An apparatus and method for melting and forming metal in a vacuum environment. Metal is melted within a metal-forming apparatus and the molten metal is filled into a mold cavity. A high-level vacuum environment is created in the apparatus by drawing air from the apparatus which is sealed from atmospheric air. This makes it possible to reduce contact with air, which can improve the quality of the metal product.

Proposed are an apparatus for molding a material, and a method for molding a material by using the apparatus. The apparatus includes first and second fixed platens (110 and 120) provided as a pair and spaced a predetermined distance from each other by tie bars (150), a movable platen (140) movable along the tie bars (150) between the first and second fixed platens (110 and 120), a mold (200) which is provided with a movable mold (220) and a fixed mold (240) and which forms a molding space (260) that is capable of being open or closed as the movable mold (220) moves in a direction toward or away from the fixed mold (240), and a pressing block (300) selectively positioned between the first fixed platen (110) and the movable mold (220) such that the pressing block is capable of applying a pressure to the movable mold (220).

Proposed are an apparatus for molding a material, and a method for molding a material by using the apparatus. The apparatus includes first and second fixed platens (110 and 120) provided as a pair and spaced a predetermined distance from each other by tie bars (150), a movable platen (140) movable along the tie bars (150) between the first and second fixed platens (110 and 120), a mold (200) which is provided with a movable mold (220) and a fixed mold (240) and which forms a molding space (260) that is capable of being open or closed as the movable mold (220) moves in a direction toward or away from the fixed mold (240), and a pressing block (300) selectively positioned between the first fixed platen (110) and the movable mold (220) such that the pressing block is capable of applying a pressure to the movable mold (220).

A die casting insert for producing die casted metal parts from liquid metal. The die casting insert has an outer casing shaped to be fixed in the die block of the die casting apparatus. The die casting insert also has a stopper with a purge opening that is adapted to evacuate contaminants topping the liquid metal as pressure is applied to the liquid metal. The stopper, fitted to mate with the hollow inner cavity of the injection sleeve, is constructed to seal the hollow inner cavity of the injection sleeve except at the purge opening when in a first position; and to permit the flow of the liquid metal into at least one molding cavity when the stopper is in a second position. The die casting insert also has an activation mechanism configured to shift the stopper between the first position and the second position.

A die casting insert for producing die casted metal parts from liquid metal. The die casting insert has an outer casing shaped to be fixed in the die block of the die casting apparatus. The die casting insert also has a stopper with a purge opening that is adapted to evacuate contaminants topping the liquid metal as pressure is applied to the liquid metal. The stopper, fitted to mate with the hollow inner cavity of the injection sleeve, is constructed to seal the hollow inner cavity of the injection sleeve except at the purge opening when in a first position; and to permit the flow of the liquid metal into at least one molding cavity when the stopper is in a second position. The die casting insert also has an activation mechanism configured to shift the stopper between the first position and the second position.

A mold and cavity are coupled to a vacuum tank via a pressure reducing path. A first back-cleaning filter 4a is disposed between the cavity and the vacuum tank in the pressure reducing path. The vacuum tank and the second dry pump are series-connected via a mechanical booster pump. The vacuum tank is sucked by the mechanical booster pump and the second dry pump, thereby always maintaining a predetermined vacuum degree in the vacuum tank. When carrying out die casting, first, after the mold is closed, a release agent is applied on an inner peripheral surface of the mold. Next, while reducing a pressure in the cavity using the vacuum tank, a molten metal is injected to the cavity. When the molten metal is solidified, the mold is opened and a cast product is taken out from the mold.

A die casting insert for producing die casted metal parts from liquid metal. The die casting insert has an outer casing shaped to be fixed in the die block of the die casting apparatus. The die casting insert also has a stopper with a purge opening that is adapted to evacuate contaminants topping the liquid metal as pressure is applied to the liquid metal. The stopper, fitted to mate with the hollow inner cavity of the injection sleeve, is constructed to seal the hollow inner cavity of the injection sleeve except at the purge opening when in a first position; and to permit the flow of the liquid metal into at least one molding cavity when the stopper is in a second position. The die casting insert also has an activation mechanism configured to shift the stopper between the first position and the second position.

A die casting insert for producing die casted metal parts from liquid metal. The die casting insert has an outer casing shaped to be fixed in the die block of the die casting apparatus. The die casting insert also has a stopper with a purge opening that is adapted to evacuate contaminants topping the liquid metal as pressure is applied to the liquid metal. The stopper, fitted to mate with the hollow inner cavity of the injection sleeve, is constructed to seal the hollow inner cavity of the injection sleeve except at the purge opening when in a first position; and to permit the flow of the liquid metal into at least one molding cavity when the stopper is in a second position. The die casting insert also has an activation mechanism configured to shift the stopper between the first position and the second position.

A piston of a die-casting apparatus comprises: a piston head fabricated of a first material; an elongate, inner carrier coupled to the piston head; a generally annular body seated on the carrier adjacent the piston head; and a wear ring disposed on the piston head, the wear ring being fabricated of a second material. The first material has a higher toughness and a lower hardness than the second material.

A piston of a die-casting apparatus comprises: a piston head fabricated of a first material; an elongate, inner carrier coupled to the piston head; a generally annular body seated on the carrier adjacent the piston head; and a wear ring disposed on the piston head, the wear ring being fabricated of a second material. The first material has a higher toughness and a lower hardness than the second material.