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US20050133187A1 - Die casting method system and die cast product - Google Patents

Die casting method system and die cast product Download PDF

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Publication number
US20050133187A1
US20050133187A1 US10/736,557 US73655703A US2005133187A1 US 20050133187 A1 US20050133187 A1 US 20050133187A1 US 73655703 A US73655703 A US 73655703A US 2005133187 A1 US2005133187 A1 US 2005133187A1
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US
United States
Prior art keywords
casting
tube
metal
cast
mold
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
US10/736,557
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English (en)
Inventor
Sean Seaver
Robert Hollacher
Chuck Barnes
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.)
SPX Technologies Inc
Original Assignee
Individual
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Priority to US10/736,557 priority Critical patent/US20050133187A1/en
Priority to EP04814468A priority patent/EP1694454A4/fr
Priority to PCT/US2004/042289 priority patent/WO2005058529A2/fr
Assigned to SPX CORPORATION reassignment SPX CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: BARNES, CHARLES, HOLLACHER, ROBERT, SEAVER, SEAN
Publication of US20050133187A1 publication Critical patent/US20050133187A1/en
Abandoned legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D19/00—Casting in, on, or around objects which form part of the product
    • B22D19/0072—Casting in, on, or around objects which form part of the product for making objects with integrated channels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/007—Semi-solid pressure die casting

Definitions

  • the present invention relates generally to die casting. More particularly, the present invention relates to the casting of components having internal passages.
  • passages are typically for fluids, such as for example, water, oils, and gases, and are generally introduced by machining the passages into the product after it has been cast.
  • a method for production of a casting incorporating a passage comprising disposing at least one tube in a mold and casting a metal around the tube.
  • the metal may be molten or semi-solid metal and comprise aluminum and aluminum alloys.
  • the tubes of the invention may also comprise any metal, including, but not limited to, steel, and be crimped or clamped in some embodiments.
  • the outer surface of the tubes can be treated prior to casting. Such treatments include spraying the surface with an aluminum composition, shot blasting, and/or metal plating.
  • fluids may be passed through the cast-in tubes before, during, and after casting. Molds of the present invention may comprise passages that match the direction of the tube through the casting.
  • a system for production of a casting incorporating a passage comprising a disposing means that places at least one tube in a mold and a casting means that casts a metal around the tube.
  • the metal may be molten or semi-solid metal and comprise aluminum and aluminum alloys.
  • the tubes of the invention may also comprise any metal, including, but not limited to, steel, and be crimped or clamped in some embodiments.
  • the outer surface of the tubes can be treated prior to casting. Such treatments include spraying the surface with an aluminum composition, shot blasting, and/or metal plating.
  • fluids may be passed through the cast-in tubes before, during, and after casting. Molds of the present invention may comprise passages that match the direction of the tube through the casting.
  • Another embodiment of the invention provides a cast product having at least one tube and metal cast around the tube.
  • FIG. 1 is a diagrammatic representation of a tube and mold, designed with passages to hold the tube.
  • FIG. 2 is a cross-sectional view taken along the 2 - 2 in FIG. 1 .
  • FIG. 3 is a diagrammatic representation of an alternate tube design and mold, also designed with a passage to accommodate the tube.
  • FIG. 4 is a cross-sectional view taken from the 4 - 4 in FIG. 3 .
  • FIG. 5 is a diagrammatic representation of a tube design that crosses over itself.
  • FIG. 6 is a diagrammatic representation of two tubes that comprise an intersection.
  • An embodiment in accordance with the present invention provides a method for the production of castings with incorporated passages, where the castings are from cast metal and where tubes are cast-in with a superheated molten metal to form the passages.
  • the cast metal may be any metal including, but not limited to steel, zinc, magnesium, or combinations thereof.
  • aluminum and aluminum alloys are cast.
  • Aluminum alloys include 357 alloy, 380 alloy, ADC12 alloy, 356.2 alloy, and other aluminum-silicon alloys.
  • presses and die cast methods may be used with the present invention.
  • squeeze casting, gravity casting, and high and low pressure die casting methods may all be used.
  • vertical die cast presses may also be used.
  • Vertical die cast presses manufactured by THT Presses preferred in some applications are disclosed in U.S. Pat. Nos. 5,660,223 and 5,429,175, assigned to and commercially available from THT Presses, Inc., Dayton, Ohio.
  • THT presses of this invention may be classified as “indexing-type” or “shuttle-type.” Though the indexing press will be detailed in an embodiment below, both types of presses may be used in the instant invention.
  • the THT presses such as a 200 Ton Indexing Shot Machine, a 1000 Ton Shuttle Machine, or a 100 Ton Shuttle Machine, in particular, are capable of operating at a higher speed and with a shorter cycle time than previously known die casting presses and which, as a result, produce higher quality parts with reduced porosity.
  • the die casting presses are also simpler and less expensive in construction, requiring less maintenance and therefore more convenient to service.
  • SSM casting is defined broadly herein to encompass any casting technique whereby the metal introduced into a die cavity is greater than 20% granular (i.e., solids). SSM casting techniques that are known in the art include, but are not limited to, rheocasting and thixocasting.
  • SSM casting may be preferred in some embodiments of the present invention because it is performed at lower temperatures where often 20% -70% of the metal is granular and thus in a slurry, rather than liquid state.
  • the cooler temperatures can extend the useful life of the dies.
  • the slurry state of the metal reduces turbulence within the metal flow as it is introduced into the die, so as to reduce the incorporation of air and gas into the metal as it is being cast. Thus, porosity and quality control complications are reduced.
  • vertical die cast presses are used with SSM casting techniques.
  • SSM is cast using a vertical die casting apparatus.
  • the indexing time i.e., the delay between indexing between the pour station 80 and transfer station 85
  • the indexing time can be used to control the time the molten metal is cooled in the shot sleeve to reach the SSM range. That is, the amount of time the metal spends in the shot sleeve before it is injected into the molds can be regulated or optimized for a desirable microstructure.
  • molten metal at a predetermined temperature may be poured into the shot sleeve of shuttle presses, i.e. presses that lack the indexing feature.
  • the shear forces present in SSM casting may be more suitable to the present invention in some embodiments over traditional molten metal casting methods.
  • larger tubes ranging from about 0.25 inches to about 0.37 inches in outer diameter may be incorporated into the cast-in tube castings than otherwise possible.
  • aluminum-silicon alloys can be used.
  • aluminum alloys with up to but less than about 11.7 weight percent Si are defined “hypoeutectic”, whereas those with greater than about 11.7 weight percent Si are defined “hypereutectic”.
  • the term “about” has been incorporated in this disclosure to account for the inherent inaccuracies associated with measuring chemical weights and measurements known and present in the art.
  • aluminum-silicon copper alloys and/or aluminum-copper alloys may be used with the present invention.
  • Tubes that may be cast-in in the present invention may comprise any metal, preferably steel or hydraulic tubing in some embodiments.
  • the steel tubes can have a composition with less than about 0.17 weight percent carbon, less than about 0.35 weight percent silicon, less than about 0.04 weight percent sulfur, less than about 0.04 weight percent phosphorus and between about 0.40-0.80 weight percent manganese.
  • the tubes are free from surface defects, blow holes and cracks.
  • Tubes of the present invention can be of varying wall thickness.
  • the wall thickness and composition is preferably strong enough to withstand pressures of 6,000 psi to 20,000 psi and more preferably, pressures of 8,000 psi to 12,000 psi.
  • the corresponding wall thickness may range from about 0.02 inches to about 0.04 inches, but a wider range may also be acceptable.
  • FIGS. 1 and 2 there is shown a die 1 into which a guide 2 has been cut.
  • the guide 2 can be cut to fit the path of a tube 3 which is to be embedded into the metal cast.
  • the tube 3 may of any design or path.
  • the tube 3 may have one opening on one face of the mold or cast and then another opening on another face of the mold or cast as shown in FIG. 1 .
  • tube 3 may have and opening on one face and then be tapered, crimped, or clamped at the other end such that fluids become trapped inside the cast as shown in FIGS. 3 and 4 .
  • tubes may have paths that cross over ( FIG. 5 ) or intersect ( FIG. 6 ). All such configurations and others are within the scope of the present invention.
  • more than one tube may be incorporated into a cast-in tube mold or product. All such tubes should be accounted for in the design of the mold such that guide 2 may be cut into each half of the mold to accommodate the tube or tubes.
  • the tubes 3 may optionally be machined at one or more openings 4 . For example, threading for screws or bolts may be inserted.
  • the outer surface of the tubes may be coated with a thin surface layer to reduce the likelihood of tube movement (such as slipping or rolling) within the cast product.
  • Coatings may include, such as, for example, alumina and aluminum oxide, and may be sprayed on or plated. The thickness of such coating applications will be apparent to one of ordinary skill in the art.
  • Other treatments to the outer surface of the tubes can include shot blasting or grating.
  • the tube 3 is generally located by gravity in the mold 1 by predetermined guide 2 in the lower half of the mold.
  • the tubes are then secondarily located and secured using a reverse passages in the upper half of the mold such that the tube is secured and crimped or clamped in place.
  • the metal is be cast is heated in a range from about 10° C. to about 15° C. above the liquidus temperature (i.e., the semi-solid temperature).
  • the liquidus temperature i.e., the semi-solid temperature
  • the melt temperature is then allowed to cool to form a semi-solid slurry before it is finally cast.
  • the mold 1 and tube 3 design is such that, optionally, a cooling medium can be passed through the tubing before, during, and/or after the casting process is taking place.
  • a cooling medium can be passed through the tubing before, during, and/or after the casting process is taking place.
  • couplers may be added to the open end of the tube allow for entry of fluids for cooling. The couplers could then be removed, machined, or sheared from the final cast product. This procedure may enhance internal casting cooling rates and thus, cycle times.
  • internal cooling has the potential to improve the metallurgical properties and/or casting integrity of the final cast product. Alternatively, improved tube bonding with the cast is possible.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Continuous Casting (AREA)
US10/736,557 2003-12-17 2003-12-17 Die casting method system and die cast product Abandoned US20050133187A1 (en)

Priority Applications (3)

Application Number Priority Date Filing Date Title
US10/736,557 US20050133187A1 (en) 2003-12-17 2003-12-17 Die casting method system and die cast product
EP04814468A EP1694454A4 (fr) 2003-12-17 2004-12-16 Systeme et procede de moulage sous pression, produit coule sous pression
PCT/US2004/042289 WO2005058529A2 (fr) 2003-12-17 2004-12-16 Systeme et procede de moulage sous pression, produit coule sous pression

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US10/736,557 US20050133187A1 (en) 2003-12-17 2003-12-17 Die casting method system and die cast product

Publications (1)

Publication Number Publication Date
US20050133187A1 true US20050133187A1 (en) 2005-06-23

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US10/736,557 Abandoned US20050133187A1 (en) 2003-12-17 2003-12-17 Die casting method system and die cast product

Country Status (3)

Country Link
US (1) US20050133187A1 (fr)
EP (1) EP1694454A4 (fr)
WO (1) WO2005058529A2 (fr)

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20070017658A1 (en) * 2005-07-19 2007-01-25 International Business Machines Corporation Cold plate apparatus and method of fabrication thereof with a controlled heat transfer characteristic between a metallurgically bonded tube and heat sink for facilitating cooling of an electronics component
US20090178640A1 (en) * 2006-06-30 2009-07-16 Daimler Ag Cast steel piston for internal combustion engines
EP2151875A3 (fr) * 2008-08-07 2013-11-06 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Procédé et dispositif de fabrication d'un composant doté d'une pièce d'insertion intégrée
ITMI20121739A1 (it) * 2012-10-16 2014-04-17 Unical Ag Spa Procedimento per la realizzazione di uno scambiatore di calore ad elementi pressofusi.
JP2014124639A (ja) * 2012-12-25 2014-07-07 Aisin Seiki Co Ltd 鋳ぐるみ用のパイプの保持装置
TWI472388B (zh) * 2009-12-01 2015-02-11 Metal Ind Res & Dev Ct Casting with metal insert and its manufacturing method
US10105671B2 (en) * 2014-11-11 2018-10-23 H.C. Starck Inc. Microreactor systems and methods
CN110625089A (zh) * 2019-10-28 2019-12-31 宁波优耐特模具有限公司 新能源汽车驱动电机ecu壳体模具及壳体制造工艺

Citations (20)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1234878A (en) * 1913-09-15 1917-07-31 Mccord And Company Process of producing fluid-conduits in castings.
US3360008A (en) * 1964-10-07 1967-12-26 Raymond Int Inc Molded manifold construction and method of forming
US3683960A (en) * 1970-11-19 1972-08-15 Jerry Kirsch Block manifold for fluid control systems and method of making the same
US3888297A (en) * 1973-11-02 1975-06-10 Canron Ltd Method of producing ferrous castings with cast-in ferrous inserts
US4285385A (en) * 1978-06-28 1981-08-25 Hitachi, Ltd. Method for the production of heat exchangers
US4344477A (en) * 1979-04-16 1982-08-17 Nippon Light Metal Co., Ltd. Method of die casting a metallic cast product having a metallic hollow member embedded therein
US4516594A (en) * 1984-04-03 1985-05-14 Diesel Equipment Limited Multi-part valve with a valve seat skeleton and cast valve body
US4620507A (en) * 1981-03-06 1986-11-04 Hiromichi Saito Stave cooler
US4832106A (en) * 1981-07-25 1989-05-23 Hoesch Werke Aktiengesellschaft Production of castings containing steel tubes
US4836246A (en) * 1987-08-03 1989-06-06 Colt Industries Inc. Manifold for distributing a fluid and method for making same
US4865112A (en) * 1988-07-07 1989-09-12 Schwarb Foundry Company Method of casting metals with integral heat exchange piping
US5054818A (en) * 1988-11-09 1991-10-08 Hutchinson Joining and connecting block between flexible elastomer material ducts
US5305818A (en) * 1990-08-02 1994-04-26 Montupet S.A. Process for producing a moulded part, made of aluminium or an aluminium alloy, equipped with integrated channels
US5429175A (en) * 1993-07-01 1995-07-04 Tht Presses Inc. Vertical die casting press and method of operation
US5660223A (en) * 1995-11-20 1997-08-26 Tht Presses Inc. Vertical die casting press with indexing shot sleeves
US5740851A (en) * 1995-06-19 1998-04-21 Trinova Corporation Component with cast-in fluid passageways
US6257310B1 (en) * 1999-08-19 2001-07-10 Reliance Electric Technolgies, Llc Method for making heat sink vacuum
US6293305B1 (en) * 1997-02-14 2001-09-25 Spirax Sarco Industria E Comercio Ltda. Fluid flow distributor
US20020146945A1 (en) * 2001-04-09 2002-10-10 Hideaki Saito Tilt device for outboard engine
US6739378B2 (en) * 2000-01-14 2004-05-25 Nippon Light Metal Co., Ltd. Internal chill casting method for manufacturing a cast product containing a pipe therein

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS5573455A (en) * 1978-11-28 1980-06-03 Keiichiro Miyazaki Pipe body insert casting method weld-combining straight pipe and bend
JPS6221454A (ja) * 1985-07-17 1987-01-29 Asahi Malleable Iron Co Ltd 中空鋳物の製法
JPS6221453A (ja) * 1985-07-17 1987-01-29 Asahi Malleable Iron Co Ltd 中空鋳物およびその製法
FR2708495B1 (fr) * 1993-08-03 1995-09-08 Renault Procédé de fabrication d'un élément de carter à tubes insérés et élément de carter obtenu par ce procédé.
FI107789B (fi) * 1999-02-03 2001-10-15 Outokumpu Oy Valumuotti jäähdytyselementin valmistamiseksi ja muotissa valmistettu jäähdytyselementti

Patent Citations (20)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1234878A (en) * 1913-09-15 1917-07-31 Mccord And Company Process of producing fluid-conduits in castings.
US3360008A (en) * 1964-10-07 1967-12-26 Raymond Int Inc Molded manifold construction and method of forming
US3683960A (en) * 1970-11-19 1972-08-15 Jerry Kirsch Block manifold for fluid control systems and method of making the same
US3888297A (en) * 1973-11-02 1975-06-10 Canron Ltd Method of producing ferrous castings with cast-in ferrous inserts
US4285385A (en) * 1978-06-28 1981-08-25 Hitachi, Ltd. Method for the production of heat exchangers
US4344477A (en) * 1979-04-16 1982-08-17 Nippon Light Metal Co., Ltd. Method of die casting a metallic cast product having a metallic hollow member embedded therein
US4620507A (en) * 1981-03-06 1986-11-04 Hiromichi Saito Stave cooler
US4832106A (en) * 1981-07-25 1989-05-23 Hoesch Werke Aktiengesellschaft Production of castings containing steel tubes
US4516594A (en) * 1984-04-03 1985-05-14 Diesel Equipment Limited Multi-part valve with a valve seat skeleton and cast valve body
US4836246A (en) * 1987-08-03 1989-06-06 Colt Industries Inc. Manifold for distributing a fluid and method for making same
US4865112A (en) * 1988-07-07 1989-09-12 Schwarb Foundry Company Method of casting metals with integral heat exchange piping
US5054818A (en) * 1988-11-09 1991-10-08 Hutchinson Joining and connecting block between flexible elastomer material ducts
US5305818A (en) * 1990-08-02 1994-04-26 Montupet S.A. Process for producing a moulded part, made of aluminium or an aluminium alloy, equipped with integrated channels
US5429175A (en) * 1993-07-01 1995-07-04 Tht Presses Inc. Vertical die casting press and method of operation
US5740851A (en) * 1995-06-19 1998-04-21 Trinova Corporation Component with cast-in fluid passageways
US5660223A (en) * 1995-11-20 1997-08-26 Tht Presses Inc. Vertical die casting press with indexing shot sleeves
US6293305B1 (en) * 1997-02-14 2001-09-25 Spirax Sarco Industria E Comercio Ltda. Fluid flow distributor
US6257310B1 (en) * 1999-08-19 2001-07-10 Reliance Electric Technolgies, Llc Method for making heat sink vacuum
US6739378B2 (en) * 2000-01-14 2004-05-25 Nippon Light Metal Co., Ltd. Internal chill casting method for manufacturing a cast product containing a pipe therein
US20020146945A1 (en) * 2001-04-09 2002-10-10 Hideaki Saito Tilt device for outboard engine

Cited By (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20070017658A1 (en) * 2005-07-19 2007-01-25 International Business Machines Corporation Cold plate apparatus and method of fabrication thereof with a controlled heat transfer characteristic between a metallurgically bonded tube and heat sink for facilitating cooling of an electronics component
US7673389B2 (en) * 2005-07-19 2010-03-09 International Business Machines Corporation Cold plate apparatus and method of fabrication thereof with a controlled heat transfer characteristic between a metallurgically bonded tube and heat sink for facilitating cooling of an electronics component
US20100071876A1 (en) * 2005-07-19 2010-03-25 International Business Machines Corporation Cold plate apparatus with a controlled heat transfer characteristic between a metallurgically bonded tube and heat sink for facilitating cooling of an electronics component
US8245401B2 (en) * 2005-07-19 2012-08-21 International Business Machines Corporation Casted heat sink and tube cold plate with peritectically reacted metals
US20090178640A1 (en) * 2006-06-30 2009-07-16 Daimler Ag Cast steel piston for internal combustion engines
US8528513B2 (en) * 2006-06-30 2013-09-10 Daimler Ag Cast steel piston for internal combustion engines
EP2151875A3 (fr) * 2008-08-07 2013-11-06 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Procédé et dispositif de fabrication d'un composant doté d'une pièce d'insertion intégrée
TWI472388B (zh) * 2009-12-01 2015-02-11 Metal Ind Res & Dev Ct Casting with metal insert and its manufacturing method
ITMI20121739A1 (it) * 2012-10-16 2014-04-17 Unical Ag Spa Procedimento per la realizzazione di uno scambiatore di calore ad elementi pressofusi.
JP2014124639A (ja) * 2012-12-25 2014-07-07 Aisin Seiki Co Ltd 鋳ぐるみ用のパイプの保持装置
US10105671B2 (en) * 2014-11-11 2018-10-23 H.C. Starck Inc. Microreactor systems and methods
US10507449B2 (en) 2014-11-11 2019-12-17 H.C. Starck Inc. Microreactor systems and methods
US11110426B2 (en) 2014-11-11 2021-09-07 H.C. Starck Inc. Microreactor systems and methods
US11642644B2 (en) 2014-11-11 2023-05-09 H.C. Starck Solutions Coldwater, LLC Microreactor systems and methods
CN110625089A (zh) * 2019-10-28 2019-12-31 宁波优耐特模具有限公司 新能源汽车驱动电机ecu壳体模具及壳体制造工艺

Also Published As

Publication number Publication date
WO2005058529A2 (fr) 2005-06-30
WO2005058529A3 (fr) 2005-09-29
EP1694454A2 (fr) 2006-08-30
EP1694454A4 (fr) 2007-04-04

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AS Assignment

Owner name: SPX CORPORATION, NORTH CAROLINA

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:SEAVER, SEAN;HOLLACHER, ROBERT;BARNES, CHARLES;REEL/FRAME:016155/0928

Effective date: 20050411

STCB Information on status: application discontinuation

Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION