Denso Corporation

Nippondenso Co., Ltd.

Toyo Machinery and Metal Co., Ltd.

Nippon Light Metal Company, Ltd.

Other

Hiromi Takagi

Tomoyuki Hatano

Takeshi Nagasaka

Sumi Yoshikawa

Hideaki Harada

Naohiko Tsuzuki

Ikuo Ozawa

Akio Hashimoto

Fumitaka Takehisa

Mitsuyoshi Yokoi

Yasushi Hibi

Shunji Mochizuki

Hitoshi Oosawa

Norihisa Sasano

Toshiki Sugiyama

Hiroshi Horikawa

Noriaki Maeda

Kazuaki Kafuku

Harumi Okai

Takaaki Ikari

Kouji Yamada

Tetsuro Suganuma

Minoru Furuhata

Koji Tsuboe

Isao Uenaka

Yasuhiko Itou

Shunji Moohizuki

Susumu Miyakawa

Tadao Okura

Masahiko Hoshino

A high strength aluminum alloy casting obtained by casting an aluminum alloy comprised of 7.5 to 11.5 wt % of Si, 3.8 to 4.8 wt % of Cu, 0.45 to 0.65 wt % of Mg, 0.4 to 0.7 wt % of Fe, 0.35 to 0.45 wt % of Mn, and the balance of Al and not more than 0.2 wt % of unavoidable impurities, wherein this aluminum alloy has 0.1 to 0.3 wt % of Ag added to it or contains 0.1 to 1.0 wt % of at least one element selected from the group of second additive elements comprised of Rb, K, Ba, Sr, Zr, Nb, Ta, V, and Pd and rare earth elements, and a method of production of a high strength aluminum alloy casting comprising the steps of filling a melt of an aluminum alloy in a mold to obtain a casting, taking out the aluminum alloy casting from the mold, solubilizing the high strength aluminum alloy casting by heating in a temperature range of 495 to 505&#xb0; C. for 2 to 6 hours, quenching the high strength aluminum alloy casting after the solubilization, and age hardening the high strength aluminum alloy casting by heating in a temperature range of 160 to 220&#xb0; C. for 2 to 6 hours after quenching.

High strength aluminum alloy casting and method of production of same

A die casting machineto fill by injecting molten metal into a die cavityincludes a variable displacement pumpdriven by a servo motorfor discharging hydraulic fluid from a hydraulic fluid tank, an injection cylinderwith a slidable pistonassembled therein, hydraulic fluid pipes a and c for supplying hydraulic fluid discharged by the variable displacement pumpto the injection cylinderhydraulic fluid pipes d, e, g and a logic valveconnected to hydraulic fluid pipe c for supplying hydraulic fluid ejected from the injection cylinderto hydraulic fluid pipe c with the pistonslid by the hydraulic fluid supplied to the injection cylinder

Die casting machine

A direct-acting type diecasting machine having an inexpensive and simplified hydraulic circuit is provided, which includes: a mold clamping cylinder for clamping and opening/closing a mold in a direct-acting manner; a single two-way hydraulic pump driven by a driving motor for supplying hydraulic fluid to the mold clamping cylinder in two directions; a hydraulic circuit for driving the mold clamping cylinder by controlling supply of hydraulic fluid from the two-way hydraulic pump to the mold clamping cylinder and discharge of hydraulic fluid from the mold clamping cylinder which proceeds in accordance with movement of a piston of the mold clamping cylinder; and a hydraulic controller for controlling rotational speed of the driving motor associated with the two-way hydraulic pump in opening/closing the mold at high speed and controlling torque of the driving motor in clamping the mold.

Diecasting machine

A casting method and casting mold able produce a casting having an island and connecting portion is disclosed. A casting having a body, an opening provided so as to pass through the body, an island arranged separated from the body in the opening, and a connecting portion joining the island and body is cast using a casting mold. The casting mold is provided with a body gate connected to a body cavity for forming the body and an opening gate connected to an island/connecting portion cavity for forming the island and the connecting portion. The body gate and opening gate are connected to a runner through body pin gates and opening pin gates; in addition, a die casting mold able to suitably change between a three-part mold structure and a two-part mold structure to cast a die casting is disclosed. The three-part mold structure die casting mold, a movable mold, a first cavity, a connection sleeve, a first runner, a pin gate, and an extension sleeve. When forming the two-part mold structure die casting mold, the fixed mold is removed, the extension sleeve insert inserted in the extension sleeve is removed, and the pin gate is filled by a pin gate insert. Further, the intermediate mold insert and the movable mold insert are replaced to form the two-part mold structure die casting mold forming the second cavity and second runner moving the movable mold with respect to the intermediate mold.

Casting method and casting mold

A diecasting machine capable of realizing highly precise injection of molten metal at high-speed without using an accumulator is provided, which includes: an injection cylinder for loading molten metal into a mold cavity by injection; a single two-way hydraulic pump driven by a driving motor for supplying hydraulic fluid to the injection cylinder in two directions; a hydraulic circuit for driving the injection cylinder by controlling supply of hydraulic fluid from the two-way hydraulic pump to the injection cylinder and discharge of hydraulic fluid from the injection cylinder which proceeds in accordance with movement of a piston of the injection cylinder; and a hydraulic controller for controlling rotational speed of the driving motor associated with the two-way hydraulic pump in injection/loading the molten metal and controlling torque of the driving motor in dwelling.

The newly proposed cast aluminum alloy product has the composition consisting of 6.5-8.0% Si, 0.25-0.45% Mg, 0.08-0.40% Fe, 0.001-0.01% Ca, P less than 0.001%, 0.02-0.1% Ti, 0.001-0.01% B, optionally one or two of 0.05-0.3% Cr and 0.05-0.2% Mn, and the balance being Al except inevitable impurities. It has the metallurgical structure that an &#x3b1;-Al phase in a surface layer is of average grain size different by 50 &#x3bc;m or less from an &#x3b1;-Al phase in an inner part, and that a maximum size of eutectic Si particles is 400 &#x3bc;m or smaller. It is manufactured by injecting a molten aluminum alloy into metal dies at an injection speed of 0.05-0.25 m/second, and then cooling the injected alloy at a cooling speed of 20&#xb0; C./or higher in a temperature range between liquidus and solidus curves in a state charged with a pressure of 30 MPa or higher. Since the cast product is good of ductility, it is used as a member for coupling another member therewith by calking or the like.

Plastically worked cast aluminum alloy product, a manufacturing method thereof and a coupling method using plastic deformation thereof

A front-end structure comprising a panel body ( ) to which a center member ( ), being fixed to a body of a vehicle at a front end of the vehicle and supporting, at least, a driving engine (E/G), is joined, wherein the panel body ( ) is molded out of aluminum by die-casting and a joining section ( ) of the panel body ( ) to which the center member ( ) is joined has a mechanical strength higher than that of any other sections of the panel body ( ) near the joining section ( ) except the joining section ( ).

Front-end structure of a vehicle

A molten metal vessel includes a first chamber for containing molten metal such as molten aluminum therein, a filtration chamber in which impurities contained in the molten metal are removed, and a second chamber for reserving clean molten metal to be supplied to a casting die. The molten metal flows from the first chamber to the second chamber through the filtration chamber. A pair of filters, preferably a pair of cylindrical filters, are disposed in the filtration chamber, so that the impurities contained in the molten metal can be filtered twice. The filters are attached to the bottom of the filtration chamber where molten metal oxides hardly develop, so that the filters are easily replaced with new ones for the maintenance purpose. A rod-shaped heater may be disposed in the cylindrical filters to keep the molten metal temperature in a strictly controlled range. Thus, the impurities are effectively removed from the molten metal through the filters which are easily replaceable.

Molten metal vessel for filtering impurities

Die release lubricant is made from powder solid lubricant, adhesion enhancer made of organic or inorganic compound and volatile solvent. Before melted metal is injected into a die for casting, the die release lubricant is sprayed to an inside surface of the die. The die release lubricant is in a liquid state and is uniformly applied to the inside surface of the die. As a result, application efficiency of the die release lubricant is improved while an amount of thermal decomposition gas generated during casting is reduced.

Die release lubricant

A holding furnace apparatus for holding molten metal and a molten metal holding method using the same are provided. The holding furnace includes generally a furnace body defining therein a reservoir chamber in which molten metal is held, an inlet port through which an ingot is supplied, an outlet port through which the molten metal held in the reservoir chamber is drawn outside, and an upper furnace wall defining the reservoir chamber together with the furnace body. The upper furnace wall has an inclined wall surface which is, when the reservoir chamber is filled with the molten metal at a given level, exposed to the molten metal so as to direct impurities contained in the molten metal rising to the surface of the molten metal to the inlet port.

Molten metal holding furnace and method of holding molten metal within

An apparatus and method for spraying solid lubricant to obtain coatings thereof on inner surfaces of an injection sleeve and a spool bushing of a die-casting machine. The die-casting machine further includes a first spraying assembly 1 having nozzles 11 and 12 directed to the injection sleeve 85 and a second spraying assembly 2 having a nozzle 21 directed to the spool bushing 86. The nozzles 11, 12 and 21 are connected to a tank 4 for the solid lubricant. The first and second spray assemblies 1 and 2 are provided with corresponding moving devices 3 and 23 for obtaining a desired movement of the nozzles 11 and 12 and 21, respectively. Nozzle cleaning devices 71 and 72 are provided for cleaning the nozzles 11 and 12 and 21, respectively after the completion of the spraying operation.

Die-casting apparatus with spraying device for solid lubricant and

A method of discriminating the quality of die-cast articles when casting an article by pressurizing and filling a molten metal into a die through an injecting sleeve using an injecting plunger. The method has the steps of measuring at least one of the operational parameters of a die temperature, a gas pressure in a die cavity, a molten metal pressure in a die cavity, an injecting sleeve temperature, an injecting plunger travel speed, and an injection plunger displacement; and discriminating the quality of a die-cast article by comparing the measured parameter value with a reference value determined on the basis of a predetermined interrelationship between the operational parameter and an allowance limit of the amount of a casting defect.

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Nagoya, Japan

Hiromi Takagi