A reinforced magnesium matrix composite includes a quasicrystal and alumina mixture particles reinforcement phase and a magnesium alloy matrix, where the weight ratio of the quasicrystal and alumina mixture particles reinforcement phase to the magnesium alloy matrix is (4-8) to 100; the magnesium alloy matrix including by weight 1000 parts of magnesium, 90 parts of aluminum, 10 parts of zinc, 1.5-5 parts of manganese, 0.5-1 part of silicon and 0.1-0.5 part of calcium; the quasicrystal and alumina mixture particles reinforcement phase including by weight 40 parts of magnesium, 50-60 parts of zinc, 5-10 parts of yttrium and 8-20 parts of nanometer alumina particles of which the diameter is 20-30 nm; and the quasicrystal and alumina mixture particles reinforcement phase having a size of 100-200 mesh.

A cylinder head includes an inner structural member having a plate forming a deck face of the cylinder head and forming at least one dished cylinder roof, and a plurality of cylinder head bolt columns extending from the plate. An outer member is supported by the inner structural member and forms a cooling jacket, intake ports, and exhaust ports. Passages of the cooling jacket are lined with metal walls in contact with the composite structure of the outer member. A method of forming a cylinder head includes positioning a structural insert and a lost core insert in a tool, and injecting material into the tool to form a body surrounding the structural insert and the lost core insert thereby forming a head preform. The lost core insert is shaped to form a cooling jacket and has a lost core material generally encapsulated in a metal shell.

A method includes producing a light metal cast component from a melt of an aluminium casting alloy. The alloy contains, by weight, silicon with 3.5 to 5.0%, magnesium with 0.2 to 0.7%, titanium with 0.07 to 0.12%, boron with a maximum of 0.012%, and optionally further alloy elements together with less than 1.5%, the rest, aluminium as well as unavoidable impurities, wherein the melt is produced from a base melt, a first grain refiner of an aluminium-silicon alloy and a second grain refiner of an aluminium-titanium-alloy, wherein the melt, in relation to the total weight, contains in total an amount of 0.1 to 5.0% of the first and the second grain refiner; wherein the casting is carried out by a low-pressure method and the melt is acted upon by compacting after the casting.

A method of casting a metal alloy ingot, including the following steps: providing a one side open-ended mould including a plurality of sides and a bottom plate defining a mould cavity with a mould opening, the open-ended mould being pivotable around a horizontal rotational axis between a position so that the mould opening points upwards and a position so that the mould opening points side-wards or down-wards; positioning the open-ended mould such that the mould opening points side-wards or down-wards; providing a casting container with an upwardly positioned aperture; filling the casting container with molten metal for one casting operation; coupling the casting container to the open-ended mould so that the casting container is located below the mould while the mould opening points side-wards or down-wards; rotating the open-ended mould together with the casting container around the horizontal rotational axis for approximately 90 to 180 from a position whereby the mould opening points side-wards or down-wards to a position whereby the mould opening points upwards such that the molten metal is conveyed through the mould opening into the open-ended mould until reaching a desired thickness, whereby the molten metal in the open-ended mould is cooled directionally through its thickness where the solidification front remains substantially monoaxial.

Cylinder liners, methods of forming the same, and outer surface designs of a cylinder liner having as-cast projections with certain functional shapes are provided. The as-cast projections increase the clamping performance of the cylinder liner and do not result in any air gaps between a cast aluminum block and the cylinder liner.

The present invention provides an aluminum-diamond composite which combines high thermal conductivity and a coefficient of thermal expansion close to a semiconductor clement, and in which the difference between the thicknesses of both surfaces is reduced so as to be suitable for use as a heat sink etc. for a semiconductor element. Provided is a flat plate-shaped aluminum-diamond composite that has an aluminum-diamond composite part and a surface layer that coats both surfaces of the composite part and includes a metal that has aluminum as a principal component, Wherein: the composite part is composed of a composite material that is composed of an aluminum or aluminum alloy matrix and diamond particles dispersed in said matrix; the composite material is composed of a diamond powder in which diamond particles having a particle size of 1-20 m, inclusive, make up 10-40 vol of the diamond particles and diamond particles having a particle size of 100-250 m, inclusive, make up 50-80 vol %, said powder not containing diamond particles having a particle size of less than 1 m or diamond particles having a particle size of more than 250 m; and the average value for the differences in in-plane thickness per 50 mm50 mm is 100 m or less.

A method and alloys for low pressure permanent mold casting without a coating are disclosed. The method includes preparing a permanent mold casting die that is devoid of die coating or lubrication along the die surface, preparing a permanent mold casting alloy, pushing the alloy into the die under low pressure, cooling the permanent mold casting, and removing the casting from the die. One alloy has 4.5-11.5% by weight silicon; 0.45% by weight maximum iron; 0.20-0.40% by weight manganese; 0.45-0.110% by weight strontium; 0.05-5.0% by weight copper; 0.01-0.70% by weight magnesium; and the balance aluminum. Another alloy has 4.2-5.0% by weight copper; 0.005-0.45% by weight iron; 0.20-0.50% by weight manganese; 0.15-0.35% by weight magnesium; 0.045-0.110% by weight strontium; 0.50% by weight maximum nickel; 0.10% by weight maximum silicon; 0.15-0.30% by weight titanium; 0.05% by weight maximum tin; 0.10% by weight maximum zinc; and the balance aluminum.

Methods for casting high strength, high ductility lightweight metal components are provided. The casting may be die-casting. A molten lightweight metal alloy is introduced into a cavity of a mold. The molten lightweight metal alloy is solidified and then a solid component is removed from the mold. The solid component is designed to have a thin wall. For example, the solid component has at least one dimension of less than or equal to about 2 mm. In this way, a chill zone microstructure is formed that extends across the at least one dimension of the solid lightweight metal alloy component. The solid component thus may be substantially free of dendritic microstructure formation, enabling more extensive alloy chemistries than previously possible during casting. Such methods may be used to form high strength, high ductility, and lightweight metal alloy vehicle components.

A geothermally powered aluminum production subsystem includes a geothermal system with a wellbore extending from a surface into an underground magma reservoir. A hopper receives a bauxite ore that is crushed and provided to a digestor. The digestor is heated by a heat transfer fluid heated by the geothermal system, and a product of the digestor is used to prepare aluminum.

A high strength and toughness die-casting aluminum alloy without heat treatment, a preparation method and an article thereof are provided. Aluminum alloy includes the following components in percentage by mass: 7.0-10.0 wt. % of silicon, not more than 0.05 wt. % of copper, not more than 0.4 wt. % of magnesium, 0.3-0.7 wt. % of manganese, not more than 0.2 wt. % of iron, not more than 0.07 wt. % of zinc, not more than 0.2 wt. % of titanium, 0.015-0.03 wt. % of strontium, 0.01-0.1 wt. % of vanadium, 0.01-0.1 wt. % of zirconium, and other unavoidable impurity elements, each not more than 0.05 wt. %. The total amount of other unavoidable impurity elements is not more than 0.25 wt. %, and the rest is aluminum.