Composite parts and methods for making the same are disclosed. A composite part may include an internal insert component that is coated on at least a portion of its surface with certain types of particles, an external part component cast around the coated insert, and a particle-rich region that is formed between the two components, where the particle-rich region includes particles from the coated insert. A method for producing a composite part may include the steps of: positioning an internal insert component that is coated on at least a portion of its surface within a mold cavity of a casting die; casting a molten material of the external part component around the coated insert; and solidifying the molten material to form the external part component of the composite part.

Composite parts and methods for making the same are disclosed. A composite part may include an internal insert component that is coated on at least a portion of its surface with certain types of particles, an external part component cast around the coated insert, and a particle-rich region that is formed between the two components, where the particle-rich region includes particles from the coated insert. A method for producing a composite part may include the steps of: positioning an internal insert component that is coated on at least a portion of its surface within a mold cavity of a casting die; casting a molten material of the external part component around the coated insert; and solidifying the molten material to form the external part component of the composite part.

An undercut processing mechanism includes: a core pin for forming an inner circumferential surface of a tubular projection; a slide core for forming an outer circumferential surface of the tubular projection; a sliding piece for causing the core pin to advance/retract in an axial direction of the tubular projection; a retaining piece for causing the sliding piece to advance/retract; a holder for accommodating the retaining piece such that the retaining piece can advance/retract; and a movement amount restrictor for restricting a movement amount of the core pin. The retaining piece is operable to advance/retract in a state where a stationary die and a movable die are closed. When the core pin retracts in conjunction with retraction of the retaining piece and a movement amount of the core pin reaches a restricted distance, the core pin and the slide core retract together, thereby allowing an undercut portion to be demolded.

An undercut processing mechanism includes: a core pin for forming an inner circumferential surface of a tubular projection; a slide core for forming an outer circumferential surface of the tubular projection; a sliding piece for causing the core pin to advance/retract in an axial direction of the tubular projection; a retaining piece for causing the sliding piece to advance/retract; a holder for accommodating the retaining piece such that the retaining piece can advance/retract; and a movement amount restrictor for restricting a movement amount of the core pin. The retaining piece is operable to advance/retract in a state where a stationary die and a movable die are closed. When the core pin retracts in conjunction with retraction of the retaining piece and a movement amount of the core pin reaches a restricted distance, the core pin and the slide core retract together, thereby allowing an undercut portion to be demolded.

A casting method and cast manifold are provided. The method allows configuring conduits, such as conduits in a fuel feed boss and/or a base rocket, which are part of the manifold for removing a ceramic core from the cast without forming extraneous holes in the body of the manifold. Absence of such extraneous holes in turn allows eliminating sealing plugs and welds, which otherwise would be needed for sealing the extraneous holes.

A diecasting tool has an insert for producing a cooled motor housing. The diecasting tool has mould halves including: a stationary mould half; and movable mould half. One of the mould halves has a cylindrically extending annular gap having a central axis. The moveable mould half is arranged so as to be movable parallel to the central axis. The insert is arranged in the cylindrically extending annular gap. The insert is a bush. One end of the bush projects into a mould cavity, which is formed by the stationary mould half and the movable mould half, and is at least partially surrounded in a form-fitting manner by the casting material in a state when the casting material is cast.

A diecasting tool has an insert for producing a cooled motor housing. The diecasting tool has mould halves including: a stationary mould half; and movable mould half. One of the mould halves has a cylindrically extending annular gap having a central axis. The moveable mould half is arranged so as to be movable parallel to the central axis. The insert is arranged in the cylindrically extending annular gap. The insert is a bush. One end of the bush projects into a mould cavity, which is formed by the stationary mould half and the movable mould half, and is at least partially surrounded in a form-fitting manner by the casting material in a state when the casting material is cast.

A method for manufacturing a mold element using a manufacturing device comprising a die and a counter-mold defining a molding cavity in the closed position, comprises: opening the manufacturing device; placing at least one insert 22, produced by laser sintering, against a molding surface of the die; mounting at least one wedge 28 on the die so as to bear against said insert in order to immobilize it relative to said molding surface; closing the manufacturing device, the counter-mold pressing onto said wedge in order to keep said insert pressed against said molding surface; injecting aluminium into the molding cavity of the manufacturing device; opening the manufacturing device; and extracting from the manufacturing device the mold element provided with a molding face formed by at least part of said insert and by the aluminum.

A method for manufacturing a mold element using a manufacturing device comprising a die and a counter-mold defining a molding cavity in the closed position, comprises: opening the manufacturing device; placing at least one insert 22, produced by laser sintering, against a molding surface of the die; mounting at least one wedge 28 on the die so as to bear against said insert in order to immobilize it relative to said molding surface; closing the manufacturing device, the counter-mold pressing onto said wedge in order to keep said insert pressed against said molding surface; injecting aluminium into the molding cavity of the manufacturing device; opening the manufacturing device; and extracting from the manufacturing device the mold element provided with a molding face formed by at least part of said insert and by the aluminum.

A die casting insert for producing die casted metal parts from liquid metal. The die casting insert has an outer casing shaped to be fixed in the die block of the die casting apparatus. The die casting insert also has a stopper with a purge opening that is adapted to evacuate contaminants topping the liquid metal as pressure is applied to the liquid metal. The stopper, fitted to mate with the hollow inner cavity of the injection sleeve, is constructed to seal the hollow inner cavity of the injection sleeve except at the purge opening when in a first position; and to permit the flow of the liquid metal into at least one molding cavity when the stopper is in a second position. The die casting insert also has an activation mechanism configured to shift the stopper between the first position and the second position.