A multi-directional casting machine for casting a frame of a vehicle is described herein. The casting machine may include a central hub having a cover die portion and a plurality of ejector die portions translatable relative to the cover die portion and configured to meet at the central hub. The plurality of ejector die portions include first and second ejector die portions configured to translate along a first axis and a third ejector die portion configured to translate along a second axis extending substantially perpendicular to the first axis between closed and open positions. The first, second, and third ejector die portions are adjacent a first, second, and third sides, respectively, of the cover die portion in the closed positions and spaced apart from the cover die portion in the open positions. The plurality of ejector die portions form a mold cavity corresponding to a portion of a vehicle frame.

A three-plate pressure die casting mold for producing at least one metallic die casting part by die casting a metal melt, includes first, second and third mold parts and at least one mold cavity as well as a sprue system. A relatively movable pressure plate is arranged in the third mold part, which, when opening the die casting mold, presses the sprue produced in the sprue system against the first mold part, whereby the sprue is retained and tears off from the die casting part in a defined manner. A method for pressure die casting using the three-plate pressure die casting mold is disclosed.

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 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.

An excellent cast and forged product that is superior in mechanical properties and has a microstructure and which may not only be a thin but also be a thick product can be made without using complicated process steps or equipment. A semisolid casting and forging method is provided in which a metal melt is teemed so that it is supercooled into a lower die in a press so controlled that the metal melt has a rate of solidification as desired, thereby preparing a semisolid slurry; an upper die is brought into contact with the semisolid slurry; and thereafter at least one of the upper and lower dies is moved relatively towards the other at a rate of movement between 0.1 and 1.5 m/sec, thereby compressing the semisolid slurry to mold it into a product. The semisolid slurry preferably has crystal grains of a grain size of 50 m or less.

A design for repair casting having a repairable ultra-large single-piece casting and a replacement part. The ultra-large single-piece casting includes a main body portion, at least one predefined replaceable portion integrally cast with the main body portion, and a cut-guide delineating the predefined replaceable portion from the main body portion. The cut-guide includes a continuous channel defined on an exterior surface of the single-piece casting. The cut-guide further includes a rib extending from a channel wall on the main body portion. A damaged replaceable portion is excisable from the main-body portion by cutting through the single-piece casting along the cut-guide. The excised damaged replaceable portion may be replaced with the replacement part, which has substantially the same geometry, dimensions, and mechanical properties as an undamaged replaceable portion. The replacement part may be joined to the main body portion by mechanical means or by welding.

A method of fabricating a die cast article is disclosed and includes forming an insert with an additive manufacturing process to define a cavity for generating desired part geometry. The insert is then mounted within a mold tool, material is injected into the cavity to fill the cavity and form a cast article.

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 casting die is formed from a mold half with a mold insert disposed at least partly in a relief of the mold half. The mold insert is mounted movably in the relief.

A die casting mold includes a mold frame with at least two mold inserts and with at least one slider, the mold frame comprising a frame pocket for arranging the at least two mold inserts and the at least one slider, the at least two mold inserts delimiting a cavity with an undercut corresponding to the at least one slider, the mold frame comprising a first and a second mold frame halves disposed on opposite sides of a parting plane. At least one of the first and the second mold frame halves is formed by a plurality of mold frame parts connected to one another in a form-fitting manner, one of the plurality of mold frame parts having a locking surface, which, as viewed along a locking axis, is effective as a slider lock against a displacement of the at least one slider directed outwardly as viewed from the cavity.