A device (10) for producing die-cast components with a die-casting mold (12) and a discharge device which is provided for controlled evacuation of a mold cavity and which includes at least one vacuum unit (18) and at least one suction line (20) which connects the die-casting mold. The suction line (20) terminates at a mold vacuum valve (21) in the mold cavity. The device is connected to a central control system (1). A filter module (2) is inserted in the at least one suction line (20) which contains at least one filter, a moisture sensor, and a pressure sensor.

The casting mold is provided with: the molding wall portion forming the internal space; the supporting portion supports the heater to the molding wall portion; and the filling port allows the molten metal to flow into the internal space. The heater has: the end portion (the fixed portion) supported by supporting portion; and the extending portion extended from the end portion. The internal space has: the supporting region accommodating the end portion; and the extending region accommodating the extending portion. The filling ports respectively open to the portions of the molding wall portion facing the supporting regions.

The casting mold is provided with: the molding wall portion forming the internal space; the supporting portion supports the heater to the molding wall portion; and the filling port allows the molten metal to flow into the internal space. The heater has: the end portion (the fixed portion) supported by supporting portion; and the extending portion extended from the end portion. The internal space has: the supporting region accommodating the end portion; and the extending region accommodating the extending portion. The filling ports respectively open to the portions of the molding wall portion facing the supporting regions.

A method of over-molding a hybrid sub-assembly onto a base structure includes providing a mold for an over-molding process. The mold may comprise a lower mold tool, an upper mold tool, and a tube locator positioned on one of the upper mold tool or lower mold tool. A base structure formed of a first material is located into the tube locator. A mandrel tool is inserted into an opening in the base structure. The upper and lower mold tools are closed and clamped shut. A second material, such as a lighter weight or lower density material is heated to at least a semi-solid or slurry state. The semi-solid or slurry is injected into the mold to form a molded sub-assembly that is mechanically bonded to the base structure.

The heater (structure) has the gaps facing the molding wall portion of the casting mold. The casting mold is provided with: the molding wall portion forming the internal space; and the gap-portion filling ports (filling ports) that open to portions of the molding wall portion facing the gaps of the heater and that allow the molten metal to flow into the internal space.

The heater (structure) has the gaps facing the molding wall portion of the casting mold. The casting mold is provided with: the molding wall portion forming the internal space; and the gap-portion filling ports (filling ports) that open to portions of the molding wall portion facing the gaps of the heater and that allow the molten metal to flow into the internal space.

A CAE analysis die model is produced such that a cavity of a die for obtaining a cast product is divided into multiple elements. Fluidity analysis and solidification analysis are performed under a predetermined casting condition by means of the die model to calculate, for each element, a factor regarding growth of a solidification structure, a factor regarding purity of molten metal, and a factor regarding a hole defect. Mechanical characteristics of each portion of the cast product are obtained by a regression expression obtained by multiple regression analysis using mechanical characteristics of the cast product as an objective variable and using each factor as an explanatory variable.

A CAE analysis die model is produced such that a cavity of a die for obtaining a cast product is divided into multiple elements. Fluidity analysis and solidification analysis are performed under a predetermined casting condition by means of the die model to calculate, for each element, a factor regarding growth of a solidification structure, a factor regarding purity of molten metal, and a factor regarding a hole defect. Mechanical characteristics of each portion of the cast product are obtained by a regression expression obtained by multiple regression analysis using mechanical characteristics of the cast product as an objective variable and using each factor as an explanatory variable.

A vacuum die casting method may include: coupling a fixed die and a movable die to each other; closing a molten metal pouring hole formed in a sleeve using an injection plunger operated in the sleeve, which is formed on a lower side of the fixed die or the movable die; performing vacuum decompression in a cavity formed between the fixed die and the movable die using a vacuum decompression device connected to chill vent blocks provided on upper portions of the fixed die and the movable die; supplying oxygen in the cavity using an oxygen supply device connected to the chill vent blocks after completing the step of performing vacuum decompression; and supplying a molten metal to the cavity through the molten metal pouring hole.

Apparatus and methods for creating cast metal objects in space and other environments. Molds are created using additive manufacturing and are injected with a castable metal having a melting point lower than a mold melting point. In some aspects, the additive manufacturing device and the metal casting unit are contained in the same unit.