A hybrid die cast system (10) having an inner liner insert (12) that enables the configuration of a component (18) produced by the system (10) to be easily changed by changing the inner liner insert (12) without having to rework the die housing (16) is disclosed. Because the inner liner insert (12) only need be removed and replaced to change the configuration of an outer surface (18) of a component (18) produced by the system (10), the cost savings is significant in contrast with conventional systems in which the die would have to be reworked. The system (10) may also include a cooling system (20) for controlling the casting process by controlling the rate of solidification and the rate of cooling of the casting. Local heating and cooling may be used to control the microstructure, enhance mold fill and reduce casting defects such as porosity.

A hybrid die cast system (10) having an inner liner insert (12) that enables the configuration of a component (18) produced by the system (10) to be easily changed by changing the inner liner insert (12) without having to rework the die housing (16) is disclosed. Because the inner liner insert (12) only need be removed and replaced to change the configuration of an outer surface (18) of a component (18) produced by the system (10), the cost savings is significant in contrast with conventional systems in which the die would have to be reworked. The system (10) may also include a cooling system (20) for controlling the casting process by controlling the rate of solidification and the rate of cooling of the casting. Local heating and cooling may be used to control the microstructure, enhance mold fill and reduce casting defects such as porosity.

A molding machine for molding material is provided. The machine includes a cavity to be filled with molten metal and a conduit system leading to the cavity, thus forming a system of interconnected hollow spaces. At least one pressure member is moveable in at least part of the conduit system. A centrifugal pump in fluid communication with a reservoir of molten metal is provided, the pump providing molten metal to the hollow space receiving the at least one pressure member.

A molding machine for molding material is provided. The machine includes a cavity to be filled with molten metal and a conduit system leading to the cavity, thus forming a system of interconnected hollow spaces. At least one pressure member is moveable in at least part of the conduit system. A centrifugal pump in fluid communication with a reservoir of molten metal is provided, the pump providing molten metal to the hollow space receiving the at least one pressure member.

An apparatus for injecting molten metal into a die cast machine is provided. The apparatus includes a molten metal reservoir having a first open end in fluid communication with a die casting mold and a second open end. The molten metal reservoir includes at least one first cooling fluid path positioned about at least a portion of an outer surface of the molten metal reservoir and in thermal contact with the molten metal reservoir. The apparatus further includes a plunger sized to fit within the second open end. The plunger includes a plunger tip and a second cooling fluid path defined within the plunger tip and in thermal contact with the molten metal reservoir. A plurality of thermal actuators are also provided. Each of the plurality of thermal actuators controls a volume of cooling fluid flowing through one first cooling fluid path of the at least one first cooling fluid path or the second cooling fluid path.

An apparatus for injecting molten metal into a die cast machine is provided. The apparatus includes a molten metal reservoir having a first open end in fluid communication with a die casting mold and a second open end. The molten metal reservoir includes at least one first cooling fluid path positioned about at least a portion of an outer surface of the molten metal reservoir and in thermal contact with the molten metal reservoir. The apparatus further includes a plunger sized to fit within the second open end. The plunger includes a plunger tip and a second cooling fluid path defined within the plunger tip and in thermal contact with the molten metal reservoir. A plurality of thermal actuators are also provided. Each of the plurality of thermal actuators controls a volume of cooling fluid flowing through one first cooling fluid path of the at least one first cooling fluid path or the second cooling fluid path.

A die casting method includes stirring an aluminum alloy liquid in a stirrer under an airtight vacuum condition. The stirrer includes an electromagnetic inductor and a stirring rod. The aluminum alloy liquid is simultaneously subjected to an electromagnetic stirring in a direction of a magnetic field generated by the electromagnetic inductor and a mechanical stirring under a rotation action of the stirring rod. The aluminum alloy liquid is stirred for 20-80 minutes until the aluminum alloy liquid becomes semisolid to obtain a semisolid aluminum alloy slurry. The method further includes injecting the semisolid aluminum alloy slurry into a filter die to perform die casting molding at an injection speed of 1.5-2.5 m/s, an injection specific pressure of 30-80 MPa, a pressurization pressure of 60-80 MPa, and a temperature of the filter die of 250-400° C., and maintaining pressure for 7-30 seconds to obtain the filtering cavity.

A vacuum sensor system includes a vacuum pump, vacuum tank, solenoid valve, filters, vacuum block, sensors, and a central processing unit (CPU). The vacuum sensor system monitors the performance of a vacuum system connected to a high pressure die casting machine to ensure that the components cast in the mold or die will have a greater yield of acceptable parts. More specifically, the vacuum sensor system uses sensors to monitor and analyze the vacuum pressure at multiple locations to determine which components are clogging and causing a loss of vacuum pressure in the system. When the CPU detects an anomaly in the pressure, the CPU provides notification in one or more of the following ways: sending a command to shut down the die casting machine; visual notification on the screen of the CPU; an audible warning signal; a visual notification on a semaphore installed on the machine; and/or an electronic notification to one or more users via email, text, or other form of telecommunication.

A vacuum sensor system includes a vacuum pump, vacuum tank, solenoid valve, filters, vacuum block, sensors, and a central processing unit (CPU). The vacuum sensor system monitors the performance of a vacuum system connected to a high pressure die casting machine to ensure that the components cast in the mold or die will have a greater yield of acceptable parts. More specifically, the vacuum sensor system uses sensors to monitor and analyze the vacuum pressure at multiple locations to determine which components are clogging and causing a loss of vacuum pressure in the system. When the CPU detects an anomaly in the pressure, the CPU provides notification in one or more of the following ways: sending a command to shut down the die casting machine; visual notification on the screen of the CPU; an audible warning signal; a visual notification on a semaphore installed on the machine; and/or an electronic notification to one or more users via email, text, or other form of telecommunication.

A system for injecting semisolid metal into a mold, the system including a mold having a mold chamber, at least one press device having a cylinder, an injection chamber, and a thrust piston, a positioning device supporting a blending device having an active portion and a cover, and an actuating device that selectively injects the semisolid metal into the mold.