Composite parts (10), methods of making the same (400), and tooling systems (200) for making the same are disclosed. According to one example, a high-pressure die casting process is used to manufacture a composite part (10) that is made from a composite metal material (12) with a metal matrix phase (20) and a particle phase (22) and includes an interior region (14) and an exterior region (16), where an average concentration of the particle phase (22) in the composite metal material (12) is higher in the exterior region (16) than in the interior region (14). An interior surface (206a, 206b) of a die mold (206) may be coated with a particle phase (22) (e.g., a ceramic-based material) and a molten metal matrix phase (20) (e.g., an aluminum-based material) may then be introduced into the die mold (206) such that a composite part (10) is formed with an exterior region (16) or outer layer that is particle-rich compared to an interior region (14).

A castable, moldable, and/or extrudable structure using a metallic primary alloy. One or more additives are added to the metallic primary alloy so that in situ galvanically-active reinforcement particles are formed in the melt or on cooling from the melt. The composite contains an optimal composition and morphology to achieve a specific galvanic corrosion rate in the entire composite. The in situ formed galvanically-active particles can be used to enhance mechanical properties of the composite, such as ductility and/or tensile strength. The final casting can also he enhanced by heat treatment, as well as deformation processing such as extrusion, forging, or rolling, to further improve the strength of the final composite over the as-cast material.

A castable, moldable, and/or extrudable structure using a metallic primary alloy. One or more additives are added to the metallic primary alloy so that in situ galvanically-active reinforcement particles are formed in the melt or on cooling from the melt. The composite contains an optimal composition and morphology to achieve a specific galvanic corrosion rate in the entire composite. The in situ formed galvanically-active particles can be used to enhance mechanical properties of the composite, such as ductility and/or tensile strength. The final casting can also he enhanced by heat treatment, as well as deformation processing such as extrusion, forging, or rolling, to further improve the strength of the final composite over the as-cast material.

An aluminum alloy for casting, made of an Al—Si—Cu—Mg alloy which consists of specific amounts of Si, Cu, and Mg, in addition to specifically desired amounts of titanium, phosphorus, boron, and optional additional chemical elements sodium and strontium, with the balance of the aluminum alloy comprising aluminum and any impurities. When a content of phosphorus is defined as X mass %, the content of phosphorus, a content of Y mass % of sodium, and a content of Z mass % of strontium satisfy the following relationships: 0.45Y+0.24Z+0.003≤X≤0.45Y+0.24Z+0.01; 0≤Y≤0.01; and 0≤Z≤0.03. The aluminum alloy ensures surface smoothness of a cast article by specifying the phosphorus content. This minimizes a surface segregation layer, even in production of a cast article using a molten metal containing a eutectic structure modifier such as sodium.

An aluminum alloy for casting, made of an Al—Si—Cu—Mg alloy which consists of specific amounts of Si, Cu, and Mg, in addition to specifically desired amounts of titanium, phosphorus, boron, and optional additional chemical elements sodium and strontium, with the balance of the aluminum alloy comprising aluminum and any impurities. When a content of phosphorus is defined as X mass %, the content of phosphorus, a content of Y mass % of sodium, and a content of Z mass % of strontium satisfy the following relationships: 0.45Y+0.24Z+0.003≤X≤0.45Y+0.24Z+0.01; 0≤Y≤0.01; and 0≤Z≤0.03. The aluminum alloy ensures surface smoothness of a cast article by specifying the phosphorus content. This minimizes a surface segregation layer, even in production of a cast article using a molten metal containing a eutectic structure modifier such as sodium.

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.

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.

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.

An injection device of light metal injection molding machine and an injection control method thereof are provided, in which a melt in a supply unit is supplied into an injection unit through a communication passage, a plunger of the injection unit is retracted to measure the melt, the communication passage is closed, and the plunger is advanced to inject the melt into a mold device through an injection nozzle of the injection unit. After the injection and before the measurement, the plunger is advanced under a pressure at which the melt does not come out from the injection nozzle to make the melt in the injection unit flow back into the supply unit through the opened communication passage.