JP4580930B2 - Pressure casting flow system - Google Patents

Description

  The present invention relates to an improved alloy flow system for use in pressure casting of alloys.

In many recent patent applications, the Applicant has disclosed an invention relating to the pressure casting of alloys utilizing what is referred to as a controlled expansion port (CEP). These applications include PCT International Application AU98 / 00987 (Patent Document 1) regarding pressure casting of magnesium alloys and PCT International Application AU01 / 01058 (Patent Document 2) regarding pressure casting of aluminum alloys. These are also another PCT international application AU01 / 00595 (patent document 3) and PCT international application AU01 / 01290 (patent document 4), and an Australian provisional application each filed on August 23, 2001. PR7214, PR7215, PR7216, PR7217 and PR7218 are included. These other applications relate to the pressure casting process of magnesium, aluminum or other pressure castable alloys and the equipment used for the pressure casting of these alloys.
PCT International Application AU98 / 00987 PCT International Application AU01 / 01058 PCT International Application AU01 / 00595 PCT International Application AU01 / 01290

  As described above, CEP is used in the invention of the aforementioned patent application. The CEP is a relatively short portion of the alloy flow path, which increases in cross-sectional area from the inlet end to the outlet end of the CEP, so that the alloy flowing through the CEP exits with respect to the inlet end. The flow rate is substantially low at the edges. This decrease in flow rate is due to the state change of the alloy in the flow within the CEP. That is, when the molten alloy is received from the pressurized source to the inlet end of the CEP, the decrease from the flow rate obtained at the inlet end to the flow rate obtained at the outlet end indicates that the state of the alloy is different from the molten state at the inlet end. , By changing to a semi-solid or thixotropic state at the exit end.

  Most preferably, the alloy is kept in a semi-solid or thixotropic state in the flow from the outlet end and in substantially the entire flow in the communicating cavity of the flow path. When the alloy in the cavity and from the cavity back to the CEP or into the CEP is hardened sufficiently rapidly, the resulting casting is a micro having fine spherical or circular primary particles of modified dendrite shape in a secondary phase matrix. Can be characterized by structure.

  In our co-pending PCT international application AU03 / 00195, we disclosed a metal flow system for high pressure die casting and a method for producing alloy castings using a high pressure die casting machine. The system and method of that application utilizes a flow path that includes CEP and also includes a CEP outlet module, referred to as CEM, that passes the alloy from the outlet end of the CEP and flows it into the cavity. Within the CEP, the alloy changes from a molten state to a semi-solid state by sufficiently reducing the flow rate from the appropriate flow rate at the inlet end. The CEM is shaped to control the alloy flow so that the flow rate gradually decreases from the flow rate at the outlet end of the CEP. As a result, the alloy flow rate is significantly lower than the flow rate at the outlet end of the CEP at the location where the flow path communicates with the cavity, and the state change that occurs in the CEP is maintained substantially throughout the cavity, and the alloy is rapidly moved in the cavity. It is cured and returns along the flow path towards the CEP.

  Applicants have discovered that such forms of CEM can be effectively used for other applications. The use of this form of CEM is quite surprising since it is contrary to the conventional practice, system or equipment of high pressure die casting.

  As mentioned above, “CEM” means CEP exit module. This term is not appropriate in the present invention that does not use CEP. The present invention utilizes a flow path having an outlet module through which the alloy passes as it travels from the runner to the cavity. Although the outlet module of the present invention is in a form suitable for CEM, it is distinguished here as a flow-path exit module (FEM).

The present invention relates to a metal flow device for high pressure die casting of an alloy using a machine having or being operable to have a pressurized source of molten alloy and a mold defining at least one cavity. Defining a metal flow path that allows the alloy received from the pressure source to flow into the cavity;
(A) the first portion of the length of the flow path includes a runner;
(B) the second portion of the length of the flow path from the exit end of the runner includes a flow path exit module (FEM);
At the mass flow rate of the alloy that can be produced by the machine, the alloy flow rate at the outlet end of the runner is 60 m / s to 180 m / s for the magnesium alloy and 40 m / s to 120 m / s for the alloys other than the magnesium alloy. the runner has a cross-sectional area at least at the exit end of the runner, the FEM has a shape that increases the cross-sectional area in the direction of the alloy flow, thereby controlling the alloy flow, and the alloy flow rate is At locations where the flow rate is progressively reduced from the level at the exit end and the flow path communicates with the cavity, the alloy flow rate is less than the flow rate at the exit end of the runner, and when the cavity fill is complete, the alloy flows into the flow path within the cavity. Can be solidified along the runner, reducing the FEM cross-sectional area from changing the alloy from a molten state to a semi-solid state exhibiting thixotropic properties While also providing a device characterized by the alloy flow velocity was increased so as to reduce to less than 80% of the alloy flow velocity at the outlet end of the runner.

The present invention also provides a pressure casting machine for high pressure die casting of an alloy, wherein the machine includes a pressurized source of molten alloy, a mold defining at least one cavity, and an alloy received from the pressurized source in the cavity. Has or is operable to provide a metal flow device defining a metal flow path allowing flow into the
(A) the first portion of the length of the flow path includes or consists of a runner;
(B) the second portion of the length of the flow path from the exit end of the runner includes a flow path exit module (FEM);
At the mass flow rate of the alloy that the machine can produce, the alloy flow rate at the exit end of the runner is 60 m / s to 180 m / s for the magnesium alloy and 40 m / s to 120 m / s for the alloys other than the magnesium alloy. the FEM has a shape that increases the cross-sectional area in the direction of the alloy flow, thereby controlling the alloy flow, so that the alloy flow rate is At locations where the flow rate is progressively reduced from the level at the exit end and the flow path communicates with the cavity, the alloy flow rate is less than the flow rate at the exit end of the runner, and when the cavity fill is complete, the alloy flows into the flow path within the cavity. Can be solidified along the runner, and the FEM cross-sectional area is suppressed from changing the alloy from a molten state to a semi-solid state exhibiting thixotropic properties While also providing a device characterized by the alloy flow velocity was increased so as to reduce to less than 80% of the alloy flow velocity at the outlet end of the runner.

The present invention is also operable to have or provide a pressurized source of molten alloy and a mold defining at least one cavity along the flow path from the pressurized source toward the cavity. A method for producing an alloy casting using a flowing high-pressure die casting machine,
(A) In the first part of the channel length, the alloy flows along the runner;
(B) In the second part of the length of the flow path between the first part and the cavity, the alloy flow is controlled so that the flow rate is progressive from the level at the outlet end of the runner to the flow rate at the position communicating with the cavity. The flow velocity is less than the flow velocity at the exit end of the runner,
At the mass flow rate of the alloy that can be produced by the machine, the alloy flow rate at the outlet end of the runner is 60 m / s to 180 m / s for the magnesium alloy and 40 m / s to 120 m / s for the alloys other than the magnesium alloy. The runner has a cross-sectional area such that s is at least at the exit end of the runner, and the alloy flow in the FEM is controlled while suppressing the change of the alloy from a molten state to a semi-solid state exhibiting thixotropic properties. The method is characterized in that the above control is performed so that the alloy flow rate is less than 80% of the alloy flow rate at the outlet end.

  As described above, the second portion of the flow path reduces the alloy flow rate below the flow rate level at the exit end of the runner. In this specification, the second portion of the flow path is more simply referred to as a “flow-path exit module” or “FEM”.

  Preferably, the runner has a flow rate at the outlet end of the runner of about 60 m / s to 180 m / s for magnesium and about 40 m for alloys other than magnesium alloys at the flow rate of the alloy that the machine can produce. / S to 120 m / s at least at the exit end of the runner. In one embodiment, the FEM increases the cross-sectional area in the cross direction relative to the direction extending beyond the runner exit end, so reducing the flow rate can change the state of the alloy from a molten state to a semi-solid state exhibiting thixotropy. Can hinder. In other embodiments, the increase in cross-sectional area is an increase that prevents the alloy from changing state due to a decrease in flow rate and allows the cavity to be filled with molten alloy. A gate defined at the outlet end of the flow path can restrict the flow of alloy through it, but it is not necessary to provide such a restriction. In one form, the gate is at the exit end of the FEM. In another form, the exit end of the FEM is spaced from the gate by a second runner having a cross-sectional area at least equal to the cross-sectional area at the exit end of the FEM.

  According to the present invention, it is possible to achieve filling of the cavity using molten metal. That is, the alloy can remain in the molten state until it is received in the flow path in a molten state from a pressurized source and solidifies in the cavity. This differs from the earlier invention by the applicant based on the use of CEP, where the molten alloy changes to a semi-solid state that exhibits thixotropic properties. . In this respect, the present invention can be said to be similar to the conventional high pressure die casting method. However, the present invention is significantly different from conventional methods.

  In Applicants' early invention based on the use of CEP, the resulting semi-solid state alloy typically has a solids content that can exhibit thixotropic properties. From this, the alloy has greater than about 25% by weight solids, usually at least about 30% by weight, for example from about 60 to 65% by weight solids. Although the cavities can be filled with molten metal according to the present invention, the alloy entering the cavities may have a small solids content. However, the low solids content obtained by the present invention is insufficient for the alloy to exhibit thixotropic properties.

  In a cold chamber pressure die casting machine, dendrite primary particles form in the shot sleeve. These can reach a size of about 60 μm or more and can be disadvantageous for casting. When the present invention is utilized in a cold chamber machine, there remains a possibility that such particles form in the shot sleeve. When this occurs, the deformed particles contain or contribute to the solids content of the alloy flowing into the cavity.

  It has also been found that using the present invention, a small amount of solids may form as a result of the alloy flowing along the flow path. The weight percentage of these solids is insufficient for the alloy to exhibit the complete thixotropic nature. The solids content is less than about 25% by weight, for example, less than about 20 or 22% by weight, usually less than about 17% by weight. This also applies to the combination of solids obtained from dendritic primary particles formed in the shot sleeve and solids resulting from the alloy flowing along the flow path when using a cold chamber machine.

  Even when a solid is present in the alloy flowing into the cavity using the present invention, the solid has a very small particle size. This can be achieved by the microstructure of a sufficiently rapidly solidified casting made using the present invention. Thus, the casting can exhibit a microstructure with primary circular dendrite particles of 50 μm or less, indicating that the solid formed in the alloy flow along the flow path is generally less than or equal to its size.

  A solid with a small particle size indicates that the alloy is subjected to very strong shear forces in the flow along the flow path. These forces are caused by a significant decrease in flow rate from the runner flow rate as the alloy flows through the FEM. The strength of this force is apparent from the flow model measurement. This strong shear force is also shown in the main features of the microstructure that can be formed in castings made using the present invention.

  The first feature of the microstructure is the above-mentioned circular dendrite primary particles, and the fine particle size and uniform distribution of these particles. A second feature of the microstructure is that when using a cold chamber machine, there is substantially no large branched dendritic particles that can be formed in the shot sleeve. It can be seen that the shear force is strong enough to break such particles. A further feature is that there is virtually no pressure casting defects resulting from the pores when using both hot and cold chamber machines. There are no defects in the separated parts due to the entrained gas, and the microstructure of the castings made according to the invention is, for example, from entrained air in a very small, substantially uniformly distributed shape. Arise. The fine and uniform distribution of the gas is such that the adverse effects on the physical properties are substantially suppressed.

  When the alloy flow velocity decreases, the shape of the FEM must always increase the cross-sectional area in the direction of the alloy flow. The alloy flow can be a substantially constant mass flow rate. However, the increase in FEM cross-sectional area causes the alloy to progressively but substantially decrease in flow velocity from the runner exit end to the location where the alloy flows into the cavity. FEM achieves similar results as CEP when flow velocity reduction occurs. Despite this similarity, even if the flow rate of the alloy in the runner is similar to that required at the inlet end of the CEP to cause a change of state, the decrease in flow rate will cause the alloy to move from the molten state. It does not change to a semi-solid state that exhibits thixotropic properties. That is, the decrease in flow velocity in FEM is such that state changes are prevented at least to that extent.

  Since the FEM increases the cross-sectional area with respect to the flow direction, the flow device of the present invention is different from the flow systems used in conventional die casting. In the prior art, a substantially constant flow rate is usually maintained except for the position where the flow path communicates with the cavity. In the flow system used in the prior art, the flow rate increases abruptly so that the alloy flows into the cavity as a narrow high-speed jet by means of a restriction, called a gate, which is located in communication with the cavity. In the flow path according to the present invention, it is not necessary to provide a gate restriction, and the alloy can flow into the cavity with a relatively thick flow. In the metal flow device of the present invention, the flow path may have a cross-sectional area larger than that of the runner at a position where the flow path communicates with the cavity. In the prior art, the cross-sectional area of the gate is smaller than the cross-sectional area of the runner. However, although the flow path according to the present invention does not need to have a gate restriction, this is not essential and a restriction gate may be provided. In any case, the flow path of the present invention is different from that of the prior art regardless of whether or not a throttle gate is provided. The first portion of the flow path including the runner has a remarkably small cross-sectional area as compared with the conventional runner. Also, the second part of the flow path from the runner exit end to the FEM exit end has an increased cross-sectional area with respect to the flow direction, thereby reducing the required flow rate of the alloy flowing through the FEM. In these respects, although there are necessary and important differences, the flow path of the present invention is somewhat similar to that of PCT International Application AU03 / 00195.

  As will be described later, the flow rate of the runner of the present invention, which is higher than the flow rate of the runner used in conventional pressure die casting, is necessary for using the present invention. In a pressure casting machine capable of supplying an alloy at a constant mass flow rate, in order to obtain a higher flow rate at that mass flow rate, the runner required for the present invention always has a cross-sectional area compared to a conventional runner. Must be small. In this respect, the runner of the present invention is substantially the same as that required by the teachings of PCT International Application AU03 / 00195. However, in the flow path of the present invention, the alloy flow from the exit end of the runner flows directly into the FEM. In contrast, in the configuration of PCT International Application AU03 / 00195, the alloy flow flows directly into the CEP from the runner exit end and directly or indirectly into the FEM from the CEP exit end. Furthermore, in the present invention, in order to prevent the development of thixotropy, the degree to which the alloy changes to a semi-solid state is limited. In contrast, in the configuration of PCT International Application AU03 / 00195, FEM facilitates the maintenance of a semi-solid alloy produced in CEP and having thixotropic properties.

  The outlet end of the FEM is provided at a position where the flow path communicates with the cavity. While this is preferred, the exit end of the FEM may be spaced from its location by a secondary runner that does not significantly limit alloy flow. Thus, the cross-sectional area of the secondary runner can be made substantially equal to the cross-sectional area of the outlet end of the FEM. The secondary runner in the system of the present invention has a larger cross-sectional area than the runner of the first portion of the flow path, which is the reverse of the relationship between the secondary and main runners in conventional pressure casting.

  The FEM of the device of the present invention can take various shapes. In the first configuration, the FEM defines or includes a channel that is substantially wider than the depth and has a cross-sectional area that is greater than the area of the runner outlet that can receive the molten alloy. In the first configuration, the width of the channel can be at least one order of magnitude greater than its depth and is preferably arranged in a plane extending in the direction intersecting the runner. The channel is intended to radially expand the alloy flowing into it from the runner, thereby reducing the flow rate. The cross-sectional area of the channel increases in the direction of the alloy flow, thereby further reducing the alloy flow rate.

  In the first shape, the channel can be substantially flat or, if appropriate for the cavity for a given casting, the channel can be curved across its width. Alternatively, however, the channel may be a sawtooth or wavy structure that defines peaks and valleys across its width, somewhat in the form of a cooling vent. The channel can be increased in cross-sectional area by making one of the channel width and depth constant along its length and increasing the other progressively, preferably uniformly. However, if desired, each of the width and depth can be increased in the direction of the alloy flow. When using a sawtooth or wavy shape, this shape has the advantage of maximizing the flow length for a given spacing between the runner outlet end and the location where the flow path communicates with the cavity, but generally only increases the width. So convenient.

  In the first configuration, the FEM defines a channel having a width that is substantially greater than its depth, but the configuration generally includes the alloy flow path through the opening having a width that is substantially greater than the depth and the cavity. It communicates. This may be suitable for filling cavities by indirect or edge feeding, especially when the cavities are for producing thin castings.

  In the second configuration, the FEM of the device according to the invention defines or includes a channel having a width and depth of the same order of dimensions and having a gradually increasing cross section in the direction of the alloy flow. This shape also provides the low flow rate required at the location where the flow path communicates with the cavity in that it has an increasing cross section.

  Depending on the shape of the cavity in communication with the cavity, the second shaped channel of the FEM can open at the end away from the runner that can receive the molten alloy, with the open end defining its position. Define. However, it is preferred that the location be defined by an elongated opening extending along the side of the channel. In this preferred configuration, the channel can extend substantially linearly from the runner along the side of the cavity, with the elongated opening along the side of the channel adjacent to the edge of the cavity. Preferably, however, the channel is curved to facilitate the proper length of the channel to provide the end of the channel away from the runner extending along the side edges of the cavity. Particularly in such curved channels, the flow path can be branched beyond the runner in the direction of the alloy flow to provide at least two channels with ends having elongated openings as described above. In a bifurcated configuration, the opening in each channel can communicate with the cavity at the common edge of the cavity or at each edge. If two curved channels communicate with the cavity at a common edge, the ends of each channel away from the runner terminate at a short distance from each other, so that their side openings extend longitudinally along the common edge of the cavity. Will be spaced in the direction. However, in an alternative configuration, the two channels can merge at their ends, thereby forming the respective arms of a closed loop, in which case the openings can be separated again or they can be A single elongated opening common to each arm can be formed.

  The gradual decrease in alloy flow rate in the FEM of the metal flow system of the present invention and the gradual increase in the cross-sectional area of the second part that causes this decrease can be continuous. Also, the gradual decrease in speed and the increase in area can be substantially uniform, or it can be stepped along at least one section of the second portion. The first and second forms of FEM described above are well suited to provide a continuous decrease in velocity caused by a continuous increase in cross-sectional area, for example along at least the majority of the length of the second portion.

  In a third configuration that provides a gradual decrease in flow rate, the FEM includes a chamber into which the alloy received from the runner flows, wherein the chamber achieves a gradual decrease in alloy flow rate. In a third configuration, the FEM includes channel means having a shape that communicates between the chamber and the cavity and at least substantially maintains the flow rate level obtained within the chamber. The communicating channel means may be of a shape similar to that of the first shape of the FEM described above, and it may have a substantially uniform or slightly increasing cross section. Alternatively, the channel means can have at least one channel, preferably at least two channels, said channel, if desired, said one channel or each channel having a substantially uniform cross-sectional area. Except for this, it is similar to the second shape of the FEM described above.

  The third shaped chamber can have a variety of suitable shapes. In a preferred configuration, it can have the shape of an annular disc. The configuration is suitable for use when the means for communicating is at least one channel. If the means communicating in the arrangement includes at least two channels, the channels can communicate with one common cavity or with each cavity.

  At least one channel of the FEM third shape communication means may open into the cavity at the end opening of the channel or at the elongated side opening in the description of the second shape.

  In each form of the invention, the FEM is most preferably placed parallel to the separation plane of the mold that defines the cavity. The first part of the flow path can be placed in the same way so that its runner is also parallel to the separation plane, with the alloy received from the sprue or runner part passing through one mold part towards the separation plane. Extend. Alternatively, the first part of the flow path can pass through such a mold part, where the runner outlet is located at or close to the separation plane.

  The flow rates for the use of CEP in achieving a change from a molten state to a thixotropic semi-solid alloy are detailed in the aforementioned patent application. However, for magnesium alloys, the CEP inlet end flow rate is generally greater than about 60 m / s, and preferably about 140 to 165 m / s. For aluminum alloys, the inlet end flow velocity is typically greater than 40 m / s, for example about 80 to 120 m / s. For other metals such as zinc, copper alloys, etc. that can be converted to a semi-solid state with thixotropy, the CEP inlet end flow velocity is generally similar to that for aluminum alloys, but depending on the characteristics unique to the individual alloy Can be changed. The reduction in flow rate to be obtained during CEP is generally such that a flow rate at the CEP outlet end that is about 50-80%, for example 65-75%, of the inlet end flow rate is obtained.

  With the FEM according to the present invention, CEP is not used. Also, the alloy can remain molten in the flow to the cavity, but the alloy does not change to a level that exhibits thixotropic properties, even if some solids are formed. Nevertheless, the runner flow rate is similar to that required when using CEP, at least at the exit end of the runner. Thus, for magnesium, the flow velocity at the exit end of the runner or the entrance end of the FEM will be about 60 m / s or more, preferably about 130 m / s to 160 m / s, although it may reach about 180 m / s. is there. For aluminum alloys and other alloys such as zinc and copper alloys, the flow velocity at the runner outlet end or FEM inlet end is the same as when using the CEP described above.

  The reduction in flow rate achieved by FEM is usually very large. In fact, the reduction may exceed that with CEP. Thus, the decrease in flow rate at the CEP is a 50 to 80%, for example 65 to 75% decrease from the flow rate at the inlet end of the CEP, but a much larger decrease is possible with the FEM. Due to practical requirements, FEM with an effective flow length as short as possible is preferred. The length of the FEM varies depending on the average cross-sectional area and is 15 to 35 mm. Also preferably, the FEM has an overall length that is less than the effective flow length by having a wavy, bent or serrated structure that increases back pressure in the flow system.

  As with CEP, the length of the FEM depends on the cross-sectional area at the exit end of the runner that receives the alloy flow. CEP causes the alloy to change state from a molten state to a semi-solid state exhibiting thixotropy, but FEM is expected to have a shorter length than CEP for the required cross-sectional area at the runner exit end. Long flow lengths cause the cross-sectional area to increase more gently from the runner inlet end in the FEM, but longer lengths provide conditions for no state change or state change in the range required for CEP. May be necessary. But it turns out that it is not. Rather, it has been found that for the required cross-sectional area at the exit end of the runner, the FEM needs to be shorter than that required for a CEP with such a runner.

  The above description of the invention relates to a cavity or a specific cavity. However, it will be appreciated that the present invention is applicable to multi-cavity molds. In such a case, the FEM defined by the system of the present invention can be split or extended to provide a separate flow to a common cavity or each of at least two cavities. Indeed, as shown, providing such a separate flow from a common FEM generally facilitates obtaining the necessary reduction in alloy flow rate.

  In order that the present invention may be more reliably understood, the following description is made with reference to the accompanying drawings.

  With reference to FIGS. 1 and 2, there are shown two cavities 10 and 11 defined by a fixed mold half 12 and a movable mold half 13, each of which is a high pressure casting machine (not shown). Used to make each casting within. Each cavity 10, 11 is arranged to receive an alloy from a pressurized source of molten alloy in the machine, where the alloy is placed in each cavity by a common alloy feeder 14 according to a first embodiment of the invention. move on. This embodiment follows the first shape of the present invention described above.

  The alloy feeder 14 defines a flow path for the molten alloy having a first portion defined by the nozzle 16 shown in more detail in FIG. 2 and a second portion 18 referred to as FEM as described above, This flow path extends between the cavities and across the outlet end of the nozzle 16.

  In general shape and detail, the nozzle 16 includes an elongate annular housing 20 by which the first portion of the metal flow path defines a runner 22 bore. The housing 20 has its outlet end properly received within the insert 26 of the fixed mold half 12 while its inlet end abuts against the fixture 28 of the platen 29. Around the housing 20 are layers of an electrical resistance coil 30, an outer coil 30, and an insulator 32. An insulating gap 34 is also provided between the insulator 32 and the insert 26 except for a short distance at the outlet end of the housing 20 where the housing 20 is in metal-to-metal contact with the insert 26. . Further, the gap 34 extends between the insulator 32 and the fixture 28. Coil 30 and insulator 32 are provided to control the thermal energy level of housing 20 and the temperature of the alloy flowing through runner 22.

  In the nozzle 16 configuration, the runner 22 has a constant cross-sectional area throughout its length, except for a short distance at its outlet end that tapers toward the cross-section of the outlet end 22a of the runner 22. . The bore of the housing 20 extends from the exit end 22a of the runner 22 to a very short end portion 35. This can provide a transition of the metal flow path to the FEM 18 and, like the FEM 18, serves to reduce the flow rate of the alloy compared to the level at the end 22a of the runner 22. Alternatively, the divergent end 35 can cooperate with a spreader cone as described with reference to FIGS. In this case, the divergent end 35 can further reduce the alloy flow rate considerably.

  The alloy flow path FEM 18 is defined by a shallow rectangular channel 36 having a bore in the housing 20 open in the center. The channel 36 is defined by the mold halves 12 and 13 and has a width and length dimension parallel to the separation plane PP between the mold halves 12 and 13. Thus, the channel 36 is perpendicular to the nozzle 16.

  The channel 36 provides alloy flow to each of the cavities 10 and 11, where the alloy flow rate is reduced from the level at the exit end 22 a of the runner 22. This is accomplished by an alloy that extends radially outward from the end 22a in the channel 36, as shown by the dashed circle shown in FIG. Thus, the molten alloy travels in the channel 36 through an expanding front that is tangential to the radial direction from the end 22a. The expanding flow of the alloy is limited when it reaches the opposite side of the channel 36, but is divided to continue to flow at a reduced flow rate to each of the open ends 36a and 36b of the channel 36, which channel 36 causes the cavity 36 to 10 and 11 communicate with each other. In the portion of the channel 36 that leads to the cavity 10, the opposing sides of the channel 36 are substantially parallel so that a reduced flow rate favorable to the cavity 10 is obtained at a short distance in front of the open end 36a. However, at the portion of the channel 36 that leads to the cavity 11, the opposite sides spread out in the direction of flow, so that the flow rate continues to decrease at the open end 36b to obtain a preferred reduced flow rate for the cavity 11 different from that described above. It is possible to be. The alloy flow continues to fill each cavity 10,11. The overall alloy flow within each cavity 10, 11 can be at a sufficiently low flow rate below the flow rate at the end 22a of the runner 22, and its back pressure against the alloy flow can be maintained at a suitable level.

  The mold halves 12, 13 are configured so that the exit of the runner 22 in each cavity 10, 11 and along the channel 36 by extraction of thermal energy from the alloy in each cavity 10, 11 when cavity filling is complete. The structure is such that the alloy up to the end 22a is rapidly solidified. This is facilitated because the channel 36 has a thin cross section. Further, the heat energy extraction is mainly performed by the mold half 12 and the insert 26 thereof, and thus the metal-to-metal contact between the housing 20 and the insert 26 around the end 22a despite the heating by the coil 30. Thus, the cooling can proceed into the end 22a.

  3 and 4 show a second embodiment of an apparatus for producing castings, in this case using a single cavity mold of a high-pressure casting machine. This second embodiment also follows the first shape of the present invention as described above, but utilizes a sawtooth channel shape rather than a flat channel as in FIGS. Parts corresponding to those in FIGS. 1 and 2 are given the same reference numerals plus 100. However, although the mold half is not shown, only a portion of the housing 120 of the nozzle 116 is shown.

  3 and 4, the end of the channel 136 of the FEM 118 has a circular flat portion 40 with which the runner 122 communicates. Further, as described above, the channel 136 has a portion 42 between the portion 40 and the cavity 110, and the portion 42 has a sawtooth shape that defines a peak 42 a and a valley 42 b, and flows through the portion 42. It extends transverse to the direction of alloy flow.

  Although the movable mold half is not shown, the spreader cone 46 of the half is shown. When the mold halves are clamped together, the cone 46 is received over the outlet end 122a of the runner 122 and into the divergent end 135 of the bore of the nozzle housing 120. Thus, the alloy flowing from the runner 122 spreads in a frustoconical shape before entering the channel 136. Depending on the cone angle between the portion 135 and the core 46, the flow rate of the alloy entering the channel 136 is typically substantially unchanged, but can be the same or slightly different from the flow rate obtained at the outlet end 122a of the CEP 122.

  Within the channel 136, the molten alloy received from the runner 122 first spreads radially, thereby reducing the flow rate. As the flow rate flows through the portion 42 of the channel 136, the flow rate decreases further toward the open end 136a due to the opposing sides of the channel 136 diverging toward the end 136a. Thus, the alloy that flows into and fills the cavity 110 can be maintained by a suitable back pressure. The sawtooth structure (with one or more teeth) of the portion 42 of the channel 136 increases the back pressure to the required level. Apart from the detailed differences, the overall performance of the configurations of FIGS. 3 and 4 is substantially the same as that described in FIGS.

  FIG. 5 shows a first variant of the embodiment of FIGS. The modification of FIG. 5 is generally the same as the shape of FIGS. 3 and 4 except that the outlet end 122a of the runner 122 is in direct communication with the channel 136. That is, there is no divergent portion of the bore in the housing 120 and therefore a spreader cone is not necessary.

  The partial view of FIG. 6 (cavity not shown) shows a second variant of the embodiment of FIGS. 6 has the same overall shape as FIGS. 3 and 4 except that the portion 42 of the channel 136 of the FEM 118 is not a sawtooth, but is wavy or bent. However, an appropriate back pressure can be obtained by the structure shown in FIG.

  The third embodiment of FIGS. 7 and 8 also follows the first shape of the invention described above. 7 and 8, parts corresponding to those in FIGS. 1 and 2 are given the same reference numerals plus 200, respectively.

  Similar to the embodiment of FIGS. 3 and 4, the third embodiment of FIGS. 7 and 8 is for making castings using a single cavity mold. However, in this case, the channel 236 of the FEM 118 does not include a portion having a sawtooth profile. Rather, channel 236 has a flat top and bottom major surface. Also, these surfaces are slightly recessed in the direction of the alloy flow toward the outlet end 236a and the cavity 210, and the opposing sides of the channel 236 are diverging in that direction. With this configuration, the channel 236 increases in cross-sectional area in the flow direction toward the elongated thin open end 236a so that the alloy flow rate is significantly lower than the flow rate at the exit end 222a of the runner 222 and at an appropriate level at the end 236a. It gradually decreases until.

  In the embodiment of FIGS. 7 and 8, the runner 222 extends parallel to the separation plane PP between the mold halves 212, 213 and communicates with the end of the channel 236 spaced from the cavity 210. The runner 222 is aligned with the channel 236 of the FEM 218 and the centerline of the cavity 210 and is defined by the halves 212, 213 rather than the nozzles. The supply of alloy to the inlet end of the runner 222 can be through a main runner or nozzle bore, such a main runner or nozzle bore being at a right angle to the plane P-P, the stationary mold half 212. Extending through.

  Within channel 236 is an arcuate wall 50 that extends between the top and bottom major surfaces of channel 236. The wall 50 defines a recess 52 that opens toward the exit end 222a of the runner 222 so that any solid slug etc. that is carried into the chamber 236 with the alloy from the previous casting cycle can be captured and retained. .

  Operation in the embodiment of FIGS. 7 and 9 will be generally understood from the description with respect to FIGS. 1 and 2 and FIGS.

  The fourth embodiment of FIGS. 9 and 10 is similar in many respects to the first embodiment of FIGS. 9 and 10 are also in accordance with the first form of the invention described above, and each corresponding to the portion of FIGS. 1 and 2 has a corresponding reference numeral plus 300.

  In the embodiment of FIGS. 9 and 10, the configuration is for producing a casting using a high pressure casting machine. The machine has a mold that defines two cavities 310, 311 between its mold halves 312, 313. The half also defines an elongated channel 336 extending between cavities 310, 311 parallel to the separation plane PP. Channel 336 forms a molten alloy flow path FEM 318, the first portion of which is provided by runner 322. A runner 322 is defined by a housing 320 of the nozzle that is mounted within the stationary mold half 312 at a right angle to the plane PP. The runner 322 communicates with the channel 336 in the middle between the cavities 310, 311 and is split so that the alloy flows and flows in opposite directions toward the cavities 310, 311.

  From the outlet end 322 a of the runner 322, the alloy extends into the bore end 335 of the housing 320 and then enters the central region 54 of the channel 336. In region 54, the depth of channel 336 increases and in region 54, a circular recess is provided that can help stabilize the alloy flow. From region 54, the alloy is split to flow in opposing directions toward each open end 336 a, 336 b of channel 336 and then into the respective cavities 310, 311.

  The alloy received into the runner 322 from the machine's pressurized source reduces the flow rate in the FEM 318. The alloy flow path is such that the flow velocity decreases from the value of the exit end 322a of the runner 322 at the end 335 and then further decreases to the respective open ends 336a, 336b of the channel 336. This further flow velocity reduction occurs as the alloy spreads in region 54 from the outlet end of housing 320 to the opposite side of channel 336 in the radial direction. The alloy then flows along the channel 336 to the opposite ends 336a, 336b, where the opposite sides are slightly diverging from the region 54 to both ends 336a, 336b, reducing the flow rate. Keep doing. Finally, the channel 336 is inclined at an angle with respect to the end of each cavity 310, 311 with which the open ends 336a, 336b communicate, so that the ends 336a, 336b are relative to the longitudinal direction of the channel 336. Having an area larger than the perpendicular cross section, the alloy flow rate at the ends 336a, 336b can subsequently be reduced.

  With this configuration, the alloy passing through the open ends 336a, 336b has a flow rate substantially lower than the flow rate at the exit end 322a of the runner 322. This substantially low flow rate facilitates maintaining sufficient back pressure of the alloy during filling of cavities 310, 311. This configuration also facilitates rapid solidification of the alloy in the cavities 310, 311 when filling is complete, and the solidification rapidly proceeds from the cavities 310, 311 along the channel 336 to the exit end 322 a of the runner 322. be able to.

  In one embodiment according to FIG. 9, the coupling area of the open ends 336a, 336b of the channel 336 is approximately 45% greater than the area of the exit end 322a of the runner 322, thereby causing a corresponding decrease in the flow velocity at the ends 336a, 336b. From this point, each open end 336a, 336b has an area smaller than the area of runner end 322a, and each open end 336a, 336b substantially halves the total alloy flow (of ends 36a, 36b in the arrangements of FIGS. 1 and 2). As in the case).

  In this example, the open ends 336a, 336b can have a width of 30 mm and a depth of 0.9 mm. This configuration is appropriate for a cavity 310 having a 2 mm depth dimension perpendicular to the plane PP and a cavity 311 having a corresponding dimension of 1 mm. In each cavity, the alloy can flow in front to fill the cavity, and the alloy spreads away from the respective open ends 336a, 336b. Thus, the alloy flow rate can be further reduced within each cavity 310, 311 to maintain sufficient back pressure.

  In the configuration of FIGS. 9 and 10, the slope of the open ends 336a, 336b is such that the alloy is oriented in the direction across the cavities of the respective cavities 310, 311 and this proves advantageous. ing. This slope has been found to increase the back pressure against the alloy flow. Adjacent to the end 336b, the channel 336 is provided with a short portion 336c, which is inclined with respect to the plane P-P, which also helps maintain a suitable back pressure. It becomes.

  11 and 12 show a fifth embodiment of the present invention according to the second shape of the present invention described above. 11 and 12, the illustrated alloy flow device has an alloy flow path that extends to the cavity 62 parallel to the separation plane PP between the stationary mold half 60 and the movable mold half 61. The flow path includes a runner 63 that defines a first portion of the flow path. The second part of the flow path includes an FEM in the form of a channel 66, which has opposing C-arms 67, 68. Only a part of the arm 67 is shown, and the shape of the arm 67 is the same as that of the arm 68, but is opposite.

  Each arm 67, 68 of the FEM channel 66 has a respective first portion 67a, 68a that extends laterally outward from the enlarged portion 69 at the outlet end 63a of the runner 63. From the outer end of the portion 68a, the arm 68 has a second portion 68b, which extends in the same direction as the runner 63, but away from it. Beyond the portion 68 b, the arm 68 has a third portion 68 c that extends inwardly toward the extension of the runner 63. Although not shown, the arm 67 also has respective second and third portions beyond the portion 67 a, which correspond to the portions 68 b and 68 c of the arm 68. Each arm 67, 68 communicates with the cavity 62 within a U-shaped recess 72 at one end of the cavity 62.

  The runner 63 and the FEM channel 66 are symmetrical trapezoidal in cross section as shown for the portion 67a of the arm 67 in FIG. The runner 63 has a uniform cross-sectional area over most of its length, but tapers to the area of the outlet end 63a of the runner 63 at a location adjacent to its outer end. From the enlarged portion 69 of the flow path, each arm 67, 68 of the channel 66 increases in cross-sectional area from the maximum portion adjacent to the remote end thereof.

  The embodiment is based on FIGS. 11 and 12 and is suitable for producing magnesium alloy castings in a hot chamber pressure die casting machine with a single cavity mold, and the molten magnesium from the machine source. The alloy is pressure-supplied to the inlet end of the runner 63 at a flow rate of 50 m / sec. In the taper part to the exit end 63a of the runner 63, the flow rate of the molten alloy was increased to obtain 112.5 m / s. From the enlarged portion 69, the alloy was evenly divided to flow along each arm. For positions A through E shown for arm 68, the alloy flow rates were increased to 90 m / s in A, 80 m / s in B, 70 m / s in C, 60 m / s in D, and 50 m / s in E, respectively.

  Each arm had an elongated opening through which the arm communicated with the cavity 62. With respect to positions C, D, E and the end of arm 68, the opening for arm 68 (and also for arm 67) is 0.5 mm from C to D, 0.6 mm from D to E, And from E to the end can have an average width of 0.8 mm. The total length of each opening was 35.85 mm, and the overall flow velocity through it decreased from 70 m / s at C to less than 50 m / s at the end of each arm beyond E.

  FIG. 13 shows a modification of the configuration of FIGS. 11 and 12, and corresponding parts are given the same reference numerals plus 100. FIG. 13 shows a main runner 70 that supplies the alloy to the runner 163. In this case, the arms 167, 168 of the FEM channel 166 are each in communication with the cavity along the straight end of the cavity. With this configuration, the flow rate of the molten alloy can be set to 150 m / sec at the outlet end 163a of the runner 163 for use in the magnesium alloy. Within each arm of channel 166, the flow velocity is reduced to 95 m / sec at A, 85 m / sec at B, 75 m / sec at C, and 65 m / sec at the ends of each arm 167,168. The opening from each arm to the cavity is from immediately before each position D to the end of each arm. The operation according to this configuration is as described with reference to FIGS.

14 and 15 show more detailed details regarding the runner 163 and channel FEM 166 of the variation of FIG. In this regard, as detailed with reference to FIG. 13, suitable cross-sectional areas and flow rates for magnesium alloys are as follows:
Position Area (mm ² )
163a 8.5
A 6.0
B 6.8
C 8.0
D 9.6

  As is apparent, the area shown for positions A to D is for one arm of FEM channel 166. In this regard, however, it is necessary to take into account that the area of the exit end 163a of the runner 163 is for only half of the alloy flowing through the runner.

  FIG. 16 shows a portion of a flow device of another embodiment of the present invention as viewed from a direction perpendicular to the separation plane. 17 and 18 show alternative examples of the configuration of FIG.

  In FIGS. 16-18, the runner through which the molten alloy flows is only shown at the end 80 defining the outlet end 80a. However, runner 80 constitutes the first part of the flow system flow path, while channel 82, chamber 84 and channel 86 constitute the second part or FEM of the flow system. Molten alloy flows from runner 80 to channel 82 and into chamber 84, and then the alloy flows through each channel 86 into a single or respective cavity (not shown). The channel 82 has a larger cross-sectional area than the exit end of the runner 80, which can be constant or can be increased to the chamber 84. In either case, an alloy flow rate lower than the flow rate at the outlet end of the runner 80 is obtained. Within the chamber 84, the alloy flow can spread and the flow rate is further reduced. From the chamber 84, the alloy flow is split to extend along each channel 86, and, like the channel 82, each channel 86 further reduces the alloy flow rate in or along it. When the alloy flow is split, the channel 86 can have a smaller cross-sectional area than the channel 82, although the flow velocity is still reduced.

  Chamber 84 can be thinner than channel 82 and channel 86 as shown in FIG. 17, or thicker as shown in FIG. As an alternative, it can be as thick as the channel.

  The operation using the configuration of FIGS. 16 to 18 will be generally understood from the above description of the embodiment.

  FIG. 19 shows a casting 90 that can be manufactured using another embodiment of the present invention. The casting includes a pair of side-by-side tension bars 91 joined together at adjacent ends by a metal tether 92, the tether being a metal between each cavity in which the tension bar 91 was cast. It is solidified in a channel provided to flow. The casting 90 is shown immediately after casting, so it includes a metal 93 that has hardened along a portion of the metal flow path that supplied the alloy to the cavity. The metal 93 includes a metal section 94 hardened in the FEM and a metal section 95 hardened in the runner of the metal flow path.

  To obtain the tension bar 91, the casting 90 is cut along the joint between each end of the tie 92 and the respective side surface of each bar 91, and the metal 93 is the side surface of the tension bar 91 to which it is attached. Disconnected from. The shape of the cut metal 93 is shown in more detail in FIGS. Of course, the metal 93 has the same shape as the corresponding section 96 of the metal flow device of the present invention. Further description of metal 93 in FIGS. 20 and 21 is made with reference to metal 93 as if depicting a corresponding section 96. The metal sections 94 and 95 are thus viewed as representing the corresponding metal flow system FEM 97 and runner 98, respectively. The shaded portions represent the respective mold halves 101 and 102 that are separable on the separation line PP and that define the cavity and the metal flow system.

  As can be seen from FIGS. 20 and 21, the FEM 97 is generally square and the runners 98 are aligned in the longitudinal direction. The exit end 98a of the runner 98 communicates with the FEM 97 at the center of one end of the FEM. Thus, the molten alloy flows from runner 98 along runner 98, and the alloy flows through FEM 97 toward the end away from runner 98a. However, towards its remote end, the FEM 97 opens laterally to the short secondary runner 100, through which the alloy enters the first of the continuous cavities in which the pull bar 91 is cast. can go.

  Along the first portion of the length from runner outlet 98a, FEM 97 is shaped to create resistance throughout the alloy flow. This is accomplished by staggered ribs 101a and 101b that extend transverse to the alloy flow through the FEM 97 and are limited by respective mold portions that protrude into the generally square shape of the FEM. The width of the FEM 97 and the minimum distance A between successive ribs are calculated so as to obtain the flow rate required for a given alloy. Thus, for example, molten magnesium alloy reduces the flow rate from 150 m / s at the runner 98 inlet 98a in the FEM flow.

  In the illustrated embodiment, preferably the flow rate of the molten alloy in the runner is very fast, as detailed above. Thus, in the case of a magnesium alloy, the flow velocity in the runner and at the inlet end of the FEM is, for example, 60 m / s or more, for example up to about 180 m / s, preferably from about 130 m / s to 160 m / s. In the case of other alloys such as aluminum, zinc and copper alloys, the flow rate is for example 40 m / s or more, for example up to about 160 m / s, preferably about 80 m / s to 120 m / s. As a result, since the pressurized source of molten alloy can generate a predetermined mass flow rate, the runner used in the present invention is correspondingly more suitable than the runner for adapting to the very low runner flow velocity in the conventional pressure die casting. Has a small cross-sectional area. This facilitates the return of the molten alloy along the runner from the solid-liquid boundary when one casting cycle is complete. This boundary is close to the exit end of the runner. Further, since the amount of the alloy in the runner is reduced, the temperature control of the molten alloy in the runner becomes easy.

  More preferred alloy flow rates in the runner are within the above range, but will vary depending on the shape of the FEM used and the shape and size of the casting being produced. The shape of the FEM, particularly the length of its effective flow path, varies with the decrease in flow rate made in the FEM. The decrease in the flow rate made in the FEM is usually a decrease of 20% or more from the flow rate in the runner, but is preferably 30% or more, and sometimes 50% or more. It is usually essential to use a high runner flow rate to reduce the flow rate more significantly. In any case, the flow rate reduction must be sufficiently gradual to at least avoid the transition of the alloy from a molten state to a thixotropic semi-solid state, at least in the flow to the inlet end of the cavity.

  As detailed herein, the FEM reduces the flow rate by increasing the cross-sectional area of the flow path from the area of the runner outlet end. This decrease in the flow velocity is a decrease to the extent performed by the conventional die casting method. Therefore, the increase in the cross-sectional area of the FEM is such that the area at the outlet end of the FEM is the same as the cross-sectional area of the conventional runner. Despite this, the volume of the FEM is substantially smaller than the volume of the corresponding length portion of a conventional runner. Along with the substantially small runner cross-sectional area required by the present invention, this allows the volume of metal that hardens in the flow system at the end of a single casting cycle and the metal to be removed from the casting and reused. Is substantially less than the sprue and runner metal regenerated in the conventional method. Thus, less shot weight is required for each cycle during the manufacture of the casting, which has other advantages such as lower recycling costs, faster cycle times, reduced injection area and, in some cases, lower temperature molds can be used. to be born. However, it is important to note that in addition to these advantages, the present invention provides good results even when the casting does not have a low inherent level of porosity due to the semi-solid filling achieved with CEP. The casting is able to be manufactured.

  Each metal flow device of the embodiment of FIGS. 1-21 will vary depending on the machine to be used. Thus, the device must be operable in the required manner at an alloy mass flow rate that the machine can operate. Thus, the runner in the first part of the flow path of the device has a cross-sectional area that produces the required alloy flow rate at the mass flow rate described above. The runner need not have its cross-sectional area over its entire length, for example, it can have its cross-sectional area only at the exit end of the runner. Thus, the runner can be stepped down from a large cross-sectional area at the outlet end so that the required flow rate is obtained at the outlet end. Furthermore, the FEM has a constant length and increases the cross-sectional area along the length in the flow direction. Therefore, the shear force generated in the alloy does not change the state of the alloy to a semi-solid state having thixotropic properties. If shear produces solids in the alloy, this should be less than 25%, preferably about 20% to 22%, for example less than 17% by weight. However, even in this case, it is known that the above-described excellent microstructure can be obtained, so that it does not necessarily mean that a solid should not be generated. That is, the strong shearing force is in a completely molten alloy state so that a microstructure can be obtained in the solidification of the casting. This shear force clearly assists in nucleation or agglomeration of the molten surface.

  Castings within the commercial range were produced to perform two series of two tests based on conventional methods and operations according to the present invention. In the first test, a magnesium alloy was produced by a hot chamber machine of some kind and capacity. In the second test, the aluminum alloy was produced by a type and volume of cold chamber machine. Regarding the casting of magnesium, the specifications common to the conventional method and the method according to the present invention are shown in Table 1, and the characteristics unique to each embodiment are shown in Table 2 and Table 3, respectively. For this aluminum casting, the corresponding data are shown in Tables 4-6. In the respective tables 2, 3, 4 and 6, the average speed value of the piston and the average speed value of the runner are those of the second stage of rapid filling.

  Each of the magnesium alloy castings of each product detailed in Table 1 was produced under the conventional casting conditions detailed in Table 2 or under the conditions according to the invention detailed in Table 3. For each casting produced under the conditions detailed in Table 3, a metal flow apparatus corresponding to the embodiment illustrated in FIGS. 14 and 15 was used. Each of the castings detailed in Table 2 or Table 3 was found to be good. However, the castings produced according to the invention exhibited an excellent microstructure. This advantage is due to the microstructure uniformity across the casting and the shape of the microstructure elements. Castings produced under conventional conditions exhibited individual particles in a normal branched dendritic pattern, and in some cases, the void area due to entrainment of air was 1.5% or more. In contrast, castings produced in accordance with the present invention exhibited fine elliptical or circular individual particles. Further, the latter casting had substantially no pore region, and the pore region was 1.5% or less within a range where the pores can be measured, and was distributed substantially uniformly and finely.

  Castings M1, M2 and M3 produced in accordance with the present invention indicate that the cavity filling was performed with an alloy having a relatively low level of solids content of less than 20%. This is not the case with the microstructure of the casting M4, which indicates that the microstructure of the casting M4 was made with an alloy having a very small amount of solid content, even with cavity filling. However, in the case of casting M4, solid remelting may have occurred in the cavity due to the relatively large amount being sent and the resulting slower cooling.

  Each of the aluminum alloy castings of each product detailed in Table 4 was produced under the conventional casting conditions detailed in Table 5 or under the conditions according to the invention detailed in Table 6. For each casting produced in tests A1 and A2 under the conditions detailed in Table 6, a metal flow apparatus corresponding to the example of FIGS. 20 and 21 was used. For the castings of tests A3 and A5, the apparatus shown in FIGS. 14 and 15 was used. The following experimental apparatus was used for each casting of the test A4 and the tests A6 to A10. Again, compared to castings produced under conventional conditions, the castings produced in accordance with the present invention exhibited an excellent microstructure. This microstructural difference is essentially the same as that for magnesium alloy castings.

  It can be clearly seen that the microstructures of the castings A8 and A9 brackets are the result of the cavity filling being performed by an alloy with negligible, if any, solid component. Regarding the microstructures of the castings A1 to A7, although it can be seen that each of these is a result of cavity filling with a trace amount of solid components, the state is relatively unclear. None of the castings A1 to A9 exhibited large independent particles formed by main phase solidification in the shot sleeve. In any case, it can be seen that when such large particles are formed in the shot sleeve, the large particles are broken and the fine particles are increased under a strong shearing force spreading in the FEM.

  The experimental metal flow device used for each of the above test A4 and tests A6 to 10 is formed on each side of each mold part that defines a separation plane between the molds. That is, both the runner and FEM extend along the separation plane. When viewed in a direction perpendicular to this plane, the FEM has side edges that diverge from each other in the direction from the exit end of the runner to an elongated gate extending transversely to the longitudinal direction of the runner. Thus, the runner ends at the tip of the FEM, and the FEM has a delta or triangular shape as seen from the above points. When viewed in a side view parallel to the separation plane, the FEM is curved or arched between the runner's outflow end and the gate because the surface of one mold is convex and the surface of the other mold is concave. It is in the shape. This configuration is such that the convex portion is bent beyond the end of the runner, and the alloy flow from the exit end of the runner is redirected by this surface portion, so that the FEM triangle portion of the FEM as the alloy passes through the elongated gate. It is to fill the volume.

  Finally, it will be understood that various changes, modifications and / or additions may be made to the arrangement and arrangement of the parts described above without departing from the spirit or scope of the invention.

FIG. 3 is a schematic view of a two-cavity mold arrangement on a separation plane between a fixed mold part and a movable mold part, showing the first embodiment of the present invention. It is an expanded sectional view on line II of FIG. Fig. 2 is a schematic view similar to Fig. 1 showing a second embodiment of the invention with a single cavity. FIG. 4 is a side view of the arrangement of FIG. 3. It is a figure similar to FIG. 4 which shows the 1st modification of a 2nd embodiment. It is a figure similar to FIG. 4 which shows the 2nd modification of a 2nd embodiment. It is a figure similar to FIG. 3 which shows the 3rd embodiment of this invention. FIG. 8 is a side view of the arrangement of FIG. 7. FIG. 2 is a schematic view similar to FIG. 1, showing a fourth embodiment of the present invention. FIG. 10 is a partial cross-sectional view along line XX in FIG. 9. It is a figure similar to FIG. 3, and shows the 5th embodiment of this invention. It is a fragmentary sectional view on line XII-XII of FIG. It is a figure similar to FIG. 11, and is a figure which shows the 1st modification of the 5th embodiment of this invention. It is a figure similar to FIG. 1, and is a figure which shows the 2nd modification of the 5th embodiment of this invention. It is a fragmentary sectional view on line XV-XV of FIG. It is a figure similar to FIG. 3, and shows the sixth embodiment of the present invention. FIG. 17 is a side view of the arrangement of FIG. 16. It is a figure similar to FIG. 17, and shows the modification of a 6th embodiment. It is a top view of the casting made using the 7th embodiment of the present invention. It is a schematic plan view of a part of the seventh embodiment. It is a side view of arrangement | positioning shown in FIG.

Claims (21)

A metal flow apparatus for high pressure die casting of an alloy using a molten alloy pressure source and a machine having or operable to provide a mold defining at least one cavity, the apparatus from the pressure source Defining a metal flow path that allows the received alloy to flow into the cavity;
(A) the first portion of the length of the flow path includes or consists of a runner;
(B) the second portion of the length of the flow path from the exit end of the runner includes a flow path exit module (FEM);
At the mass flow rate of the alloy that can be produced by the machine, the alloy flow rate at the outlet end of the runner is 60 m / s to 180 m / s for the magnesium alloy and 40 m / s to 120 m / s for the alloys other than the magnesium alloy. the runner has a cross-sectional area at least at the exit end of the runner, the FEM has a shape that increases the cross-sectional area in the direction of the alloy flow, thereby controlling the alloy flow, and the alloy flow rate is At locations where the flow rate is progressively reduced from the level at the exit end and the flow path communicates with the cavity, the alloy flow rate is less than the flow rate at the exit end of the runner, and when the cavity fill is complete, the alloy flows into the flow path within the cavity. Can be solidified along the runner, and the FEM cross-sectional area is suppressed from changing the alloy from a molten state to a semi-solid state exhibiting thixotropic properties While also metal flow system, wherein the alloy flow velocity was increased so as to reduce to less than 80% of the alloy flow velocity at the outlet end of the runner.   The apparatus of claim 1, wherein increasing the FEM cross-sectional area reduces the alloy flow rate to less than 50% of the alloy flow rate at the runner exit end.   3. The device according to claim 1 or 2, wherein the solids content of the alloy can be less than 25% by weight by increasing the cross-sectional area.   The device according to claim 1 or 2, wherein the increase in the cross-sectional area enables the solids content of the alloy to be less than 20 or 22% by weight.   3. The device according to claim 1 or 2, wherein the solids content of the alloy can be less than 17% by weight by increasing the cross-sectional area.   6. A device according to any one of the preceding claims, wherein a gate is defined at the outlet end of the flow path for constricting the alloy flowing therethrough.   6. A device according to any one of the preceding claims, wherein a gate is defined at the outlet end of the flow path that does not restrict the alloy flowing therethrough.   8. An apparatus according to claim 6 or 7, wherein the gate is at the exit end of the FEM.   8. The apparatus of claim 6 or 7, wherein the FEM outlet end is spaced from the gate by a further runner of the flow path having a cross-sectional area at least equal to the cross-sectional area at the FEM outlet end. In a pressure casting machine for high pressure die casting of an alloy, the machine is capable of flowing a pressurized source of molten alloy, a mold defining at least one cavity, and an alloy received from the pressurized source into the cavity. Having or being operable to have a metal flow device defining a metal flow path;
(A) the first portion of the length of the flow path includes or consists of a runner;
(B) the second part of the length of the flow path from the exit end of the runner includes a flow-path exit module (FEM);
At the mass flow rate of the alloy that can be produced by the machine, the alloy flow rate at the outlet end of the runner is 60 m / s to 180 m / s for the magnesium alloy and 40 m / s to 120 m / s for the alloys other than the magnesium alloy. the runner has a cross-sectional area at least at the exit end of the runner, the FEM has a shape that increases the cross-sectional area in the direction of the alloy flow, thereby controlling the alloy flow, and the alloy flow rate is At locations where the flow rate is progressively reduced from the level at the exit end and the flow path communicates with the cavity, the alloy flow rate is less than the flow rate at the exit end of the runner, and when the cavity fill is complete, the alloy flows into the flow path within the cavity. Can be solidified along the runner, reducing the FEM cross-sectional area from changing the alloy from a molten state to a semi-solid state exhibiting thixotropic properties While also the pressure casting machine, wherein the alloy flow velocity was increased so as to reduce to less than 80% of the alloy flow velocity at the outlet end of the runner.   The machine of claim 10, wherein increasing the FEM cross-sectional area reduces the alloy flow rate to less than 50% of the alloy flow rate at the runner exit end.   12. A machine according to claim 10 or 11 wherein the solids content of the alloy can be reduced to less than 25% by weight by increasing the cross-sectional area.   12. A machine according to claim 10 or 11 wherein the solids content of the alloy can be less than 20 or 22% by weight by increasing the cross-sectional area.   12. A machine according to claim 10 or 11, wherein the increase in the cross-sectional area allows the solids content of the alloy to be less than 17% by weight. In a method of producing an alloy casting using a pressurized source of molten alloy and a high pressure die casting machine having a mold defining at least one cavity, the alloy flows from the source along the flow path to the cavity,
(A) the alloy flows along the runner in a first portion of the length of the flow path;
(B) In the second part of the length of the channel between the first section and the cavity and including the flow-path exit module (FEM), the alloy flow is controlled and thereby the flow rate Gradually decreases from the level at the exit end of the runner to the flow rate at the position communicating with the cavity, which is less than the flow rate at the exit end of the runner,
At the mass flow rate of the alloy that can be produced by the machine, the alloy flow rate at the outlet end of the runner is 60 m / s to 180 m / s for the magnesium alloy and 40 m / s to 120 m / s for the alloys other than the magnesium alloy. The runner has a cross-sectional area such that s is at least at the exit end of the runner, and the alloy flow in the FEM is controlled while suppressing the change of the alloy from a molten state to a semi-solid state exhibiting thixotropic properties. A production method characterized in that the control is performed so that the alloy flow rate is less than 80% of the alloy flow rate at the outlet end.   The method of claim 15, wherein increasing the cross-sectional area reduces the alloy flow rate to less than 50% of the alloy flow rate at the runner exit end.   The method according to claim 15 or 16, wherein the increase in the cross-sectional area enables the solids content of the alloy to be less than 25% by weight.   17. A method according to claim 15 or 16, wherein the increase in cross-sectional area allows the solids content of the alloy to be less than 20 or 22% by weight.   The method according to claim 15 or 16, wherein the solids content of the alloy is less than 17% by weight by increasing the cross-sectional area.   20. A method according to any one of claims 15 to 19, wherein a gate is defined at the outlet end of the flow path for compressing the alloy flowing therethrough.   20. A method according to any one of claims 15 to 19, wherein a gate is defined at the outlet end of the flow path that does not compress the alloy flowing therethrough.

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