A process of forming an erosion, oxidation, and wear resistant shot chamber, either a gooseneck or a shot sleeve, 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. Such a shot chamber is expected to have an improved service life for die casting of corrosive metals and alloys, including hot chamber die casting of aluminum alloys. An improved hot dipping process using stirring in the molten metal bath is also disclosed.

A mold structure and the replacement method thereof. The mold structure has a lower molding plate, at least one lower die core, a plurality of lower supporters, a plurality of first positioning units, an upper molding plate, at least one upper die core, a plurality of upper supporters and a plurality of merging units. The upper die core and the lower die core are passed through by a plurality of fasteners, and fixed on the upper molding plate and the lower molding plate respectively. The upper supporters and the lower supporters are disposed around the upper die core and the lower die core respectively, and passed through by a plurality of fasteners to fix them on the upper molding plate and the lower molding plate respectively. A part of a first positioning unit protruding out of a lower supporter is inserted into a merging unit. The present invention provides an accurate way to fix die cores, improves procedures in conventional molding, further reduces process time and saves cost.

A hybrid die cast system (10) having an inner liner insert (12) that enables the configuration of a component (18) produced by the system (10) to be easily changed by changing the inner liner insert (12) without having to rework the die housing (16) is disclosed. Because the inner liner insert (12) only need be removed and replaced to change the configuration of an outer surface (18) of a component (18) produced by the system (10), the cost savings is significant in contrast with conventional systems in which the die would have to be reworked. The system (10) may also include a cooling system (20) for controlling the casting process by controlling the rate of solidification and the rate of cooling of the casting. Local heating and cooling may be used to control the microstructure, enhance mold fill and reduce casting defects such as porosity.

A mold device of related art has a problem that a total volume of the device becomes large. In an example aspect of the present disclosure, a mold device includes a fixed mold base for supporting a fixed mold, a mobile mold base for supporting a mobile mold, a frame to which the fixed mold base is fixed, provided to extend in a direction in which the mobile mold base is moved, and formed into a wall shape, and holding means for movably supporting the mobile mold base to the frame. The frame is provided along at least one side of the mobile mold base except an upper surface thereof with the mold device installed, and the holding means support the mobile mold base at one side of the mobile mold base.

A diecasting tool system has a machine-related base plate, at least one set of contour-imparting mould components which in an assembled position on the base plate form a casting contour for an associated cast part to be cast, and a plurality of not contour-imparting tool receptacle module components. The base plate, the tool receptacle module components and the contour-imparting mould components are configured for releasably assembling the associated set of contour-imparting mould components and an assigned set of the tool receptacle module components on a fastening side of the base plate for casting the respective cast part. The base plate on the fastening side has a fastening grid of a plurality of fastening points which are disposed so as to be distributed in a regular or irregular pattern across a fastening region. The set of contour-imparting mould components conjointly with the assigned set of the tool receptacle module components is able to be assembled on the base plate in at least two different orientations, and/or a plurality of sets of contour-imparting mould components with a respectively assigned set of the tool receptacle module components are present for selective assembling on the base plate.

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 core is located in each relief, the expendable core having an inner surface and an outer surface with an aperture extending therethrough. The outer surface and inner surface of the expendable 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 cores is also disclosed. The expendable 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 an erosion, oxidation, and wear resistant shot chamber, either a gooseneck or a shot sleeve, 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. Such a shot chamber is expected to have an improved service life for die casting of corrosive metals and alloys, including hot chamber die casting of aluminum alloys. An improved hot dipping process using stirring in the motel metal bath is also disclosed.

A diecasting tool system has a machine-related base plate, at least one set of contour-imparting mould components which in an assembled position on the base plate form a casting contour for an associated cast part to be cast, and a plurality of not contour-imparting tool receptacle module components. The base plate, the tool receptacle module components and the contour-imparting mould components are configured for releasably assembling the associated set of contour-imparting mould components and an assigned set of the tool receptacle module components on a fastening side of the base plate for casting the respective cast part. The base plate on the fastening side has a fastening grid of a plurality of fastening points which are disposed so as to be distributed in a regular or irregular pattern across a fastening region. The set of contour-imparting mould components conjointly with the assigned set of the tool receptacle module components is able to be assembled on the base plate in at least two different orientations, and/or a plurality of sets of contour-imparting mould components with a respectively assigned set of the tool receptacle module components are present for selective assembling on the base plate.

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 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.