US20130220568A1 - Process for Producing Die-Cast Parts - Google Patents

Process for Producing Die-Cast Parts Download PDF

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Publication number
US20130220568A1
US20130220568A1 US13/634,394 US201013634394A US2013220568A1 US 20130220568 A1 US20130220568 A1 US 20130220568A1 US 201013634394 A US201013634394 A US 201013634394A US 2013220568 A1 US2013220568 A1 US 2013220568A1
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US
United States
Prior art keywords
aluminum alloy
working space
solids content
nanoparticles
oxide
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US13/634,394
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English (en)
Inventor
Rudiger Franke
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Rheinfelden Alloys GmbH and Co KG
Original Assignee
Rheinfelden Alloys GmbH and Co KG
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Filing date
Publication date
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Application filed by Rheinfelden Alloys GmbH and Co KG filed Critical Rheinfelden Alloys GmbH and Co KG
Assigned to RHEINFELDEN ALLOYS GMBH & CO. KG reassignment RHEINFELDEN ALLOYS GMBH & CO. KG ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: FRANKE, RUDIGER
Publication of US20130220568A1 publication Critical patent/US20130220568A1/en
Abandoned legal-status Critical Current

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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/007Semi-solid pressure die casting
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/08Cold chamber machines, i.e. with unheated press chamber into which molten metal is ladled
    • B22D17/10Cold chamber machines, i.e. with unheated press chamber into which molten metal is ladled with horizontal press motion
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/20Accessories: Details
    • B22D17/30Accessories for supplying molten metal, e.g. in rations
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D25/00Special casting characterised by the nature of the product
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C1/00Making non-ferrous alloys
    • C22C1/02Making non-ferrous alloys by melting
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C1/00Making non-ferrous alloys
    • C22C1/02Making non-ferrous alloys by melting
    • C22C1/026Alloys based on aluminium
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C26/00Alloys containing diamond or cubic or wurtzitic boron nitride, fullerenes or carbon nanotubes
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C32/00Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ
    • C22C32/001Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with only oxides
    • C22C32/0015Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with only oxides with only single oxides as main non-metallic constituents
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C32/00Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ
    • C22C32/0089Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with other, not previously mentioned inorganic compounds as the main non-metallic constituent, e.g. sulfides, glass
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C26/00Alloys containing diamond or cubic or wurtzitic boron nitride, fullerenes or carbon nanotubes
    • C22C2026/002Carbon nanotubes

Definitions

  • the invention relates to a process for producing die-cast parts made of an aluminum alloy.
  • the invention is based on the object of providing a process of the type mentioned in the introduction, with which process a partially solid aluminum alloy melt can be provided continuously in a cost-effective manner and further processed to form die-cast parts. It is a further object of the invention to provide a process for producing die-cast parts which are reinforced with nanoparticles and are made of an aluminum alloy, with which process a partially solid aluminum alloy melt can be provided continuously in a cost-effective manner under the action of shearing forces typical of the process with a high fine dispersion of nanoparticles and further processed to form die-cast parts.
  • the first object is achieved according to the invention in that the aluminum alloy is exposed to high shearing forces in a mixing and kneading machine, having a housing with a working space, which is surrounded by an inner housing sleeve, and a worm shaft, which rotates about a longitudinal axis and moves to and fro translationally in the longitudinal axis in the inner housing sleeve and is provided with kneading blades, and with kneading bolts, which are fastened to the inner housing sleeve and protrude into the working space, wherein liquid aluminum alloy is fed to the working space at one end of the housing and, at the other end of the housing, is removed from the working space as partially solid aluminum alloy with a predefined solids content, is transferred into a filling chamber of a die-casting machine and is introduced into a casting mold by means of a piston, wherein the solids content of the aluminum alloy in the working space is set to the predefined solids content by cooling and heating the
  • the high shearing forces present in the kneading process in the partially solidified phase state continuously comminute dendritic branches which form, and this leads to an increased ductility of the die-cast parts.
  • the high compression forces additionally lead to a greater transfer of heat, which ultimately makes it possible to set the solids content in the aluminum alloy more precisely.
  • the second object is achieved according to the invention in that nanoparticles are mixed with the aluminum alloy and finely dispersed in the aluminum alloy by high shearing forces in a mixing and kneading machine, having a housing with a working space, which is surrounded by an inner housing sleeve, and a worm shaft, which rotates about a longitudinal axis and moves to and fro translationally in the longitudinal axis in the inner housing sleeve and is provided with kneading blades, and with kneading bolts, which are fastened to the inner housing sleeve and protrude into the working space, wherein liquid aluminum alloy and nanoparticles are fed to the working space at one end of the housing and, at the other end of the housing, are removed from the working space as partially solid aluminum alloy with a predefined solids content and with nanoparticles finely dispersed in the aluminum alloy, are transferred into a filling chamber of a die-casting machine and are introduced into a casting mold
  • the high shearing forces present in the kneading process in the partially solidified phase finely disperse the nanoparticles, which is required for the strength-increasing effect thereof.
  • the inner housing sleeve is surrounded by an outer housing sleeve such that an intermediate space preferably in the form of a hollow cylinder is formed, and cold and/or hot gases are conducted through the intermediate space for cooling and heating the working space.
  • Air preferably compressed air
  • hot gases preferably combustion gases
  • the gases are preferably conducted through the intermediate space in countercurrent to the direction in which the aluminum alloy is transported.
  • the solids content of the aluminum alloy is preferably set to 40 to 80%, in particular to more than 50%.
  • the partially solid aluminum alloy is removed from the working space as a partially solid metal strand.
  • the continuously emerging, partially solid metal strand is split into partially solid metal portions and the partially solid metal portions are transferred into the filling chamber of the die-casting machine.
  • the content of the nanoparticles in the alloy is preferably between about 0.1 and 10% by weight.
  • Suitable, cost-effective nanoparticles consist preferably of fumed silica, such as e.g. Aerosil®.
  • nanoparticles such as e.g. the known carbon nanotubes (CNT) and also further, nanoscale particles which are produced, for example, by the known Aerosil® process and are made of metal and semimetal oxides, such as e.g.
  • Al 2 O 3 aluminum oxide (Al 2 O 3 ), titanium dioxide (TiO 2 ), zirconium oxide (ZrO 2 ), antimony(III) oxide, chromium(III) oxide, iron(III) oxide, germanium(IV) oxide, vanadium(V) oxide or tungsten(VI) oxide.
  • FIG. 1 shows a longitudinal section through a die-casting machine with an upstream mixing and kneading machine
  • FIG. 2 shows a longitudinal section through part of a mixing and kneading machine
  • FIG. 3 shows a cross section through the mixing and kneading machine shown in FIG. 1 ;
  • FIG. 4 shows characteristic shearing and stretching flow fields in a product mass, triggered by a kneading blade moving past a kneading bolt;
  • FIG. 5 shows the continuous production of partially solid starting material for die casting with an arrangement according to FIG. 1 .
  • a plant, shown in FIG. 1 , for die casting die-cast parts which are optionally reinforced with nanoparticles and are made of an aluminum alloy has a die-casting machine 10 and a mixing and kneading machine 30 upstream of the die-casting machine 10 .
  • the die-casting machine 10 which is shown only in part in the drawing, is a commercially available machine for conventionally die casting aluminum alloys and has, inter alia, a filling chamber 12 , which is connected to a stationary side 18 of a casting mold, with an opening 16 for receiving the metal which is to be ejected from the filling chamber 12 and introduced into a mold cavity 14 of the casting mold by means of a piston 20 .
  • the mixing and kneading machine 30 is shown in detail in FIGS. 2 and 3 .
  • the basic design of such a mixing and kneading machine is known, for example, from CH-A-278 575.
  • the mixing and kneading machine 30 has a housing 31 with a working space 34 , which is surrounded by an inner housing sleeve 32 and in which there is arranged a worm shaft 36 , which rotates about a longitudinal axis x and moves to and fro translationally in the longitudinal axis x in the inner housing sleeve 32 .
  • the worm shaft 36 is interrupted in the circumferential direction such that individual kneading blades 38 are formed.
  • Axial through openings 40 are thereby formed between the individual kneading blades 38 .
  • Kneading bolts 42 protrude from the inner side of the inner housing sleeve 32 into the working space 34 .
  • the kneading bolts 42 on the housing side engage into the axial through openings 40 of the kneading blades 38 arranged on the main or worm shaft 36 .
  • a drive shaft 44 arranged concentrically to the worm shaft 36 is guided out of the inner housing sleeve 32 at the end and is connected to a drive unit (not shown in the drawing) for executing a rotational movement of the worm shaft 36 .
  • a device interacting with the worm shaft 36 for executing the translational movement of the worm shaft 36 is likewise not shown in the drawing.
  • the cylindrical inner housing sleeve 32 of the mixing and kneading machine 30 which delimits the working space 34 , is surrounded by a cylindrical outer housing sleeve 46 .
  • the inner housing sleeve 32 and the outer housing sleeve 46 form a dual sleeve and thereby enclose an intermediate space 48 in the form of a hollow cylinder.
  • An introduction opening 50 for feeding liquid aluminum alloy and optionally nanoparticles into the working space 34 is provided at that end of the housing 31 which is close to the drive side of the worm shaft 36 .
  • an introduction opening 50 is shown in the drawing, two separate introduction openings for the aluminum alloy and for the nanoparticles can be provided. In principle, it is also possible to admix the nanoparticles with the liquid aluminum alloy even before the metal is introduced into the kneading and mixing machine 30 .
  • An outlet opening 52 for removing partially solid aluminum alloy optionally with nanoparticles dispersed therein is provided at that end of the inner housing sleeve 32 which is remote from the drive side of the worm shaft 36 .
  • Inlet openings 54 , 56 for introducing cold or hot gases into the intermediate space 48 are provided in the outer housing sleeve 46 at that end of the housing 31 which is remote from the drive side of the worm shaft 36 .
  • outlet openings 58 , 60 for the discharge of the gases from the intermediate space 48 are provided at that end of the housing 31 which is close to the drive side of the worm shaft 36 .
  • the inlet and outlet openings 54 , 56 and 58 , 60 are according to FIG. 3 arranged distributed uniformly about the circumference of the outer housing sleeve 46 .
  • FIG. 4 shows, in a schematic illustration, characteristic shearing and stretching flow fields in a product mass P, as triggered by a kneading blade 38 moving past a kneading bolt 42 in the case of a mixing and kneading machine 30 formed according to the prior art.
  • the direction in which the kneading blade 38 rotates is indicated schematically by a curved arrow A, whereas the translational movement of the kneading blade 38 is indicated by a double-headed arrow B.
  • the rotational movement of the kneading blade 38 means that its tip splits the product mass P, as indicated by arrows C, D.
  • gap 41 There is a gap 41 , the width of which varies depending on the rotation and translational movement of the worm shaft 36 , between the kneading bolt 42 and the main face 39 of the kneading blade 38 , which faces toward the kneading bolt 42 , and the kneading blade 38 moving past the latter.
  • a shearing process is brought about in the product mass P in this gap 41 , as indicated by arrow E.
  • the product mass P expands and reorientates itself both upstream and downstream of the kneading bolt 42 , as indicated by rotation arrows F, G.
  • An aluminum alloy melt kept just above the liquidus temperature of the alloy is fed to the working space 34 in metered form alone or together with nanoparticles via the introduction opening 50 .
  • the pinching of the partially solidified aluminum alloy with nanoparticles between the kneading blades 38 and the kneading bolts 42 results in the application of high shearing forces, which both lead to the comminution of dendritic branches and finely disperse the nanoparticles present in the form of agglomerates. Efficient, homogenizing mixing results from the combination of a radial and longitudinal mixing effect.
  • the solids content of the aluminum alloy in the working space 34 is set such that it is in the desired range when the metal is removed through the outlet opening 52 .
  • the desired solids content of the aluminum alloy is set by measuring the change in viscosity of the metal melt in the kneading and mixing machine 30 .
  • the viscosity which rises as the solids content of the partially solid aluminum alloy increases, can be determined, for example, by measuring the rotational resistance at the drive shaft 44 of the worm shaft 36 .
  • By determining the rotational resistance for defined solids contents it is possible to specify appropriate setpoint values, to which measured actual values are regulated by controlling the flow of cold and hot gases through the intermediate space 48 between the inner housing sleeve 32 and the outer housing sleeve 46 .
  • the aluminum alloy having the desired solids content and optionally comprising finely dispersed nanoparticles is introduced via the introduction opening 16 into the filling chamber 12 of the die-casting machine 10 , and is injected intermittently from the latter into the mold cavity 14 of the casting mold from the filling chamber 12 in a known manner by means of the piston 20 .
  • the aluminum alloy having the desired solids content and optionally comprising finely dispersed nanoparticles is continuously ejected via the outlet opening 52 in the form of a partially solid metal strand 70 .
  • Partially solid metal portions 72 are cut to length from the partially solid metal strand 70 , for example using a rotating blade.
  • the partially solid metal portions 72 usually each correspond to the quantity of metal required for producing an individual die-cast part and, for each shot, are transferred individually into the filling chamber 12 of the die-casting machine 10 and injected intermittently from the latter into the mold cavity 14 of the casting mold from the filling chamber 12 in a known manner by means of the piston 20 .
  • the partially solid metal strand 70 usually leaves the mixing and kneading machine 30 in the direction of the longitudinal axis x of the worm shaft 36 in a horizontal direction, although another, e.g. vertical, outlet direction is also conceivable.
  • the cross section of the metal strand 70 is determined by the cross section of the outlet opening 52 , and is usually circular.
  • the partially solid metal portions 72 can be grasped by tongs, for example, and transferred into the filling chamber 12 of the die-casting machine 10 .

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Inorganic Chemistry (AREA)
  • Powder Metallurgy (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)
  • Manufacture Of Metal Powder And Suspensions Thereof (AREA)
  • Organic Low-Molecular-Weight Compounds And Preparation Thereof (AREA)
  • Manufacture And Refinement Of Metals (AREA)
  • Continuous Casting (AREA)
US13/634,394 2010-03-24 2010-08-19 Process for Producing Die-Cast Parts Abandoned US20130220568A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
EP10157519 2010-03-24
EP10157519.9 2010-03-24
PCT/EP2010/062089 WO2011116838A1 (de) 2010-03-24 2010-08-19 Verfahren zur herstellung von druckgussteilen

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US20130220568A1 true US20130220568A1 (en) 2013-08-29

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US13/634,394 Abandoned US20130220568A1 (en) 2010-03-24 2010-08-19 Process for Producing Die-Cast Parts

Country Status (16)

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US (1) US20130220568A1 (pt)
EP (1) EP2393619B1 (pt)
KR (1) KR20130055563A (pt)
CN (1) CN102834203A (pt)
AU (1) AU2010349399A1 (pt)
BR (1) BR112012023916A2 (pt)
CA (1) CA2792432A1 (pt)
DK (1) DK2393619T3 (pt)
ES (1) ES2423326T3 (pt)
HR (1) HRP20130605T1 (pt)
MX (1) MX2012010807A (pt)
PL (1) PL2393619T3 (pt)
PT (1) PT2393619E (pt)
RU (1) RU2012143377A (pt)
SI (1) SI2393619T1 (pt)
WO (1) WO2011116838A1 (pt)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20130266470A1 (en) * 2010-11-25 2013-10-10 Rolls Royce Deutschland Ltd & Co Kg Method for the manufacturing high-temperature resistant engine components

Families Citing this family (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2522885A1 (de) 2011-05-11 2012-11-14 Rheinfelden Alloys GmbH & Co. KG Dichtungsanordnung
EP2564953A1 (en) * 2011-09-05 2013-03-06 Rheinfelden Alloys GmbH & Co. KG Process for producing formed parts
CN103008610B (zh) * 2012-12-18 2015-05-27 华南理工大学 锌合金蜗轮的挤压铸造方法
AT518824A1 (de) * 2016-05-31 2018-01-15 Lkr Leichtmetallkompetenzzentrum Ranshofen Gmbh Verfahren zur Herstellung eines Profils aus einer Metalllegierung
AT518825A1 (de) * 2016-05-31 2018-01-15 Lkr Leichtmetallkompetenzzentrum Ranshofen Gmbh Verfahren zur Herstellung eines Profils aus einer Metalllegierung
DE102021203642B3 (de) 2021-04-13 2022-09-08 Volkswagen Aktiengesellschaft Lagerkern für ein Gummi-Metalllager, Gummi-Metalllager und Kraftfahrzeug mit einem solchen

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US2892224A (en) * 1957-05-09 1959-06-30 Nat Lead Co Heating of dies by internal combustion
US4007771A (en) * 1974-01-15 1977-02-15 Welsch M Process for the production of aluminum
US20060151137A1 (en) * 2003-07-02 2006-07-13 Honda Motor Co., Ltd Molding of slurry-form semi-solidified metal
US20070183253A1 (en) * 2006-02-06 2007-08-09 Buss Ag Mixing and Kneading Machine

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IT1257114B (it) * 1992-09-29 1996-01-05 Weber Srl Procedimento per l'ottenimento di masselli reocolati, in particolare adatti a venire utilizzati per la produzione di pressocolati ad alte prestazioni meccaniche.
IT1260684B (it) * 1993-09-29 1996-04-22 Weber Srl Metodo ed impianto per la pressocolata in semiliquido di componenti ad alte prestazioni meccaniche a partire da masselli reocolati.
JP3817786B2 (ja) * 1995-09-01 2006-09-06 Tkj株式会社 合金製品の製造方法及び装置
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KR100607218B1 (ko) * 1998-03-31 2006-08-01 다카다 가부시키가이샤 반고상 상태로부터 사출성형에 의해 금속부품을 제조하는방법 및 장치
HUP0102977A3 (en) * 1998-07-24 2002-02-28 Semi Solid Technologies Inc Ca Apparatus, vessel and method for delivering semi-solid liquid metal to a die casting device
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JP4224083B2 (ja) * 2006-06-15 2009-02-12 日精樹脂工業株式会社 複合金属材料の製造方法及び複合金属成形品の製造方法

Patent Citations (4)

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Publication number Priority date Publication date Assignee Title
US2892224A (en) * 1957-05-09 1959-06-30 Nat Lead Co Heating of dies by internal combustion
US4007771A (en) * 1974-01-15 1977-02-15 Welsch M Process for the production of aluminum
US20060151137A1 (en) * 2003-07-02 2006-07-13 Honda Motor Co., Ltd Molding of slurry-form semi-solidified metal
US20070183253A1 (en) * 2006-02-06 2007-08-09 Buss Ag Mixing and Kneading Machine

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20130266470A1 (en) * 2010-11-25 2013-10-10 Rolls Royce Deutschland Ltd & Co Kg Method for the manufacturing high-temperature resistant engine components

Also Published As

Publication number Publication date
BR112012023916A2 (pt) 2016-08-02
SI2393619T1 (sl) 2013-08-30
KR20130055563A (ko) 2013-05-28
HRP20130605T1 (en) 2013-08-31
RU2012143377A (ru) 2014-05-10
EP2393619A1 (de) 2011-12-14
PT2393619E (pt) 2013-07-09
DK2393619T3 (da) 2013-07-08
EP2393619B1 (de) 2013-04-03
CA2792432A1 (en) 2011-09-29
AU2010349399A1 (en) 2012-09-27
MX2012010807A (es) 2013-01-22
CN102834203A (zh) 2012-12-19
ES2423326T3 (es) 2013-09-19
PL2393619T3 (pl) 2013-09-30
WO2011116838A1 (de) 2011-09-29

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