Hot-chamber die casting systems for casting aluminum, copper, titanium, and their alloys, as well as other high temperature and/or reactive metals. The hot-chamber die casting system comprises an injection system that includes a cylinder, a plunger reciprocable within the cylinder, and a gooseneck that defines a passage fluidically connected to a cylinder chamber within the cylinder, wherein surfaces of the cylinder, plunger, and gooseneck that contact a molten metal during injection casting are defined by a refractory material that does not react with the molten metal, or have been treated to reduce the rate of dissolution of their surface material into the molten metal during injection casting.

Various embodiments provide apparatus and methods for melting materials and for containing the molten materials within melt zone during melting. Exemplary apparatus may include a vessel configured to receive a material for melting therein; a load induction coil positioned adjacent to the vessel to melt the material therein; and a containment induction coil positioned in line with the load induction coil. The material in the vessel can be heated by operating the load induction coil at a first RF frequency to form a molten material. The containment induction coil can be operated at a second RF frequency to contain the molten material within the load induction coil. Once the desired temperature is achieved and maintained for the molten material, operation of the containment induction coil can be stopped and the molten material can be ejected from the vessel into a mold through an ejection path.

Various embodiments provide apparatus and methods for melting materials and for containing the molten materials within melt zone during melting. Exemplary apparatus may include a vessel configured to receive a material for melting therein; a load induction coil positioned adjacent to the vessel to melt the material therein; and a containment induction coil positioned in line with the load induction coil. The material in the vessel can be heated by operating the load induction coil at a first RF frequency to form a molten material. The containment induction coil can be operated at a second RF frequency to contain the molten material within the load induction coil. Once the desired temperature is achieved and maintained for the molten material, operation of the containment induction coil can be stopped and the molten material can be ejected from the vessel into a mold through an ejection path.

A die-casting machine has a casting mould, a casting chamber, a casting piston arranged in an axially movable manner in the casting chamber, a melt inlet channel which leads into the casting chamber, a shut-off valve in the melt inlet channel, a melt outlet channel which leads from the casting chamber to the casting mould, and a control unit for controlling the casting piston. The control unit and the shut-off valve are configured, after completing a filling phase in a subsequent refilling phase firstly to bring the shut-off valve into an open position and to control the casting piston to move back into the casting start position, in order to supply the casting chamber with melt material via the melt inlet channel, and to control the shut-off valve into its closed position again before the casting piston has reached its casting start position by virtue of its return movement, and to control the casting piston to back-suction melt material in the melt outlet channel by virtue of the further return movement of the casting piston.

A die-casting machine has a casting mould, a casting chamber, a casting piston arranged in an axially movable manner in the casting chamber, a melt inlet channel which leads into the casting chamber, a shut-off valve in the melt inlet channel, a melt outlet channel which leads from the casting chamber to the casting mould, and a control unit for controlling the casting piston. The control unit and the shut-off valve are configured, after completing a filling phase in a subsequent refilling phase firstly to bring the shut-off valve into an open position and to control the casting piston to move back into the casting start position, in order to supply the casting chamber with melt material via the melt inlet channel, and to control the shut-off valve into its closed position again before the casting piston has reached its casting start position by virtue of its return movement, and to control the casting piston to back-suction melt material in the melt outlet channel by virtue of the further return movement of the casting piston.

A casting unit for a die casting machine has a casting container with a casting chamber, a casting piston, which is arranged in an axially movable manner in the casting chamber, a melt bath connection opening, a melt inlet channel from the melt bath connection opening to the casting chamber, a melt outlet channel, which leads out of the casting chamber separately from the melt inlet channel, and a shut-off control valve for the melt inlet channel. The shut-off control valve has a valve main body arranged on the casting container, a valve seat and a valve closing body. The valve main body is held on the casting container at a lateral valve assembly region of the casting container in a manner accessible from the outside and includes the melt bath connection opening, and/or the casting piston is of a spool type, and the shut-off control valve is located with its valve closing body in the melt inlet channel at a flow-technical distance from the melt bath connection opening on the one hand and from the casting chamber on the other hand.

A casting unit for a die casting machine has a casting container with a casting chamber, a casting piston, which is arranged in an axially movable manner in the casting chamber, a melt bath connection opening, a melt inlet channel from the melt bath connection opening to the casting chamber, a melt outlet channel, which leads out of the casting chamber separately from the melt inlet channel, and a shut-off control valve for the melt inlet channel. The shut-off control valve has a valve main body arranged on the casting container, a valve seat and a valve closing body. The valve main body is held on the casting container at a lateral valve assembly region of the casting container in a manner accessible from the outside and includes the melt bath connection opening, and/or the casting piston is of a spool type, and the shut-off control valve is located with its valve closing body in the melt inlet channel at a flow-technical distance from the melt bath connection opening on the one hand and from the casting chamber on the other hand.

One aspect relates to an injection molding system for the injection molding of amorphous metals, an injection molding unit for the injection molding of amorphous metals and an injection molding process for amorphous metals. The injection molding system includes a channel for feeding a molten metal and a slider unit including a slider and a pressure system. The slider is located between the channel and at least one injection molding cavity and is movable between a rest position and an injection position. In the rest position, the slider blocks the access of the molten metal to the injection molding cavity and in the injection position it allows the molten metal to access the injection molding cavity. The pressure system holds the slider in the rest position and allows the slider to move to the injection position when a minimum pressure is exceeded.

A motor plate type coil forming apparatus forms a plate type coil wound on a stator of a motor by a squeeze casting method. In particular, the apparatus includes: i) a main frame including a lower frame and an upper frame; ii) a mold unit including a lower mold elastically connected to the lower frame to be movably installed in a vertical direction, and an upper mold movably installed in the upper frame in the vertical direction corresponding to the lower mold; and iii) a molten metal pressurizing unit including a plunger that is movably installed in the lower frame in a vertical direction corresponding to the lower mold. In particular, the lower mold may include a sleeve provided to be vertically coupled to the plunger, and a plurality of coil forming parts provided to form a cavity connected to the sleeve.

A motor plate type coil forming apparatus forms a plate type coil wound on a stator of a motor by a squeeze casting method. In particular, the apparatus includes: i) a main frame including a lower frame and an upper frame; ii) a mold unit including a lower mold elastically connected to the lower frame to be movably installed in a vertical direction, and an upper mold movably installed in the upper frame in the vertical direction corresponding to the lower mold; and iii) a molten metal pressurizing unit including a plunger that is movably installed in the lower frame in a vertical direction corresponding to the lower mold. In particular, the lower mold may include a sleeve provided to be vertically coupled to the plunger, and a plurality of coil forming parts provided to form a cavity connected to the sleeve.