The present invention discloses a new process for the injection of metallic materials into polymer-based moulds, the mould itself required for a process of this nature, and the apparatus which will execute the process and will employ the mould, in such a way that moulds with greater or lesser properties of flexibility are subjected to a pressurised injection of metal thereon, it being possible to adjust and coordinate the parameters of pressure, flowrate, closure of the mould, and the conditions of the material, thanks to a new polymer-based mould which adapts its configuration to the rest of the system and to the pressurised injection of the material.

There is provided a nitrided layer repair method in which a molten metal is pressurized and solidified, and thus a nitrided layer formed on a cavity surface of a mold used to form a casting object is repaired. In the nitrided layer repair method, a nitriding source is applied to the cavity surface, and the cavity surface of the mold is nitrided by heating and pressurizing the cavity surface using the molten metal.

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 method for die casting a metal alloy in a cavity, implementing a mold comprising induction heater to heat the molding surfaces of the cavity. The cavity is filled with the metal alloy by injection and preheated to a nominal preheating temperature T1. The metal in the cavity is solidified. The mold is opened and the part is ejected therefrom. The molding surfaces of the cavity is heated by induction while the part is no longer in contact with said surfaces. The molding surfaces of the cavity is sprayed, the mold being opened, by a release agent. The mold is closes and the cavity is heated the temperature T1.

A casting device is provided with: a pair of cylinders; a core pin holding member to which core pins are attached; and a pair of bent members. The cylinder is disposed in parallel with a second limb of the bent member, and a rod is coupled to a surface on the inner side of a first limb of the bent member. The second limb is coupled to the core pin holding member via a coupling mechanism so as to be freely attachable to/detachable from the core pin holding member.

The present invention relates to a steel for a mold, having a composition containing, on a % by mass basis, 0.25%<C<0.38%, 0.01%<Si<0.30%, 0.92%<Mn<1.80%, 0.8%<Cr<2.2%, 0.8%<Mo<1.4%, and 0.25%<V<0.58%, with the balance being Fe and inevitable impurities, and a mold manufactured by additive manufacturing by using the steel for a mold.

A die casting apparatus for manufacturing metal parts for automotive vehicle applications is provided. The die casting apparatus includes upper and lower dies presenting forming surfaces and a mold cavity therebetween. A replaceable insert and sub-inserts provide portions of the forming surfaces of the dies in areas most prone to wear and erosion. The replaceable inserts and sub-inserts can be removed and replaced during high volume production, without having to replace the entire die. A wear and/or heat resistant coating can be applied to the inserts and sub-inserts to further increase service life. A plurality of cooling channels can also be formed in the inserts and sub-inserts to improve cycle time and quality of the parts.

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 mold block includes a tool body with a contoured finished surface adapted to receive a tool insert having a forming surface for forming a bottle neck in a molding operation. The tool body defines an internal channel for heat transfer with the forming surface. At least a portion of the channel is offset generally equidistant from the finished surface to provide a path contoured for conformal cooling of the insert. The tool body has a pair of ports intersecting the channel. Several methods for forming a mold block are disclosed and include machining a contoured finished surface adapted to receive a tool insert on a tool body, forming a heat transfer channel within the tool body, and forming a pair of ports into the tool body. At least a portion of the channel is offset generally equidistant from the finished surface for conformal cooling of the insert.

A hot runner feed system is provided for a diecasting mold, wherein the feed system has a melt manifold and feed block construction having an entry-side feed inflow opening, at least one first and one second exit-side feed outflow opening which open into a mold separation plane between a fixed mold half and a movable mold half of the diecasting mold, and a casting runner-duct structure that extends so as to branch out from the feed inflow opening to the feed outflow openings. The melt manifold and feed block construction at least in an exit-side block region that includes the two feed outflow openings in a transverse direction parallel with the mold separation plane in relation to a predefined nominal operating extent is made so as to be shortened by an expansion dimension which has been predefined as a thermal transverse expansion of this block region when heated from a room temperature range to a predefined operating temperature range that is elevated in relation to said room temperature range.