A cooling insert for a die, such as a distributor for a high pressure die casting assembly, and a method of manufacturing the cooling insert, is provided. The cooling insert can be formed of H13 tool steel and is manufactured using an investment casting process, for example, a process which uses a printed investment casting shell. The cooling insert includes complex cooling channels to improve cooling and reduce the duration of the casting process.

A cooling insert for a die, such as a distributor for a high pressure die casting assembly, and a method of manufacturing the cooling insert, is provided. The cooling insert can be formed of H13 tool steel and is manufactured using an investment casting process, for example, a process which uses a printed investment casting shell. The cooling insert includes complex cooling channels to improve cooling and reduce the duration of the casting process.

A high-temperature die casting die includes a first die plate with a first recess and a second die plate with a second recess, the first and second recesses defining a main part cavity and gating. A grain selector is in fluid communication with the main cavity, and an in situ zone refining apparatus is adapted to apply a localized thermal gradient to at least one of the first and second die plates. The localized thermal gradient and the at least one die plate are movable relative to each other so as to apply the localized thermal gradient along a first direction extending from the grain selector longitudinally across the main part cavity.

A high-temperature die casting die includes a first die plate with a first recess and a second die plate with a second recess, the first and second recesses defining a main part cavity and gating. A grain selector is in fluid communication with the main cavity, and an in situ zone refining apparatus is adapted to apply a localized thermal gradient to at least one of the first and second die plates. The localized thermal gradient and the at least one die plate are movable relative to each other so as to apply the localized thermal gradient along a first direction extending from the grain selector longitudinally across the main part cavity.

A method to manufacture reticulated metal foam via a dual investment solid mold includes pouring molten metal material into a mold while the mold is located on a chill plate. A method to manufacture reticulated metal foam includes pouring molten metal material into a mold while the mold is located on a chill plate, the chill plate configured to apply an externally driven temperature gradient in the mold so that solidification progresses from the chilled end to the non-chilled end

A method to manufacture reticulated metal foam via a dual investment solid mold includes pouring molten metal material into a mold while the mold is located on a chill plate. A method to manufacture reticulated metal foam includes pouring molten metal material into a mold while the mold is located on a chill plate, the chill plate configured to apply an externally driven temperature gradient in the mold so that solidification progresses from the chilled end to the non-chilled end

A method of casting a camshaft including iron includes determining a cooling rate profile based on a chemical composition of the camshaft and a target bearing life of the camshaft. The method includes casting the camshaft including cooling the camshaft in a chiller based on the cooling rate profile. The method includes imparting the camshaft with a microstructure comprising carbide, ledeburite, pearlite, ausferrite, or combinations thereof.

A casting process of a central rotary joint includes the steps of obtaining an upper casting mold, a lower casting mold, and a sand core through 3-dimensional printing, inserting the chill into the sand core, placing the sand core with the chill in the lower mold, inverting the upper mold onto the lower mold to form a assembled mold and define a casting cavity and a vertical pouring channel connected to the casting cavity between the upper and lower molds, injecting liquid iron into the casting cavity through the vertical pouring channel, unmolding after the liquid iron is condensed to obtain the central rotary joint. Through the vertical pouring channel, the chill and related processes, the sequential solidification of the liquid iron is achieved, effectively avoiding deformation and shrinkage porosity caused by the shrinkage of the liquid iron and graphite expansion during the solidification process.

A casting process of a central rotary joint includes the steps of obtaining an upper casting mold, a lower casting mold, and a sand core through 3-dimensional printing, inserting the chill into the sand core, placing the sand core with the chill in the lower mold, inverting the upper mold onto the lower mold to form a assembled mold and define a casting cavity and a vertical pouring channel connected to the casting cavity between the upper and lower molds, injecting liquid iron into the casting cavity through the vertical pouring channel, unmolding after the liquid iron is condensed to obtain the central rotary joint. Through the vertical pouring channel, the chill and related processes, the sequential solidification of the liquid iron is achieved, effectively avoiding deformation and shrinkage porosity caused by the shrinkage of the liquid iron and graphite expansion during the solidification process.