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 shaping tool includes a cooling system having one or more cooling passages configured for enhanced cooling. The cooling passages provide latent heat cooling of a heated material that is in contact with a shaping surface of the tool. Cooling fluid flows along the cooling passages in a two-phase flow regime in which a portion of the cooling fluid is liquid and a portion of the cooling fluid is vapor. A two-phase portion of the cooling passage can be shaped to follow a three-dimensional contour of the shaping surface. Opposing walls of the cooling passage can be provided by passage surfaces of separately formed pieces of the tool. The latent heat cooling provided by suitably configured cooling channels extracts more heat from the material being shaped in the tool than traditional cooling systems.

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 cooling system (10) for molding fixtures, and particularly for foundry molds, comprising:water treatment means (II)compressed air generation means (12)means (13) for pressurizing the treated watera device (14) for mixing air with the treated water, and for the controlled ejection of atomized water under pressure toward a cooling circuit (16) of a molding fixture.

A digital full-automatic die casting apparatus, including a longitudinal mounting plate, a mold arranged on a front surface of the longitudinal mounting plate, a mold locking device including a plurality of mold locking mechanisms surrounding a periphery of the mold, an injection device arranged on a back surface of the longitudinal mounting plate, and a PLC controller electrically connected to the mold locking device and the injection device respectively, The mold locking mechanism includes a mold locking fixed-point assembly arranged on the longitudinal mounting plate, and a hydraulic mold locking assembly connected to the mold locking fixed-point assembly; the mold locking fixed-point assembly includes a fixed-point servo motor arranged on the longitudinal mounting plate and electrically connected to the PLC controller, a fixed-point screw connected to the mold, a nut screwed to the fixed-point screw, and a transmission structure connected between the fixed-point servo motor and the nut.

A casting insert includes a casting insert wall formed substantially of a liquid-phase-sintered refractory metal alloy, a cavity formed by the casting insert wall, and at least one cooling duct, which is different from the cavity and which is formed at least partly within the cavity and/or which is formed at least partly within the casting insert wall. The casting insert wall has a wall thickness which can be defined as a normal distance between a point of the casting insert wall which faces the cavity and a point on an outer surface of the casting insert wall. The wall thickness is, at least in sections, less than 25% of a diameter of the casting insert.

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 method of over-molding a hybrid sub-assembly onto a base structure includes providing a mold for an over-molding process. The mold may comprise a lower mold tool, an upper mold tool, and a tube locator positioned on one of the upper mold tool or lower mold tool. A base structure formed of a first material is located into the tube locator. A mandrel tool is inserted into an opening in the base structure. The upper and lower mold tools are closed and clamped shut. A second material, such as a lighter weight or lower density material is heated to at least a semi-solid or slurry state. The semi-solid or slurry is injected into the mold to form a molded sub-assembly that is mechanically bonded to the base structure.

A casting apparatus for manufacturing a cast product from molten metal includes a molten metal and a cooling portion. The molten metal contacts a surface for contact with the molten metal. The cooling portion forms a cooling flow passage. The cooling flow passage is configured to cool the molten metal contacting surface. At least a part of an inner surface of the cooling flow passage is constituted of a welding portion formed by welding, the welding portion sealing the cooling flow passage. The welding portion is constituted such that an exposure to the molten metal becomes equal to or less than a predetermined ratio with respect to an area of the welding portion constituting the inner surface of the cooling flow passage.

A method of heat regulation of a mold comprises the steps of: providing a pump suitable to introduce a heat regulation fluid into the mold;setting a set point pressure for said heat regulation fluid, said set point pressure being chosen so as to make the pump operate at maximum efficiency;detecting the pressure drop of the circuit in which the heat-regulation fluid circulates;performing feedback control of the pump pressure so as to annul the difference between said set-point pressure and said pressure drop.