Some embodiments provide methods and systems for casting articles. One example of a method includes providing and positioning a thermal blanket within a mold cavity and then introducing a molten material into the mold cavity and into contact with the thermal blanket. The method allows the molten material to remain in a molten state during a dwell time that extends from the introduction of the molten material at least until the mold cavity is filled. In another example, a method of using a thermal blanket includes keeping a molten material in a molten state during a dwell time extending from first introduction of the molten material until pressurization. Systems including a variety of mold types, one or more thermal blankets, and in some cases preforms and/or inserts are also provided. Also described is a novel thermal blanket and method of manufacturing the same.

Disclosed is an injection tip for injecting liquid metal under pressure, suitable for being inserted between a liquid metal supply conduit and an injection opening of a mould, the injection tip having a tubular in shape, made from electrically insulating refractory material and in that it includes a channel suitable for the flow of liquid metal between a first end referred to as the upstream end, suitable for being connected to the conduit, and a second end, referred to as the downstream end, suitable for being connected to the mould, and an electromagnetic coil, positioned between the ends, the axis of which merges with at least a portion of the axis of the channel. Also disclosed is a casting machine using such a tip and a method for casting metal using the machine.

A die casting plunger tip assembly includes a first portion having a closed end defining an outer face and a tip cover disposed on the outer face of the closed end. The tip cover includes a support structure extending from an inner surface of the tip cover toward the closed end. The support structure is positioned in contact with the outer face of the closed end and a cavity is formed between the outer face of the closed end and the tip cover.

A process of forming a low cost, erosion, oxidation, and wear resistant one-piece composite liner or insert that can be installed into a shot chamber in a die casting machine is provided. The process utilizes a thin inner layer of refractory metal to serve as the working surfaces of a shot chamber. The thin refractory layer is bonded metallurgically to a thick low cost material to form a one-piece liner thick enough to resist thermal distortion during die casting operation. A self-healing erosive wear resistant coating is applied on the working surface of the refractory metal layer. Such a one-piece composite liner is expected to have an improved service life for die casting of corrosive metals and alloys.

A diecasting mold, comprising a first mold plate which is hot in operation and comprising at least one diecasting nozzle with an outlet point for a melt, and a second mold plate which forms a cold side. A mold cavity is formed between the first and second mold plates in a closed state of the diecasting mold, in which mold cavity a molded part can be produced from solidified melt introduced into the mold cavity via at least one melt channel, at least one diecasting nozzle and the at least one gate. The diecasting mold further comprises a demolding system, the demolding system comprising an ejector assembly, a drive device, and a force transmission device. A hot chamber system for diecasting metal melt according to the hot chamber method is also taught, a method for diecasting metal, and a use of a diecasting mold.

An apparatus and method for extending service life of a shot chamber and for seasoning a molten alloy are provided. The apparatus can be placed on a shot chamber of a die casting machine, absorbing the impact of the molten alloy during pouring, delivering the molten alloy smoothly into a shot chamber, and seasoning the molten alloy so that the alloy can be die cast at temperatures below its liquidus. The use of such an apparatus is expected to significantly increase the service life and a shot chamber in addition to improve the mechanical properties of the resultant cast component.

Shot sleeves for high temperature die casting include a low modulus single crystal nickel-based alloy having less than 1 ppm sulfur, a low modulus single crystal nickel-based alloy doped with a sulfur active element, a low modulus single crystal nickel-based alloy having a protective oxide coating, or a combination of two or more of the foregoing.

A high-pressure die casting apparatus including a shot sleeve extending through a first die half to a molding surface, and a plunger received in the shot sleeve is provided. The shot sleeve includes a side wall presenting a fluid passageway and a partial end wall disposed in a fixed position relative to the side wall. The partial end wall defines a wall opening adjacent the molding surface. Fluid is poured into the shot sleeve while the die apparatus is open, and the partial end wall prevents the fluid from flowing out of the shot sleeve. The plunger then presses the material into the mold cavity until only a portion of the material remains in the shot sleeve and blocks the wall opening. After the solidified material is ejected from the apparatus, the portion of material blocking the wall opening prevents lubricant from entering the shot sleeve.

A shot sleeve for a die-casting apparatus is described. The shot sleeve has a piston bore, and comprises an elongate body having an axial bore, and a sleeve liner formed on a surface of the axial bore. The sleeve liner defines a surface of the piston bore.

A device for die casting a metal component included a die casting mold which has a cavity that forms the component. The cavity is connected to a source for a metal melt by at least one temperature controlled supply channel. The metal melt is introduced into the cavity via at least one casting valve. The supply channel forms an annular channel, in which metal melt can be circulated via a conveying apparatus.