A metal casting method and a plastic injection molding method in which an insert is molded in molten material such that no molten material enters the interior of the insert. The usage of a wire thread insert as insert has the advantage that for example in an aluminum cast part thread holes can be produced already as part of the casting process. For this purpose, the casting mold, the insert, as well as the casting method are described.

A metal casting method and a plastic injection molding method in which an insert is molded in molten material such that no molten material enters the interior of the insert. The usage of a wire thread insert as insert has the advantage that for example in an aluminum cast part thread holes can be produced already as part of the casting process. For this purpose, the casting mold, the insert, as well as the casting method are described.

A mold assembly and method for fabricating an infiltrated drill bit may comprise a mold forming a bottom of the mold assembly, a funnel operatively coupled to the mold, an infiltration chamber defined at least partially by the mold and the funnel to receive and contain matrix reinforcement materials and a binder material used to form the infiltrated drill bit, a displacement core arranged within the infiltration chamber and having one or more legs that extend therefrom, a metal blank arranged about the displacement core within the infiltration chamber, and one or more thermal elements. A method may comprise providing a mold assembly having component parts that include a mold that forms a bottom of the mold assembly and a funnel operatively coupled to the mold, imparting thermal energy to the infiltration chamber with one or more thermal element, and heating contents contained within the infiltration chamber.

A mold assembly and method for fabricating an infiltrated drill bit may comprise a mold forming a bottom of the mold assembly, a funnel operatively coupled to the mold, an infiltration chamber defined at least partially by the mold and the funnel to receive and contain matrix reinforcement materials and a binder material used to form the infiltrated drill bit, a displacement core arranged within the infiltration chamber and having one or more legs that extend therefrom, a metal blank arranged about the displacement core within the infiltration chamber, and one or more thermal elements. A method may comprise providing a mold assembly having component parts that include a mold that forms a bottom of the mold assembly and a funnel operatively coupled to the mold, imparting thermal energy to the infiltration chamber with one or more thermal element, and heating contents contained within the infiltration chamber.

An example mold assembly for fabricating an infiltrated downhole tool includes a mold defining a bottom of the mold assembly and a funnel operatively coupled to the mold. An infiltration chamber is defined at least partially by the mold and the funnel to receive and contain matrix reinforcement materials and a binder material used to form the infiltrated downhole tool. A thermal mass is positioned within the infiltration chamber above the infiltrated downhole tool for imparting heat to the infiltrated downhole tool following an infiltration process.

An example mold assembly for fabricating an infiltrated downhole tool includes a mold defining a bottom of the mold assembly and a funnel operatively coupled to the mold. An infiltration chamber is defined at least partially by the mold and the funnel to receive and contain matrix reinforcement materials and a binder material used to form the infiltrated downhole tool. A thermal mass is positioned within the infiltration chamber above the infiltrated downhole tool for imparting heat to the infiltrated downhole tool following an infiltration process.

A method of fabricating a metal matrix composite (MMC) tool includes coating at least a portion of an interior of a mold assembly with one or more layers of a material coating, where the mold assembly defines at least a portion of an infiltration chamber. Reinforcing materials are deposited into the infiltration chamber, and infiltrated with a binder material. One or more layers of the material coating may then be reacted with the binder material to form an outer shell on selected outer surfaces of the MMC tool.

A method of fabricating a metal matrix composite (MMC) tool includes coating at least a portion of an interior of a mold assembly with one or more layers of a material coating, where the mold assembly defines at least a portion of an infiltration chamber. Reinforcing materials are deposited into the infiltration chamber, and infiltrated with a binder material. One or more layers of the material coating may then be reacted with the binder material to form an outer shell on selected outer surfaces of the MMC tool.

The method for the production of an element subject to wear, comprising a metal matrix and at least a core of hard material. The method provides a first step in which a temporary aggregation structure is prepared with at least partly open pores, which volatilize or in any case eliminate at least partly when subjected to heating. A second step in which, on the whole internal and external surface of said temporary aggregation structure, a liquid mixture of a binder with metal powders which contain hard elements or their precursors is uniformly distributed. A third step in which the temporary aggregation structure is deteriorated by means of a thermal action of controlled heating, so as to take at least part of the temporary aggregation structure to evaporation, rendering free a volume inside the core, and to consolidate the mixture according to the conformation of the temporary aggregation structure. A fourth step in which the core is disposed in a mold so as to only partly occupy the free volume of the mold. A fifth step in which a molten metal material is cast in the mold, which metal occupies the free volume and the volume that has been made free, both inside and outside the core, so as to anchor to the latter and thus form a single body.

The method for the production of an element subject to wear, comprising a metal matrix and at least a core of hard material. The method provides a first step in which a temporary aggregation structure is prepared with at least partly open pores, which volatilize or in any case eliminate at least partly when subjected to heating. A second step in which, on the whole internal and external surface of said temporary aggregation structure, a liquid mixture of a binder with metal powders which contain hard elements or their precursors is uniformly distributed. A third step in which the temporary aggregation structure is deteriorated by means of a thermal action of controlled heating, so as to take at least part of the temporary aggregation structure to evaporation, rendering free a volume inside the core, and to consolidate the mixture according to the conformation of the temporary aggregation structure. A fourth step in which the core is disposed in a mold so as to only partly occupy the free volume of the mold. A fifth step in which a molten metal material is cast in the mold, which metal occupies the free volume and the volume that has been made free, both inside and outside the core, so as to anchor to the latter and thus form a single body.