A shot sleeve assembly for use in the high pressure die casting of aluminum silicon alloys containing 0.40% maximum Fe is also disclosed. The shot sleeve assembly includes a shot sleeve including a pouring hole and a bushing assembly. The bushing assembly includes a refractory metal tube constructed of erosion resistant material surrounded by a bushing of conventional tool steel. The tube includes an opening and an impingement site located opposite the opening. The bushing includes an opening aligned with the opening of the tube, and an end plate. The bushing assembly is readily removed and inserted into the shot sleeve such that the openings of the bushing assembly align with the pouring hole of the shot sleeve. A method of replacing an impingement site of a shot sleeve with an erosion resistant material is also disclosed.

An insert for a steel shot sleeve of a high-pressure die casting assembly used to form aluminum vehicle components is provided. The insert is formed by additive manufacturing, for example laser sintering, and is located opposite a pouring hole of the shot sleeve. The insert includes multiple layers formed of metals and ceramic designed to reduce damage to the shot sleeve caused while casting the components. For example, a cylindrical body of the shot sleeve can be formed of steel, and the insert can include a base layer formed of the steel. The insert can include middle layers formed of a mixture of the steel; an alloy of chromium, iron, and molybdenum; and zirconium oxide. The insert can also include an inner layer formed of the zirconium oxide. The amount of ceramic increases and the amount of metal decreases in the direction moving toward the inner layer.

Embodiments provide methods, apparatuses and systems for depositing a thermal insulator coating onto a desired surface of a mold cavity or insert or preform. Embodiments also provide casting methods using a thermal insulator coating.

An example die casting system includes a die comprised of a plurality of die components that define a die cavity configured to receive a molten metal. One of the die components comprises a material that is not reactive with the molten metal and has a melting temperature above 815 degrees Celsius. The die casting system may be used in a method for die casting a gas turbine engine component.

The present disclosure provides a carbide refining method of a high-carbon high-alloy steel. The carbide refining method of a high-carbon high-alloy steel includes the following steps: formulating a raw material according to chemical element compositions of the high-carbon high-alloy steel, and smelting to obtain a high-carbon high-alloy molten steel; performing an overheat treatment on the high-carbon high-alloy molten steel to Tm+(50?100)? C., to obtain a high-carbon high-alloy melt, and making the high-carbon high-alloy melt to be deposited in a preset water-cooled copper mold at a speed of 30?160 g/s by an inert gas, to obtain a high-carbon high-alloy billet through solidification molding; and performing a heat treatment process on the high-carbon high-alloy billet.

A molding machine cylinder comprising a lining layer having a structure comprising 20-50% by area of tungsten carbide particles and 1-10% by area of tungsten-based metal carboboride particles in a nickel-based alloy matrix, and containing 1-7.5% by mass of Fe, can be produced by a centrifugal casting method comprising a first step of heating at higher than 1140 C. and lower than 1200 C., and a second step of heating at 1080-1140 C. after melting the raw material powder.

A process of forming a low cost, erosion, oxidation, and wear resistant composite liner or insert that can be installed into a shot chamber in a die casting machine is provided. The process utilizes a self-healing erosive wear resistant coating on a liner of refractory metal to serve as the working surfaces of a shot chamber. The refractory liner is bonded to a low cost material so that the liner can be made extremely thin. Such a composite liner is expected to have an improved service life for die casting of corrosive metals and alloys.

A process for permanent mold casting of metals and their alloys includes the steps of providing at least a mold equipped with a plurality of cooling nozzles, making a layer of coolant permeable materials covering the nozzles and maintaining the materials at desired temperatures, delivering a molten metal into the mold, supplying predetermined amount of coolant to each nozzles to contact the external surface of the casting at desired rate, time, and duration to achieve an acceptable level of progressive solidification from the distal end of the casting towards the riser until the casting has reached desired temperatures.

A piston head for making a piston of a press for a die-casting machine comprises a head body wherein at least one ring seat suitable to receive a respective sealing ring, is obtained. A lubrication circuit is obtained in the head body and comprises at least one lubrication end duct leading into a surface channel which runs through the bottom wall of the ring seat in order to convey the lubricant towards gaps between sealing ring and head.

Disclosed is an apparatus for loading one or more alloy ingots into a molding machine. The apparatus includes a holder configured to hold a plurality of the alloy ingots and dispense one or more of the alloy ingots into a melt zone of the molding machine through an opening in a mold of the machine. The holder is moved in a perpendicular direction with respect to an axis along a center of the opening in the mold between a first position in line with the opening in the mold to dispense one or more of the alloy ingots and a second position away from the opening in the mold. The apparatus can carry ingots of amorphous alloy material so that when the machine melts and molds the material, it forms a bulk amorphous alloy containing part.