Provided herein is a system, apparatus, and method for venting a direct chill casting mold by venting excess casting gas and retaining oxide from atop a casting during the direct chill casting process. Methods of venting casting gas from a direct chill casting mold include: supplying the direct chill casting mold with molten metal through a transition plate; supplying a casting gas through a casting surface of the direct chill casting mold; venting the casting gas from a gas pocket in the transition plate, wherein venting the casting gas from the gas pocket in the transition plate is performed in response to a pressure of the casting gas in the gas pocket reaching a predetermined pressure.

An apparatus for the simultaneous casting of multiple components using a directional solidification process includes; a pouring cup arranged on a centerline, an array of moulds encircling the pouring cup and centre line, an array of feed channels extending from the pouring cup to a top end of each mould, and a heat deflector. The heat deflector comprises a wall arranged between the array of moulds and the centerline extending along the length of the moulds and in thermal contact with the moulds.

An apparatus for the simultaneous casting of multiple components using a directional solidification process includes; a pouring cup arranged on a centerline, an array of moulds encircling the pouring cup and centre line, an array of feed channels extending from the pouring cup to a top end of each mould, and a heat deflector. The heat deflector comprises a wall arranged between the array of moulds and the centerline extending along the length of the moulds and in thermal contact with the moulds.

A die cast machine includes a die component and a back block supporting the die component, which includes a protrusion, the protrusion having a second cross-sectional shape and a first height. The cross-sectional shape is substantially similar to the cross-sectional shape of the recessed area of the die component, the protrusion being received within the recessed area. The first height of the protrusion is less than the depth of the recessed area. The die cast machine also includes a chill block positioned between the die component and the back block, the chill block having a cross-sectional shape and a second height. The cross-sectional shapes are all substantially similar. A sum of the first height and the second height is substantially similar to the depth of the recessed area.

A die cast machine includes a die component and a back block supporting the die component, which includes a protrusion, the protrusion having a second cross-sectional shape and a first height. The cross-sectional shape is substantially similar to the cross-sectional shape of the recessed area of the die component, the protrusion being received within the recessed area. The first height of the protrusion is less than the depth of the recessed area. The die cast machine also includes a chill block positioned between the die component and the back block, the chill block having a cross-sectional shape and a second height. The cross-sectional shapes are all substantially similar. A sum of the first height and the second height is substantially similar to the depth of the recessed area.

A hybrid chill with enhanced heat transfer for casting of a sand cast aluminum engine block of a vehicle is provided. The hybrid chill comprises a base comprising an outer wall having a first side and a second side. Each of the first and second sides extends from a first longitudinal end to an opposite second longitudinal end. The outer wall is closed to define a hollow portion. The base further comprises a heat transfer fluid in a liquid phase disposed in the hollow portion. The heat transfer fluid has a boiling point of between 320 C. and 400 C. at 1 bar for enhanced heat transfer during casting. The chill further comprises a plurality of crankcase members. Each member is disposed on the first side. Each member is spaced apart from a respective adjacent member defining an open recess.

A hybrid chill with enhanced heat transfer for casting of a sand cast aluminum engine block of a vehicle is provided. The hybrid chill comprises a base comprising an outer wall having a first side and a second side. Each of the first and second sides extends from a first longitudinal end to an opposite second longitudinal end. The outer wall is closed to define a hollow portion. The base further comprises a heat transfer fluid in a liquid phase disposed in the hollow portion. The heat transfer fluid has a boiling point of between 320 C. and 400 C. at 1 bar for enhanced heat transfer during casting. The chill further comprises a plurality of crankcase members. Each member is disposed on the first side. Each member is spaced apart from a respective adjacent member defining an open recess.

A mold body for use in a mold includes a mold cavity, a chill cavity, a fill channel, and a chill material having a thermal conductivity that is greater than the thermal conductivity of the mold body disposed within the chill cavity. The chill cavity is formed adjacent the mold cavity and is separated from the mold cavity by a chill wall. The fill channel is in communication with the chill cavity and with an exterior surface of the mold body.

A mold body for use in a mold includes a mold cavity, a chill cavity, a fill channel, and a chill material having a thermal conductivity that is greater than the thermal conductivity of the mold body disposed within the chill cavity. The chill cavity is formed adjacent the mold cavity and is separated from the mold cavity by a chill wall. The fill channel is in communication with the chill cavity and with an exterior surface of the mold body.

A casting mold with a multi-functional chill, a multi-functional chill, and a casting process facilitated by the multi-functional chill are disclosed herein. In addition to affecting the cooling rate of a casting inside the mold, the multi-functional chill may support and/or index the mold during handling and/or conveyance. The present invention allows for conveyance and/or handling of the mold or casting, with or without the mold, and allows for easy indexing and easy interaction with conveying and handling devices during and after heat treatment.