Rheo-casting Patents (Class 164/900)
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Publication number: 20040055724Abstract: A method for the refining of primary silicon in hypereutectic alloys by mixing a hypereutectic alloy and a solid/semi-solid hypoeutectic alloy is described. The method provides control of the morphology, size, and distribution of primary Si in a hypereutectic Al—Si casting by mixing a hypoeutectic Al—Si liquid with one that is hypereutectic to impart desirable mechanical properties.Type: ApplicationFiled: November 14, 2002Publication date: March 25, 2004Applicant: SPX CorporationInventors: Deepak Saha, Diran Apelian, Rathindra DasGupta
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Publication number: 20040055734Abstract: A method for manufacturing a metallic material for rheocasting or thixoforming and a metallic material formed using the method are provided. The method includes: applying an electromagnetic field to a vessel and loading a molten metal into the vessel; and cooling the molten metal to form a metallic material for rheocasting or thixoforming. The entire volume of molten metal is rapidly and uniformly cooled throughout, from the wall toward the center of the vessel, without generating latent heat caused by the formation of solidification layers at the early stage of cooling. The molten metal in the vessel is cooled rapidly below its liquidus temperature within 1-10 seconds after the loading of the molten metal into the vessel, so that numerous uniform crystal nuclei are created throughout the entire volume of molten metal to form a metallic material having uniform, micro, spherical particles.Type: ApplicationFiled: April 22, 2003Publication date: March 25, 2004Inventors: Chun Pyo Hong, Jae Min Kim, Min Soo Kim, Masayuki Itamura
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Publication number: 20040055735Abstract: The present invention provides a method and apparatus for manufacturing a high-quality semi-solid metallic slurry containing fine, uniform spherical particles that can be readily and conveniently applied to a subsequent process, with improvements in energy efficiency and mechanical properties, cost reduction, convenience of casting, and shorter manufacturing time. The semi-solid metallic slurry manufacturing method includes applying an electromagnetic field to a space containing a slurry vessel, loading a molten metal into the slurry vessel in a state where the electromagnetic field is applied to the space, and drawing the slurry vessel out from the space.Type: ApplicationFiled: May 29, 2003Publication date: March 25, 2004Inventors: Chun Pyo Hong, Jae Min Kim, Min Soo Kim, Masayuki Itamura
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Publication number: 20040055727Abstract: Provided are a method and apparatus for continuously manufacturing quality billets for thixocasting that have a fine, uniform, spherical particle structure, in a short time, with improvements in energy efficiency and mechanical properties, cost reduction, convenience of casting, and shorter manufacturing time. The method involves applying an electric field to a domain of a sleeve defined by first and second plungers inserted through each end of the sleeve and loading a molten metal into the domain of the sleeve to form a semi-solid metallic slurry, moving the first plunger toward the second plunger to compress the semi-solid metallic slurry and form a billet via cooling, and shifting the billet toward the second plunger to discharge the billet from the sleeve.Type: ApplicationFiled: May 30, 2003Publication date: March 25, 2004Inventors: Chun Pyo Hong, Jae Min Kim, Min Soo Kim, Masayuki Itamura
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Publication number: 20040050523Abstract: A process for transforming a metal alloy (28) having a liquidus temperature and a solidus temperature into a part solid/part liquid shaped body. The metal alloy (28) is poured in the molten state at a temperature (TMo) into a mould (10) having an essentially cylindrical mould wall (12), whereby the mould (10) at the start of filling exhibits a starting temperature that lies below the liquidus temperature, the mould (10) is set into an eccentric rotational movement at a starting temperature for the metal alloy (28) lying above the liquidus temperature and the rotational movement maintained until the metal alloy (28) has cooled to a to a discharging temperature lying between the liquidus temperature and the solidus temperature corresponding to a desired solid/liquid ratio in the shaped body and the shaped body removed from the mould (10) at the discharging temperature.Type: ApplicationFiled: April 24, 2003Publication date: March 18, 2004Inventors: Reinhard Winkler, Gunther Hollrigl, Walter Rohner, Helmut Schelling, Thomas Burbach
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Patent number: 6681836Abstract: A predetermined amount of molten metal 12 is supplied to a heat-insulating crucible 18. After that, a chill block 46, which is cooled to a predetermined temperature of not more than a temperature of the molten metal 12, is immersed and rotated in the molten metal 12. Accordingly, the molten metal 12 is agitated while being cooled to give no directivity of cooling. It is possible to obtain semisolidified metal 20 which is formed into slurry uniformly and effectively as a whole. The semisolidified metal 20 is discharged from the heat-insulating crucible 18, and it is supplied to a forming machine 22 to apply a forming treatment thereto. Accordingly, it is possible to produce the desired slurry efficiently and economically.Type: GrantFiled: July 20, 2000Date of Patent: January 27, 2004Assignee: Honda Giken Kogyo Kabushiki KaishaInventors: Kazuya Sakamoto, Nobumasa Hamazoe, Kenji Ohwada, Atsushi Suzuki
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Patent number: 6681837Abstract: An air releasing check structure of a metal injecting machine has a seat rod installed between a rear seat of a feeding screw rod and the extruding head at a front end of the front section. A periphery of the seat rod is enclosed by a check toggle. If the material to be ejected has bubbles so that it is not extruded effectively, the bubbles will flow to the exhausting grooves of the check toggle. Then the bubbles are drained out. Thereby, the bubbles in the material are vented out so that the material becomes dense. When the material becomes dense with high tension, the pressure of material will be greater than the force for buckling the elastic toggles so that the elastic toggles expand. As a result, the elastic toggle will further isolate the exhausting groove. Thereby, the material moves forwards to be ejected from the extruding head.Type: GrantFiled: December 19, 2002Date of Patent: January 27, 2004Inventors: Chi Yin Wu, Hou Wang, Chirn Shun Hsn
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Publication number: 20040003912Abstract: The present invention relates to a method and apparatus for preparing a metal or metal-alloy product for a casting process—wherein the product is brought into a partly solidified (semi-solidified) state before casting—in which the product contains crystallization nuclei uniformly distributed throughout its volume. The method involves introducing an amount of a chosen alloy (in pulverized form) and an amount of a chosen melt, which is at a temperature above the liquefaction temperature of the alloy, into a crystallization vessel, which is heated to below the liquefaction temperature of the alloy, and mixing the melt and the alloy together in the crystallization vessel by means of electrical and/or magnetic forces to create the desired product.Type: ApplicationFiled: March 12, 2003Publication date: January 8, 2004Inventor: Evgenij Sterling
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Publication number: 20040003911Abstract: A vessel for processing feed stock material into molten or semi-molten state. The vessel includes a body defining an interior surface, an inlet, for receiving the feed stock material and an outlet discharging the material. The sidewall of the body comprises three layers, referred to as the shell, an intermediate layer and a liner. The intermediate layer is disposed between the shell and the liner and is formed of a material softer than the materials forming the shell and the liner. The presence of the intermediate layer minimizes the thermal gradient along the thickness of the barrel.Type: ApplicationFiled: June 28, 2002Publication date: January 8, 2004Applicant: Thixomat, Inc.Inventors: Ralph E. Vining, D. Matthew Walukas, Raymond F. Decker
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Patent number: 6666258Abstract: An injection molding system includes a melt furnace in which a metal is melted, a feeder suitable for holding the melted metal, an injection chamber containing a first piston and an injection nozzle, a first conduit connecting the melt furnace to the feeder and a second conduit connecting the feeder to the injection chamber.Type: GrantFiled: June 30, 2000Date of Patent: December 23, 2003Assignee: Takata CorporationInventor: Kaname Kono
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Publication number: 20030230392Abstract: 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: ApplicationFiled: June 13, 2002Publication date: December 18, 2003Inventors: Frank Czerwinski, Damir Kadak
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Patent number: 6655445Abstract: A metal injection molding apparatus is provided with features which reduce the amount of metal which enters the drive mechanism of the apparatus. The apparatus contains a piston having the head and the shaft, the shaft having a diameter smaller than the diameter of the head. At least one piston ring circumscribes the piston shaft. The apparatus contains an injection chamber having an accumulation portion and a shaft housing portion. The shaft housing portion has openings in the sidewalls and a polygonal internal cross section. The accumulation portion of the injection chamber is maintained at a higher temperature than the shaft housing portion.Type: GrantFiled: November 4, 2002Date of Patent: December 2, 2003Assignee: Takata CorporationInventor: Kaname Kono
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Patent number: 6640875Abstract: An injection molding method of a metal material in a liquid phase state, by which the material can be transferred, metered, and deaerated smoothly by operating the movement and rotation of the screw. After injection, retraction resistance made of the metal material that went into a clearance between the heating cylinder and screw flights is removed in advance by rotating the screw for a set number of times at a forward position. Then, the metal material in the liquid phase state is accumulated in a front chamber by forcing the screw to retract for a set distance, and applying a back pressure to the screw rotating at a retraction position, thereby starting transfer of the metal material. Subsequently, the rotation of the screw is stopped, whereupon the accumulation is completed. Then, the accumulated metal material is pressed by moving the screw forward.Type: GrantFiled: September 28, 2000Date of Patent: November 4, 2003Assignee: Nissei Plastic Industrial Co., Ltd.Inventors: Takahiro Kobayashi, Mamoru Miyagawa
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Method and apparatus for manufacturing metallic parts by injection molding from the semi-solid state
Publication number: 20030201088Abstract: An injection molding system includes a feeder in which a metal is melted and a first chamber into which a desired amount of melted metal is introduced. A piston in a second chamber first retracts to create suction, assisting in drawing in the melted metal into the second chamber from the first chamber and evacuating gas. A ram then pushes some melted metal remaining in the first chamber into the second chamber, forcing out gas present in the second chamber. The piston then injects the melted metal out of the second chamber into a mold. The melted metal is maintained in a semi-solid state prior to injection into the mold.Type: ApplicationFiled: May 19, 2003Publication date: October 30, 2003Applicant: TAKATA CORPORATIONInventor: Kaname Kono -
Publication number: 20030196775Abstract: A metal alloy is heated to a molten state and is poured into 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 is cooled to a semi-solid slurry and a globular, generally non-dendritic microstructure. A retractable cooling pin is temporarily inserted into a center portion of the slurry while in the shot sleeve to obtain optimum cooling. A center portion of the 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. Another shot sleeve filled with the molten allow is transferred, and the process is repeated.Type: ApplicationFiled: April 24, 2003Publication date: October 23, 2003Applicant: THT Presses Inc.Inventors: Richard J. Kamm, John L. Jorstad
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Patent number: 6634412Abstract: 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: GrantFiled: June 28, 2000Date of Patent: October 21, 2003Assignee: Commonwealth Scientific and Industrial Research OrganisationInventors: Morris Taylor Murray, Matthew Alan Cope
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Patent number: 6623570Abstract: A casting alloy of the AlMgSi type comprises Magnesium 3.0 to 7.0 wt. % Silicon 1.7 to 3.0 wt. % Manganese 0.2 to 0.48 wt. % Iron 0.15 to 0.35 wt. % Titanium as desired max. 0.2 wt. % Ni 0.1 to 0.4 wt % and aluminum as the rest along with production related impurities, individually at most 0.02 wt. %, in total at most 0.2 wt. %, with the further provision that the magnesium and silicon are present in the alloy in a Mg:Si weight ratio of 1.7:1, corresponding to the composition of the quasi binary eutectic made up of the solid state phases Al and Mg2Si, whereby the deviation from the exact composition of the quasi-binary eutectic amounts to at most −0.5 to +0.3 wt. % for magnesium and −0.3 to +0.5 wt. % for silicon the finely dispersed precipitates of the intermetallic phase Mg2Si results in high ductility.Type: GrantFiled: February 8, 2002Date of Patent: September 23, 2003Assignee: Alcan Technology & Management Ltd.Inventors: Reinhard Winkler, Gunter Höllrigl, Jürgen Wuest, Klaus Währisch
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Publication number: 20030173051Abstract: To accommodate high power densities associated with high performance integrated circuits, an integrated circuit package includes a heat-dissipating structure in which heat is dissipated from a surface of a die to an integrated heat spreader (IHS) through a high capacity thermal interface formed of metal that has been injected in a semi-solid state. In one embodiment, vacuum and a shear-controlled viscosity enable semi-solid metallic material to fill a narrow chamber between the die surface and a specially shaped mold plate that doubles as an IHS, without inducing voids in the solidified metal. In another embodiment, an injection machine is disclosed. Methods of fabrication, as well as application of the package to an electronic assembly and to an electronic system, are also described.Type: ApplicationFiled: March 12, 2002Publication date: September 18, 2003Applicant: Intel CorporationInventors: Agostino C. Rinella, Paul A. Koning
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Patent number: 6619370Abstract: In a semi-molten metal injection molding method of producing a thin molded product by injecting a semi-molten metal M of a magnesium alloy, in a semi-melting state, into a cavity of a mold through a product gate, characterized in that it is made possible to obtain a high-quality thin molded product by maintaining satisfactory fluidity of the semi-molten metal M. A grain size of the solid fraction in the melt M is set to not more than 0.13 times the average thickness of the product portion of the thin molded product and a molten metal velocity at the product gate is set to not less than 30 m/s and, moreover, a solid fraction Fs (%) of the semi-molten metal M and a grain size D (&mgr;m) of the solid phase of the semi-molten metal M are set so as to define the relationship Fs×D≦1500.Type: GrantFiled: July 1, 1999Date of Patent: September 16, 2003Assignee: Mazda Motor CorporationInventors: Kazuo Sakamoto, Kyoso Ishida, Yukio Yamamoto
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Publication number: 20030141033Abstract: A metal alloy is heated to a molten state, and a grain refiner may be added. The refined molten alloy is poured into a large diameter 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 approximately fifty percent solids and a globular, generally non-dendritic microstructure. A center portion of the 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. A second shot sleeve filled with the molten alloy is transferred to the metal transfer station, and the process is repeated.Type: ApplicationFiled: January 31, 2002Publication date: July 31, 2003Applicant: THT Presses Inc.Inventors: Richard J. Kamm, John L. Jorstad
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Patent number: 6595266Abstract: Molten aluminum alloy at a temperature between Tl and Tl+60° C. is contacted with a cooling unit to form a semi-solid melt portion containing primary particles, and is maintained at a temperature between (Tl−Ts)/2+Ts and Tl+40° C. by the cooling unit. The semi-solid melt portion is conveyed to a holding furnace where it is maintained at a solid-liquid coexisting temperature for a time that allows the primary particles to grow and stabilize in a globularized state.Type: GrantFiled: October 5, 1999Date of Patent: July 22, 2003Assignee: Ahresty Corp.Inventor: Shin Orii
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Publication number: 20030111205Abstract: An apparatus for manufacturing semi-finished products and molded articles of metallic materials includes an extruder for producing a flow of the metals, with appliances being connected thereafter for shaping the semi-finished products and the molded articles. The extruder has a screw system consisting of two or more meshing screws. This design has an improved functionality and can produce components with reproducible quality.Type: ApplicationFiled: January 27, 2003Publication date: June 19, 2003Applicant: Krauss-Maffei Kunststofftechnik GmbHInventors: Andreas Dworog, Erwin Burkle, Hans Wobbe, Rainer Zimmet, Jochen Zwiesele
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Patent number: 6578621Abstract: The purpose of this invention is to prevent sludge from flowing into a measuring chamber by partitioning the inside of a melt cylinder into a melt stirring part and a molten metal flow passage part, and to stabilize supply of the metallic material and measurement of the molten metal. A nozzle member 14 of which the inside of the rear part is formed into a measuring chamber 13 is attached to the tip of a melt cylinder 11. The end face of the opening periphery of the measuring chamber 13 of the nozzle member 14 faced to the inside of the melt cylinder is projectingly formed into a ring-shaped bearing 14b. A hollow stirring shaft 16 provided with stirring blades 15 on the outer periphery is supported by the bearing 14b and a bearing member 21 in the rear end of the melt cylinder so as to be freely rotatable with a suction port 25 bored in the side wall of the tip part.Type: GrantFiled: March 7, 2002Date of Patent: June 17, 2003Assignee: Nissei Plastic Industrial Co., Ltd.Inventors: Kiyoto Takizawa, Toshiyasu Koda, Yuji Hayashi, Mamoru Miyagawa
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Publication number: 20030094258Abstract: Apparatus for casting metallic materials, includes a processing device for preparing metallic material in free-flowing form and a storage container in communication with the processing device for receiving a continuous flow of prepared metallic material. An injection unit including a piston and cylinder arrangement is arranged separately from and connected to the storage container by a flow connection which includes a flow regulating device to control a flow therethrough. The storage container and the piston and cylinder arrangement are heated separately by a heating assembly, thereby ensuring short cycle times and establishment of great variability during a casting operation.Type: ApplicationFiled: November 20, 2002Publication date: May 22, 2003Applicant: DEMAG ERGOTECH GMBHInventors: Mark Hartmann, Andreas Lohmuller, Sabine Pahlke, Bernd Troger
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Patent number: 6564854Abstract: In a semi-solid alloy including a large amount of a liquid phase portion, that is, semi-solid alloy with less than 50% of solid phase rate, there is a tendency for a solid phase portion to concentrate into the central portion in the direction of thickness, that is the internal portion. In order to enhance corrosion resistance at a portion where high corrosion resistance is particularly required in parts molded by semi-solid injection, the above tendency is utilized. By utilizing the tendency, a layer consisting of a liquid phase portion is partially formed at the semi-solid state on a surface portion where high corrosion resistance is required.Type: GrantFiled: December 29, 1999Date of Patent: May 20, 2003Assignee: Mazda Motor CorporationInventors: Nobuo Sakate, Shoji Hirabara, Kazuo Sakamoto, Yukio Yamamoto
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Patent number: 6562155Abstract: A process for producing an aluminum alloy semi-molten billet for use as a transporation unit, including the steps of: producing an aluminum alloy having a composition consisting essentially of, in weight %, 0.5 or less Cu, 5.0 to 10.0 Si, 0.2 to 0.7 Mg, 0.35 or less Zn, 0.55 or less Fe, 0.5 or less Mn, 0.005 to 0.5 Ti, and the balance aluminum; introducing working strain into a melt of the aluminum alloy by means of molding flask-assisted cold forging at a distortion rate of 10 to 40%, at a working introduction velocity of 10 mm or less per second, and at a temperature of 200° C. or lower; and, thereafter heat-treating such a strain introduced melt at temperatures in a range of 576 to 585° C.Type: GrantFiled: September 18, 2000Date of Patent: May 13, 2003Assignee: Kyusyu Mitsui, Aluminum Co., Ltd.Inventors: Shigeru Mikubo, Masafumi Mizouti, Yasuyuki Murayama, Tsunaki Iwashita, Akihiko Kamio, Tatsuo Sato
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Publication number: 20030079854Abstract: A hot chamber method of die casting material in a semisolid state. The semisolid material has a high viscosity, which can be controlled by controlling the fraction of solid phase and the morphology of the solid phase. By controlling the viscosity of the melt, turbulence and consequent gas entrapment can be minimized or eliminated. Further, shrinkage is substantially reduced, thereby reducing porosity and hot tearing to form stronger, more reliable castings.Type: ApplicationFiled: November 29, 2002Publication date: May 1, 2003Inventors: Merton C. Flemings, Sergio Gallo
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Patent number: 6554057Abstract: 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.Type: GrantFiled: January 28, 2002Date of Patent: April 29, 2003Assignee: Alcan Technology & Management Ltd.Inventors: Grégoire Arnold, Christophe Bagnoud, Mirsolaw Plata
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Patent number: 6546991Abstract: The apparatus is described for manufacturing semi-finished products and molded articles of metallic materials. The device incorporates an extruder for producing a flow of the metals, with appliances being connected thereafter for shaping the semi-finished products and the molded articles. The extruder has a screw system consisting of two or more meshing screws. This design has an improved functionality and can produce components with reproducible quality.Type: GrantFiled: August 16, 2001Date of Patent: April 15, 2003Assignee: Krauss-Maffei Kunststofftechnik GmbHInventors: Andreas Dworog, Erwin Bürkle, Hans Wobbe, Rainer Zimmet, Jochen Zwiesele
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Publication number: 20030066620Abstract: An injection molding system includes a feeder in which a metal is melted and a first chamber into which a desired amount of melted metal is introduced. A piston in a second chamber first retracts to create suction, assisting in drawing in the melted metal into the second chamber from the first chamber and evacuating gas. A ram then pushes some melted metal remaining in the first chamber into the second chamber, forcing out gas present in the second chamber. The piston then injects the melted metal out of the second chamber into a mold. The melted metal is preferably maintained in a liquid state throughout the system.Type: ApplicationFiled: November 18, 2002Publication date: April 10, 2003Applicant: TAKATA CORPORATIONInventor: Kaname Kono
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Patent number: 6544469Abstract: An apparatus for producing a metal formed product comprises a molten metal-holding furnace; a semisolidified metal-producing mechanism; a cooling member-restoring mechanism arranged adjacent to the semisolidified metal-producing mechanism, for applying a restoring treatment so that chillers have a desired function; a forming machine for forming semisolidified metal to have a predetermined shape; and an articulated robot capable of transporting a crucible to the molten metal-holding furnace, the semisolidified metal-producing mechanism, and the forming machine. The semisolidified metal-producing mechanism includes first to third agitators. The cooling member-restoring mechanism includes first to third treating sections. These components are arranged in a direction of back and forth movement of the articulated robot. Accordingly, it is possible to efficiently obtain the metal formed product having a high quality.Type: GrantFiled: December 15, 2000Date of Patent: April 8, 2003Assignee: Honda Giken Kogyo Kabushiki KaishaInventors: Atsushi Suzuki, Kazuya Sakamoto, Kenji Ohwada, Tomonori Taoka, Koichi Kuroki, Takahiro Suenaga, Takashi Idegomori, Kenichi Katahira, Hideomi Ito, Akira Noda, Kazuaki Kobayashi, Masayoshi Kai, Shinji Kazama
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Publication number: 20030062144Abstract: By determining an amount of a metal to be prepared into a slurry in its liquid state, thereafter applying a motion to the melted metal via a mechanical or physical means when at least a part of the melted metal reaches a temperature below the liquidus temperature and cooling the melted metal in a slurry preparing container to prepare the melted metal into a metal slurry in a semi-solid state, and by concurrently making the semi-solid metal slurry in the slurry preparing container with a shape to be kept almost unchanged, and feeding the semi-solid metal slurry in a state wherein the shape is nearly kept as it is into the shot sleeve/prechamber of the part making machine, a semi-solid metal slurry with the non-dendritic (spherical) primary crystal particles being fine and almost uniform can be fed into the part making machine, with no need of any specifically complex process but with a simple system and plain equipment. Thus, a shaped part with high quality can be produced.Type: ApplicationFiled: October 23, 2002Publication date: April 3, 2003Inventors: Shunzo Aoyama, Chi Liu, Toshiyuki Sakazawa, Ye Pan
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Patent number: 6540006Abstract: An injection molding system includes a feeder in which a metal is melted and a first chamber into which a desired amount of melted metal is introduced. A piston in a second chamber first retracts to create suction, assisting in drawing in the melted metal into the second chamber from the first chamber and evacuating gas. A ram then pushes some melted metal remaining in the first chamber into the second chamber, forcing out gas present in the second chamber. The piston then injects the melted metal out of the second chamber into a mold. The melted metal is preferably maintained in a liquid state throughout the system.Type: GrantFiled: April 26, 2001Date of Patent: April 1, 2003Assignee: Takata CorporationInventor: Kaname Kono
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Publication number: 20030056930Abstract: The invention relates to a pre-treatment device and method for production of a thixotropic metal bolt (10), in a casting chamber (30) of a thixo-moulding unit. The pre-treatment device comprises a container (14), for accommodating a metal bolt (10), an oven (20), for converting the metal bolt (10) in the container (14) into a partly fluid thixotropic state and a transport unit for transporting and feeding the thixotropic metal bolt (10), into the casting chamber (30). The container (14) is a cylinder-shape heating tube (14), with closable sides. Furthermore, the pre-treatment device is so arranged that, during the entire pre-treatment, namely the heating process in the oven (20), the transport into the casting chamber (30) and the period in the casting chamber (30), the metal bolt (10) remains in the heating tube (14).Type: ApplicationFiled: September 3, 2002Publication date: March 27, 2003Inventors: Miroslaw Plata, Christophe Bagnoud, Gregoire Arnold, Martin Bolliger
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Publication number: 20030041998Abstract: 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.Type: ApplicationFiled: August 28, 2002Publication date: March 6, 2003Inventors: Hideyuki Suzuki, Koichiro Sato, Ryuichi Onoda
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Publication number: 20030037900Abstract: A method of producing a semi-solid material without stirring, including heating a metal alloy to form a metallic melt, transferring a select amount of the melt into a vessel, nucleating the melt by regulating the transferring of the melt into the vessel, and crystallizing the melt within the vessel by cooling the melt at a controlled rate to produce a semi-solid material having a microstructure comprising rounded solid particles dispersed in a liquid metal matrix. In one form of the invention, a temperature-controlled shot sleeve is provided for receiving and cooling an amount of metallic melt at a controlled rate to produce the semi-solid material. The shot sleeve has a number of heat transfer zones adapted to independently control the temperature of the melt disposed adjacent various portions of the shot sleeve. The shot sleeve also includes a ram operable to discharge the semi-solid material directly into a die mold to form a near-net-shape part.Type: ApplicationFiled: August 17, 2001Publication date: February 27, 2003Inventors: Walter L. Winterbottom, Dan V. Chirieac, Jason M. Unruh, Jian Lu
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Publication number: 20030006020Abstract: A die casting system includes a vessel defining a reservoir with a controlled heater and an agitator for maintaining the bath of semi-solid metal in a homogeneous isothermal state, a transfer system capable of transferring a known quantity of metal in its semi-solid state to a mold cavity in a die casting machine, the transfer system including a heated suction tube, a vacuum source for vacuum ladling semi-solid metal from the bath to a die, and a plunger tip providing a path for free air flow to allow evacuation of the suction tube during casting and a metal replacement system for replacing the known quantity of transferred metal with a similar amount of liquid metal so that a stable homogeneous isothermal bath of semi-solid metal is controllably maintained to be available for die casting operations.Type: ApplicationFiled: September 10, 2002Publication date: January 9, 2003Inventors: Kevin L. Richard, Richard I. Neill, Christopher S. Rice, Shinya Myojin, Patricio F. Mendez, Timothy B. Gage, John F. O'Daniels, Charles E. Barron
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Patent number: 6502624Abstract: Methods for semisolid manufacturing of precision parts, turbine rotors for example, comprised of a plurality of high melting point alloys are given. Generally, a semisolid/thixotropic process is operated under vacuum utilizing a cooled mold. The process preferably comprises a vacuum chamber, inductive heaters to bring two or more high melting point slugs to either a solid or thixotropic phase, and a plunger that accelerates one or more high melting point solid slugs into one or more thixotropic slugs and then into a mold. Prior to heating, preconditioning at least one of the slugs to form a non-dendritic microstructure simplifies processing. The semisolid microstructure solidifies as the completed forged assembly cools. Thixotropic forging of a multi-alloy assembly achieves optimized properties in specific locations of the final product.Type: GrantFiled: April 18, 2000Date of Patent: January 7, 2003Assignee: Williams International Co., L.L.C.Inventors: Samuel B. Williams, Timothy A. Nielsen
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Publication number: 20030000676Abstract: A pouring apparatus for castings uses separate systems for supplying billets and delivering the semi-molten material, making it possible to readily modify the discharge flows and pressure. A pouring apparatus for castings that comprises solid material supply means for supplying solid material to a melting basin; heating means for heating the melting basin to semi-melt solid material supplied to the melting basin; a conveyance chamber provided adjacent to the melting basin; and delivery means for discharging, from a discharge nozzle, semi-molten material conveyed from the melting basin to the conveyance chamber.Type: ApplicationFiled: July 1, 2002Publication date: January 2, 2003Applicant: Tetsuichi MOTEGIInventors: Tetsuichi Motegi, Kiichi Miyazaki, Yoshitomo Tezuka, Kiyotaka Yoshihara
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Publication number: 20020185257Abstract: 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.Type: ApplicationFiled: April 19, 2002Publication date: December 12, 2002Inventors: Vivek M. Sample, Scott E. Reighard, Vincent A. Paola, Ronald G. Chabal
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Publication number: 20020179280Abstract: The invention relates to a diecasting method used to produce cast parts from a semi-solidified alloy melt. According to the inventive method, the alloy melt is transformed to a semi-solidified state by stimulating the crystallization process, it is then introduced into a casting chamber and the cast pieces are produced by applying pressure. First an exogenous metal suspension is produced outside the casting chamber in a closed-off space that functionally communicates with the casting chamber and forms a casting unit therewith. The metal suspension is set into motion before it is introduced into the casting chamber, thereby forming a hollow rotating body that is maintained rotating until the suspension homogeneity for the casting reached. The invention further relates to a device for carrying out the inventive method. The device comprises a vertical casting chamber with a plunger and a treatment container disposed outside the casting chamber.Type: ApplicationFiled: September 24, 2001Publication date: December 5, 2002Inventors: Gerhard Peleschka, Evgueni Sterling
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Publication number: 20020170696Abstract: An apparatus for molding a metal material. The apparatus includes a vessel with portions defining a passageway through the vessel. An inlet is located toward one end and a member or agitation means is located within the passageway. A plurality of heaters are located a length of the vessel. The first of the heaters is located immediately downstream of the inlet and is a low frequency induction coil heater whereby the temperature gradient through the vessel's sidewall is minimized.Type: ApplicationFiled: May 18, 2001Publication date: November 21, 2002Inventors: Ron Akers, Ralph E. Vining, D. Matthew Walukas, Raymond F. Decker, Chris Pedder
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Patent number: 6478075Abstract: A die casting method and a casting that is obtained through use of the die casting method. The die casting method can solve problems such as air catching occurring at the time of injection into the cavity of a die and molten metal run defect, thereby enabling efficient production of defect-free perfect castings. Via a mouth piece 7 and a molten-metal feed port 4, molten metal from a molten metal feeder flows into a casting sleeve 2 while undergoing laminar flow. When the molten metal reaches a predetermined level, a plunger tip 5 is moved upward within the casting sleeve 2 and stops at a position where the side surface of the plunger tip 5 closes the molten-metal feed port 4. The molten metal that has flowed into the casting sleeve 2 is cooled by a cooling medium flowing through passages 2b formed within the casting sleeve 2 so that said molten metal forms primary crystals. Simultaneously, through use of a high frequency coil 6, the molten metal is subjected to electromagnetic agitation.Type: GrantFiled: December 30, 1999Date of Patent: November 12, 2002Assignee: Hitachi Metals, Ltd.Inventors: Ryoichi Shibata, Takeo Kaneuchi
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Patent number: 6470955Abstract: A die casting system includes a vessel defining a reservoir with a controlled heater and an agitator for maintaining the bath of semi-solid metal in a homogeneous isothermal state, a transfer system capable of transferring a known quantity of metal in its semi-solid state to a mold cavity in a die casting machine, the transfer system including a heated suction tube, a vacuum source for vacuum ladling semi-solid metal from the bath to a die, and a plunger tip providing a path for free air flow to allow evacuation of the suction tube during casting and a metal replacement system for replacing the known quantity of transferred metal with a similar amount of liquid metal so that a stable homogeneous isothermal bath of semi-solid metal is controllably maintained to be available for die casting operations.Type: GrantFiled: July 22, 1999Date of Patent: October 29, 2002Assignee: Gibbs Die Casting Aluminum Co.Inventors: Kevin L. Richard, Richard I. Neill, Jr., Christopher S. Rice, Shinya Myojin, Patricio F. Mendez, Timothy B. Gage, John F. O'Daniels, Charles E. Barron
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Patent number: 6470956Abstract: In a semi-molten metal injection molding method of producing a thick molded article by injecting a semi-molten melt M of a magnesium alloy, in a semi-melting state, into a cavity 13 of a mold 11 through a product gate 17, characterized in that it is made possible to obtain a high-quality thick molded article free from internal defects. A solid fraction of the semi-molten melt M is set to not less than 10%, and more preferably within a range of 40 to 80%. A sectional area Sg of a product gate portion of the thick molded article corresponding to the product gate 17 is set to not less than 0.1 times a sectional area Sp in the vicinity of the product gate 17 in the product portion corresponding to the cavity 13. Furthermore, a product gate velocity Vg mm/s of the semi-molten melt M, a sectional area Sg mm2 of the product gate portion of the thick molded article and a volume Vp mm3 of the product portion are set so as to satisfy the following relationships: Vg≦8.0×104; and, Vg×Sg/Vp≧10.Type: GrantFiled: August 9, 2001Date of Patent: October 29, 2002Assignee: Mazda Motor CorporationInventors: Kazuo Sakamoto, Kyoso Ishida, Yukio Yamamoto
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Publication number: 20020153123Abstract: A method of continuous casting aluminum alloys between a pair of rolls. Molten aluminum alloy is delivered to a roll bite between the rolls and passes into the roll nip in a semi-molten state. A solid strip of cast aluminum alloy exits the nip at speeds of about 25 to about 400 feet per minute. Thin gauge (0.07-0.25 inch) strip may be produced at rates of up to 2000 pounds per hour per inch of cast strip width.Type: ApplicationFiled: February 19, 2002Publication date: October 24, 2002Inventor: Ali Unal
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Publication number: 20020124988Abstract: The purpose of this invention is to prevent sludge from flowing into a measuring chamber by partitioning the inside of a melt cylinder into a melt stirring part and a molten metal flow passage part, and to stabilize supply of the metallic material and measurement of the molten metal. A nozzle member 14 of which the inside of the rear part is formed into a measuring chamber 13 is attached to the tip of a melt cylinder 11. The end face of the opening periphery of the measuring chamber 13 of the nozzle member 14 faced to the inside of the melt cylinder is projectingly formed into a ring-shaped bearing 14b. A hollow stirring shaft 16 provided with stirring blades 15 on the outer periphery is supported by the bearing 14b and a bearing member 21 in the rear end of the melt cylinder so as to be freely rotatable with a suction port 25 bored in the side wall of the tip part.Type: ApplicationFiled: March 7, 2002Publication date: September 12, 2002Applicant: NISSEI PLASTIC INDUSTRIAL CO., LTD.Inventors: Kiyoto Takizawa, Toshiyasu Koda, Yuji Hayashi, Mamoru Miyagawa
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Patent number: 6428636Abstract: 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: GrantFiled: July 26, 1999Date of Patent: August 6, 2002Assignee: Alcan International, Ltd.Inventors: Don Doutre, Gary Hay, Peter Wales
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Patent number: 6427755Abstract: Precision castings such as brake calipers and other cast metal parts requiring a fine finish and having complex internal geometries can be produced by casting a shot of a semi-solid thixotropic metal alloy in a die having one or more inserts that have a lower melting point than the solid-to-semi-solid transition temperature of the thixotropic alloy. A core of the same or similar material may also be placed in the die between the inserts. Then, after the shot solidifies to form a casting, the inserts and core (if present) are melted from the casting.Type: GrantFiled: April 28, 2000Date of Patent: August 6, 2002Assignee: Chipless Metals LLCInventor: James A. Buckley
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Publication number: 20020084053Abstract: A hot chamber method of die casting material in a semisolid state. The semisolid material has a high viscosity, which can be controlled by controlling the fraction of solid phase and the morphology of the solid phase. By controlling the viscosity of the melt, turbulence and consequent gas entrapment can be minimized or eliminated. Further, shrinkage is substantially reduced, thereby reducing porosity and hot tearing to form stronger, more reliable castings.Type: ApplicationFiled: February 28, 2002Publication date: July 4, 2002Inventors: Merton C. Flemings, Sergio Gallo