An inner door panel (30) for a vehicle side door that includes an integrated side impact beam (70) formed as part of the door in a die casting process. The inner door panel (30) includes an outer frame having a top rail (38), a bottom rail (40), an inner side rail (42) and an outer side rail (44) defining a central opening (34). The impact beam (70) includes a main beam portion (72), a first end support portion (74) and a second end support portion (78). The first end support portion is formed to the side rail (42) and the second end support portion (78) is formed to the outer side rail (44), where the main beam portion (72) extends across the opening (34).

A molten metal feed pipe for feeding a molten metal of an nonferrous alloy includes an outer tube made of a ferrous material, an inner tube made of a molten metal resistant material, and an intermediate member made of a compact of a fibrous non-organic material, which is disposed between the outer tube and the inner tube. The intermediate member, positioned in the central region of the molten metal feed pipe with respect to the longitudinal axial direction of the molten metal feed pipe, is disposed between the outer tube and the inner tube with the intermediate member being compressed in a radial direction of the molten metal feed pipe.

A cylinder liner for insertion into an aluminum internal-combustion engine block may include a cylindrical body of cast iron having a circumferential external surface. The cylinder liner may also have a coating deposited on and surrounding the external surface. The external surface may have a specific roughness, and the coating may include at least 98% by volume of pure nickel, and a remainder composed of impurities.

An aluminum alloy includes 6 to 8.5 wt % of magnesium (Mg), 4 to 6 wt % of silicon (Si), 0.4 to 0.8 wt % of iron (Fe), 0.2 to 0.5 wt % of manganese (Mn), 0.01 to 0.1 wt % of copper (Cu), 0.05 to 0.15 wt % of titanium (Ti), and the remainder being aluminum (Al), and may be in use for die-casting electronic components or communication components which require weight reduction and high corrosion resistance.

A molten metal processing device including an assembly mounted on the casting wheel, including at least one vibrational energy source which supplies vibrational energy to molten metal cast in the casting wheel while the molten metal in the casting wheel is cooled, and a support device holding the vibrational energy source. An associated method for forming a metal product which provides molten metal into a containment structure included as a part of a casting mill, cools the molten metal in the containment structure, and couples vibrational energy into the molten metal in the containment structure.

The invention relates to a method of casting a metal alloy ingot. The method includes providing an on one side open-ended mould having a mould cavity, 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, and filling said casting container with molten metal for one casting operation. The method also includes locating the casting container below the mould while the mould opening points side-wards or down-wards, and rotating the mould together with the casting container to a position whereby the mould opening points upwards such that the molten metal is conveyed into the open-ended mould until a desired thickness. Molten metal in the open-ended mould is cooled directionally through its thickness where the solidification front remains substantially monoaxial.

New 2xxx aluminum alloys having are disclosed. The new 2xxx aluminum alloys generally include 2.5-3.9 wt. % Cu, 0.82-1.20 wt. % Li, 0.5-2.0 wt. % Zn, 0.10-0.60 wt. % Mn, 0.05-0.35 wt. % Mg, from 0.05 to 0.50 wt. % of at least one grain structure control element, wherein the at least one grain structure control element is selected from the group consisting of Zr, Sc, Cr, V, Hf, other rare earth elements, and combinations thereof, up to 0.22 wt. % Ag, up to 0.15 wt. % Fe, up to 0.12 wt. % Si, and up to 0.15 wt. % Ti, the balance being aluminum, incidental elements and impurities. The new 2xxx aluminum alloys may realize an improved combination of two or more of strength, fracture toughness, elongation, and corrosion resistance.

Methods and systems are provided for continuously producing cast metal components. An exemplary method includes feeding molten metal into a first mold at a fill station; maintaining a pressurized chamber at an elevated pressure; moving the first mold into the pressurized chamber, wherein the molten metal solidifies in the first mold under the elevated pressure; and removing the first mold from the pressurized chamber.

A coating for a carrier material made of a steel material for joining to an aluminum material includes a first sublayer on the core part side and a second sublayer on the outside. On average, the coating includes approximately 1 to 10 wt. % silicon and iron, the remainder being aluminum. The first sublayer at least approximately includes 42 wt. % iron, 11 wt. % silicon, and no more than approximately 45 wt. % aluminum, which constitutes the remainder, and has a thickness of no more than approximately 3.5 μm. The second sublayer includes approximately 1 to 10 wt. % silicon, the remainder being aluminum, and has a thickness of approximately 5 to approximately 95 μm.

A die cast component includes an insert element with a plurality of form-fitting elements which are designed for the form-fitting connection of the insert element with a casting material. A ratio of a component wall thickness to a wall thickness of the insert element is a maximum of 4.