comprises a storage tank storing molten metal, a positioning member atop the storage tank, a feeding pipe connected to the positioning member and having one end passing through an opening of the storage tank and placed below a surface of the molten metal. A container of fixed volume is connected to another end of the feeding pipe and has a control valve and an air pump. A columnar supporting post has one end connected to the feeding pipe and another end connected to a weight sensor.

Abstract: According to the present invention, between the mold-clamping process S1 in which the mold 1 is closed and the injection-pressure increase (solidifying) process S3, the gate-melting process for heating the hot runner 21 to melt the plug (metallic material) of the gate 27, the mold-lubricant coating process for spraying the lubricant onto the wall surface of the cavity 10, and the material-metering process are simultaneously carried out in parallel to each other. Thus, the molding cycle time can be reduced to a great extent.

Abstract: A molten metal pouring time determining apparatus determines a proper time for pouring molten metal into a die. A mass of metal is placed in a melting pot. The melting pot and the metal mass are radio frequency (RF) induction heated with RF signal modulated with a low frequency signal. A light receiver receives light emitted by the metal mass heated in the melting pot and develops a received-light representative signal. A high-pass filter extracts a high frequency component developed by a sudden change in the received-light representative signal caused by the melting of the metal mass. A comparator develops an output signal when the output signal of the high-pass filter exceeds a reference signal. When the comparator output signal remains above the reference signal for a predetermined time period, a timer generates a molten metal pouring command signal.

Abstract: When casting metal articles in a mould by forcing molten metal upwardly through a filling tube by gas pressure in a closed chamber, the datum level just below that of a connector connecting the filling tube to the mould is registered by a level sensor in a sensing tube while the latter's upper end is connected to atmosphere through a vent tube. At the same moment, the pressure is measured by a pressure sensor and recorded by a control unit and maintained constant by the latter after the emptying of the sensing tube, by connecting its upper end to the chamber through an equalizing tube, until the pressure is increased to fill the mould according to a predetermined function of time programmed into the control unit. The starting point for the filling of all moulds in succession is the same, regardless of the amount of metal in the supply unit.

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: In a die-casting machine having an injection cylinder device (10) for injecting molten material to a casting die and a boost cylinder device (20) for boosting a hydraulic oil supplied to the injection cylinder device (10), back-pressure of the injection cylinder device (10) and back-pressure of the boost cylinder device (20) are synchronously controlled by a flow-rate control valve (17) capable of continuously adjusting flow-rate of the hydraulic oil discharging channel (16). Accordingly, boosting characteristic can be made in accordance with burr critical boost curve, thereby avoiding burr occurrence in die-casting products in advance. Therefore, high-quality die-casting products without burrs can be manufactured even in a high-speed casting method or using low-accuracy dies.

Abstract: Apparatus for pouring of molten metal from a vessel onto the gating system of a mold includes a shield assembly that diverts any abnormal flow of molten metal occurring between normal flow of molten metal onto the gating system when molds are indexed for pouring. The shield assembly protects sensitive components of the mold, such as the gating and casting patterns in a lost foam casting process, from abnormal flow of molten metal.

Abstract: A one-piece, composite open-bottom casting mold with integral withdrawal section is fabricated by thermal spraying of materials compatible with and used for the continuous casting of shaped products of reactive metals and alloys such as, for example, titanium and its alloys or for the gas atomization thereof.

Abstract: While rotating a chamber 10 with a crucible 18 for heating ingots 28 of metal and a mold 23 for receiving molten metal from the crucible 18 enclosed therein from a normal position to a reversed position, when an arrival of the chamber 10 at a preset reference position is detected by a rotary plate 36 and a position sensor 37, a pressure gas is introduced into the chamber 10 at a time point delayed from the reference position by a preset delay time. The delay time is preset so that the pressurize gas starts pressing the molten metal into a sprue runner 26 immediately after a mouth of the sprue runner 26 is completely closed by the molten metal poured from the crucible 18. Thus, the molten metal is promptly pressed through the sprue runner 26 into a cavity 27 of the mold 23 before it starts solidifying due to the contact with the mold 23 having a temperature lower than that of the molten metal.

Abstract: An improved method for forming cores to be utilized in a loss core plastic molding process includes the use of a flow meter. The flow meter ensures that sufficient molten metal is delivered into a cavity for the loss core elements. In this way, the present invention eliminates the occurrence of gaps, spaces or cavities in the molded loss core part. Most preferably a magnetic flow meter is utilized which can monitor the amount of molten metal having flown through the flow meter.

Abstract: An apparatus and method for pressure casting a battery part wherein the state of molten lead is monitored so that when the molten lead enters a liquid-to-solid transformation stage, the volume of the mold available for the lead to solidify therein is quickly reduced through a volume contraction step to thereby cause the molten lead to flow into the remaining volume at the same time one maintains pressure on the molten lead. As the molten lead solidifies under the reduced volume and high pressure it produces a battery part that is substantially free of both tears and cracks. In an alternate method, the lead is allowed to solidify and at least a portion of the lead is mechanically deformed through a volume contraction step to cause cracks or tears in the battery part to be eliminated thereby providing a battery part free of cracks or tears.

Abstract: In casting metal objects in casting cavities (2) in moulds (1), connectable to a pressurized mould-filling furnace (5) through a delivery tube (8) and a connector (9), an external riser (13) is connected to and extends upwardly from the junction of the tube (8) and the connector (9). The riser (13) is used as a temporary reservoir in which the level of molten metal is regulated by controlling the gas pressure in space 7 in the furnace (5) such that the filling head, defined as the difference in level between the metal in the casting cavities (2) and that in the external riser (13), is kept constant or made to vary in a desired manner, e.g. so as to cause the level in the cavities to ascend at a substantially constant rate. The invention makes it inter alia possible to produce high-quality aluminum castings in sand moulds, e.g. using automatic foundry equipment of the DISAMATIC® type.

Abstract: A multiple-slide die-casting machine is equipped with improved mechanical structure and unique injection control system to improve the quality of molded products, to achieve flash free castings of improved surface finish. The clamping assemblies are mounted on one side of a base plate of the machine for applying clamping force to the mold sections in a preloaded state. A reinforcement ring interconnects the clamping assemblies to inhibit deflection of the base plate and the brackets which support the clamping assemblies so that an accurate parting line between the contacting surfaces of mold sections is insured.

Abstract: A die-casting machine provided with a sleeve through which molding material is injected into a cavity formed by a pair of mold dies, an injection plunger slidably mounted in the sleeve, an injection cylinder having an injection piston connected through a piston rod with the injection plunger, and a boost cylinder formed with an inner diameter larger than that of the injection cylinder and mounted adjacent to the injection cylinder thereon in a side opposite to the piston rod, wherein the injection cylinder and boost cylinder are communicated with a conduit connected to each hydraulic chamber on a piston rod side of the cylinders and connected to a flow rate control valve arranged on a side of meter out with respect to the cylinders, thereby controlling a speed of the injection plunger in accordance with a flow rate of pressurized oil flowing in said valve, wherein the machine further provides a switching valve for supplying pressurized oil to the boost cylinder when reaction forces acting on the injection plu

Abstract: A process for die-casting aluminum and aluminum alloys is such that the molten metal is introduced into a filling chamber and injected from the filling chamber into a mold cavity by a piston. The mold cavity is evacuated in advance, after which it is flooded with oxygen. After flooding with oxygen and before injecting the molten metal into it, the mold cavity is again evacuated. Finally, the molten metal is injected into the hollow mold cavity. The process enables die-cast parts to be produced with low tendency to forming pores and blisters.

Abstract: In a die-casting machine having an injection cylinder device (10) for injecting molten material to a casting die and a boost cylinder device (20) for boosting a hydraulic oil supplied to the injection cylinder device (10), back-pressure of the injection cylinder device (10) and back-pressure of the boost cylinder device (20) are synchronously controlled by a flow-rate control valve (17) capable of continuously adjusting flow-rate of the hydraulic oil discharging channel (16). Accordingly, boosting characteristic can be made in accordance with burr critical boost curve, thereby avoiding burr occurrence in die-casting products in advance. Therefore, high-quality die-casting products without burrs can be manufactured even in a high-speed casting method or using low-accuracy dies.

Abstract: A control system and method for controlling a low-pressure die casting machine wherein the pressure within the dies more accurately tracks the desired recipe pressure. The control system senses pressure in the dies and compares the sensed pressure to desired pressure. Should the difference between the sensed pressure and the desired pressure be indicative of a problem in the casting operation, subsequent casting cycles are prevented. Should the difference between the sensed pressure and the desired pressure by indicative of a potential catastrophic failure, the current casting cycle is immediately terminated, thereby minimizing the possibility of catastrophic failure. The control system has commercially available and easily replaceable components and, thus, can be quickly repaired to reduce machine downtime should any component fail.

Abstract: A metal material is placed in a crucible 4. An inverter 16 outputs a voltage amplitude-modulated with a low frequency signal. The output voltage is used to RF induction heat the crucible. A photodiode 30 receives light emitted by the metal material in the crucible and develops a received-light-representative signal. A high-pass filter 34 extracts, from the received-light-representative signal, a frequency component having a frequency above the frequency of the low frequency signal. A comparator 40 develops an output signal when the output signal of the high-pass filter exceeds a reference signal provided from a peak sample-and-hold circuit 42 to which the output signal of the high-pass filter is applied as an input thereto.

Abstract: A melt filling pressure difference control method controls a pressure difference used to supply melt from a holding furnace to a cavity of a casting machine by generating a pressure difference between an interior space of holding furnace and the cavity formed inside the mold. The method includes the steps of setting up a program pattern comprising time-varying characteristics of pressure difference target values, controlling the pressure difference so as to follow the program pattern that was set up, detecting whether the melt surface has risen to a predetermined level inside the cavity, compensating the program pattern based on the melt surface level when the melt surface has risen to a predetermined level inside cavity, and controlling the pressure difference between space inside the holding furnace and the cavity so as to follow the compensated program pattern.

Abstract: In a die-casting machine having an injection cylinder device (10) for injecting molten material to a casting die and a boost cylinder device (20) for boosting a hydraulic oil supplied to the injection cylinder device (10), back-pressure of the injection cylinder device (10) and back-pressure of the boost cylinder device (20) are synchronously controlled by a flow-rate control valve (17) capable of continuously adjusting flow-rate of the hydraulic oil discharging channel (16). Accordingly, boosting characteristic can be made in accordance with burr critical boost curve, thereby avoiding burr occurrence in die-casting products in advance. Therefore, high-quality die-casting products without burrs can be manufactured even in a high-speed casting method or using low-accuracy dies.

Abstract: An apparatus and method for pressure casting a battery part wherein the state of molten lead is monitored so that when the molten lead enters a liquid-to-solid transformation stage, the volume of the mold available for the lead to solidify therein is quickly reduced through a volume contraction step to thereby cause the molten lead to flow into the remaining volume at the same time one maintains pressure on the molten lead. As the molten lead solidifies under the reduced volume and high pressure it produces a battery part that is substantially free of both tears and cracks. In an alternate method, the lead is allowed to solidify and at least a portion of the lead is mechanically deformed through a volume contraction step to cause cracks or tears in the battery part to be eliminated thereby providing a battery part free of cracks or tears.