SG180156A1 - Die casting system machine configurations - Google Patents
Die casting system machine configurations Download PDFInfo
- Publication number
- SG180156A1 SG180156A1 SG2011081460A SG2011081460A SG180156A1 SG 180156 A1 SG180156 A1 SG 180156A1 SG 2011081460 A SG2011081460 A SG 2011081460A SG 2011081460 A SG2011081460 A SG 2011081460A SG 180156 A1 SG180156 A1 SG 180156A1
- Authority
- SG
- Singapore
- Prior art keywords
- shot tube
- die
- die casting
- recited
- casting system
- Prior art date
Links
- 238000004512 die casting Methods 0.000 title claims abstract description 79
- 229910052751 metal Inorganic materials 0.000 claims abstract description 39
- 239000002184 metal Substances 0.000 claims abstract description 39
- 238000004891 communication Methods 0.000 claims abstract description 8
- 239000012530 fluid Substances 0.000 claims abstract description 8
- 238000002347 injection Methods 0.000 claims abstract description 7
- 239000007924 injection Substances 0.000 claims abstract description 7
- 239000000463 material Substances 0.000 claims description 38
- 238000002844 melting Methods 0.000 claims description 31
- 230000008018 melting Effects 0.000 claims description 31
- 238000000034 method Methods 0.000 claims description 14
- 230000006698 induction Effects 0.000 claims description 10
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 6
- 238000010438 heat treatment Methods 0.000 claims description 4
- 238000000829 induction skull melting Methods 0.000 claims description 4
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 3
- 239000000919 ceramic Substances 0.000 claims description 3
- 229910002804 graphite Inorganic materials 0.000 claims description 3
- 239000010439 graphite Substances 0.000 claims description 3
- 239000007787 solid Substances 0.000 claims description 3
- 230000007246 mechanism Effects 0.000 description 9
- 238000005266 casting Methods 0.000 description 7
- 239000002826 coolant Substances 0.000 description 6
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 4
- 229910052802 copper Inorganic materials 0.000 description 4
- 239000010949 copper Substances 0.000 description 4
- 230000008569 process Effects 0.000 description 4
- 210000003625 skull Anatomy 0.000 description 4
- 229910045601 alloy Inorganic materials 0.000 description 3
- 239000000956 alloy Substances 0.000 description 3
- 238000001816 cooling Methods 0.000 description 3
- 238000005495 investment casting Methods 0.000 description 3
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 2
- 229910052786 argon Inorganic materials 0.000 description 2
- 229910010293 ceramic material Inorganic materials 0.000 description 2
- 238000011109 contamination Methods 0.000 description 2
- 239000011261 inert gas Substances 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- 229910000838 Al alloy Inorganic materials 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
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 239000012768 molten material Substances 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
- 238000012856 packing Methods 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 239000003870 refractory metal Substances 0.000 description 1
- 229910000601 superalloy Inorganic materials 0.000 description 1
- 230000008646 thermal stress Effects 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
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
- B22D17/02—Hot chamber machines, i.e. with heated press chamber in which metal is melted
- B22D17/04—Plunger machines
-
- 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
- B22D17/2038—Heating, cooling or lubricating the injection unit
-
- 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
- B22D17/08—Cold chamber machines, i.e. with unheated press chamber into which molten metal is ladled
- B22D17/10—Cold chamber machines, i.e. with unheated press chamber into which molten metal is ladled with horizontal press motion
-
- 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
- B22D17/14—Machines with evacuated die cavity
-
- 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
- B22D17/2023—Nozzles or shot sleeves
-
- 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
- B22D17/30—Accessories for supplying molten metal, e.g. in rations
Abstract
OF THE DISCLOSURE A die casting system includes a die, a shot tube and a shot tube plunger. The die casting system is positioned relative to a surface. 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 molten metal into the die cavity. Each of the die, the shot tube and the shot tube plunger are inclined at an angle relative to the surface during injection of the molten metal into the die cavity.Figure 1
Description
DIE CASTING SYSTEM MACHINE CONFIGURATIONS
This disclosure relates generally to casting, and more particularly to die casting system machine configurations.
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. Existing machine configurations for die casting systems have not been effective to cast components made from high temperature alloys.
A die casting system includes a die, a shot tube and a shot tube plunger. The die is comprised of 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 molten metal into the die cavity. The die casting system is positioned relative to a surface. Each of the die, the shot tube and the shot tube plunger are positioned at an angle relative to the surface during injection of the molten metal into the die cavity.
In another exemplary embodiment, a die casting system includes a die, a shot tube and a shot tube plunger. The die is comprised of a plurality of die components that define a die cavity. The shot tube is in fluid communication with the die cavity and includes an integrated melting unit configured to heat a charge of material from a position inside the shot tube. The shot tube plunger is moveable within the shot tube to communicate the charge of material into the die cavity.
In yet another exemplary embodiment, a method of die casting a component includes loading a charge of materialinto a shot tube of a die casting system, heating the charge of material at a position inside the shot tube, and injecting the charge of material into a die cavity of the die casting system to form the component.
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.
Figure 2 illustrates an example machine configuration of a die casting system.
Figure 2B illustrates a positioning system of the example die casting system of
Figure 2.
Figure 3 illustrates another example machine configuration of a die casting system.
Figure 3B illustrates an example shot tube plunger of the die casting system of
Figure 3.
Figure 4 illustrates yet another example machine configuration of a die casting system.
Figure 5 schematically illustrates an example implementation of the die casting system machine configurations of Figure 3 and Figure 4.
Figure 1 illustrates a die casting system 10 having a machine configuration 11.
In this example, the die casting system 10 includes a horizontal machine configuration. The die casting system 10 includes a reusable die 12 having a plurality of die elements 14, 16 that function to cast a component 15. Although 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 define 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 located in 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. The mechanism 30 could include a hydraulic assembly or other suitable mechanism, including, but not limited to, pneumatic, electromechanical or any combination thereof.
The shot tube 24 receives a molten metal from a melting unit 25,such as a crucible, for forming the component 15. In this example, the molten metal is melted in the melting unit 25 at a location that is separate from the shot tube 24. However, this disclosure is not limited to melting units located separate from the other die casting system components.
Materials capable of being used to diecast a component 15 include, but are not limited to, nickel based super alloys, titanium alloys, high temperature aluminum alloys, copper based alloys, iron alloys, molybdenum, tungsten, niobium or other refractory metals. This disclosure is not limited to the disclosed alloys, and it should be understood that any high melting temperature material may be utilized to 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 shot tube 24 receives a sufficient amount of molten material 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.
Although the casting of a single component is depicted, the die casting system could be configured to cast multiple components in a single shot (see Figures 3 and 4, for example).
Although not necessary, at least a portion of 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 cast component 15, such as excess porosity of the diecastcomponent that can occur as a result of exposure to oxygen. In one example, 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 on the type of component 15 being cast, among other conditions and factors. In the illustrated example, the melting unit 25, 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 metal are each performed under vacuum. In another example, the vacuum chamber 34 is backfilled with an inert gas, such as Argon, for example.
The machine configuration 11 of the die casting system 10 depicted in Figure 1 is illustrative only and could include more or less sections, parts and/or components.
This disclosure extends to all forms of die casting, including but not limited to, horizontal systems, vertical systems, vacuum systems, or non-vacuum systems.
Described below are additional machine configurations ofdie castingsystems capable of casting components made from high melting temperature materials. The example machine configurations described below and depicted in Figures 2-5 maintain thermal control of the molten metal received by the die casting system components and thereby minimize thermal losses (i.e., heat of the molten metal) during injection. In addition, the example machine configurations extend part life and reduce the defects caused by transfer of the molten metal from a location separate from the die casting system components.
Figure 2 illustrates an example machine configuration 111of a die casting system 110. In this disclosure, like reference numerals signify like features, and reference numerals identified in multiples of 100 signify slightly modified features.
Moreover, selected features of one example embodiment may be combined with selected features of other example embodiments and still fall within the scope of this disclosure.
In this example, the die casting system 110 is positioned relative to a surface 40, such as a machine shop floor, for example. The surface 40 is substantially flat.
The die casting system 110 is substantially similar to the die casting system 10 of
Figure 1, except that the die casting system 110 is positioned at an angle a relative to the surface 40. That is, the machine configuration 111 includes an inclined positioning of the die casting system 110 relative to the surface 40.
In this example, the die 12, the shot tube 24 and the shot tube plunger 28 are each angled relative to the surface 40 at an angle a. The machine configuration 111 therefore changes the orientation of the die casting system 110 relative to the surface 40 such that the surface area contact between molten metal andthe interior of the shot tube 24 is reduced. Reduction of the surface area contact of the molten metal with the shot tube 24 minimizes thermal losses of the molten metal that can occur during injection, and reduces the thermal stresses acting upon the shot tube 24.
The depicted angle a is for illustrative purposes only and is not meant to limit this disclosure. In one example, the die casting system 110 is angled relative to the surface 40 at an angle of about 5° to about 85°. In another example, the die casting system 110 is angled relative to the surface 40 at an angle of about 30° to about 45°.
In this disclosure, the term “about” is intended to include the defined ranges and any slight modifications thereof, such as within a range of accepted tolerances.
The die casting system 110 could be permanently inclined relative to the surface 40, such as by mounting the die casting system 110 to an inclined surface 41.
In another example, as depicted in Figure 2B, the die casting system 110 includes a positioning system 42 that selectively inclines the die casting system 110 relative to the surface 40. In this example, the positioning system 42 includes cylinders 44 that are selectively actuable to position the die casting system 110 at a desired angle a relative to the surface 40. The positioning system 42 could include any appropriate hydraulic, pneumatic, electromechanical and/or other configurations for positioning the components of the die casting system 110 at a desired inclined angle o.
Although not depicted, the die casting system 110 could be positioned within a vacuum chamber powered by a vacuum source to render a vacuum die casting system, or a die casting system 110 could be positioned within a chamber that is backfilled with an inert gas, such as Argon, for example.
Figure 3 illustrates another example machine configuration 211 for a die casting system 210. In this example, the machine configuration 211 of the die casting system 210 includes a vertical, bottom feed configuration. Although a vertical, bottom feed configuration is depicted, the advantages of this disclosure are applicable to other configurations including, but not limited to, horizontal, side feed and top feed configurations.
The die casting system 210 includes a die 212 having a plurality of die elements 214, 216 that define a die cavity 220. A shot tube 224 is in fluid communication with the die cavity 220. A gate 221 connects the shot tube 224 to the die cavity 220. A shot tube plunger 228 is received within the shot tube 224 and is moveable between a retracted and injected position (in the direction of arrow A) within the shot tube 224 by a mechanism 230.
The shot tube 224 includes an integrated melting unit 225 configured to heat a charge of material237 from an interior position IP of the shot tbe 224. In this example, the integrated melting unit 225 includes an induction coil 227 mounted about the shot tube 224. The induction coil 227 of the integrated melting unit 225 induces a current within the shot tube 224 to melt and/or superheat the charge of material237 within the interior position IP of the shot tube 224. That is, the charge of material 237 can be either melted from inside of the shot tube 224, or can be melted separate from the shot tube 224 (such as in a crucible) and then transferred to the shot tube 224 and heated to a desired temperature inside of the shot tube 224. The induction coil 227 is powered by a power source 229 in a known manner.
The example shot tube 224 can include a first sleeve 231 and a second sleeve 233. In this example, the first sleeve 231 is a graphite sleeve and the second sleeve 233 is a ceramic sleeve. The induction coil 227 is positioned around the second sleeve 233 to melt and/orheat a charge of material 237 (such as an ingot of a high melting temperature material) within the second sleeve 233. The charge of material 237 is transformed into molten metal and/or superheated once induced by the induction coil 227. The shot tube plunger 228 packs the molten metal into the first sleeve 231 of the shot tube 224. The first sleeve 231is capable of withstanding the pressure of the packed molten metal.
The sleeves 231, 233 are not limited to graphite and ceramic materials. For example, the first sleeve 231 could also be comprised of metallic or ceramic materials, while the second sleeve 233 could include other materials. The actual materials utilized for the first sleeve 231 and the second sleeve 233 will vary depending upon design specific parameters, including but not limited to, the melting temperature of the charge of material 237 and the packing pressures created during injection of the shot tube plunger 228.
Figure 3B depicts example features of the shot tube plunger 228. The shot tube plunger 228 could include a cooled copper plunger 250. In this example, the cooled copper plunger 250 includes cooling channels 251 that receive a coolant 253, such as water, from a coolant source 255. The coolant 253 is circulated through the coolant channels 251 to remove heat from the shot tube plunger 228 as a result of direct contact with the molten metal during injection.
As depicted in Figure 3, the die casting system 210 could be positioned within a vacuum chamber 234 that includes a vacuum source 235. A vacuum is applied in the vacuum chamber 234 via the vacuum source 235 to render a vacuum die casting process. In the illustrated example, each of the shot tube 224, the integrated melting unit 225 and the die 212 are positioned within the vacuum chamber 234 during the die casting process such that the melting, injecting and solidifying of the metal are all performed under vacuum. Although a vacuum chamber 234 is depicted in Figure 3, the die casting system 210 may also be utilized in non-vacuumed environments.
Figure 4 illustrates yet another example machine configuration 311associated with a die casting machine 310. The die casting system 310 is substantially similar to the die casting system 210 of Figure 3. However, the example die casting system 310 includes a slightly modified integrated melting unit 325. In this example, the integrated melting unit 325 includes an induction skull melting system 327. That is, in this example machine configuration 311, the induction skull melting system 327 replaces the induction coil 227 depicted in Figure 3.
The die casting system 310 also includes a die 312 having a plurality of die elements 314, 316 that define a die cavity 320. A shot tube 324 is in fluid communication with the die cavity 320. A gate 321 connects the shot tube 324 to the die cavity 320. A shot tube plunger 328 is received within the shot tube 324 and is moveable between a retracted and injected position (in the direction of arrow A) within the shot tube 324 by a mechanism 230. Although not depicted, the die casting system 310 could be positioned within a vacuum chamber powered by a vacuum source to render a vacuum die casting system.
The induction skull melting system 327 of the integrated melting unit 325 includes wall segments 91 which are surrounded by an induction coil 93. In this example, the wall segments 91 are copper wall segments. The wall segments 91 and the induction coil 93 include cooling chambers 95 that receive a coolant, such as water, from a coolant source 97 to cool the wall segments 91 during contact with molten metal. A magnetic field is induced by the induction coil 93 and passes through the wall segments 91to heat and melt the charge of material 337 to form molten metal.
The shot tube plunger 328 is moveable to pack the molten metal within a sleeve 331 of the shot tube 324 to prepare the molten metal to be injected into the die cavity 320. In this example, the shot tube plunger 328 is a copper shot tube plunger and could include cooling channels (similar to those depicted by Figure 3B) to cool the shot tube plunger 328 during contact with the molten metal.
Figure 5 schematically illustrates an example implementation 100 of the machine configurations 211, 311 of Figured and Figure 4. The example implementation100 schematically depicts a method of die casting a component 15.
The component 15 could include an aeronautical component, such as an airfoil or vane, for example. However, the casting of non-aeronautical components is also contemplated as within the scope of this disclosure.
The example implementation 100 includes loading a charge of material 237, 337 within a shot tube 224, 324 of a die casting system 210, 310, which is depicted at step block 102. In one example, the charge of material 237, 337 is molten metal that is melted in a melting unit 25 (See Figure 1) separate from the die casting systems210, 310 and poured into the shot tube 224, 324. In another example, the charge of material 237, 337 is a solid ingot of material that is positioned inside the shot tube 224, 324 prior to melting. The charge of material 237, 337 is a high melting temperature material.
Next, at step block 104, the charge of material 237, 337 is heated from a positioninside of the shot tube 224, 324. The charge of material 237, 337 is heated with an integrated melting unit 225, 325. A skull 75 forms on an interface defined between the shot tube plunger 228, 328 and the molten metal to seal the shot tube 224, 324. Once the charge of material 237, 337 is either melted or achieves a desired temperature, the molten metal is advanced through the integrated melting unit 225, 325 at step block 106. During advancement, the shot tube plunger 228, 328 pushes on the skull 75 formed at step block 104. Formation and advancement of the skull 75 protects the shot tube 224, 324 from exposure to the molten metal and protects the molten metal from contamination.
At step block 108, the shot tube plunger 228, 328 crushes the skull 75 and the molten metal is rapidly injected into the die cavity 220, 320 of the die 212, 312. The molten metal solidifies within the die cavity 220, 320 to form the component 15 at step block 110. Finally, at step block 112, the die 212, 312 is opened and the component 15 is removed relative to the die 212, 312. The component 15 can be subjected to finishing operations once removed from the die 212, 312.
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 (17)
1. A die casting system positioned relative to a surface, comprising: a die comprised of a plurality of die components that define a die cavity; a shot tube in fluid communication with said die cavity; and a shot tube plunger moveable within said shot tube to communicate molten metal into said die cavity, wherein each of said die, said shot tube and said shot tube plunger are inclined at an angle relative to the surface during injection of said molten metal into said die cavity.
2. The system as recited in claim 1, wherein said angle is between 5° and 85°.
3. The system as recited in claim 1, wherein said angle is between 30° and 45°.
4 The system as recited in claim 1, comprising a positioning system that selectively positions said die, said shot tube and said shot tube plunger at said angle.
5. The system as recited in claim 4, wherein said positioning system includes cylinders actuable to position said die, said shot tube and said shot tube plunger at said angle.
6. A die casting system, comprising: a die comprised of a plurality of die components that define a die cavity; a shot tube in fluid communication with said die cavity, wherein said shot tube includes an integrated melting unit configured to heat a charge of material from a position inside of said shot tube; and a shot tube plunger moveable within said shot tube to communicate said charge of material into said die cavity.
7. The system as recited in claim 6, wherein said shot tube includes a first sleeve and a second sleeve, and said integrated melting unit includes an induction coil.
8. The system as recited in claim 7, wherein said first sleeve is a graphite sleeve and said second sleeve is a ceramic sleeve.
9. The system as recited in claim 6, wherein said integrated melting unit includes an induction skull melting system.
10. The system as recited in claim 6, wherein said shot tube plunger includes a cooled copper shot tube plunger.
11. The system as recited in claim 6, wherein the die casting system is a vertical die casting system.
12. A method of die casting a component, comprising the steps of: (a) loading a charge of material within a shot tube of a die casting system; (b) heating the charge of material at a position inside said shot tube; and ©) injecting the charge of material into a die cavity of the die casting system to cast the component.
13. The method as recited in claim 12, wherein the charge of material is a molten metal and said step (a) includes the step of: pouring the molten metal into the shot tube.
14. The method as recited in claim 13, wherein said step (b) includes the step of: heating the molten metal to a desired temperature inside of the shot tube.
15. The method as recited in claim 12, wherein the charge of material is an ingot of material and said step (a) includes the step of: positioning the solid ingot of material inside of the shot tube.
16. The method as recited in claim 15, wherein said step (b) includes the step of: melting the solid ingot of material into a molten metal inside of the shot tube.
17. The method as recited in claim 12, wherein said step (b) includes the step of: heating the charge of material with an integrated melting unit associated with the shot tube of the die casting system.
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US12/940,075 US20120111522A1 (en) | 2010-11-05 | 2010-11-05 | Die casting system machine configurations |
Publications (1)
Publication Number | Publication Date |
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SG180156A1 true SG180156A1 (en) | 2012-05-30 |
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ID=44905686
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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SG2011081460A SG180156A1 (en) | 2010-11-05 | 2011-11-04 | Die casting system machine configurations |
Country Status (3)
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US (1) | US20120111522A1 (en) |
EP (1) | EP2450125B1 (en) |
SG (1) | SG180156A1 (en) |
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US20150298207A1 (en) * | 2012-05-04 | 2015-10-22 | Apple Inc. | Inductive coil designs for the melting and movement of amorphous metals |
US8813813B2 (en) * | 2012-09-28 | 2014-08-26 | Apple Inc. | Continuous amorphous feedstock skull melting |
US10197335B2 (en) * | 2012-10-15 | 2019-02-05 | Apple Inc. | Inline melt control via RF power |
US8944140B2 (en) * | 2013-03-14 | 2015-02-03 | Crucible Intellectual Property, Llc | Squeeze-cast molding system suitable for molding amorphous metals |
US9925583B2 (en) | 2013-07-11 | 2018-03-27 | Crucible Intellectual Property, Llc | Manifold collar for distributing fluid through a cold crucible |
US20150343526A1 (en) * | 2014-05-30 | 2015-12-03 | Crucible Intellectual Property, Llc | Application of ultrasonic vibrations to molten liquidmetal during injection molding or die casting operations |
KR101517571B1 (en) * | 2014-06-26 | 2015-05-06 | 고동근 | A device and a method of melting and forming under vacuum environment |
US9873151B2 (en) | 2014-09-26 | 2018-01-23 | Crucible Intellectual Property, Llc | Horizontal skull melt shot sleeve |
KR101786229B1 (en) * | 2015-12-01 | 2017-11-16 | 현대자동차주식회사 | Mold apparatus for high pressure casting |
US20170266719A1 (en) * | 2016-03-21 | 2017-09-21 | Purdue Research Foundation | Hot-chamber die casting systems and methods |
DE102018109322A1 (en) * | 2018-04-19 | 2019-10-24 | Engel Austria Gmbh | Melting unit for a molding machine and molding machine |
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US3672440A (en) * | 1969-06-13 | 1972-06-27 | Toshiba Machine Co Ltd | Apparatus for die casting ferrous metals |
JPS57206560A (en) * | 1981-06-15 | 1982-12-17 | Nissan Motor Co Ltd | Production of die casting |
SE8500545L (en) * | 1985-02-06 | 1986-08-07 | Asea Ab | PREPARATION OF CASTING GOODS |
DE3640370A1 (en) * | 1985-11-26 | 1987-05-27 | Ube Industries | INJECTION METHOD OF AN INJECTION MOLDING MACHINE |
JPS63127748U (en) * | 1987-02-14 | 1988-08-22 | ||
JPH0215860A (en) * | 1988-06-30 | 1990-01-19 | Honda Motor Co Ltd | Casting device |
JPH02160156A (en) * | 1988-12-14 | 1990-06-20 | Tokyo Yogyo Co Ltd | Sleeve for aluminum die casting machine |
US5195572A (en) * | 1989-07-11 | 1993-03-23 | Rex-Buckeye Company, Inc. | Two part shot sleeve for die casting |
US5252130A (en) * | 1989-09-20 | 1993-10-12 | Hitachi, Ltd. | Apparatus which comes in contact with molten metal and composite member and sliding structure for use in the same |
US5048592A (en) * | 1989-10-18 | 1991-09-17 | Allper Ag | Plunger for a diecasting machine |
US5076343A (en) * | 1990-08-24 | 1991-12-31 | Briggs & Stratton Corporation | Die cast plunger lubrication system |
US5570502A (en) * | 1991-04-08 | 1996-11-05 | Aluminum Company Of America | Fabricating metal matrix composites containing electrical insulators |
JPH05131255A (en) * | 1991-08-21 | 1993-05-28 | Leotec:Kk | Injection-formed metal-refractory combined sleeve for half-melted or molten metal |
JP2674422B2 (en) * | 1992-04-29 | 1997-11-12 | 株式会社デンソー | Solid lubricant spraying device and spraying method |
US5323838A (en) * | 1992-07-08 | 1994-06-28 | Asahi Glass Company Ltd. | Injection sleeve for die casting and a method of casting an aluminum or an aluminum alloy part |
JP3049648B2 (en) * | 1993-12-13 | 2000-06-05 | 日立金属株式会社 | Pressure molding method and pressure molding machine |
CN1051035C (en) * | 1994-06-14 | 2000-04-05 | 株式会社东芝 | Sleeve for die carting machines and die casting machine using the same |
JP3808167B2 (en) * | 1997-05-01 | 2006-08-09 | Ykk株式会社 | Method and apparatus for manufacturing amorphous alloy molded article formed by pressure casting with mold |
US6237672B1 (en) * | 1998-12-30 | 2001-05-29 | Dbm Industries, Ltd. | Self lubricating and cleaning injection piston for cold chamber injection unit |
US6311761B1 (en) * | 1999-12-22 | 2001-11-06 | Ronald G. Steininger | Plunger tip for die casting apparatus |
US20040084816A1 (en) * | 2002-10-29 | 2004-05-06 | Terry Hildreth | Metal injecting apparatus |
JP4339135B2 (en) * | 2004-01-15 | 2009-10-07 | Ykk株式会社 | Injection casting equipment for forming amorphous alloys |
JP4688145B2 (en) * | 2005-06-09 | 2011-05-25 | 日本碍子株式会社 | Die casting apparatus and die casting method |
US20080017345A1 (en) * | 2006-07-20 | 2008-01-24 | Husky Injection Molding Systems Ltd. | Molding-system valve |
-
2010
- 2010-11-05 US US12/940,075 patent/US20120111522A1/en not_active Abandoned
-
2011
- 2011-11-04 EP EP11187864.1A patent/EP2450125B1/en active Active
- 2011-11-04 SG SG2011081460A patent/SG180156A1/en unknown
Also Published As
Publication number | Publication date |
---|---|
US20120111522A1 (en) | 2012-05-10 |
EP2450125A2 (en) | 2012-05-09 |
EP2450125A3 (en) | 2015-01-21 |
EP2450125B1 (en) | 2020-09-30 |
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