Rheo-casting Patents (Class 164/900)
  • Patent number: 11122709
    Abstract: An electronic device includes a top plate having a first surface and a second surface that is positioned at an elevation that is lower than an elevation of the first surface, the second surface extending from a first end part of the top plate to a second end part of the top plate, a bottom plate provided under the top plate, and a circuit board placed between the top plate and the bottom plate and mounted with an electronic component. The top plate has opposing first and second edges and opposing third and fourth edges that are perpendicular to the first and the second edges, the first end part being formed at the first edge and the second end part being formed at the second edge.
    Type: Grant
    Filed: October 17, 2019
    Date of Patent: September 14, 2021
    Assignee: KIOXIA CORPORATION
    Inventor: Akitoshi Suzuki
  • Patent number: 11085265
    Abstract: A sealing tool for conveyance within a tubular member within a wellbore extending into a subterranean formation. The sealing tool includes a mandrel and a eutectic sealing material disposed about the mandrel. The eutectic sealing material has a eutectic temperature at which the eutectic sealing material melts. The sealing tool also includes means for heating the eutectic sealing material to at least the eutectic temperature. The eutectic sealing material is transferred onto an inner surface of the tubular member by activating the heating means to heat the eutectic sealing material to at least the eutectic temperature to melt the eutectic sealing material.
    Type: Grant
    Filed: September 25, 2015
    Date of Patent: August 10, 2021
    Assignee: Schlumberger Technology Corporation
    Inventor: Oscar Rivas Diaz
  • Patent number: 10035215
    Abstract: A wire fusing apparatus including a first body having a first surface, a second body having a second surface, and a heating unit is provided. The second body is pivoted to the first body to rotate relatively to the first body enabling the first and second bodies to be in an expanded or a closed state. When the first and second bodies are in the closed state, the first and second surfaces define a closed containing groove for containing two independent wires butt jointed with each other. The first surface, the second surface and the containing groove each has a heat-conducting region, and the heat-conducting regions contact each other when the first and second bodies are in the closed state. The heating unit disposed on the first or second body contacts one of the heat-conducting regions for heat-fusing a butt-jointing point of the wires to form a fused wire.
    Type: Grant
    Filed: July 24, 2014
    Date of Patent: July 31, 2018
    Assignees: XYZprinting, Inc., Kinpo Electronics, Inc., Cal-Comp Electronics & Communications Company Limited
    Inventors: Shih-Jer Din, Yang-Teh Lee, Yi-Lin Chiu
  • Patent number: 9555468
    Abstract: A plant and a process are disclosed for producing components made of an aluminum alloy for vehicles and white goods, through the steps of: providing thixotropic billets made of an aluminum alloy; sizing the billets depending on a ratio between weight and size of the component to be produced, thereby obtaining crop ends of material; heating the crop ends in a range of temperatures during which both a solid phase and a liquid phase coexist with a prevalence in the solid phase (more than 50%) in heating means (5); loading, through loading means (9), the crop ends in an injecting vessel made of non-magnetic steel for further workings; removing, through scalping devices, an external part of the crop ends that has become cooled when passing from the heating means (5) to the loading means (9); firstly injecting the crop ends through a press; secondly injecting the crop ends through the press in 18 milliseconds by using a closed-loop control system and increasing the injection unit power with respect to a closing uni
    Type: Grant
    Filed: September 12, 2012
    Date of Patent: January 31, 2017
    Inventor: Lucio Megolago Albani
  • Patent number: 9038705
    Abstract: A die casting method and apparatus are provided, thereby making it possible to produce a thin diecast product that has hitherto been considered impossible to realize, and a diecast product is also provided. A semi-solidified metallic material is formed having particles in solid phase of a particle size less than 30 ?m, and is thereupon injected into a die. A die casting machine has a sleeve into which a melt of metallic material is poured, and the semi-solidifying material there when it has a certain proportion of solid phase reached is injected into the die with a plunger to which pressure is applied. The melt of metallic material is poured into the sleeve so that the material occupies inside the sleeve at a proportion in vertical cross-sectional area of 30% or less. The particle size in this semi-solid material is held unvaried in a product as diecast.
    Type: Grant
    Filed: September 18, 2012
    Date of Patent: May 26, 2015
    Assignee: TOHOKU UNIVERSITY
    Inventors: Masayuki Itamura, Kouichi Anzai
  • Patent number: 9027378
    Abstract: A digital manufacturing system comprises a build chamber, a build platform disposed within the build chamber, at least one extrusion line configured to heat a metal-based alloy up to a temperature between solidus and liquidus temperatures of the metal-based alloy, a deposition head disposed within the build chamber and configured to deposit the heated metal-based alloy onto the build platform in a predetermined pattern, an umbilical having a first end located outside of the build chamber and a second end connected to the deposition head, and at least one gantry assembly configured to cause relative motion between the build platform and the deposition head within the build chamber, where the at least one gantry assembly comprises a motor disposed outside of the build chamber.
    Type: Grant
    Filed: April 8, 2011
    Date of Patent: May 12, 2015
    Assignee: Stratasys, Inc.
    Inventors: S. Scott Crump, J. Samuel Batchelder, Timothy Sampson, Robert Zinniel, John Barnett
  • Patent number: 9022093
    Abstract: A method of casting a semi-liquid or semi-solid iron-based alloy, the method including: applying, to a part or to the whole of an uppermost surface of an inner surface of a die, a lubricating die-release agent in which particles including at least one selected from molybdenum disulfide, graphite, tungsten disulfide, boron nitride, chrome oxide and boric oxide are dispersed in a solvent; and thereafter casting by using the die.
    Type: Grant
    Filed: June 15, 2009
    Date of Patent: May 5, 2015
    Assignee: Nippon Steel & Sumitomo Corporation
    Inventor: Yoshiaki Shia
  • Patent number: 8998501
    Abstract: The invention concerns a bearing component (Ia, Ib, 1, 7, 9) for a rolling (13, 14, 16) or sliding bearing (19), wherein the bearing component (Ia, Ib, 1, 7, 9) is one of an inner ring (Ia, 1), an outer ring (Ib, 7), a rolling element (9), a cage, or a guide ring. The bearing component (Ia, Ib, 1, 7, 9) comprises a first material (2), and a second material (3) joined to the first material (2), wherein the second material (3) and the first material (2) having been joined by a semi-solid metal process.
    Type: Grant
    Filed: May 26, 2008
    Date of Patent: April 7, 2015
    Assignee: Aktiebolaget SKF
    Inventors: Patrik Dahlman, Martin Friis
  • Patent number: 8591804
    Abstract: A method of metal injection molding on an injection molding machine having a heated barrel with an increasing temperature gradient is disclosed. A first step includes providing a metal alloy feedstock including a first component having a first melting point and a second component having a second melting point that is higher than the first melting point, the first melting point and the second melting point selected to match the temperature gradient of the heated barrel of the injection molding machine. A second step includes feeding the metal alloy feedstock into the injection molding machine. A third step includes melting the metal alloy feedstock within the heated barrel of the injection molding machine. A fourth step includes maintaining the percentage of solids to liquids in the metal alloy feedstock of the first component and second component within a processable range of about 5% to about 30%.
    Type: Grant
    Filed: May 31, 2011
    Date of Patent: November 26, 2013
    Assignee: Cool Polymers, Inc.
    Inventors: Kevin A. McCullough, James D. Miller
  • Patent number: 8376026
    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.
    Type: Grant
    Filed: May 25, 2010
    Date of Patent: February 19, 2013
    Assignee: National Research Council of Canada
    Inventors: Chang-Qing Zheng, Dany Drolet
  • Patent number: 8357225
    Abstract: The present disclosure provides a method for making magnesium-based composite material. The method comprises the following steps. Firstly, a semi-solid-state magnesium-based material is provided. Secondly, at least one nanoscale reinforcement is added into the semi-solid-state magnesium-based material to obtain a semi-solid-state mixture. Thirdly, the semi-solid-state mixture is heated to a liquid-state mixture. Fourthly, the liquid-state mixture is ultrasonically processed. Fifthly, the liquid-state mixture is cooled to obtain the magnesium-based composite material.
    Type: Grant
    Filed: July 10, 2010
    Date of Patent: January 22, 2013
    Assignees: Tsinghua University, Hon Hai Precision Industry Co., Ltd.
    Inventors: Wen-Zhen Li, Shi-Ying Liu
  • Patent number: 8327914
    Abstract: A semi-solid metal alloy injection feed system for reduced inclusion injection molding 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 mold, 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 mold, 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.
    Type: Grant
    Filed: May 25, 2010
    Date of Patent: December 11, 2012
    Assignee: National Research Council of Canada
    Inventors: Chang-Qing Zheng, Florentin Laplume
  • Patent number: 8297339
    Abstract: A semi-molten or semi-solid molding method is used to cast a scroll member having a tabular panel, a spiral section and a columnar part. The method includes filling a cavity formed inside of the molding die with semi-molten or semi-solid metal from a section for forming the columnar part via a runner that forms a channel. The cavity forms a space for casting the scroll member. An angle of intersection ?1 between the runner and the section for forming the columnar part is set such that to 97°??1?135°, and/or a ratio R/?S is set such that 0.12?R/?S?0.96. R is a radius of curvature of a chamfered section in which the runner intersects the section for forming the columnar part, and ?S is the square root of a cross-sectional area S of the section for forming the columnar part.
    Type: Grant
    Filed: September 1, 2010
    Date of Patent: October 30, 2012
    Assignee: Daikin Industries, Ltd.
    Inventors: Masateru Yamamoto, Ryohei Deguchi, Satoshi Yamamoto
  • Patent number: 8287622
    Abstract: The present disclosure provides a method for making aluminum-based composite material. The method includes the following steps. First, a aluminum-based material in semi-solid state is provided. Second, at least one nanoscale reinforcement is added into the aluminum-based material in semi-solid state to obtain a mixture in semi-solid state. Third, the mixture in semi-solid state is heated to a mixture in liquid state. Fourth, the mixture in liquid state is ultrasonically processed. Fifth, the mixture in liquid state is cooled to obtain the aluminum-based composite material.
    Type: Grant
    Filed: July 10, 2010
    Date of Patent: October 16, 2012
    Assignees: Tsinghua University, Hon Hai Precision Industry Co., Ltd.
    Inventors: Wen-Zhen Li, Shi-Ying Liu
  • Patent number: 7987894
    Abstract: An apparatus for fabrication of a magnesium-based carbon nanotube composite material, the apparatus includes a thixomolding machine, and a feeding device. The thixomolding machine includes a heating barrel, a feeding inlet, a nozzle, a heating portion, and a plunger. The heating barrel includes a first end and a second end. The feeding inlet is disposed at the first end. The nozzle is disposed at the second end. The heating portion is disposed around the heating barrel. The plunger is disposed at a center of the heating barrel. The feeding device includes a hopper; an aspirator connected to the hopper, a first container, and a second container. The hopper is in communication with the first container and the second container. A method for fabricating a magnesium-based carbon nanotube composite material is also provided.
    Type: Grant
    Filed: August 21, 2008
    Date of Patent: August 2, 2011
    Assignees: Tsinghua University, Hon Hai Precision Industry Co., Ltd.
    Inventors: Kam-Shau Chan, Cheng-Shi Chen, Guang-Liang Sheu, Qing-Chun Du, Wen-Zhen Li
  • Patent number: 7942987
    Abstract: A digital manufacturing system comprises a build chamber, a build platform disposed within the build chamber, at least one extrusion line configured to heat a metal-based alloy up to a temperature between solidus and liquidus temperatures of the metal-based alloy, a deposition head disposed within the build chamber and configured to deposit the heated metal-based alloy onto the build platform in a predetermined pattern, an umbilical having a first end located outside of the build chamber and a second end connected to the deposition head, and at least one gantry assembly configured to cause relative motion between the build platform and the deposition head within the build chamber, where the at least one gantry assembly comprises a motor disposed outside of the build chamber.
    Type: Grant
    Filed: June 24, 2008
    Date of Patent: May 17, 2011
    Assignee: Stratasys, Inc.
    Inventors: S. Scott Crump, J. Samuel Batchelder, Timothy Sampson, Robert L. Zinniel, John Barnett
  • Patent number: 7921900
    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.
    Type: Grant
    Filed: June 22, 2010
    Date of Patent: April 12, 2011
    Assignee: CSIR
    Inventors: Hristov Lillian Ivanchev, Daniel Jeremias Wilkins
  • Patent number: 7798200
    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.
    Type: Grant
    Filed: May 18, 2007
    Date of Patent: September 21, 2010
    Assignee: Husky Injection Molding Systems Ltd.
    Inventor: Jan Marius Manda
  • Patent number: 7766071
    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.
    Type: Grant
    Filed: October 28, 2004
    Date of Patent: August 3, 2010
    Assignee: CSIR
    Inventors: Hristov Lillian Ivanchev, Daniel Jeremias Wilkins
  • Patent number: 7730934
    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.
    Type: Grant
    Filed: May 18, 2007
    Date of Patent: June 8, 2010
    Assignee: Husky Injection Molding Systems Ltd.
    Inventor: Jan Marius Manda
  • Patent number: 7694715
    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.
    Type: Grant
    Filed: January 23, 2007
    Date of Patent: April 13, 2010
    Assignee: Husky Injection Molding Systems Ltd.
    Inventors: Frank Czerwinski, Robert Domodossola, Giuseppe Edwardo Mariconda, Derek Kent William Smith
  • Patent number: 7694714
    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.
    Type: Grant
    Filed: February 9, 2006
    Date of Patent: April 13, 2010
    Assignee: Husky Injection Molding Systems Ltd.
    Inventor: Jan Marius Manda
  • Patent number: 7661458
    Abstract: A magnesium metal thin plate manufacturing method includes at least a casting process of supplying a molten metal obtained by melting a magnesium metal to a molten metal bath, drawing out the molten metal, supplying the molten metal into the gap between a pair of casting rolls composed of at least a pair of casting upper roll and casting lower roll, applying pressure to the molten metal, and casting a plate solidified at a predetermined temperature and having a predetermined thickness, and a rolling process of rolling the cast plate by means of at least a pair of rolling rolls by applying pressure thereto to manufacture a magnesium metal thin plate. With the above arrangement, there can be provided a magnesium metal thin plate manufacturing method and manufacturing apparatus that can effectively manufacture a magnesium metal thin plate by plastic working without requiring a heat energy generation step again in rolling.
    Type: Grant
    Filed: March 1, 2004
    Date of Patent: February 16, 2010
    Assignee: Gonda Metal Industry Corporation Ltd.
    Inventors: Toshio Haga, Kazunari Yoshida, Yoshio Gonda
  • Patent number: 7621315
    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.
    Type: Grant
    Filed: January 22, 2009
    Date of Patent: November 24, 2009
    Assignees: UT-Battelle, LLC, University of Tennessee Research Foundation
    Inventors: Qingyou Han, Xiaogang Jian, Hanbing Xu, Thomas T. Meek
  • Patent number: 7540316
    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.
    Type: Grant
    Filed: August 16, 2006
    Date of Patent: June 2, 2009
    Assignee: iTherm Technologies, L.P.
    Inventors: Wayne N. Collette, Kyle B. Clark, Valery Kagan, Stefan von Buren
  • Patent number: 7516772
    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.
    Type: Grant
    Filed: December 27, 2004
    Date of Patent: April 14, 2009
    Assignee: Honda Motor Co., Ltd.
    Inventors: Satoshi Matsuura, Hiroto Shoji, Takaharu Echigo, Masashi Hara, Hiroki Takano, Yusuke Toyoda, Katsuhiro Shibata, Takahiro Mizukami, Hirohide Shibata
  • Patent number: 7509993
    Abstract: A metal matrix nanocomposite is formed by heating a metal above its liquidus temperature, adding nanoparticles, and then agitating the mixture with high-frequency (and preferably ultrasonic) vibration. The mixture can then be cooled below the liquidus of the metal to a semisolid state, and placed in a mold to form it into some desired shape. The formed mixture can then be quenched or otherwise allowed to cool to provide an article in finished (or nearly so) form.
    Type: Grant
    Filed: August 13, 2005
    Date of Patent: March 31, 2009
    Assignee: Wisconsin Alumni Research Foundation
    Inventors: Lih-Sheng Turng, Michael P. DeCicco, Xiaochun Li
  • Patent number: 7493934
    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.
    Type: Grant
    Filed: March 29, 2007
    Date of Patent: February 24, 2009
    Assignee: UT-Battelle, LLC
    Inventors: Qingyou Han, Xiaogang Jian, Hanbing Xu, Thomas T. Meek
  • Patent number: 7472674
    Abstract: A piston for an internal combustion engine is formed from a metal part cast in one piece. Heating of a billet is carried out so as to bring it to an intermediate temperature between its solidus temperature and its liquidus temperature, and shaping thereof by thixoforging is carried out.
    Type: Grant
    Filed: December 4, 2003
    Date of Patent: January 6, 2009
    Assignee: Ascometal
    Inventor: Marc Robelet
  • Patent number: 7469738
    Abstract: A injection-molding process injects a semi-solid slurry with a solids content ranging from approximately 60% to 85% into a mold at a velocity sufficient to completely fill the mold. The slurry is injected under laminar or turbulent flow conditions and produces a molded article that has a low internal porosity.
    Type: Grant
    Filed: December 14, 2004
    Date of Patent: December 30, 2008
    Assignee: Husky Injection Molding Systems, Ltd.
    Inventors: Frank Czerwinski, Damir Kadak
  • Patent number: 7451805
    Abstract: A pouring apparatus for molten metal includes a stirrer installed in a reservoir. The stirrer is rotated by a rotational drive mechanism installed on the reservoir. Molten solder is placed into the reservoir, high melting point metal particles are charged into the molten solder, stirring is performed with the stirrer to uniformly disperse the metal particles in the molten solder, and then the molten solder and dispersed metal particles are cast into a mold. Casting can be performed quickly after charging the metal particles into the molten solder, so the metal particles do not significantly melt into the molten solder.
    Type: Grant
    Filed: March 31, 2005
    Date of Patent: November 18, 2008
    Assignee: Senju Metal Industry Co., Ltd.
    Inventor: Minoru Ueshima
  • Patent number: 7441584
    Abstract: A metal alloy is heated to a molten state and then poured into a shallow shot chamber defined by a shot sleeve and a shot piston of a vertical die cast press. A homogenizing member having L-shape arms projecting outwardly from a vertical shaft is inserted into the molten metal, and the shaft and arms are simultaneously rotated and orbited by a six axes robot for moving more solidified semi-solid metal cooled by the shot sleeve and shot piston into a more liquified semi-solid metal within a central portion of the shot chamber to form a homogenizing slurry. The force required to move the homogenizing member is used to determine the solid fraction of the slurry and to stop the homogenizing process after a predetermined force is detected. A hydraulic cylinder actuates the piston to transfer the semi-solid slurry upwardly from the shot chamber into a die cavity.
    Type: Grant
    Filed: March 2, 2006
    Date of Patent: October 28, 2008
    Assignee: T.H.T Presses, Inc.
    Inventors: Eric W. Cruse, Richard J. Kamm, Larry T. Siefring
  • Patent number: 7353858
    Abstract: Disclosed is: (i) a cap for servicing a molding-system valve, and (ii) a method of a cap for servicing a molding-system valve, amongst other things.
    Type: Grant
    Filed: May 17, 2006
    Date of Patent: April 8, 2008
    Assignee: Husky Injection Molding Systems Ltd.
    Inventor: Jan Marius Manda
  • Patent number: 7343959
    Abstract: The present invention provides a pressure casting method of a magnesium alloy. In the method, a molten magnesium alloy is cooled to form a partially molten state containing a solid-phase, and the partially molten state is further cooled to form a solid-phase granularly crystallized solid material. The solid material is partially-melted and pressure cast into a mold by a molding machine. A ratio of primary crystals in said solid material is set to 55 to 65%. The solid material is partially-melted in a solid-phase and liquid-phase coexisting state at a selected heating temperature so that a semi-solid having thixotropic properties and having the size of a main solid phase of 50 to 250 ?m and a solid-phase ratio of 30 to 70% is formed. The semi-solid is pressure cast into a mold through a nozzle while maintaining the semi-solid state to form metal products having a ratio of primary crystals of 20 to 50%.
    Type: Grant
    Filed: August 16, 2006
    Date of Patent: March 18, 2008
    Assignees: Nissei Plastic Industrial Co., Ltd., Chiba Institute of Technology
    Inventors: Tetsuichi Motegi, Kazutoshi Takayama, Kiyoto Takizawa
  • Publication number: 20080060779
    Abstract: A SOD (slurry-on-demand) casting method and charge is provided for casting a low-solid-fraction, namely 10 to 30% solid-fraction, alloy.
    Type: Application
    Filed: September 13, 2006
    Publication date: March 13, 2008
    Inventor: Adam E. Kopper
  • Publication number: 20080041551
    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.
    Type: Application
    Filed: August 16, 2006
    Publication date: February 21, 2008
    Applicant: iTherm Technologies, L.P.
    Inventors: Wayne N. Collette, Kyle B. Clark, Valery Kagan, Stefan von Buren
  • Patent number: 7331372
    Abstract: To insert a cylindrical metallic raw material into a melting cylinder provided in a heating holding cylinder of a metal molding apparatus and to efficiently semi-melt or completely melt the cylindrical metallic raw material, a clearance between an inner circumferential surface of the melting cylinder and an outer circumferential surface of the cylindrical metallic raw material is limited to a range in which the clearance does not exceed 1.0 mm with respect to the inner diameter of the melting cylinder and the diameter of the metallic raw material during thermal expansion and the insertion of the metallic raw material in a non-thermal expansion state into the thermally expanding melting cylinder is possible, from a linear expansion coefficient of a metallic raw material and a linear expansion coefficient of a material of the melting cylinder.
    Type: Grant
    Filed: February 24, 2005
    Date of Patent: February 19, 2008
    Assignee: Nissei Plastic Industrial Co., Ltd.
    Inventors: Kiyoto Takizawa, Toshiyasu Koda, Mamoru Miyagawa, Kazuo Anzai, Koji Takei, Ikuo Uwadaira, Ko Yamazaki
  • Patent number: 7299854
    Abstract: A metal alloy is heated to a molten state, and a grain refiner may be added. The molten alloy is poured into a shallow chamber of a shot sleeve of a vertical die cast press and on top of a shot piston. The shot sleeve is transferred to an injection station while the molten alloy cools to a semi-solid slurry with a globular, generally non-dendritic micro structure. An inner portion of the shallow slurry is injected upwardly by the piston through a gate opening into a die cavity while an outer more solid portion of the slurry is entrapped in an annular recess. After the slurry solidifies, the shot piston retracts, and the shot sleeve is transferred to a position where the residual biscuit is removed. The shot piston may have internal grooves to provide a large heat transfer area for cooling water to absorb heat from the molten alloy.
    Type: Grant
    Filed: March 10, 2006
    Date of Patent: November 27, 2007
    Assignee: T.H.T. Presses, Inc.
    Inventors: Richard J. Kamm, John L. Jorstad
  • Patent number: 7284592
    Abstract: A molten material supply unit includes a heating cylinder. The heating cylinder may receive and heat the material in a substantially vacuum condition. A molding apparatus may include a pressurizing and charging unit in addition to the molten material supply unit. The pressurizing and charging unit is adapted to receive the melted material from the molten material supply unit and to charge the melted material into a die under pressure.
    Type: Grant
    Filed: March 8, 2004
    Date of Patent: October 23, 2007
    Assignee: Limtech Corporation
    Inventor: Fujio Yamada
  • Patent number: 7264037
    Abstract: Made up of a step of preparing a map expressing a correlation between solid phase percentage and viscosity of a slurry-form semi-solid metal (27) for a given metal composition; a step of setting a target viscosity corresponding to a target solid phase percentage using this map; a viscosity measuring step of measuring the viscosity of a semi-solid metal in a vessel (13) while cooling it; and a step of carrying out cooling until this viscosity reaches the target viscosity, by these steps being carried out in from the preparation of the map expressing the correlation between solid phase percentage and viscosity of the semi-solid metal to the end of cooling of the semi-solid metal the solid phase percentage of the semi-solid metal is made to match the target solid phase percentage.
    Type: Grant
    Filed: June 29, 2004
    Date of Patent: September 4, 2007
    Assignee: Honda Motor Co., Ltd.
    Inventors: Koichi Kuroki, Takeshi Masaki, Hideaki Onda, Shinji Kazama, Tetsuya Muramatsu, Tetsuji Umemoto, Kenji Ohwada, Tomonori Taoka, Akira Noda, Hiromichi Baba, Kenichi Yasuda
  • Patent number: 7255151
    Abstract: An injection-molding process for molding a metal alloy into a near net shape article that is characterized in that the processing temperature of the alloy at injection is approaching the liquidus, preferably having a maximum solids content of %, whereby a net-shape molded article can be produced that has a homogeneous, fine equi-axed structure without directional dendrites, and a minimum of entrapped porosity. Advantageously, the resulting solid article has optimal mechanical properties without the expected porosity and solidification shrinkage attributed to castings made from super-heated melts.
    Type: Grant
    Filed: November 10, 2004
    Date of Patent: August 14, 2007
    Assignee: Husky Injection Molding Systems Ltd.
    Inventor: Frank Czerwinski
  • Patent number: 7237594
    Abstract: An injection-molding process for molding a metal alloy into a near net shape article that is characterized in that the processing temperature of the alloy at injection is approaching the liquidus, preferably having a maximum solids content of 5%, whereby a net-shape molded article can be produced that has a homogeneous, fine equi-axed structure without directional dendrites, and a minimum of entrapped porosity. Advantageously, the resulting solid article has optimal mechanical properties without the expected porosity and solidification shrinkage attributed to castings made from super-heated melts. Also disclosed is a metal-matrix composite including a metallic component, and also including a reinforcement component embedded in the metallic component, the metallic component and the reinforcement component molded, at a near-liquidus temperature of the metallic component, by a molding machine.
    Type: Grant
    Filed: November 14, 2005
    Date of Patent: July 3, 2007
    Assignee: Husky Injection Molding Systems Ltd.
    Inventor: Frank Czerwinski
  • Patent number: 7234505
    Abstract: A metal flow system, for use in casting aluminium alloy using a pressure casting machine, is provided by a component of a die or mould assembly, for the machine, which defines a die cavity. The component defines at least part of an alloy flow path for the flow of aluminium alloy from a pressurized source of substantially molten aluminium alloy of the machine to the die cavity. The flow path includes at least one runner and a controlled expansion port, referred to also as a CEP, which has an inlet through which the CEP is able to receive aluminium alloy from the runner and an outlet through which aluminium alloy is able to flow from the CEP for filling the die cavity.
    Type: Grant
    Filed: February 21, 2003
    Date of Patent: June 26, 2007
    Assignee: Commonwealth Scientific and Industrial Research Organisation
    Inventors: Morris Taylor Murray, Matthew Alan Cope
  • Patent number: 7225858
    Abstract: Apparatus for producing a semi-solid metal alloy from a molten charge includes vertically aligned treatment zones which are provided by vertically aligned passages defined by a plurality of spirally wound flow pipes which are interspersed between spirally wound induction coils. A container is mounted on a charging arrangement which displaces a first charge upwardly into the first treatment zone. Successive charges are introduced in a similar fashion thereby urging the previously introduced charge upwardly along the train of zones and until the leading charge is ejected from the top of the apparatus. The charge in each zone is subjected to controlled cooling and an induced electromagnetic field. The strength of the field and the rate of cooling are controlled to impede dendritic crystallisation and to promote globular primary crystal formation.
    Type: Grant
    Filed: February 3, 2004
    Date of Patent: June 5, 2007
    Assignee: CSIR
    Inventors: Retief Bruwer, Jeremias Daniel Wilkins, Lillian Hristov Ivanchev, Pierre Rossouw, Oliver Frank Rudolf August Damm
  • Patent number: 7216690
    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.
    Type: Grant
    Filed: June 17, 2004
    Date of Patent: May 15, 2007
    Assignee: UT-Battelle LLC
    Inventors: Qingyou Han, Xiaogang Jian, Hanbing Xu, Thomas T. Meek
  • Patent number: 7152658
    Abstract: A process and an apparatus for continuous casting of metallic materials in a semi-solid state is disclosed. A solid metallic material is processed by heating the material in a first container with an inductive heater to a temperature above the solidus temperature. The processed metallic material is then transported to a storage container, from there to an injection unit and subsequently to a casting tool.
    Type: Grant
    Filed: August 7, 2003
    Date of Patent: December 26, 2006
    Assignee: Demag Ergotech GmbH
    Inventors: Mark Hartmann, Andreas Lohmüller, Sabine Pahlke, Bernd Tröger
  • Patent number: 7140419
    Abstract: A metallic alloy having a semi-solid range between the liquidus temperature and the solidus temperature of the metallic alloy is processed by cooling the metallic alloy from an initial metallic alloy elevated temperature to a semi-solid temperature of less than the liquidus temperature and more than the solidus temperature, and maintaining the metallic alloy at the semi-solid temperature for a sufficient time to produce a semi-solid structure in the metallic alloy of a globular solid phase dispersed in a liquid phase. The cooling may be accomplished by providing a crucible at a crucible initial temperature below the solidus temperature, pouring the metallic alloy into the crucible, and allowing the metallic alloy and the crucible to reach a thermal equilibrium between the liquidus temperature and the solidus temperature of the metallic alloy.
    Type: Grant
    Filed: June 20, 2002
    Date of Patent: November 28, 2006
    Assignee: Alcan Internatinoal Limited
    Inventors: Don Doutre, Gary Hay, Peter Wales
  • Patent number: 7137435
    Abstract: An injection apparatus in a cold chamber die casting molding machine, where a melting device of the injection apparatus includes a billet supplying device for replenishing a light metal material in the form of a billet, a melting cylinder for melting the billet from its front end and forming a molten metal for several shots, an inserting device for inserting a billet into the melting cylinder, and a plunger injection device. The amount of a molten metal for one shot is measured via an opening and shutting device of a molten metal feeding member and is fed from the melting device to the plunger injection device. In particular, the sealing of the molten metal in the melting cylinder is achieved by the contact of the side surface of a portion of the billet having an enlarged diameter with the hole of the cylinder, or by the contact of a circular solidified material formed in a circular groove in a cooling sleeve with the billet.
    Type: Grant
    Filed: November 17, 2003
    Date of Patent: November 21, 2006
    Assignee: Sodick Plustech Co., Ltd.
    Inventor: Misao Fujikawa
  • Patent number: 7121320
    Abstract: A method of shaping a semisolid metal comprising pouring a molten aluminum or magnesium alloy which contains a crystal grain refiner and which is superheated to less than 50° C. above a liquidus temperature of aluminum or magnesium, directly into a vessel without using a cooling jig, maintaining the alloy in the vessel for 30 seconds to 30 minutes as a resultant melt is cooled to a temperature where a specified liquid fraction is established such that a temperature of the poured alloy which is liquid and superheated to less than 10° C. above the liquidus temperature or which is partially solid, partially liquid and at a temperature of less than 5° C. below the liquidus temperature decreases from an initial level and passes through a temperature zone 5° C. below the liquidus temperature within at least 10 minutes, whereby fine primary crystals are generated in the alloy, recovering the alloy from the vessel, supplying the alloy into a mold, and shaping the alloy under pressure.
    Type: Grant
    Filed: December 9, 2004
    Date of Patent: October 17, 2006
    Assignee: Ube Industries, Ltd.
    Inventors: Mitsuru Adachi, Hiroto Sasaki, Yasunori Harada, Tatsuo Sakamoto, Satoru Sato
  • Patent number: 7121319
    Abstract: The provision or use, for the pressure casting of magnesium alloy in a molten or thixotropic state with a pressure casting machine having a mould or die which defines a die cavity, of a metal flow system which includes a die or mould tool means which defines at least one runner from which molten magnesium alloy is able to be injected into the die cavity. The metal flow system is of a form providing for control of metal flow velocities within the flow system, whereby substantially all of the metal flowing throughout the die cavity is in a viscous or semi-solid state. Filling of the die cavity is able to proceed progressively by semi-solid fronts of metal moving away from a gate or other site of injection.
    Type: Grant
    Filed: September 16, 2003
    Date of Patent: October 17, 2006
    Assignee: Commonwealth Scientific and Industrial Research Organisation
    Inventors: Morris Taylor Murray, Matthew Alan Cope