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 casting device includes a bore formation core and a water jacket formation core. When a cavity is formed, gas existing in a space between both cores is suctioned through a flow path formed in the bore formation core under operation of a suctioning device. When the bore formation core is viewed from a side, this flow path exists above a virtual axial line that passes a center of the bore formation core and extends along a longitudinal direction of the bore formation core.

The present disclosure relates to a casting apparatus including a support block, a die provided on one surface of the support block and configured to form a cavity in cooperation with the support block, and an insert member provided to be movable relative to the support block and configured to selectively move between a first position at which the insert member is received in the cavity and a second position at which the insert member is extracted out of the cavity, thereby obtaining an advantageous effect of simplifying a structure and a manufacturing process.

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 molding apparatus for obtaining an annular molded article has a fixed die D1 and a movable die D2 capable of forming an annular cavity C. A first block B1 and a second block B2 are formed inside the cavity C in the fixed and movable dies D1 and D2. The blocks form a flow channel R communicating with the cavity C. Thus, gas generated in the cavity C and a molten metal can flow in the flow channel R. A discharge hole B2b is formed in the second block B2 to discharge the gas flowing in the flow channel R to the outside. A forming surface of the flow channel R, in the first and second blocks B1 and B2, is formed in an outer circumferential shape following an inner circumferential shape of the cavity C.

A method of casting a casting product having tubular flow passages includes: attaching a cast-in pipe insert, having outer and inner fixing members to which both ends of pipes are coupled, respectively, to a fixed mold; assembling a movable mold with the fixed mold; injecting a molten metal into a cavity defined inside the fixed and movable molds; ejecting a casting product from the assembled molds after injecting the molten metal; and removing the outer and inner fixing members from the casting product.

A piston of a die-casting apparatus comprises: a piston head fabricated of a first material; an elongate, inner carrier coupled to the piston head; a generally annular body seated on the carrier adjacent the piston head; and a wear ring disposed on the piston head, the wear ring being fabricated of a second material. The first material has a higher toughness and a lower hardness than the second material.

A slide for the high pressure die casting of at least one closed deck engine block having at least one cylinder is disclosed. The slide includes a tool steel portion with reliefs for forming a water jacket surrounding each cylinder. At least one expendable salt core is located in each relief, the salt core having an inner surface and an outer surface with an aperture extending therethrough. The outer surface and inner surface of the salt core is coextensive with an inner surface and outer surface of the tool steel portion. A method for high pressure die casting a closed deck engine block using the disclosed slide and expendable salt cores is also disclosed. The expendable salt cores are separable from the reliefs in the slide, and form bridges or supports across a water jacket to add stiffness and rigidity to the cast engine cylinders.

A process for producing an optical element, which may be suitable for use in an infrared camera with sharp surface features and low emissivity surfaces, including the steps of casting the element in the desired shape in a zinc alloy, deburring the zinc alloy element with a thermal deburring operation, and coating the deburred zinc alloy element with an electrocoating operation.

A method of making a bullet includes metal injection molding a bullet jacket or preform, and forming the jacket or preform into a bullet.