A high heat-absorption casting core for manufacturing a cast component includes a core body. The core body has at least a portion thereof defined by metal powder. The metal powder is configured to absorb heat energy from the cast component during cooling of the component and solidification thereof. The core body may be additionally defined by a sand fraction in contact with the metal powder fraction. A system and a method for manufacturing a cast component using the high heat-absorption casting core are also envisioned.

A high heat-absorption casting core for manufacturing a cast component includes a core body. The core body has at least a portion thereof defined by metal powder. The metal powder is configured to absorb heat energy from the cast component during cooling of the component and solidification thereof. The core body may be additionally defined by a sand fraction in contact with the metal powder fraction. A system and a method for manufacturing a cast component using the high heat-absorption casting core are also envisioned.

A hybrid core for manufacturing a cast component, the hybrid core including a sand core portion having an exterior shape configured to define an interior feature of the cast component. The hybrid core also includes a metal chill element embedded within the sand core portion. The metal chill element is configured to locally absorb heat energy from the cast component during cooling of the cast component and solidification thereof. The metal chill element is constructed and arranged within the sand core portion to be removed during shake out from the cast component subsequent to the solidification thereof. A system and a method for manufacturing a cast component using such a hybrid core are also envisioned.

A hybrid core for manufacturing a cast component, the hybrid core including a sand core portion having an exterior shape configured to define an interior feature of the cast component. The hybrid core also includes a metal chill element embedded within the sand core portion. The metal chill element is configured to locally absorb heat energy from the cast component during cooling of the cast component and solidification thereof. The metal chill element is constructed and arranged within the sand core portion to be removed during shake out from the cast component subsequent to the solidification thereof. A system and a method for manufacturing a cast component using such a hybrid core are also envisioned.

A modular casting mold for casting an automotive component includes a plurality of die portions defining a mold cavity corresponding to an automotive component, at least one of the plurality of die portions is an active die portion adapted to control the temperature of the modular casting mold throughout the casting process and including features for ejecting an automotive component cast within the modular casting mold, and the modular casting mold adapted to be attached to another modular casting mold for casting a single automotive component.

A modular casting mold for casting an automotive component includes a plurality of die portions defining a mold cavity corresponding to an automotive component, at least one of the plurality of die portions is an active die portion adapted to control the temperature of the modular casting mold throughout the casting process and including features for ejecting an automotive component cast within the modular casting mold, and the modular casting mold adapted to be attached to another modular casting mold for casting a single automotive component.

A method of manufacturing a mold by a machine tool, the method including predicting a thermal fatigue life of a mold which is made of a mold material having a hardness H and on which heating during contact with a workpiece and cooling after contact with a workpiece are repeated, the method including a step for obtaining a thermal stress maximum value σ.sub.h_MAX among a plurality of thermal stress values at a position x on the mold and a temperature T.sub.h at the thermal stress maximum value, wherein the temperature at the thermal stress maximum value σ.sub.h_MAX is a temperature lower than a maximum temperature among the plurality of temperatures, the machine tool manufactures the predetermined mold shape from a mold material having one of the plurality of hardnesses in which the thermal fatigue life was obtained based on the thermal stress maximum value, the yield strength, and the contraction.

A mold temperature control system that controls temperature of mold in a diecasting machine, includes temperature sensors that detect mold temperatures of individual parts of the mold, flow controllers that control instantaneous flow rates of cooling water that cools the parts of the mold, and a control device that acquires the mold temperatures detected by the temperature sensors, computes deviations between target mold temperature and the current mold temperatures at every production cycle, converts the deviations into flow rate values, and transmits the flow rate values to the flow controllers.

The present invention relates to a guiding and centering device (10) for a forming tool (2), in particular an injection molding or die-casting tool, comprising a first mold half (1) and a second mold half (5) which are guided by guide means (7) from a closed position in which the respective separating surfaces of both mold halves (1; 5) are pressed against one another into an opened position and vice versa. This guiding and centering device (10) comprises a protruding guiding body (4) formed as a circular cylindrical bolt (12) provided at the first mold half (1), a guiding recess (6) formed as a bush (14) with an circular cylindrical inner surface (20) provided at the second mold half (5) and a rolling element cage (16) with rolling elements (17) inserted in rows (18), by means of which the two mold halves (1; 5) are guided and precisely centered in the closed position. The rolling element cage (16) is supported by the circular cylindrical inner surface (20) of the bush (14) and positioned via positioning means (30) in such a way that when closing the forming tool the circular cylindrical bolt (12) runs practically simultaneously in a first row of rolling elements (18.1) and a second row of rolling elements (18.2) of the rolling element cage (16).

A process of forming a low cost, erosion, oxidation, and wear resistant composite liner or insert that can be installed into a shot chamber in a die casting machine is provided. The process utilizes a self-healing erosive wear resistant coating on a liner of refractory metal to serve as the working surfaces of a shot chamber. The refractory liner is bonded to a low cost material so that the liner can be made extremely thin. Such a composite liner is expected to have an improved service life for die casting of corrosive metals and alloys.