US20050133187A1 - Die casting method system and die cast product - Google Patents
Die casting method system and die cast product Download PDFInfo
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- US20050133187A1 US20050133187A1 US10/736,557 US73655703A US2005133187A1 US 20050133187 A1 US20050133187 A1 US 20050133187A1 US 73655703 A US73655703 A US 73655703A US 2005133187 A1 US2005133187 A1 US 2005133187A1
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- 238000000034 method Methods 0.000 title claims abstract description 33
- 238000004512 die casting Methods 0.000 title description 7
- 238000005266 casting Methods 0.000 claims abstract description 56
- 229910052751 metal Inorganic materials 0.000 claims abstract description 45
- 239000002184 metal Substances 0.000 claims abstract description 45
- 238000004519 manufacturing process Methods 0.000 claims abstract description 7
- 229910000831 Steel Inorganic materials 0.000 claims description 9
- 229910052782 aluminium Inorganic materials 0.000 claims description 9
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 9
- 239000010959 steel Substances 0.000 claims description 9
- 239000007787 solid Substances 0.000 claims description 8
- 229910000838 Al alloy Inorganic materials 0.000 claims description 7
- 239000012530 fluid Substances 0.000 claims description 7
- 239000000203 mixture Substances 0.000 claims description 6
- 238000005422 blasting Methods 0.000 claims description 5
- 238000007747 plating Methods 0.000 claims description 4
- 238000005507 spraying Methods 0.000 claims description 4
- 238000011282 treatment Methods 0.000 claims description 4
- 239000002826 coolant Substances 0.000 claims description 3
- 229910001338 liquidmetal Inorganic materials 0.000 claims 1
- 238000013461 design Methods 0.000 abstract description 7
- 238000001816 cooling Methods 0.000 abstract description 4
- 239000000047 product Substances 0.000 description 9
- -1 for example Substances 0.000 description 6
- 229910045601 alloy Inorganic materials 0.000 description 5
- 239000000956 alloy Substances 0.000 description 5
- 238000010276 construction Methods 0.000 description 4
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- 229910000881 Cu alloy Inorganic materials 0.000 description 2
- 229910000676 Si alloy Inorganic materials 0.000 description 2
- CSDREXVUYHZDNP-UHFFFAOYSA-N alumanylidynesilicon Chemical compound [Al].[Si] CSDREXVUYHZDNP-UHFFFAOYSA-N 0.000 description 2
- 238000000576 coating method Methods 0.000 description 2
- 239000007789 gas Substances 0.000 description 2
- 230000005484 gravity Effects 0.000 description 2
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- 229910021364 Al-Si alloy Inorganic materials 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 1
- PWHULOQIROXLJO-UHFFFAOYSA-N Manganese Chemical compound [Mn] PWHULOQIROXLJO-UHFFFAOYSA-N 0.000 description 1
- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 description 1
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 description 1
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 1
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 1
- WPPDFTBPZNZZRP-UHFFFAOYSA-N aluminum copper Chemical compound [Al].[Cu] WPPDFTBPZNZZRP-UHFFFAOYSA-N 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 239000012467 final product Substances 0.000 description 1
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- 239000011777 magnesium Substances 0.000 description 1
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- 238000005259 measurement Methods 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 238000005058 metal casting Methods 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
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- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 1
- 229910052698 phosphorus Inorganic materials 0.000 description 1
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- 238000010118 rheocasting Methods 0.000 description 1
- 238000005096 rolling process Methods 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- 238000009716 squeeze casting Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 229910052717 sulfur Inorganic materials 0.000 description 1
- 239000011593 sulfur Substances 0.000 description 1
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- 238000010117 thixocasting Methods 0.000 description 1
- 238000012546 transfer Methods 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 239000011701 zinc Substances 0.000 description 1
- 229910052725 zinc Inorganic materials 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D19/00—Casting in, on, or around objects which form part of the product
- B22D19/0072—Casting in, on, or around objects which form part of the product for making objects with integrated channels
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
- B22D17/007—Semi-solid pressure die casting
Definitions
- the present invention relates generally to die casting. More particularly, the present invention relates to the casting of components having internal passages.
- passages are typically for fluids, such as for example, water, oils, and gases, and are generally introduced by machining the passages into the product after it has been cast.
- a method for production of a casting incorporating a passage comprising disposing at least one tube in a mold and casting a metal around the tube.
- the metal may be molten or semi-solid metal and comprise aluminum and aluminum alloys.
- the tubes of the invention may also comprise any metal, including, but not limited to, steel, and be crimped or clamped in some embodiments.
- the outer surface of the tubes can be treated prior to casting. Such treatments include spraying the surface with an aluminum composition, shot blasting, and/or metal plating.
- fluids may be passed through the cast-in tubes before, during, and after casting. Molds of the present invention may comprise passages that match the direction of the tube through the casting.
- a system for production of a casting incorporating a passage comprising a disposing means that places at least one tube in a mold and a casting means that casts a metal around the tube.
- the metal may be molten or semi-solid metal and comprise aluminum and aluminum alloys.
- the tubes of the invention may also comprise any metal, including, but not limited to, steel, and be crimped or clamped in some embodiments.
- the outer surface of the tubes can be treated prior to casting. Such treatments include spraying the surface with an aluminum composition, shot blasting, and/or metal plating.
- fluids may be passed through the cast-in tubes before, during, and after casting. Molds of the present invention may comprise passages that match the direction of the tube through the casting.
- Another embodiment of the invention provides a cast product having at least one tube and metal cast around the tube.
- FIG. 1 is a diagrammatic representation of a tube and mold, designed with passages to hold the tube.
- FIG. 2 is a cross-sectional view taken along the 2 - 2 in FIG. 1 .
- FIG. 3 is a diagrammatic representation of an alternate tube design and mold, also designed with a passage to accommodate the tube.
- FIG. 4 is a cross-sectional view taken from the 4 - 4 in FIG. 3 .
- FIG. 5 is a diagrammatic representation of a tube design that crosses over itself.
- FIG. 6 is a diagrammatic representation of two tubes that comprise an intersection.
- An embodiment in accordance with the present invention provides a method for the production of castings with incorporated passages, where the castings are from cast metal and where tubes are cast-in with a superheated molten metal to form the passages.
- the cast metal may be any metal including, but not limited to steel, zinc, magnesium, or combinations thereof.
- aluminum and aluminum alloys are cast.
- Aluminum alloys include 357 alloy, 380 alloy, ADC12 alloy, 356.2 alloy, and other aluminum-silicon alloys.
- presses and die cast methods may be used with the present invention.
- squeeze casting, gravity casting, and high and low pressure die casting methods may all be used.
- vertical die cast presses may also be used.
- Vertical die cast presses manufactured by THT Presses preferred in some applications are disclosed in U.S. Pat. Nos. 5,660,223 and 5,429,175, assigned to and commercially available from THT Presses, Inc., Dayton, Ohio.
- THT presses of this invention may be classified as “indexing-type” or “shuttle-type.” Though the indexing press will be detailed in an embodiment below, both types of presses may be used in the instant invention.
- the THT presses such as a 200 Ton Indexing Shot Machine, a 1000 Ton Shuttle Machine, or a 100 Ton Shuttle Machine, in particular, are capable of operating at a higher speed and with a shorter cycle time than previously known die casting presses and which, as a result, produce higher quality parts with reduced porosity.
- the die casting presses are also simpler and less expensive in construction, requiring less maintenance and therefore more convenient to service.
- SSM casting is defined broadly herein to encompass any casting technique whereby the metal introduced into a die cavity is greater than 20% granular (i.e., solids). SSM casting techniques that are known in the art include, but are not limited to, rheocasting and thixocasting.
- SSM casting may be preferred in some embodiments of the present invention because it is performed at lower temperatures where often 20% -70% of the metal is granular and thus in a slurry, rather than liquid state.
- the cooler temperatures can extend the useful life of the dies.
- the slurry state of the metal reduces turbulence within the metal flow as it is introduced into the die, so as to reduce the incorporation of air and gas into the metal as it is being cast. Thus, porosity and quality control complications are reduced.
- vertical die cast presses are used with SSM casting techniques.
- SSM is cast using a vertical die casting apparatus.
- the indexing time i.e., the delay between indexing between the pour station 80 and transfer station 85
- the indexing time can be used to control the time the molten metal is cooled in the shot sleeve to reach the SSM range. That is, the amount of time the metal spends in the shot sleeve before it is injected into the molds can be regulated or optimized for a desirable microstructure.
- molten metal at a predetermined temperature may be poured into the shot sleeve of shuttle presses, i.e. presses that lack the indexing feature.
- the shear forces present in SSM casting may be more suitable to the present invention in some embodiments over traditional molten metal casting methods.
- larger tubes ranging from about 0.25 inches to about 0.37 inches in outer diameter may be incorporated into the cast-in tube castings than otherwise possible.
- aluminum-silicon alloys can be used.
- aluminum alloys with up to but less than about 11.7 weight percent Si are defined “hypoeutectic”, whereas those with greater than about 11.7 weight percent Si are defined “hypereutectic”.
- the term “about” has been incorporated in this disclosure to account for the inherent inaccuracies associated with measuring chemical weights and measurements known and present in the art.
- aluminum-silicon copper alloys and/or aluminum-copper alloys may be used with the present invention.
- Tubes that may be cast-in in the present invention may comprise any metal, preferably steel or hydraulic tubing in some embodiments.
- the steel tubes can have a composition with less than about 0.17 weight percent carbon, less than about 0.35 weight percent silicon, less than about 0.04 weight percent sulfur, less than about 0.04 weight percent phosphorus and between about 0.40-0.80 weight percent manganese.
- the tubes are free from surface defects, blow holes and cracks.
- Tubes of the present invention can be of varying wall thickness.
- the wall thickness and composition is preferably strong enough to withstand pressures of 6,000 psi to 20,000 psi and more preferably, pressures of 8,000 psi to 12,000 psi.
- the corresponding wall thickness may range from about 0.02 inches to about 0.04 inches, but a wider range may also be acceptable.
- FIGS. 1 and 2 there is shown a die 1 into which a guide 2 has been cut.
- the guide 2 can be cut to fit the path of a tube 3 which is to be embedded into the metal cast.
- the tube 3 may of any design or path.
- the tube 3 may have one opening on one face of the mold or cast and then another opening on another face of the mold or cast as shown in FIG. 1 .
- tube 3 may have and opening on one face and then be tapered, crimped, or clamped at the other end such that fluids become trapped inside the cast as shown in FIGS. 3 and 4 .
- tubes may have paths that cross over ( FIG. 5 ) or intersect ( FIG. 6 ). All such configurations and others are within the scope of the present invention.
- more than one tube may be incorporated into a cast-in tube mold or product. All such tubes should be accounted for in the design of the mold such that guide 2 may be cut into each half of the mold to accommodate the tube or tubes.
- the tubes 3 may optionally be machined at one or more openings 4 . For example, threading for screws or bolts may be inserted.
- the outer surface of the tubes may be coated with a thin surface layer to reduce the likelihood of tube movement (such as slipping or rolling) within the cast product.
- Coatings may include, such as, for example, alumina and aluminum oxide, and may be sprayed on or plated. The thickness of such coating applications will be apparent to one of ordinary skill in the art.
- Other treatments to the outer surface of the tubes can include shot blasting or grating.
- the tube 3 is generally located by gravity in the mold 1 by predetermined guide 2 in the lower half of the mold.
- the tubes are then secondarily located and secured using a reverse passages in the upper half of the mold such that the tube is secured and crimped or clamped in place.
- the metal is be cast is heated in a range from about 10° C. to about 15° C. above the liquidus temperature (i.e., the semi-solid temperature).
- the liquidus temperature i.e., the semi-solid temperature
- the melt temperature is then allowed to cool to form a semi-solid slurry before it is finally cast.
- the mold 1 and tube 3 design is such that, optionally, a cooling medium can be passed through the tubing before, during, and/or after the casting process is taking place.
- a cooling medium can be passed through the tubing before, during, and/or after the casting process is taking place.
- couplers may be added to the open end of the tube allow for entry of fluids for cooling. The couplers could then be removed, machined, or sheared from the final cast product. This procedure may enhance internal casting cooling rates and thus, cycle times.
- internal cooling has the potential to improve the metallurgical properties and/or casting integrity of the final cast product. Alternatively, improved tube bonding with the cast is possible.
Abstract
An embodiment in accordance with the present invention provides a method for the production of castings with incorporated tubes, where the castings are from cast metal and where the tubes are cast-in with a superheated molten metal. Multiple tubes or a plurality of designs may be incorporated into the invention. The present invention also provides a method for cooling the interior of a cast product before, during, and after the product is cast.
Description
- The present invention relates generally to die casting. More particularly, the present invention relates to the casting of components having internal passages.
- In many applications, die cast products involving internal passages are necessary. These passages are typically for fluids, such as for example, water, oils, and gases, and are generally introduced by machining the passages into the product after it has been cast.
- However, where after-cast machining is currently used, such processing can add significant cost to the final product. In other cases, the complex fluid flow patterns that are most desired are often difficult, costly, or impossible to achieve using current machining methodology.
- Accordingly, it is desirable to provide a method and system to introduce passages into a die cast product before or during the casting of the product itself.
- The foregoing needs are met, to an extent, by the present invention, wherein in one embodiment of the present invention a method for production of a casting incorporating a passage is provided comprising disposing at least one tube in a mold and casting a metal around the tube. The metal may be molten or semi-solid metal and comprise aluminum and aluminum alloys. The tubes of the invention may also comprise any metal, including, but not limited to, steel, and be crimped or clamped in some embodiments.
- The outer surface of the tubes can be treated prior to casting. Such treatments include spraying the surface with an aluminum composition, shot blasting, and/or metal plating. In some embodiments of the present invention, fluids may be passed through the cast-in tubes before, during, and after casting. Molds of the present invention may comprise passages that match the direction of the tube through the casting.
- In accordance with another embodiment of the present invention a system for production of a casting incorporating a passage is provided comprising a disposing means that places at least one tube in a mold and a casting means that casts a metal around the tube. The metal may be molten or semi-solid metal and comprise aluminum and aluminum alloys. The tubes of the invention may also comprise any metal, including, but not limited to, steel, and be crimped or clamped in some embodiments.
- The outer surface of the tubes can be treated prior to casting. Such treatments include spraying the surface with an aluminum composition, shot blasting, and/or metal plating. In some embodiments of the present invention, fluids may be passed through the cast-in tubes before, during, and after casting. Molds of the present invention may comprise passages that match the direction of the tube through the casting.
- Another embodiment of the invention provides a cast product having at least one tube and metal cast around the tube.
- There has thus been outlined, rather broadly, certain embodiments of the invention in order that the detailed description thereof herein may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional embodiments of the invention that will be described below and which will form the subject matter of the claims appended hereto.
- In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of embodiments in addition to those described and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein, as well as the abstract, are for the purpose of description and should not be regarded as limiting.
- As such, those skilled in the art will appreciate that the conception upon which this disclosure is based may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
-
FIG. 1 is a diagrammatic representation of a tube and mold, designed with passages to hold the tube. -
FIG. 2 is a cross-sectional view taken along the 2-2 inFIG. 1 . -
FIG. 3 is a diagrammatic representation of an alternate tube design and mold, also designed with a passage to accommodate the tube. -
FIG. 4 is a cross-sectional view taken from the 4-4 inFIG. 3 . -
FIG. 5 is a diagrammatic representation of a tube design that crosses over itself. -
FIG. 6 is a diagrammatic representation of two tubes that comprise an intersection. - The invention will now be described with reference to the drawing figures, in which like reference numerals refer to like parts throughout. An embodiment in accordance with the present invention provides a method for the production of castings with incorporated passages, where the castings are from cast metal and where tubes are cast-in with a superheated molten metal to form the passages.
- The cast metal may be any metal including, but not limited to steel, zinc, magnesium, or combinations thereof. In some embodiments, aluminum and aluminum alloys are cast. Aluminum alloys include 357 alloy, 380 alloy, ADC12 alloy, 356.2 alloy, and other aluminum-silicon alloys.
- A variety of presses and die cast methods may be used with the present invention. For example, squeeze casting, gravity casting, and high and low pressure die casting methods may all be used. In some embodiments, vertical die cast presses may also be used. Vertical die cast presses manufactured by THT Presses preferred in some applications are disclosed in U.S. Pat. Nos. 5,660,223 and 5,429,175, assigned to and commercially available from THT Presses, Inc., Dayton, Ohio. THT presses of this invention may be classified as “indexing-type” or “shuttle-type.” Though the indexing press will be detailed in an embodiment below, both types of presses may be used in the instant invention.
- The THT presses, such as a 200 Ton Indexing Shot Machine, a 1000 Ton Shuttle Machine, or a 100 Ton Shuttle Machine, in particular, are capable of operating at a higher speed and with a shorter cycle time than previously known die casting presses and which, as a result, produce higher quality parts with reduced porosity. The die casting presses are also simpler and less expensive in construction, requiring less maintenance and therefore more convenient to service.
- The casting methods of the present invention need not be limited to die casting methods of molten metal. In fact, in some embodiments, semi-solid metal (SSM) casting may be preferred. SSM casting is defined broadly herein to encompass any casting technique whereby the metal introduced into a die cavity is greater than 20% granular (i.e., solids). SSM casting techniques that are known in the art include, but are not limited to, rheocasting and thixocasting.
- SSM casting may be preferred in some embodiments of the present invention because it is performed at lower temperatures where often 20% -70% of the metal is granular and thus in a slurry, rather than liquid state. The cooler temperatures can extend the useful life of the dies. Moreover, the slurry state of the metal reduces turbulence within the metal flow as it is introduced into the die, so as to reduce the incorporation of air and gas into the metal as it is being cast. Thus, porosity and quality control complications are reduced.
- In one embodiment, vertical die cast presses are used with SSM casting techniques. In other words, SSM is cast using a vertical die casting apparatus. Specifically, the indexing time (i.e., the delay between indexing between the pour station 80 and transfer station 85) can be used to control the time the molten metal is cooled in the shot sleeve to reach the SSM range. That is, the amount of time the metal spends in the shot sleeve before it is injected into the molds can be regulated or optimized for a desirable microstructure. Alternatively, molten metal at a predetermined temperature may be poured into the shot sleeve of shuttle presses, i.e. presses that lack the indexing feature.
- The shear forces present in SSM casting may be more suitable to the present invention in some embodiments over traditional molten metal casting methods. In such an event, larger tubes ranging from about 0.25 inches to about 0.37 inches in outer diameter may be incorporated into the cast-in tube castings than otherwise possible.
- Many metals and alloys known in the art can be used for SSM casting and can be employed with the instant invention. In some embodiments aluminum-silicon alloys can be used. By definition, aluminum alloys with up to but less than about 11.7 weight percent Si are defined “hypoeutectic”, whereas those with greater than about 11.7 weight percent Si are defined “hypereutectic”. In all instances, the term “about” has been incorporated in this disclosure to account for the inherent inaccuracies associated with measuring chemical weights and measurements known and present in the art. In yet other embodiments, aluminum-silicon copper alloys and/or aluminum-copper alloys may be used with the present invention.
- Tubes that may be cast-in in the present invention may comprise any metal, preferably steel or hydraulic tubing in some embodiments. The steel tubes can have a composition with less than about 0.17 weight percent carbon, less than about 0.35 weight percent silicon, less than about 0.04 weight percent sulfur, less than about 0.04 weight percent phosphorus and between about 0.40-0.80 weight percent manganese. Preferably, the tubes are free from surface defects, blow holes and cracks.
- Tubes of the present invention can be of varying wall thickness. Where deformation of the tube is not desirable, the wall thickness and composition is preferably strong enough to withstand pressures of 6,000 psi to 20,000 psi and more preferably, pressures of 8,000 psi to 12,000 psi. For steel tubes, the corresponding wall thickness may range from about 0.02 inches to about 0.04 inches, but a wider range may also be acceptable.
- Referring now to
FIGS. 1 and 2 there is shown a die 1 into which aguide 2 has been cut. Theguide 2 can be cut to fit the path of atube 3 which is to be embedded into the metal cast. Thetube 3 may of any design or path. For example, thetube 3 may have one opening on one face of the mold or cast and then another opening on another face of the mold or cast as shown inFIG. 1 . However, in some embodiments,tube 3 may have and opening on one face and then be tapered, crimped, or clamped at the other end such that fluids become trapped inside the cast as shown inFIGS. 3 and 4 . Alternatively, tubes may have paths that cross over (FIG. 5 ) or intersect (FIG. 6 ). All such configurations and others are within the scope of the present invention. - In addition, more than one tube may be incorporated into a cast-in tube mold or product. All such tubes should be accounted for in the design of the mold such that
guide 2 may be cut into each half of the mold to accommodate the tube or tubes. - The
tubes 3 may optionally be machined at one ormore openings 4. For example, threading for screws or bolts may be inserted. In other embodiments, the outer surface of the tubes may be coated with a thin surface layer to reduce the likelihood of tube movement (such as slipping or rolling) within the cast product. Coatings may include, such as, for example, alumina and aluminum oxide, and may be sprayed on or plated. The thickness of such coating applications will be apparent to one of ordinary skill in the art. Other treatments to the outer surface of the tubes can include shot blasting or grating. - Referring back to
FIG. 1 , once a tube design and accompanying mold are selected, thetube 3 is generally located by gravity in the mold 1 bypredetermined guide 2 in the lower half of the mold. The tubes are then secondarily located and secured using a reverse passages in the upper half of the mold such that the tube is secured and crimped or clamped in place. - Where SSM casting is desired, preferably, the metal is be cast is heated in a range from about 10° C. to about 15° C. above the liquidus temperature (i.e., the semi-solid temperature). For Al—Si alloys this generally ranges from about 585° C. to about 590° C. The melt temperature is then allowed to cool to form a semi-solid slurry before it is finally cast.
- In some applications, the mold 1 and
tube 3 design is such that, optionally, a cooling medium can be passed through the tubing before, during, and/or after the casting process is taking place. In such an embodiment, couplers may be added to the open end of the tube allow for entry of fluids for cooling. The couplers could then be removed, machined, or sheared from the final cast product. This procedure may enhance internal casting cooling rates and thus, cycle times. Also, internal cooling has the potential to improve the metallurgical properties and/or casting integrity of the final cast product. Alternatively, improved tube bonding with the cast is possible. - The many features and advantages of the invention are apparent from the detailed specification, and thus, it is intended by the appended claims to cover all such features and advantages of the invention which fall within the true spirit and scope of the invention. Further, since numerous modifications and variations will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation illustrated and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.
Claims (30)
1. A method for production of a casting incorporating a passage comprising:
disposing at least one tube in a mold to form the passage; and
casting a metal around the tube, wherein a portion of the tube is deformed during casting.
2. The method according to claim 1 , wherein the metal is a semi-solid metal.
3. The method according to claim 1 , wherein the tube comprises steel.
4. The method according to claim 1 , wherein the mold comprises guides matching the direction of the tube through the casting.
5. The method according to claim 1 , wherein the metal is an aluminum alloy.
6. The method according to claim 1 , wherein the portion of the tube is crimped or clamped.
7. The method according to claim 1 , further comprising treating at least a portion of a surface of the tube.
8. The method according to claim 7 , wherein the treating comprises spraying the surface with an aluminum composition.
9. The method according to claim 7 , wherein the treating comprises shot blasting.
10. The method according to claim 7 , wherein the treating comprising metal plating.
11. The method according to claim 1 , further comprising passing fluids through the tube before, during, or after casting.
12. A means for production of a casting incorporating a passage comprising:
disposing means that places at least one tube in a mold; and
a casting means that casts a metal around the tube.
13. The casting means according to claim 12 , wherein the metal is a semi-solid metal.
14. The casting means according to claim 12 , wherein the tube comprises steel.
15. The casting means according to claim 12 , wherein the mold comprises guides matching the direction of the tube through the casting.
16. The casting means according to claim 12 , wherein the metal is an aluminum alloy.
17. The casting means according to claim 12 , wherein the tube is crimped or clamped.
18. The casting means according to claim 12 , further comprising treating at least a portion of a surface the tube.
19. The casting means according to claim 18 , wherein the treating comprises spraying the surface with an aluminum composition.
20. The casting means according to claim 18 , wherein the treating comprises shot blasting.
21. The casting means according to claim 18 , wherein the treating comprising metal plating.
22. A cast product, comprising:
at least one tube; and
metal cast around the tube.
23. The method according to claim 1 , wherein the tube comprises aluminum.
24. The method according to claim 1 , wherein the metal is a liquid metal.
25. The method of claim 1 , wherein the casting is hollow.
26. The method of claim 1 , wherein the mold comprises openings to pass a cooling medium through the casting.
27. The method of claim 1 , wherein the casting is steel or aluminum.
28. A method for production of a casting incorporating a passage comprising:
disposing a tube in a mold to form the passage, the tube having a first end and a second end;
closing the tube at the first or second end;
deforming a portion of the tube during casting; and
casting a metal around the tube to form a product.
29. The method according to claim 28 , wherein the second end is closed during casting and is opened after casting by a metal treatment.
30. The method according to claim 28 , wherein a cooling medium is disposed in the tube.
Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/736,557 US20050133187A1 (en) | 2003-12-17 | 2003-12-17 | Die casting method system and die cast product |
PCT/US2004/042289 WO2005058529A2 (en) | 2003-12-17 | 2004-12-16 | Die casting method system and die cast product |
EP04814468A EP1694454A4 (en) | 2003-12-17 | 2004-12-16 | Die casting method system and die cast product |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/736,557 US20050133187A1 (en) | 2003-12-17 | 2003-12-17 | Die casting method system and die cast product |
Publications (1)
Publication Number | Publication Date |
---|---|
US20050133187A1 true US20050133187A1 (en) | 2005-06-23 |
Family
ID=34677212
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US10/736,557 Abandoned US20050133187A1 (en) | 2003-12-17 | 2003-12-17 | Die casting method system and die cast product |
Country Status (3)
Country | Link |
---|---|
US (1) | US20050133187A1 (en) |
EP (1) | EP1694454A4 (en) |
WO (1) | WO2005058529A2 (en) |
Cited By (8)
Publication number | Priority date | Publication date | Assignee | Title |
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US20070017658A1 (en) * | 2005-07-19 | 2007-01-25 | International Business Machines Corporation | Cold plate apparatus and method of fabrication thereof with a controlled heat transfer characteristic between a metallurgically bonded tube and heat sink for facilitating cooling of an electronics component |
US20090178640A1 (en) * | 2006-06-30 | 2009-07-16 | Daimler Ag | Cast steel piston for internal combustion engines |
EP2151875A3 (en) * | 2008-08-07 | 2013-11-06 | Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. | Method and device for manufacturing a component with an integrated insert section |
ITMI20121739A1 (en) * | 2012-10-16 | 2014-04-17 | Unical Ag Spa | PROCEDURE FOR THE CONSTRUCTION OF A HEAT EXCHANGER WITH DIE-CASTING ELEMENTS. |
JP2014124639A (en) * | 2012-12-25 | 2014-07-07 | Aisin Seiki Co Ltd | Pipe holding device for enveloped casting |
TWI472388B (en) * | 2009-12-01 | 2015-02-11 | Metal Ind Res & Dev Ct | Casting with metal insert and its manufacturing method |
US10105671B2 (en) * | 2014-11-11 | 2018-10-23 | H.C. Starck Inc. | Microreactor systems and methods |
CN110625089A (en) * | 2019-10-28 | 2019-12-31 | 宁波优耐特模具有限公司 | New energy automobile driving motor ECU shell mold and shell manufacturing process |
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US10507449B2 (en) | 2014-11-11 | 2019-12-17 | H.C. Starck Inc. | Microreactor systems and methods |
US11110426B2 (en) | 2014-11-11 | 2021-09-07 | H.C. Starck Inc. | Microreactor systems and methods |
US11642644B2 (en) | 2014-11-11 | 2023-05-09 | H.C. Starck Solutions Coldwater, LLC | Microreactor systems and methods |
CN110625089A (en) * | 2019-10-28 | 2019-12-31 | 宁波优耐特模具有限公司 | New energy automobile driving motor ECU shell mold and shell manufacturing process |
Also Published As
Publication number | Publication date |
---|---|
WO2005058529A3 (en) | 2005-09-29 |
EP1694454A4 (en) | 2007-04-04 |
EP1694454A2 (en) | 2006-08-30 |
WO2005058529A2 (en) | 2005-06-30 |
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