Abstract: A process for casting aluminum alloy parts is disclosed. The process includes the steps as follows: raising a liquid aluminum alloy; filling a mold; increasing pressure; solidifying formed by at least two stages of different pressure settings; and relieving pressure.

Abstract: A piston of a die-casting apparatus includes: a piston tip having a generally cup-shaped body having an inner front face and an inner cylindrical surface, the inner front face having a plurality of grooves formed therein for conveying cooling fluid; and an inner piston carrier coupled to the piston tip, the carrier comprising an elongate forward portion matingly engaging the piston tip.

Abstract: Apparatus for gravity flow and feeding of alloy in a casting operation has a supply vessel for holding a supply of alloy, a furnace in which the vessel is contained and in which the vessel is heatable to maintain the supply of alloy at suitable casting temperature, and a die mounted laterally outwardly from the vessel in relation to the furnace. A conduit provides communication between the vessel and the die. The apparatus further includes means for reversibly tilting an assembly including the furnace, the vessel and the die about a substantially horizontal axis to enable or prevent the flow of the alloy from the vessel to a die cavity defined by the die.

Abstract: A method for manufacturing light alloy castings by die casting with disposable cores, including a mold filling phase in which the parameters of pressure and speed of the molten alloy are controlled at levels tolerable by the cores until the cavities around the latter are filled by the molten alloy, and thereafter the pressure and speed parameters are controlled at levels suitable for completing and compacting the casting, the alloy being kept at a temperature close to its melting temperature throughout the whole path between the pump that pressurizes it and the entrance to the cavities around the cores. The invention relates also to a plant implementing said method by means of a pump connected to a mold through a duct that comes out within the casting envelope at a point close to the centroid of the cores.

Abstract: A die casting system includes a die, a shot tube, a melting system and a vacuum system. The die includes a plurality of die components that define a die cavity. The shot tube is in fluid communication with the die cavity and is operable to deliver a charge of material to the die cavity. The melting system is positioned adjacent to the die and includes an alloy loader, a melting unit and a crucible. The vacuum system defines a first chamber and a second chamber separated from the first chamber by an isolation valve. The melting system is disposed within the first chamber, and the die is disposed within the second chamber.

Abstract: A method of die casting a component having an integral seal includes defining a first portion of a die cavity of a die to include an open cell structure. A second portion of the die is defined without the open cell structure. Molten metal is injected into the die cavity, and the molten metal is solidified within the die cavity to form the component having the integral seal.

Abstract: Molten metallic material is cast into a mold that is made with a barrier to reduce gas permeability through a mold wall that forms on its innermost side a mold surface for contacting the molten metallic material. The molten metallic material is gravity cast into the mold residing in a furnace in a casting chamber under a first pressure, such as subambient pressure. Then, a gaseous pressure is provided in the casting chamber higher than the first pressure rapidly enough to reduce or eliminate the presence of localized voids in the casting solidified in the mold.

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: Metal matrix composite is made by assembling pre-forms of porous reinforcing material with an array of separator plates in a die in a pressure vessel, and infiltrating molten metal matrix material. Pre-evacuation followed by pressurisation when the molten metal matrix material is introduced into the die aids the infiltration. Re-introduction of gas during initial heating prior to melting speeds the heat-up process.

Abstract: A method of making a directionally solidified casting by casting a melt in a mold cavity of an investment mold having a core therein to form an internal casting surface feature involves evacuting the mold cavity while the investment mold is disposed on a chill member with the mold cavity communicating to the chill member, and introducing the melt into the evacuted mold cavity about the core so that the melt contacts the chill member for unidirectional heat removal and directional solidification. Then, gaseous pressure is applied to the melt cast in the mold cavity rapidly enough after introduction in the mold cavity to reduce localized void regions present in the cast melt as a result of surface tension effects between the melt and the core.

Abstract: A method of making a solid foam material including the steps of heating in a chamber a starting material that is normally solid at room temperature to a temperature that is above its melting point, injecting a blowing liquid into the melted material to produce a mixture; and rapidly decompressing the mixture to produce the solid foam material.

Abstract: A casting mold filled with free-flowing particulate matter such as sand, in which there is imbedded a vaporizable insert or pattern of wax, foam polymer or the like conforming to the shape of the desired casting, has at least two of its walls formed by flexible membranes exposed to the atmosphere for creating a more or less isobaric pressure upon the application of suction to its interior. One membrane may span the open top of a four-sided rigid shell whose perforated bottom is overlain by another such membrane; alternatively, with the sidewalls of the shell also perforated and/or vertically ribbed or fluted, five membranes may be combined into an open-topped bag lining the interior of the shell, the top of the bag being closed by a sixth membrane after introduction of the sand filling and its pattern insert.

Abstract: A system for centrifugal casting of induction melted metal includes a crucible and a porous mold secured to a casting arm. The casting arm is secured to a hollow rotatable shaft which includes two separate fluid channels extending axially therethrough. The shaft is supported on a rotary valve which provides separate flow communication with each flow channel. One flow channel provides pressurized argon to the crucible to prevent oxide formation during casting. The other channel provides a vacuum to the exterior of the mold to draw gasses out of the metal, aid in the argon flow into the mold, and to augment the centrifugal flow of the molten metal into the mold.

Abstract: A metal casting apparatus comprising an upright pressurizable housing open at its bottom adapted to receive an upright upwardly open container with a casting mold in a lower part of the container. A molten-metal receptacle is mounted in the container above the mold and undergoes tilting movement about a horizontal axis whereby the receptacle dispenses metal into the casting passage in a tilted position of the receptacle and receives molten metal in an upright position of the receptacle. Means is provided for hermetically sealing the bottom of the housing upon the insertion of the container therein with the receptacle in its upright position, while valve means is connected to the housing for evacuating and pressurizing it.

Abstract: A method and apparatus for melting and fine-casting precious metals in which a closed, gas-pressurizable crucible is arranged on top of a molding cell and connected thereto via a valve-controlled tapping passage. The melt is tapped under pressure into an evacuated mold, thereby inhibiting melt evaporation and improving melt flow into the mold branches.

Abstract: The present invention relates to a method of manufacturing a metal-impregnated body in which a porous body is immersed under sub-atmospheric pressure in a molten alloy for impregnation with said alloy or a porous body is immersed under elevated pressures produced by various gases, the pressure then being reduced to normal level, after which the porous body is introduced together with a molten alloy into a metal mold, in which said molten alloy is impregnated into said porous body. The porous body is then separated from said molten alloy.