A method for forming a vehicular brake rotor involving loading a shaped metal substrate with a mixture of metal alloying components and ceramic particles in a dieheating the contents of the die while applying pressure to melt at least one of the metal components of the alloying mixture whereby to densify the contents of the die and form a ceramic particle-containing metal matrix composite coating on the metallic substrate; and cooling the resulting coated product.

A method for forming a vehicular brake rotor involving loading a shaped metal substrate with a mixture of metal alloying components and ceramic particles in a dieheating the contents of the die while applying pressure to melt at least one of the metal components of the alloying mixture whereby to densify the contents of the die and form a ceramic particle-containing metal matrix composite coating on the metallic substrate; and cooling the resulting coated product.

A method for forming a vehicular brake rotor involving loading a shaped metal substrate with a mixture of metal alloying components and ceramic particles in a dieheating the contents of the die while applying pressure to melt at least one of the metal components of the alloying mixture whereby to densify the contents of the die and form a ceramic particle-containing metal matrix composite coating on the metallic substrate; and cooling the resulting coated product.

The present invention relates to a casting mold for a metal sheet by drawing molten metal into a mold cavity and cooling the molten metal, and the casting mold according to the present invention includes: a support portion at an upper side on which molten metal is disposed or a solid metal is placed and melted; a mold cavity at a lower side in which the metal sheet is formed as the molten metal is drawn from the support portion while filling the mold cavity and cooled; and a passageway through which the molten metal is drawn into the mold cavity from the support portion, in which the mold cavity includes a first surface at the upper side which communicates with the passageway, and a second surface at the lower side which faces the first surface, a plurality of suction portions for drawing the molten metal are formed in the second surface and extended downward from the second surface, the suction portions are connected to a vacuum source and configured to draw the molten metal by suctioning air from the mold cavity, and a blocking member, which is in contact with the second surface or the suction portions to prevent a leakage of the molten metal and allow an air flow, is disposed on the suction portions in the mold cavity.

The present invention relates to a casting mold for a metal sheet by drawing molten metal into a mold cavity and cooling the molten metal, and the casting mold according to the present invention includes: a support portion at an upper side on which molten metal is disposed or a solid metal is placed and melted; a mold cavity at a lower side in which the metal sheet is formed as the molten metal is drawn from the support portion while filling the mold cavity and cooled; and a passageway through which the molten metal is drawn into the mold cavity from the support portion, in which the mold cavity includes a first surface at the upper side which communicates with the passageway, and a second surface at the lower side which faces the first surface, a plurality of suction portions for drawing the molten metal are formed in the second surface and extended downward from the second surface, the suction portions are connected to a vacuum source and configured to draw the molten metal by suctioning air from the mold cavity, and a blocking member, which is in contact with the second surface or the suction portions to prevent a leakage of the molten metal and allow an air flow, is disposed on the suction portions in the mold cavity.

A system and method for continuous casting. The system includes a melt chamber, a withdrawal chamber, and a secondary chamber therebetween. The melt chamber can maintain a melting pressure and the withdrawal chamber can attain atmospheric pressure. The secondary chamber can include regions that can be adjusted to different pressures. During continuous casting operations, the first region adjacent to the melt chamber can be adjusted to a pressure that is at least slightly greater than the melting pressure; the pressure in subsequent regions can be sequentially decreased and then sequentially increased. The pressure in the final region can be at least slightly greater than atmospheric pressure. The differential pressures can form a dynamic airlock between the melt chamber and the withdrawal chamber, which can prevent infiltration of the melt chamber by non-inert gas in the atmosphere, and thus can prevent contamination of reactive materials in the melt chamber.

A system and method for continuous casting. The system includes a melt chamber, a withdrawal chamber, and a secondary chamber therebetween. The melt chamber can maintain a melting pressure and the withdrawal chamber can attain atmospheric pressure. The secondary chamber can include regions that can be adjusted to different pressures. During continuous casting operations, the first region adjacent to the melt chamber can be adjusted to a pressure that is at least slightly greater than the melting pressure; the pressure in subsequent regions can be sequentially decreased and then sequentially increased. The pressure in the final region can be at least slightly greater than atmospheric pressure. The differential pressures can form a dynamic airlock between the melt chamber and the withdrawal chamber, which can prevent infiltration of the melt chamber by non-inert gas in the atmosphere, and thus can prevent contamination of reactive materials in the melt chamber.

A method for forming a vehicular brake rotor involving loading a shaped metal substrate with a mixture of metal alloying components and ceramic particles in a dieheating the contents of the die while applying pressure to melt at least one of the metal components of the alloying mixture whereby to densify the contents of the die and form a ceramic particle-containing metal matrix composite coating on the metallic substrate; and cooling the resulting coated product.

A method for forming a vehicular brake rotor involving loading a shaped metal substrate with a mixture of metal alloying components and ceramic particles in a dieheating the contents of the die while applying pressure to melt at least one of the metal components of the alloying mixture whereby to densify the contents of the die and form a ceramic particle-containing metal matrix composite coating on the metallic substrate; and cooling the resulting coated product.

A method for forming a vehicular brake rotor involving loading a shaped metal substrate with a mixture of metal alloying components and ceramic particles in a dieheating the contents of the die while applying pressure to melt at least one of the metal components of the alloying mixture whereby to densify the contents of the die and form a ceramic particle-containing metal matrix composite coating on the metallic substrate; and cooling the resulting coated product.