EP2450124A2 - Shot tube plunger for a die casting system - Google Patents
Shot tube plunger for a die casting system Download PDFInfo
- Publication number
- EP2450124A2 EP2450124A2 EP11187861A EP11187861A EP2450124A2 EP 2450124 A2 EP2450124 A2 EP 2450124A2 EP 11187861 A EP11187861 A EP 11187861A EP 11187861 A EP11187861 A EP 11187861A EP 2450124 A2 EP2450124 A2 EP 2450124A2
- Authority
- EP
- European Patent Office
- Prior art keywords
- shot tube
- face
- piston head
- charge
- disposable piston
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
Links
- 238000004512 die casting Methods 0.000 title claims abstract description 43
- 239000000463 material Substances 0.000 claims abstract description 44
- 238000000034 method Methods 0.000 claims description 13
- 238000004891 communication Methods 0.000 claims description 3
- 239000012530 fluid Substances 0.000 claims description 3
- 238000002844 melting Methods 0.000 description 20
- 230000008018 melting Effects 0.000 description 20
- 229910052751 metal Inorganic materials 0.000 description 14
- 239000002184 metal Substances 0.000 description 14
- 238000002347 injection Methods 0.000 description 12
- 239000007924 injection Substances 0.000 description 12
- 230000007246 mechanism Effects 0.000 description 9
- 238000005266 casting Methods 0.000 description 4
- 229910045601 alloy Inorganic materials 0.000 description 3
- 239000000956 alloy Substances 0.000 description 3
- 239000000919 ceramic Substances 0.000 description 3
- 238000005495 investment casting Methods 0.000 description 3
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 2
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 2
- 239000007789 gas Substances 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 239000002923 metal particle Substances 0.000 description 2
- 239000011819 refractory material Substances 0.000 description 2
- 239000010959 steel Substances 0.000 description 2
- 229910000601 superalloy Inorganic materials 0.000 description 2
- 229910000838 Al alloy Inorganic materials 0.000 description 1
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 229910000640 Fe alloy Inorganic materials 0.000 description 1
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 description 1
- 229910001069 Ti alloy Inorganic materials 0.000 description 1
- 229910001297 Zn alloy Inorganic materials 0.000 description 1
- 229910052786 argon Inorganic materials 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 239000010941 cobalt Substances 0.000 description 1
- 229910017052 cobalt Inorganic materials 0.000 description 1
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 1
- 238000011109 contamination Methods 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 230000006698 induction Effects 0.000 description 1
- 238000000829 induction skull melting Methods 0.000 description 1
- 239000011261 inert gas Substances 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229910052750 molybdenum Inorganic materials 0.000 description 1
- 239000011733 molybdenum Substances 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 229910052758 niobium Inorganic materials 0.000 description 1
- 239000010955 niobium Substances 0.000 description 1
- GUCVJGMIXFAOAE-UHFFFAOYSA-N niobium atom Chemical compound [Nb] GUCVJGMIXFAOAE-UHFFFAOYSA-N 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 239000003870 refractory metal Substances 0.000 description 1
- 238000012546 transfer Methods 0.000 description 1
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 description 1
- 229910052721 tungsten Inorganic materials 0.000 description 1
- 239000010937 tungsten Substances 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
- B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
- B22D17/20—Accessories: Details
- B22D17/2015—Means for forcing the molten metal into the die
- B22D17/203—Injection pistons
Definitions
- This disclosure relates generally to a die casting system, and more particularly to a shot tube plunger for a die casting system.
- Casting is a known technique used to yield substantially net-shaped components.
- investment casting is often used in the gas turbine engine industry to manufacture net-shaped components, such as blades and vanes having relatively complex shapes.
- Investment casting involves pouring molten metal into a ceramic shell having a cavity in the shape of the component to be cast.
- Investment casting can be relatively labor intensive, time consuming and expensive.
- Die casting involves injecting molten metal directly into a reusable die to yield a net-shaped component. Die casting has typically been used to produce components that do not require high thermal mechanical performance. For example, die casting is commonly used to produce components made from relatively low melting temperature materials that are not exposed to extreme temperatures. Die casting has not traditionally been a cost effective method for manufacturing parts made from high temperature alloys.
- a shot tube plunger for a die casting system includes a first face, an opposing second face and an outer surface disposed between said first face and said opposing second face.
- a channel circumferentially extends about the outer surface. The channel is operable to receive a portion of a charge of material introduced into the die casting system.
- a die casting system in another exemplary embodiment, includes a die, a shot tube, a shot tube plunger and a disposable piston head.
- the die includes a plurality of die components that define a die cavity.
- the shot tube is in fluid communication with the die cavity.
- the shot tube plunger is moveable within the shot tube to communicate a charge of material into the die cavity.
- the disposable piston head is removably attached to the shot tube plunger.
- the disposable piston head includes a first face and an opposing second face.
- the first face includes an engagement member that contacts a portion of the charge of material and the opposing second face includes an attachment member that removably attaches the disposable piston head to the shot tube plunger.
- a method of die casting a component with a die casting system includes removably attaching a disposable head to a shot tube plunger of the die casting system, injecting a charge of material into a die cavity of the die casting system with the shot tube plunger and attached disposable piston head, and capturing a portion of the charge of material in a channel that circumferentially extends about an outer surface of the disposable piston head during the step of injecting the charge of material.
- Figure 1 illustrates a die casting system 10 including a reusable die 12 having a plurality of die elements 14, 16 that function to cast a component 15.
- the component could include aeronautical components, such as gas turbine engine blades or vanes, or non-aeronautical components.
- two die elements 14, 16 are depicted in Figure 1 , it should be understood that the die 12 could include more or fewer die elements, as well as other parts and configurations.
- the die 12 is assembled by positioning the die elements 14, 16 together and holding the die elements 14, 16 at a desired positioning via a mechanism 18.
- the mechanism 18 could include a clamping mechanism of appropriate hydraulic, pneumatic, electromechanical and/or other configurations.
- the mechanism 18 also separates the die elements 14, 16 subsequent to casting.
- the die elements 14, 16 include internal surfaces that cooperate to define a die cavity 20.
- a shot tube 24 is in fluid communication with the die cavity 20 via one or more ports 26 that extend into the die element 14, the die element 16, or both.
- a shot tube plunger 28 is received within the shot tube 24 and is moveable between a retracted and injected position (in the direction of arrow A) within the shot tube 24 by a mechanism 30.
- a shaft 31 extends between the mechanism 30 and the shot tube plunger 28.
- the mechanism 30 could include a hydraulic assembly or other suitable mechanism, including, but not limited to, hydraulic, pneumatic, electromechanical or any combination of mechanisms.
- the shot tube 24 is positioned to receive a charge of material, such as molten metal, from a melting unit 32, such as a crucible, for example.
- the melting unit 32 may utilize any known technique for melting an ingot of metallic material to prepare molten metal for delivery to the shot tube 24, including but not limited to, vacuum induction melting, electronic beam melting and induction skull melting.
- the molten metal is melted by the melting unit 32 at a location that is separate from the shot tube 24 and the die 12.
- the melting unit 32 of this example is positioned in relative close proximity to the shot tube 24 to reduce the transfer distance of the molten metal between the melting unit 32 and the shot tube 24.
- Materials capable of being used to die cast a component 15 include, but are not limited to, nickel-based super alloys, cobalt-based super alloys, titanium alloys, aluminum alloys, zinc alloys, copper-based alloys, iron alloys, molybdenum, tungsten, niobium or other refractory metals. This disclosure is not limited to the disclosed alloys, and other high melting temperature materials may be utilized to die cast the component 15. As used herein, the term "high melting temperature material” is intended to include materials having a melting temperature of approximately 1500°F (815°C) and higher.
- the molten metal is transferred from the melting unit 32 to the shot tube 24 in a known manner.
- the molten metal may be poured into a pour hole 33 of the shot tube 24.
- a sufficient amount of molten metal is poured into the shot tube 24 to fill the die cavity 20.
- the shot tube plunger 28 is actuated to inject the molten metal under pressure from the shot tube 24 into the die cavity 20 to cast the component 15.
- the die casting system 10 could be configured to cast multiple components in a single shot.
- the die casting system 10 can be positioned within a vacuum chamber 34 that includes a vacuum source 35.
- a vacuum is applied in the vacuum chamber 34 via the vacuum source 35 to render a vacuum die casting process.
- the vacuum chamber 34 provides a non-reactive environment for the die casting system 10 that reduces reaction, contamination or other conditions that could detrimentally affect the quality of the die cast component, such as excess porosity of the die cast component that can occur as a result of exposure to oxygen.
- the vacuum chamber 34 is maintained at a pressure between 1x10 -3 Torr and 1x10 -4 Torr, although other pressures are contemplated.
- the actual pressure of the vacuum chamber 34 will vary based upon the type of component 15 being cast, among other conditions and factors.
- each of the melting unit 32, the shot tube 24 and the die 12 are positioned within the vacuum chamber 34 during the die casting process such that the melting, injecting and solidifying of the high melting temperature material are all performed under vacuum.
- the chamber 34 is backfilled with an inert gas, such as Argon, for example.
- the example die casting system 10 depicted in Figure 1 is illustrative only and could include more or fewer sections, parts and/or components. This disclosure extends to all forms of die casting, including but not limited to, horizontal, inclined or vertical die casting systems and other die casting configurations.
- Figures 2A-2C illustrate an example shot tube plunger 128 for use with a die casting system, such as the die casting system 10.
- a die casting system such as the die casting system 10.
- like reference numerals signify like features, and reference numerals signified by adding 100 to the original reference number are slightly modified features.
- selected features of one example embodiment may be combined with selected features of other example embodiments within the scope of this disclosure.
- the shot tube plunger 128 is disposable. That is, the shot tube plunger 128 is removable from the shaft 31 and may be disposed of after injection of a charge of material, such as a charge of a high melting temperature material, to cast a component 15.
- the sacrificial shot tube plunger 128 can be removed either after a single injection or after multiple injections and replaced with another disposable shot tube plunger 128 for a subsequent injection.
- the shot tube plunger 128 is a single-piece device having no mechanical attachments.
- the shot tube plunger 128 is made from a material capable of withstanding contact with high melting temperature materials, such as the contact that occurs during the injection of a charge of material M during the die casting process, including but not limited to, steel, ceramic, or other refractory materials.
- the shot tube plunger 128 includes a first face 41, a second face 43, and an outer cylindrical surface 45 disposed between the first face 41 and the second face 43.
- the first face 41 faces the charge of material M within the shot tube 24, while the second face 43 faces the shaft 31.
- the shot tube plunger 128 may include an engagement member 47, an attachment member 49 and/or a channel 51.
- Figure 2A illustrates the shot tube plunger 128 having each of the engagement member 47, the attachment member 49 and the channel 51, it should be understood that the shot tube plunger 128 could include only one of these features or any combination of such features.
- the outer surface 45 of the shot tube plunger 128 could be configured to include non-cylindrical shapes.
- the first face 41 can include the engagement member 47.
- the engagement member 47 provides an additional contact area for the charge of material M to bond to during injection.
- the disposable shot tube plunger 128 remains attached to the cast component 15 (See Figure 2B ) via cast portion 17 that bonds to the engagement member 47, but is detached from the shaft 31.
- the shot tube plunger 128 is then removed from the component 15 by removing the cast portion 17 and can then be disposed of.
- the engagement member 47 includes a recess 55 (see Figure 2A ).
- the recess 55 extends from the first face 41, which faces the charge of material M, toward the second face 43.
- the recess 55 can include a variety of shapes and configurations, including but not limited to, a T-shaped configuration, a triangular configuration, a truncated configuration, etc. Other shapes are also contemplated as within the scope of this disclosure.
- the first face 41 can include a single recess 55 or multiple recesses 55.
- the engagement member 47 includes a protrusion 57 that protrudes from the first face 41 in a direction away from the second face 43 (See Figure 2C ).
- the shot tube plunger 128 could include a single protrusion 57 ( Figure 2C ) or multiple protrusions 52 ( Figure 4E ).
- the shot tube plunger 128 can also include an attachment member 49 for aligning and affixing the shot tube plunger 128 relative to the shaft 31.
- the attachment member 49 is disposed on the second face 43 of the shot tube plunger 128.
- the attachment member 49 includes a recess 59 (see Figure 2A ).
- the recess 59 can include multiple shapes and sizes.
- the recess 59 receives a corresponding protrusion 61 of the shaft 31.
- the attachment member 49 includes a protrusion 63 that extends from the second face 43 and is received within a corresponding recess 65 of the shaft 31 (See Figure 2C ).
- the shot tube plunger may also include the channel 51.
- the channel 51 circumferentially extends about the outer cylindrical surface 45.
- the channel 51 includes a circumferential groove 53 that extends radially inwardly from the outer cylindrical surface 45.
- the channel 51 could also include other configurations.
- the shot tube plunger 128 could include a single channel 51 or multiple channels 51.
- FIG 3 illustrates another example shot tube plunger 228.
- the shot tube plunger 228 includes a disposable piston head 40.
- the disposable piston head 40 is removably attached to the shot tube plunger 228 and can be disposed of subsequent to an injection of a charge of material during a die casting process.
- the disposable piston head 40 can be removed from the shaft 31 and disposed of either after a single injection or after multiple injections.
- the disposable piston head 40 is made from a material capable of withstanding contact with high melting temperature materials.
- the disposable piston head 40 could be made from steel, ceramic, or other refractory materials.
- the disposable piston head 40 defines a first height H1
- the shot tube plunger 228 defines a second height H2.
- the first height H1 of the disposable piston head 40 and the second height H2 of the shot tube plunger 228 are generally equal. Therefore, the shot tube plunger 228 may be reciprocated between a retracted and injected position without creating interference with the inner wall 25 of the shot tube 24.
- Figures 4A-4F illustrate example features of the disposable piston head 40.
- the disposable piston head 40 includes a first face 42, a second face 44 and an outer cylindrical surface 46 disposed between the first face 42 and the second face 44.
- the first face 42 faces a charge of material M (e.g., molten metal) within the shot tube 24, while the second face 44 faces the shot tube plunger 228 (shown in phantom).
- material M e.g., molten metal
- the first face 42 can include an engagement member 48.
- the engagement member 48 provides a contact area for the charge of material M to bond to during injection. Once the injection is complete and the metal is solidified within the die cavity 20, the disposable piston head 40 remains attached to the cast component 15 (See Figure 4F ) via a cast portion 17. The disposable piston head 40 can then be removed from the component 15 and disposed of.
- the engagement member 48 includes a recess 50 (see Figures 4A-4C ).
- the recess 50 extends from the first face 42, which faces the charge of material M, in a direction toward the second face 44.
- the recess 50 can include a variety of shapes and configurations, including truncated triangular configurations ( Figures 4A and 4B ) and T-shaped configurations ( Figure 4C ). Other shapes are contemplated as within the scope of this disclosure.
- the first face 42 can include a single recess 50 (See Figure 4A ) or multiple recesses 50 (See Figure 4B ).
- Figures 4D-4F illustrate another example engagement member 48 of the disposable piston head 40.
- the engagement member 48 includes a protrusion 52 that protrudes from the first face 42 in a direction away from the second face 44.
- the disposable piston head 40 can include a single protrusion 52 (See Figure 4D ), or multiple protrusions 52 (See Figure 4E ).
- the protrusions 52 may have an enlarged head to further secure bonding.
- FIGS 5A-5C illustrate another feature of the disposable piston head 40.
- the disposable piston head 40 includes an attachment member 54 for aligning and affixing the disposable piston head 40 to the shot tube plunger 228.
- the attachment member 54 is disposed on the second face 44 of the disposable piston head 40, which faces in a direction toward the shot tube plunger 228. That is, the attachment member 54 is positioned on an opposite side of the disposable piston head 40 from the charge of material M.
- the attachment member 54 includes a recess 56 (see Figures 5A and 5C ).
- the recess 55 can include multiple shapes and sizes, including but not limited to those depicted in Figure 5A and Figure 5C .
- the recess 56 receives a corresponding protrusion 60 of the shot tube plunger 228 (shown in phantom) to removably attach the disposable piston head 40 to the shot tube plunger 228.
- the attachment member 54 includes a protrusion 62 that extends from the second face 44 in a direction toward the shot tube plunger 228.
- the protrusion 62 is received within a corresponding recess 64 of the shot tube plunger 228 to removably attach the disposable piston head 40 to the shot tube plunger 228.
- FIGS 6A-6E illustrate yet another feature of the disposable piston head 40.
- the disposable piston head 40 can include a channel 58 circumferentially disposed about the outer cylindrical surface 46 of the disposable piston head 40.
- the channel 58 extends radially inward from the outer cylindrical surface 46 of the disposable piston head 40 to define a circumferential groove 66.
- the channel 58 can define any of a multitude of varying shapes and configurations, such as depicted in Figures 6A-6E .
- the outer cylindrical surface 46 of the disposable piston head 40 can include a plurality of channels 58 defined thereon.
- Figures 3-6 illustrate multiple features of the disposable piston head 40.
- the disposable piston head 40 could include one or all of the features described herein.
- the disposable piston head 40 could include the engagement member 48, the attachment member 54 and the channel 58, or any combination of these features.
- Figure 7 illustrates a disposable piston head 40 having each of the engagement member 48, the attachment member 54 and the channel 58.
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Molds, Cores, And Manufacturing Methods Thereof (AREA)
- Injection Moulding Of Plastics Or The Like (AREA)
- Moulds For Moulding Plastics Or The Like (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
Abstract
Description
- This disclosure relates generally to a die casting system, and more particularly to a shot tube plunger for a die casting system.
- Casting is a known technique used to yield substantially net-shaped components. For example, investment casting is often used in the gas turbine engine industry to manufacture net-shaped components, such as blades and vanes having relatively complex shapes. Investment casting involves pouring molten metal into a ceramic shell having a cavity in the shape of the component to be cast. Investment casting can be relatively labor intensive, time consuming and expensive.
- Another known casting technique is die casting. Die casting involves injecting molten metal directly into a reusable die to yield a net-shaped component. Die casting has typically been used to produce components that do not require high thermal mechanical performance. For example, die casting is commonly used to produce components made from relatively low melting temperature materials that are not exposed to extreme temperatures. Die casting has not traditionally been a cost effective method for manufacturing parts made from high temperature alloys.
- In an exemplary embodiment, a shot tube plunger for a die casting system includes a first face, an opposing second face and an outer surface disposed between said first face and said opposing second face. A channel circumferentially extends about the outer surface. The channel is operable to receive a portion of a charge of material introduced into the die casting system.
- In another exemplary embodiment, a die casting system includes a die, a shot tube, a shot tube plunger and a disposable piston head. The die includes a plurality of die components that define a die cavity. The shot tube is in fluid communication with the die cavity. The shot tube plunger is moveable within the shot tube to communicate a charge of material into the die cavity. The disposable piston head is removably attached to the shot tube plunger. The disposable piston head includes a first face and an opposing second face. The first face includes an engagement member that contacts a portion of the charge of material and the opposing second face includes an attachment member that removably attaches the disposable piston head to the shot tube plunger.
- In yet another exemplary embodiment, a method of die casting a component with a die casting system includes removably attaching a disposable head to a shot tube plunger of the die casting system, injecting a charge of material into a die cavity of the die casting system with the shot tube plunger and attached disposable piston head, and capturing a portion of the charge of material in a channel that circumferentially extends about an outer surface of the disposable piston head during the step of injecting the charge of material.
- The various features and advantages of this disclosure will become apparent to those skilled in the art from the following detailed description. The drawings that accompany the detailed description can be briefly described as follows.
-
-
Figure 1 illustrates an example die casting system. -
Figures 2A-2C illustrates an example shot tube plunger for use with a die casting system. -
Figure 3 illustrates another example shot tube plunger for use with a die casting system. -
Figure 4A-4F illustrates a first feature of the shot tube plunger ofFigure 3 . -
Figure 5A-5C illustrates another feature of the shot tube plunger ofFigure 3 . -
Figure 6A-6E illustrates another feature of the shot tube plunger ofFigure 3 . -
Figure 7 illustrates a disposable piston head of a shot tube plunger. -
Figure 1 illustrates adie casting system 10 including areusable die 12 having a plurality of dieelements 14, 16 that function to cast acomponent 15. The component could include aeronautical components, such as gas turbine engine blades or vanes, or non-aeronautical components. Although twodie elements 14, 16 are depicted inFigure 1 , it should be understood that thedie 12 could include more or fewer die elements, as well as other parts and configurations. - The die 12 is assembled by positioning the die
elements 14, 16 together and holding the dieelements 14, 16 at a desired positioning via amechanism 18. Themechanism 18 could include a clamping mechanism of appropriate hydraulic, pneumatic, electromechanical and/or other configurations. Themechanism 18 also separates the dieelements 14, 16 subsequent to casting. - The die
elements 14, 16 include internal surfaces that cooperate to define a diecavity 20. Ashot tube 24 is in fluid communication with thedie cavity 20 via one ormore ports 26 that extend into thedie element 14, the die element 16, or both. Ashot tube plunger 28 is received within theshot tube 24 and is moveable between a retracted and injected position (in the direction of arrow A) within theshot tube 24 by a mechanism 30. Ashaft 31 extends between the mechanism 30 and theshot tube plunger 28. The mechanism 30 could include a hydraulic assembly or other suitable mechanism, including, but not limited to, hydraulic, pneumatic, electromechanical or any combination of mechanisms. - The
shot tube 24 is positioned to receive a charge of material, such as molten metal, from amelting unit 32, such as a crucible, for example. Themelting unit 32 may utilize any known technique for melting an ingot of metallic material to prepare molten metal for delivery to theshot tube 24, including but not limited to, vacuum induction melting, electronic beam melting and induction skull melting. In this example, the molten metal is melted by themelting unit 32 at a location that is separate from theshot tube 24 and thedie 12. However, other melting configurations are contemplated as within the scope of this disclosure. Themelting unit 32 of this example is positioned in relative close proximity to theshot tube 24 to reduce the transfer distance of the molten metal between themelting unit 32 and theshot tube 24. - Materials capable of being used to die cast a
component 15 include, but are not limited to, nickel-based super alloys, cobalt-based super alloys, titanium alloys, aluminum alloys, zinc alloys, copper-based alloys, iron alloys, molybdenum, tungsten, niobium or other refractory metals. This disclosure is not limited to the disclosed alloys, and other high melting temperature materials may be utilized to die cast thecomponent 15. As used herein, the term "high melting temperature material" is intended to include materials having a melting temperature of approximately 1500°F (815°C) and higher. - The molten metal is transferred from the
melting unit 32 to theshot tube 24 in a known manner. For example, the molten metal may be poured into apour hole 33 of theshot tube 24. A sufficient amount of molten metal is poured into theshot tube 24 to fill thedie cavity 20. Theshot tube plunger 28 is actuated to inject the molten metal under pressure from theshot tube 24 into thedie cavity 20 to cast thecomponent 15. Although the casting of a single component is depicted, thedie casting system 10 could be configured to cast multiple components in a single shot. - Although not necessary, at least a part of the
die casting system 10 can be positioned within avacuum chamber 34 that includes avacuum source 35. A vacuum is applied in thevacuum chamber 34 via thevacuum source 35 to render a vacuum die casting process. Thevacuum chamber 34 provides a non-reactive environment for thedie casting system 10 that reduces reaction, contamination or other conditions that could detrimentally affect the quality of the die cast component, such as excess porosity of the die cast component that can occur as a result of exposure to oxygen. In one example, thevacuum chamber 34 is maintained at a pressure between 1x10-3 Torr and 1x10-4 Torr, although other pressures are contemplated. The actual pressure of thevacuum chamber 34 will vary based upon the type ofcomponent 15 being cast, among other conditions and factors. In the illustrated example, each of themelting unit 32, theshot tube 24 and thedie 12 are positioned within thevacuum chamber 34 during the die casting process such that the melting, injecting and solidifying of the high melting temperature material are all performed under vacuum. In another example, thechamber 34 is backfilled with an inert gas, such as Argon, for example. - The example die
casting system 10 depicted inFigure 1 is illustrative only and could include more or fewer sections, parts and/or components. This disclosure extends to all forms of die casting, including but not limited to, horizontal, inclined or vertical die casting systems and other die casting configurations. -
Figures 2A-2C illustrate an example shottube plunger 128 for use with a die casting system, such as thedie casting system 10. In this disclosure, like reference numerals signify like features, and reference numerals signified by adding 100 to the original reference number are slightly modified features. Moreover, selected features of one example embodiment may be combined with selected features of other example embodiments within the scope of this disclosure. - The
shot tube plunger 128 is disposable. That is, theshot tube plunger 128 is removable from theshaft 31 and may be disposed of after injection of a charge of material, such as a charge of a high melting temperature material, to cast acomponent 15. The sacrificialshot tube plunger 128 can be removed either after a single injection or after multiple injections and replaced with another disposableshot tube plunger 128 for a subsequent injection. In this example, theshot tube plunger 128 is a single-piece device having no mechanical attachments. Theshot tube plunger 128 is made from a material capable of withstanding contact with high melting temperature materials, such as the contact that occurs during the injection of a charge of material M during the die casting process, including but not limited to, steel, ceramic, or other refractory materials. - The
shot tube plunger 128 includes afirst face 41, asecond face 43, and an outercylindrical surface 45 disposed between thefirst face 41 and thesecond face 43. Thefirst face 41 faces the charge of material M within theshot tube 24, while thesecond face 43 faces theshaft 31. Theshot tube plunger 128 may include anengagement member 47, anattachment member 49 and/or a channel 51. AlthoughFigure 2A illustrates theshot tube plunger 128 having each of theengagement member 47, theattachment member 49 and the channel 51, it should be understood that theshot tube plunger 128 could include only one of these features or any combination of such features. It should also be understood that theouter surface 45 of theshot tube plunger 128 could be configured to include non-cylindrical shapes. - The
first face 41 can include theengagement member 47. Theengagement member 47 provides an additional contact area for the charge of material M to bond to during injection. Once the injection is complete and the charge of material M is solidified within thedie cavity 20, the disposableshot tube plunger 128 remains attached to the cast component 15 (SeeFigure 2B ) viacast portion 17 that bonds to theengagement member 47, but is detached from theshaft 31. Theshot tube plunger 128 is then removed from thecomponent 15 by removing thecast portion 17 and can then be disposed of. - In one example, the
engagement member 47 includes a recess 55 (seeFigure 2A ). Therecess 55 extends from thefirst face 41, which faces the charge of material M, toward thesecond face 43. Therecess 55 can include a variety of shapes and configurations, including but not limited to, a T-shaped configuration, a triangular configuration, a truncated configuration, etc. Other shapes are also contemplated as within the scope of this disclosure. Thefirst face 41 can include asingle recess 55 ormultiple recesses 55. In another example, theengagement member 47 includes aprotrusion 57 that protrudes from thefirst face 41 in a direction away from the second face 43 (SeeFigure 2C ). Theshot tube plunger 128 could include a single protrusion 57 (Figure 2C ) or multiple protrusions 52 (Figure 4E ). - The
shot tube plunger 128 can also include anattachment member 49 for aligning and affixing theshot tube plunger 128 relative to theshaft 31. Theattachment member 49 is disposed on thesecond face 43 of theshot tube plunger 128. In one example, theattachment member 49 includes a recess 59 (seeFigure 2A ). Therecess 59 can include multiple shapes and sizes. Therecess 59 receives a correspondingprotrusion 61 of theshaft 31. In another example, theattachment member 49 includes aprotrusion 63 that extends from thesecond face 43 and is received within a correspondingrecess 65 of the shaft 31 (SeeFigure 2C ). - The shot tube plunger may also include the channel 51. The channel 51 circumferentially extends about the outer
cylindrical surface 45. In this example, the channel 51 includes acircumferential groove 53 that extends radially inwardly from the outercylindrical surface 45. The channel 51 could also include other configurations. For example, theshot tube plunger 128 could include a single channel 51 or multiple channels 51. As theshot tube plunger 128 injects the molten metal during the die casting process, it is possible for a portion P of the molten metal to pass between aninner wall 25 of the shot tube and the outercylindrical surface 45 of theshot tube plunger 128. When this occurs, the portion P of the charge of material M is captured within the channel 51 thereby leaving theshot tube 24 free of solidified metal particles and avoiding gouging of theinner wall 25 that can occur as theshot tube plunger 128 is retracted. -
Figure 3 illustrates another example shottube plunger 228. Theshot tube plunger 228 includes adisposable piston head 40. Thedisposable piston head 40 is removably attached to theshot tube plunger 228 and can be disposed of subsequent to an injection of a charge of material during a die casting process. Thedisposable piston head 40 can be removed from theshaft 31 and disposed of either after a single injection or after multiple injections. Thedisposable piston head 40 is made from a material capable of withstanding contact with high melting temperature materials. For example, thedisposable piston head 40 could be made from steel, ceramic, or other refractory materials. - The
disposable piston head 40 defines a first height H1, and theshot tube plunger 228 defines a second height H2. In this example, the first height H1 of thedisposable piston head 40 and the second height H2 of theshot tube plunger 228 are generally equal. Therefore, theshot tube plunger 228 may be reciprocated between a retracted and injected position without creating interference with theinner wall 25 of theshot tube 24. -
Figures 4A-4F illustrate example features of thedisposable piston head 40. In these examples, thedisposable piston head 40 includes afirst face 42, asecond face 44 and an outercylindrical surface 46 disposed between thefirst face 42 and thesecond face 44. Thefirst face 42 faces a charge of material M (e.g., molten metal) within theshot tube 24, while thesecond face 44 faces the shot tube plunger 228 (shown in phantom). - The
first face 42 can include anengagement member 48. Theengagement member 48 provides a contact area for the charge of material M to bond to during injection. Once the injection is complete and the metal is solidified within thedie cavity 20, thedisposable piston head 40 remains attached to the cast component 15 (SeeFigure 4F ) via acast portion 17. Thedisposable piston head 40 can then be removed from thecomponent 15 and disposed of. - In one example, the
engagement member 48 includes a recess 50 (seeFigures 4A-4C ). Therecess 50 extends from thefirst face 42, which faces the charge of material M, in a direction toward thesecond face 44. Therecess 50 can include a variety of shapes and configurations, including truncated triangular configurations (Figures 4A and 4B ) and T-shaped configurations (Figure 4C ). Other shapes are contemplated as within the scope of this disclosure. Thefirst face 42 can include a single recess 50 (SeeFigure 4A ) or multiple recesses 50 (SeeFigure 4B ). -
Figures 4D-4F illustrate anotherexample engagement member 48 of thedisposable piston head 40. In this example, theengagement member 48 includes aprotrusion 52 that protrudes from thefirst face 42 in a direction away from thesecond face 44. Thedisposable piston head 40 can include a single protrusion 52 (SeeFigure 4D ), or multiple protrusions 52 (SeeFigure 4E ). Theprotrusions 52 may have an enlarged head to further secure bonding. -
Figures 5A-5C illustrate another feature of thedisposable piston head 40. Thedisposable piston head 40 includes anattachment member 54 for aligning and affixing thedisposable piston head 40 to theshot tube plunger 228. Theattachment member 54 is disposed on thesecond face 44 of thedisposable piston head 40, which faces in a direction toward theshot tube plunger 228. That is, theattachment member 54 is positioned on an opposite side of thedisposable piston head 40 from the charge of material M. - In one example, the
attachment member 54 includes a recess 56 (seeFigures 5A and 5C ). Therecess 55 can include multiple shapes and sizes, including but not limited to those depicted inFigure 5A and Figure 5C . Therecess 56 receives a correspondingprotrusion 60 of the shot tube plunger 228 (shown in phantom) to removably attach thedisposable piston head 40 to theshot tube plunger 228. - In another example, the
attachment member 54 includes aprotrusion 62 that extends from thesecond face 44 in a direction toward theshot tube plunger 228. Theprotrusion 62 is received within a correspondingrecess 64 of theshot tube plunger 228 to removably attach thedisposable piston head 40 to theshot tube plunger 228. -
Figures 6A-6E illustrate yet another feature of thedisposable piston head 40. Thedisposable piston head 40 can include achannel 58 circumferentially disposed about the outercylindrical surface 46 of thedisposable piston head 40. Thechannel 58 extends radially inward from the outercylindrical surface 46 of thedisposable piston head 40 to define acircumferential groove 66. - The
channel 58 can define any of a multitude of varying shapes and configurations, such as depicted inFigures 6A-6E . In addition, such as depicted inFigure 6D , the outercylindrical surface 46 of thedisposable piston head 40 can include a plurality ofchannels 58 defined thereon. As theshot tube plunger 228 injects the charge of material M during the die casting process, it is possible for a portion P of the charge of material M to pass between aninner wall 25 of theshot tube 24 and the outercylindrical surface 45 of theshot tube plunger 228. When this occurs, the portion P of the charge of material M is captured within thechannel 58 thereby leaving theshot tube 24 free of solidified metal particles and avoiding gouging of theinner wall 25 that can occur as theshot tube plunger 228 is retracted (SeeFigure 6A ). - As detailed above,
Figures 3-6 illustrate multiple features of thedisposable piston head 40. Thedisposable piston head 40 could include one or all of the features described herein. For example, thedisposable piston head 40 could include theengagement member 48, theattachment member 54 and thechannel 58, or any combination of these features.Figure 7 , for example, illustrates adisposable piston head 40 having each of theengagement member 48, theattachment member 54 and thechannel 58. - It should be understood that many of the features depicted in
Figures 1-7 of this disclosure are not illustrated to the scale they would be in practice. Indeed, many features are shown enlarged to better illustrate their design and function and should not be interpreted as limiting this disclosure in any way. - The foregoing description shall be interpreted as illustrative and not in any limiting sense. A worker of ordinary skill in the art would understand that certain modifications could come within the scope of this disclosure. For these reasons, the following claims should be studied to determine the true scope and content of this disclosure.
Claims (15)
- A die casting system (10), comprising:a shot tube plunger (128;228) having a first face (41), an opposing second face (43), and an outer surface (45) disposed between said first face (41) and said opposing second face (43), wherein a channel (51;58) circumferentially extends about said outer surface (45), said channel (51) operable to receive a portion of a charge of material (M) introduced into the die casting system (10).
- The system as recited in claim 1, wherein said channel (51) includes a circumferential groove (53) that extends radially inward from said outer surface (45).
- The system as recited in claim 1 or 2, wherein said first face (41) includes an engagement member (47).
- The system as recited in claim 3, wherein said engagement member (47) is a recess (55).
- The system as recited in claim 3, wherein said engagement member is a protrusion (57).
- The system as recited in any preceding claim, comprising a shaft (31), wherein said second face (43) includes an attachment member (49) that removably attaches said shot tube plunger (128) to said shaft (31).
- The system as recited in claim 6, wherein said attachment member (49) includes one of a recess (59) and a protrusion (63) and said shaft (31) includes the other of said recess (65) and said protrusion (61).
- The system as recited in any preceding claim, wherein said shot tube plunger (228) includes a disposable piston head (40) and said channel (58) extends circumferentially about said disposable piston head (40).
- The system as recited in claim 8, wherein said disposable piston head (40) includes:a first face (42) and an opposing second face (44), and said first face (42) includes an engagement member (48) that contacts a portion of said charge of material (M) and said opposing second face (44) includes an attachment member (54) that removably attaches said disposable piston head (40) to said shot tube plunger (228).
- A die casting system (10), comprising:a die (12) including a plurality of die components (14,16) that define a die cavity (20);a shot tube (24) in fluid communication with said die cavity (20);a shot tube plunger (228) moveable within said shot tube (24) to communicate a charge of material (M) into said die cavity (20); anda disposable piston head (40) removably attached to said shot tube plunger (228), wherein said disposable piston head (40) includes a first face (42)and an opposing second face (44), and said first face (42) includes an engagement member (48) that contacts a portion of said charge of material (M) and said opposing second face (44) includes an attachment member (54) that removably attaches said disposable piston head (40) to said shot tube plunger (228).
- The system as recited in claim 10, wherein said disposable piston head (40) includes an outer surface (46) having a channel (58) that circumferentially extends about said outer surface (46).
- The system as recited in claim 9, 10 or 11, wherein said engagement member (48) includes one of a recess (50) and a protrusion (52).
- The system as recited in any of claims 9 to 12, wherein said attachment member (54) includes one of a recess (56) and a protrusion (62) and said shot tube plunger (228) includes the other of said recess (64) and said protrusion (60) to removably attach said disposable piston head (40) to said shot tube plunger (228).
- A method of die casting a component with a die casting system (10), comprising the steps of:(a) removably attaching a disposable piston head (40) to a shot tube plunger (228) of the die casting system;(b) injecting a charge of material (M) through a shot tube (24) and into a die cavity (20) of the die casting system with the shot tube plunger (228) and attached disposable piston head (40); and(c) capturing a portion of the charge of material in a channel (51) that circumferentially extends about an outer surface of the disposable piston head (40) during the step of injecting the charge of material (M).
- The method as recited 14, comprising the steps of:(d) solidifying the charge of material (M) to form the component; and(e) removing the component from the die cavity (20) with the disposable piston head (40) still attached to the component; and, optionally, further comprising the steps of:(f) removing the disposable piston head (40) from the component; and(g) disposing of the disposable piston head (40); and/orwherein the disposable piston head (40) includes a first face (42) that faces the charge of material (M), the first face (42) including a recess (50), and wherein said step (c) includes capturing a portion of the charge of material (M) within the recess (50).
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US12/940,084 US20120111524A1 (en) | 2010-11-05 | 2010-11-05 | Shot tube plunger for a die casting system |
Publications (2)
Publication Number | Publication Date |
---|---|
EP2450124A2 true EP2450124A2 (en) | 2012-05-09 |
EP2450124A3 EP2450124A3 (en) | 2016-06-01 |
Family
ID=44905683
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP11187861.7A Withdrawn EP2450124A3 (en) | 2010-11-05 | 2011-11-04 | Shot tube plunger for a die casting system |
Country Status (3)
Country | Link |
---|---|
US (1) | US20120111524A1 (en) |
EP (1) | EP2450124A3 (en) |
SG (1) | SG180157A1 (en) |
Families Citing this family (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN103521704B (en) * | 2013-10-20 | 2015-06-03 | 吴小江 | Method for casting blade |
US10166601B2 (en) * | 2015-11-17 | 2019-01-01 | United Technologies Corporation | Die cast tip cover and method of managing radial deflection of die cast tip |
US10173261B2 (en) * | 2015-11-17 | 2019-01-08 | United Technologies Corporation | Highly cooled die casting plunger |
CN106513618A (en) * | 2016-09-29 | 2017-03-22 | 广西大学 | Precision casting method of metal parts suitable for blades |
US20220048106A1 (en) * | 2020-08-13 | 2022-02-17 | Qingyou Han | Ultrasound assisted shot chamber for die casting applications |
Family Cites Families (11)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3019495A (en) * | 1958-05-28 | 1962-02-06 | Litemetal Dicast Inc | Die casting |
US4154286A (en) * | 1977-12-27 | 1979-05-15 | Filippov Dmitry A | Installation for die-casting of metal blanks |
US4886107A (en) * | 1986-02-28 | 1989-12-12 | Zecman Kenneth P | Piston for cold chamber |
JP3330882B2 (en) * | 1998-10-23 | 2002-09-30 | 東芝機械株式会社 | Plunger chip mounting structure for die casting machine |
US6745819B2 (en) * | 2001-05-17 | 2004-06-08 | Tht Presses Inc. | Vertical die casting press and method of producing die cast metal parts |
ITMI20022698A1 (en) * | 2002-12-20 | 2004-06-21 | Cannon Spa | PROCESS AND EQUIPMENT FOR MOLDING FOR |
JP2004237295A (en) * | 2003-02-04 | 2004-08-26 | Hitachi Metals Ltd | Backflow preventive device for light alloy injection-molding machine |
JP2004268067A (en) * | 2003-03-06 | 2004-09-30 | Aisin Takaoka Ltd | Plunger tip for pressure casting |
ES2242119T3 (en) * | 2003-04-16 | 2005-11-01 | Concast Ag | TUBULAR LINGOTERA FOR CONTINUOUS COLADA. |
US7291006B2 (en) * | 2004-06-24 | 2007-11-06 | Husky Injection Molding Systems Ltd. | Check valve lip seal for an injection molding machine |
US20080017345A1 (en) * | 2006-07-20 | 2008-01-24 | Husky Injection Molding Systems Ltd. | Molding-system valve |
-
2010
- 2010-11-05 US US12/940,084 patent/US20120111524A1/en not_active Abandoned
-
2011
- 2011-11-04 SG SG2011081478A patent/SG180157A1/en unknown
- 2011-11-04 EP EP11187861.7A patent/EP2450124A3/en not_active Withdrawn
Non-Patent Citations (1)
Title |
---|
None |
Also Published As
Publication number | Publication date |
---|---|
SG180157A1 (en) | 2012-05-30 |
EP2450124A3 (en) | 2016-06-01 |
US20120111524A1 (en) | 2012-05-10 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
EP2450125B1 (en) | Die casting system machine configurations | |
EP2450124A2 (en) | Shot tube plunger for a die casting system | |
US9908175B2 (en) | Die casting system and method utilizing sacrificial core | |
US20190299278A1 (en) | Die casting system and method utilizing high melting temperature materials | |
US20160074933A1 (en) | Die casting of component having integral seal | |
EP2486994B1 (en) | Shot tube plunger for a die casting system | |
EP2551038B1 (en) | Die casting system and method | |
EP2450127B1 (en) | High temperature die casting apparatus and method therefor | |
EP2450131B1 (en) | Melting unit for a die casting system | |
US10569327B2 (en) | Method and system for die casting a hybrid component | |
EP3360624A1 (en) | Axisymmetic single crystal shot tube for high temperature die casting | |
US20130277004A1 (en) | Shot tube plunger tip portion | |
US20160311015A1 (en) | Die-casting system with enhanced adherence shot sleeve pour liner | |
US8784066B2 (en) | Die casting to produce a hybrid component | |
EP2060342A1 (en) | Liquid metal directional casting apparatus and process | |
US20160297000A1 (en) | Die-casting system with bonded ceramic shot tip | |
EP2969312B1 (en) | Shot tube for die-cast machine | |
RU2205089C1 (en) | Method for making pistons of internal combustion engines |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
PUAI | Public reference made under article 153(3) epc to a published international application that has entered the european phase |
Free format text: ORIGINAL CODE: 0009012 |
|
AK | Designated contracting states |
Kind code of ref document: A2 Designated state(s): AL AT BE BG CH CY CZ DE DK EE ES FI FR GB GR HR HU IE IS IT LI LT LU LV MC MK MT NL NO PL PT RO RS SE SI SK SM TR |
|
AX | Request for extension of the european patent |
Extension state: BA ME |
|
RIC1 | Information provided on ipc code assigned before grant |
Ipc: B22D 17/20 20060101AFI20151218BHEP |
|
PUAL | Search report despatched |
Free format text: ORIGINAL CODE: 0009013 |
|
AK | Designated contracting states |
Kind code of ref document: A3 Designated state(s): AL AT BE BG CH CY CZ DE DK EE ES FI FR GB GR HR HU IE IS IT LI LT LU LV MC MK MT NL NO PL PT RO RS SE SI SK SM TR |
|
AX | Request for extension of the european patent |
Extension state: BA ME |
|
RIC1 | Information provided on ipc code assigned before grant |
Ipc: B22D 17/20 20060101AFI20160427BHEP |
|
RAP1 | Party data changed (applicant data changed or rights of an application transferred) |
Owner name: UNITED TECHNOLOGIES CORPORATION |
|
STAA | Information on the status of an ep patent application or granted ep patent |
Free format text: STATUS: THE APPLICATION IS DEEMED TO BE WITHDRAWN |
|
18D | Application deemed to be withdrawn |
Effective date: 20161202 |