Discussed is an aluminum alloy for die casting, the aluminum alloy including a composition of approximately 2.0 to 6.0% by weight of calcium (Ca), approximately 1.0 to 3.0% by weight of manganese (Mn), approximately 0.1 to 1.0% by weight of silicon (Si), approximately 0.1 to 0.5% by weight of iron (Fe), the balance being aluminum (Al), and inevitable impurities. A size of grains of the aluminum alloy is in a range of approximately 10 to 50.

New aluminum casting alloys having 8.5-9.5 wt. % silicon, 0.8-2.0 wt. % copper (Cu), 0.20-0.53 wt. % magnesium (Mg), and 0.35 to 0.8 wt. % manganese are disclosed. The alloy may be solution heat treated, treated in accordance with T5 tempering and/or artificially aged to produce castings, e.g., for cylinder heads and engine blocks. In one embodiment, the castings are made by high pressure die casting.

New aluminum casting alloys having 8.5-9.5 wt. % silicon, 0.8-2.0 wt. % copper (Cu), 0.20-0.53 wt. % magnesium (Mg), and 0.35 to 0.8 wt. % manganese are disclosed. The alloy may be solution heat treated, treated in accordance with T5 tempering and/or artificially aged to produce castings, e.g., for cylinder heads and engine blocks. In one embodiment, the castings are made by high pressure die casting.

A self-cleaning transfer gear pump for transferring molten metal includes the following features: a transfer conduit extends upward from an outlet of a base, two rotatable gears are formed of refractory material and disposed in the gear chamber and engage each other during rotation. A boss functioning as a bearing extends from the drive gear and is adapted to be received in an opening in the base. A shaft is fastened at a lower end to the drive gear. A filter is fastened to the base so as to cover the inlet and prevents particles and objects in the molten metal from entering the gear chamber. In operational mode, a motor rotates the shaft and the drive gear whereby the drive gear and the second gear engage each other while being rotated so as to positively displace molten metal from the inlet to the outlet and along the transfer conduit to the remote location. In self-cleaning mode, the motor rotates the shaft and the drive gear effectively to draw molten metal from the transfer conduit by positive displacement, through the outlet, and toward the inlet therefore cleaning the filter by removing the particles adhering to the filter. Also included are a system with optional filter and optional self-cleaning mode but including an inlet portion of a die casting machine, and a method for operating the gear pump. A flow sensor may be used to transmit pulses into and from the transfer conduit so as to enable determination of a volume of molten metal being charged. The control of the molten metal volume being charged is not solely controlled by the flow sensor.

A self-cleaning transfer gear pump for transferring molten metal includes the following features: a transfer conduit extends upward from an outlet of a base, two rotatable gears are formed of refractory material and disposed in the gear chamber and engage each other during rotation. A boss functioning as a bearing extends from the drive gear and is adapted to be received in an opening in the base. A shaft is fastened at a lower end to the drive gear. A filter is fastened to the base so as to cover the inlet and prevents particles and objects in the molten metal from entering the gear chamber. In operational mode, a motor rotates the shaft and the drive gear whereby the drive gear and the second gear engage each other while being rotated so as to positively displace molten metal from the inlet to the outlet and along the transfer conduit to the remote location. In self-cleaning mode, the motor rotates the shaft and the drive gear effectively to draw molten metal from the transfer conduit by positive displacement, through the outlet, and toward the inlet therefore cleaning the filter by removing the particles adhering to the filter. Also included are a system with optional filter and optional self-cleaning mode but including an inlet portion of a die casting machine, and a method for operating the gear pump. A flow sensor may be used to transmit pulses into and from the transfer conduit so as to enable determination of a volume of molten metal being charged. The control of the molten metal volume being charged is not solely controlled by the flow sensor.

A die casting apparatus for manufacturing metal parts for automotive vehicle applications is provided. The die casting apparatus includes upper and lower dies presenting forming surfaces and a mold cavity therebetween. A replaceable insert and sub-inserts provide portions of the forming surfaces of the dies in areas most prone to wear and erosion. The replaceable inserts and sub-inserts can be removed and replaced during high volume production, without having to replace the entire die. A wear and/or heat resistant coating can be applied to the inserts and sub-inserts to further increase service life. A plurality of cooling channels can also be formed in the inserts and sub-inserts to improve cycle time and quality of the parts.

A die casting apparatus for manufacturing metal parts for automotive vehicle applications is provided. The die casting apparatus includes upper and lower dies presenting forming surfaces and a mold cavity therebetween. A replaceable insert and sub-inserts provide portions of the forming surfaces of the dies in areas most prone to wear and erosion. The replaceable inserts and sub-inserts can be removed and replaced during high volume production, without having to replace the entire die. A wear and/or heat resistant coating can be applied to the inserts and sub-inserts to further increase service life. A plurality of cooling channels can also be formed in the inserts and sub-inserts to improve cycle time and quality of the parts.

Nuclear waste, such as, but not limited to, spent nuclear fuel (SNF) assemblies or portions thereof, are chipped and compacted into (waste) pucks that are placed within diecast molds, and then diecast injection molding occurs within the diecast molds and around the pucks that are emplaced within those diecast molds, with injected molten alloy(s), to form solid metal ingots upon sufficient cooling after the diecasting injection that contain within the ingots the emplaced pucks. The molten alloy(s) may contain a copper alloy. The molten alloy(s) may also contain neutron absorbers. The ingots may be placed into waste capsules. The ingots and/or the waste capsules may be landed in deeply located horizontal wellbores. The deeply located horizontal wellbores may be at least partially located within deeply located geologic formations.

Nuclear waste, such as, but not limited to, spent nuclear fuel (SNF) assemblies or portions thereof, are chipped and compacted into (waste) pucks that are placed within diecast molds, and then diecast injection molding occurs within the diecast molds and around the pucks that are emplaced within those diecast molds, with injected molten alloy(s), to form solid metal ingots upon sufficient cooling after the diecasting injection that contain within the ingots the emplaced pucks. The molten alloy(s) may contain a copper alloy. The molten alloy(s) may also contain neutron absorbers. The ingots may be placed into waste capsules. The ingots and/or the waste capsules may be landed in deeply located horizontal wellbores. The deeply located horizontal wellbores may be at least partially located within deeply located geologic formations.

Nuclear waste, such as, but not limited to, spent nuclear fuel (SNF) assemblies or portions thereof, are placed within diecast molds, and then diecast injection molding occurs within the diecast molds and around the SNF assemblies or portions thereof that are emplaced within those diecast molds, with injected molten alloy(s), to form solid metal ingots upon sufficient cooling after the injection that contain within the ingots the emplaced SNF assemblies or portions thereof. The molten alloy(s) may contain a copper alloy. The molten alloy(s) may also contain neutron absorbers. The ingots may be placed into waste capsules. The ingots and/or the waste capsules may be landed in deeply located horizontal wellbores. The deeply located horizontal wellbores may be at least partially located within deeply located geologic formations.