Gm Global Technolgoy Operations, Inc.

Gary C Ward

Barry L Priem

Systems and methods allow detection and location of die coolant leaks while a die is in a die cast machine and at operating temperature. The testing can be performed during normal down time of the die casting assembly and repeated as desired. Cooling circuits of the die can be tested in zones where zones are sorted to identify particular cooling circuits as having leaks as necessary. Valving, leak sensors, air decay units, and added machine control are provided in the die cooling system to enable onboard leak testing of the die while installed in the die casting machine.

Die coolant system with an integral and automatic leak test

A system and method for thermal management of a die is disclosed wherein cooling of the die is controlled by controlling coolant flow to switch between laminar flow and turbulent flow as desired.

Die thermal management through coolant flow control

A method and apparatus for controlling the dispersion of molten metal in a mold cavity is disclosed, the control facilitated by a localized densification of foam in a lost foam casting operation for producing metal castings, wherein the filling of regions of the mold cavity which do not lend themselves to castability is maximized, an amount of backfill and casting defects are minimized, and a flow pattern of molten metal and material properties of the resulting casting are optimized.

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Saline, MI, United States of America

Gary C Ward