A die casting assembly has a cavity defined by multiple dies, the cavity includes at least one sharp corner. Each of the dies includes multiple die segments. A die segment joint between at least two of the die segments is aligned with the sharp corner.

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 die casting die includes a shoe comprised of a first material and includes a pocket. An insert is arranged in the pocket. The insert is comprised of a second material that is different from the first material and the insert provides a contoured surface. A coating is on the contoured surface. The coating provides a cast part contour.

A plant and a process are disclosed for producing components made of an aluminum alloy for vehicles and white goods, through the steps of: providing thixotropic billets made of an aluminum alloy; sizing the billets depending on a ratio between weight and size of the component to be produced, thereby obtaining crop ends of material; heating the crop ends in a range of temperatures during which both a solid phase and a liquid phase coexist with a prevalence in the solid phase (more than 50%) in heating means (5); loading, through loading means (9), the crop ends in an injecting vessel made of non-magnetic steel for further workings; removing, through scalping devices, an external part of the crop ends that has become cooled when passing from the heating means (5) to the loading means (9); firstly injecting the crop ends through a press; secondly injecting the crop ends through the press in 18 milliseconds by using a closed-loop control system and increasing the injection unit power with respect to a closing unit of the press; thirdly injecting the crop ends by coining the finished part in order to remove all porosities; extracting the molding through extracting means (13); depositing the molding onto a conveyor belt (15); and controlling a quality of the obtained molding, the molding being then sent to downstream mechanical workings and/or an heat treatment.

A mold and die metallic material, an air-permeable member for mold and die use, and a method for making the same are provided. The mold and die metallic material is made by forming a mixed material containing stainless steel fibers with an equivalent diameter of 30-300 m and a length of 0.4-5.0 mm, and stainless steel powder, heat sintering a green body of the mixed material, and heating the sintered body thus obtained in a nitrogen atmosphere and nitrided; wherein average open pore diameter thereof is 3-50 m.

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 spreader configured to be implemented in a die of a die casting system is disclosed. The spreader includes: a substrate; a hardening layer and an oxide layer. The hardening layer includes: a nitride and carbide layer disposed on the substrate and increasing hardness; and a white layer disposed on the nitride and carbide layer. The oxide layer includes: an inner transition layer disposed on the white layer and increasing resistance to oxidation; and an outer iron oxide layer disposed on the inner transition layer and increasing resistance to soldering during die casting of a part in the die casting system.

A process of forming an erosion, oxidation, and wear resistant shot chamber, either a gooseneck or a shot sleeve, is provided. The process utilizes a casting process for forming a one-piece shot chamber having a liner metallurgically bonded to the bulk portion of the shot chamber. Channels of predetermined shape and layout are built on the tubular external surface of the liner for facilitating thermal management of the shot chamber during die casting operations.

A process of forming an erosion, oxidation, and wear resistant shot chamber, either a gooseneck or a shot sleeve, is provided. The process utilizes a casting process for forming a one-piece shot chamber having a liner metallurgically bonded to the bulk portion of the shot chamber. Channels of predetermined shape and layout are built on the tubular external surface of the liner for facilitating thermal management of the shot chamber during die casting operations.

An overmoulding method for making an overmould (2) forming a decoration to be added to a part (1) or a part itself, including: providing an bauche (3) used as an injection tool, the bauche (3) having at least one through hole (4) forming a channel (5) for injecting the metal alloy (8), the bauche (3) being made of a first material with a thermal effusivity less than or equal to 7,000 W K1 m2 s or being at least partially plated with a layer made of the first material; positioning the bauche (3) inside an injection mould (6); injecting the metal alloy (8) through the through hole (4) opening into a cavity to obtain the overmould (2); and detaching the overmould (2) from the bauche (3) to form the decoration to be added or the part itself.