A first die segment for forming an internal combustion engine block has cylindrical projections, and die core pieces disposed about the cylindrical projections. A second die segment has die core stubs positioned so as to extend between adjacent die core pieces when the segments are brought together. An engine block formed by the die segments has cylindrical bores formed by the cylindrical projections extending from the deck of the block and voids formed by the die core pieces also extending from the deck and disposed about the cylindrical bores. Pockets formed by the die core stubs extend into sides of the engine block between adjacent voids. The engine block is worked below the level of the deck to undercut each of the pockets, removing material between them and the voids to result in an interconnected water jacket extending about the cylindrical bores, while leaving the deck closed.

A method of manufacturing a joint flange using a thickness-increased, machined pipe is provided. The method includes a pipe cutting operation in which a pipe is cut to a predetermined length, a flange forming operation in which a flange having a mounting hole for installing the pipe is formed by die casting, a bump-forming operation in which a thickness-increased part, which is formed by increasing a thickness of one end of the pipe, is bumped to form a first bead locked to the flange, a machining operation in which a circumference of the thickness-increased part is machined to form a sealing groove having an O-ring installed, and a fixing operation in which the pipe is inserted in the mounting hole of the flange and the other end of the pipe is pressed to form a second bead so that the pipe is pressed to a lower end of the flange.

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 producing a hollow article made of amorphous metal comprising the steps of: a) providing a metal composition, b) melting the composition according to step a) in order to obtain a melt, c) introducing the melt according to step b) into a cavity of a casting mold, the casting mold comprising an inner core, at least a portion of the lateral surface of the inner core being surrounded by a separation element, d) cooling the melt in the casting mold in order to obtain a molded part made of amorphous metal, e) removing the inner core and the separation element from the molded part according to step d) in order to obtain a hollow article made of amorphous metal. The present invention also relates to a hollow article made of amorphous metal, more particularly to a pipe made of amorphous metal.

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 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 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 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 first die segment for forming an internal combustion engine block has cylindrical projections, and die core pieces disposed about the cylindrical projections. A second die segment has die core stubs positioned so as to extend between adjacent die core pieces when the segments are brought together. An engine block formed by the die segments has cylindrical bores formed by the cylindrical projections extending from the deck of the block and voids formed by the die core pieces also extending from the deck and disposed about the cylindrical bores. Pockets formed by the die core stubs extend into sides of the engine block between adjacent voids. The engine block is worked below the level of the deck to undercut each of the pockets, removing material between them and the voids to result in an interconnected water jacket extending about the cylindrical bores, while leaving the deck closed.

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.