A plunger for die casting may include a front injector end made of an iron alloy including, by mass: about 1% to about 6% nickel, about 0.1% to about 5% copper, about 0.2% to about 2.5% aluminum, about 0.5% to about 2% manganese, and about 0.05% to about 0.2% carbon. The iron alloy may be formed into an initial shape of the front injector end, heated to a temperature greater than or equal to about 900° C. and then cooled to form a supersaturated solid solution of iron and dissolved alloying elements. Then, the iron alloy may be heated at a temperature sufficient to precipitate intermetallic nanoparticles from the supersaturated solid solution to form an intermetallic precipitate phase dispersed throughout an iron-based matrix phase. A chemical compound layer may be formed at and along a surface of the iron alloy by exposing the iron alloy to an oxygen-containing and/or nitrogen-containing environment.

A cold flake suppression method is provided. A molding device includes a sleeve, a tip, a sprue guide portion, a molding die, a sprue ring, a distributer, and a control device. The sprue guide portion includes a stamp portion, a runner portion, and a gate portion. The control device drives a supply device to slide the tip for molten metal to flow through the sleeve; sequentially calculates an amount of heat transfer changing continuously from the start of supply of molten metal until the tip slides to the position in FIG. 2, and calculates a total of the amounts as a total amount of heat transfer; and calculates a volume of the sprue guide portion based on information about the sprue guide portion input by an operator. Shapes of the sleeve and the sprue guide portion are determined to set a cold flake index equal to or less than 0.842.

A die casting machine of an embodiment includes: a base; a fixed die plate fixed onto the base and holding a fixed die; a movable die plate provided on the base to be movable in a mold opening and closing direction and holding a movable die to face the fixed die; an injection device filling a molten metal into a cavity formed by the fixed die and the movable die and applying a first pressure to the molten metal; a first pressurizing device pressurizing the molten metal filled in the cavity in a region other than a product region of the cavity and applying a second pressure to the molten metal; and a control device controlling the first pressurizing device so that the second pressure becomes higher than the first pressure.

Proposed are an apparatus for molding a material, and a method for molding a material by using the apparatus. The apparatus includes first and second fixed platens (110 and 120) provided as a pair and spaced a predetermined distance from each other by tie bars (150), a movable platen (140) movable along the tie bars (150) between the first and second fixed platens (110 and 120), a mold (200) which is provided with a movable mold (220) and a fixed mold (240) and which forms a molding space (260) that is capable of being open or closed as the movable mold (220) moves in a direction toward or away from the fixed mold (240), and a pressing block (300) selectively positioned between the first fixed platen (110) and the movable mold (220) such that the pressing block is capable of applying a pressure to the movable mold (220).

A die-casting machine has a casting mould, a casting chamber, a casting piston arranged in an axially movable manner in the casting chamber, a melt inlet channel which leads into the casting chamber, a shut-off valve in the melt inlet channel, a melt outlet channel which leads from the casting chamber to the casting mould, and a control unit for controlling the casting piston. The control unit and the shut-off valve are configured, after completing a filling phase in a subsequent refilling phase firstly to bring the shut-off valve into an open position and to control the casting piston to move back into the casting start position, in order to supply the casting chamber with melt material via the melt inlet channel, and to control the shut-off valve into its closed position again before the casting piston has reached its casting start position by virtue of its return movement, and to control the casting piston to back-suction melt material in the melt outlet channel by virtue of the further return movement of the casting piston.

A punch pin assembly includes a punch rod, a punch pin and a punch pin connection rod connected therebetween. A heat-conducting medium conveying loop is arranged in the punch rod and the punch pin connection rod. The heat-conducting medium conveying loop communicates with the outside of the punch rod separately through a first medium port and a second medium port which are formed in the punch rod.

A die casting method includes a step of supplying molten metal to a plunger sleeve, and a step of advancing a plunger in the plunger sleeve, to inject the molten metal into dies. In the step of injecting the molten metal into the dies, the plunger is once retracted before being advanced, and the plunger is kept accelerated until the plunger reaches a target maximum speed when the plunger retracted is advanced.

A casting unit for a die casting machine has a casting container with a casting chamber, a casting piston, which is arranged in an axially movable manner in the casting chamber, a melt bath connection opening, a melt inlet channel from the melt bath connection opening to the casting chamber, a melt outlet channel, which leads out of the casting chamber separately from the melt inlet channel, and a shut-off control valve for the melt inlet channel. The shut-off control valve has a valve main body arranged on the casting container, a valve seat and a valve closing body. The valve main body is held on the casting container at a lateral valve assembly region of the casting container in a manner accessible from the outside and includes the melt bath connection opening, and/or the casting piston is of a spool type, and the shut-off control valve is located with its valve closing body in the melt inlet channel at a flow-technical distance from the melt bath connection opening on the one hand and from the casting chamber on the other hand.

A casting plunger system for a die casting machine includes a stationary system part and a system part which moves relative to the stationary system part in a respective casting cycle for the introduction of melt material into a casting mould. The moved system part has a plunger, a plunger rod and a rod drive unit, and is configured to decelerate at the end of a mould filling phase of the casting cycle under the effect of pressure on the melt material. A casting method for a die casting machine is provided with such a plunger system. The moved system part has a mass which can be adjusted variably between different casting cycles, and/or the moved system part consists of a moved main system part and an additional mass unit which is arranged so as to be movable relative to the main system part and is configured to decelerate, at the end of the mould fill phase of the casting cycle, later by a predefined delay time than the main system part.

A plunger tip slides along an inner surface of the plunger sleeve and that injects a molten metal into a mold. The plunger tip includes: a tip main body; a ring-shaped hard resin member that is attached to an outer peripheral surface of the tip main body and that is in contact with the inner surface of the plunger sleeve at least during a hot period in which the plunger tip slides along the inner surface of the plunger sleeve; and a silicone resin member positioned between the tip main body and the ring-shaped hard resin member, in which a radial thickness of the silicone resin member during the hot period is thinner than a radial thickness of the silicone resin member during a cold period in which the molten metal is not supplied in the plunger sleeve.