Amcast Industrial Corporation

John P Waggoner

A high pressure forming process is used to form asymmetric scroll compressor elements wherein a single or multiple piece die is closed at one end by a stop which is formed to correspond to a side of the scroll compressor element opposite to a scroll. A punch sized to fit within the die includes an endface having a scroll shaped cavity. A blank of an appropriate metal is placed in the die against the stop and the punch is then inserted into the die and fully extended to form the blank into a scroll compressor element with a single stroke of the punch. The punch includes vent holes for allowing trapped gases and lubricants to escape as the scroll is formed. The punch may also include an ejector system to facilitate removal of the scroll compressor elements from the punch/die combination. The stop may be defined by a second punch which can be moved into the die for forming parts or can be held stationary during part formation and then moved to facilitate removal of scroll compressor elements from the punch/die combination. It may be desired in some applications to heat the die, punch, stop/punch and blanks.

Methods for making scroll compressor element

A composite blank is formed from an aluminum base blank and an aluminum brazing alloy clad material which is affixed to the base blank. Alternately, a multielement blank is formed by at least one base preform and at least one separate clad preform. The composite and multielement blanks are forged into required parts such that as the required parts are formed, the clad material forms an integral coating on the finished part in one or more positions which are to be clad. The composite blank may be formed by initially forming a base blank having one or more recesses on its surface into which clad material is inserted. Recesses can be formed in base blanks as slots during extrusion of the base blanks in a continuous form or otherwise. Clad material is then inserted into each slot on the continuous form with composite blanks being formed by cutting the resulting continuous form. Alternately, clad material can be extruded into each slot or the base blank and clad material can be co-extruded to fill each slot with clad material. A composite blank can also be formed by covering one or more continuous portions of the outer surface of a base blank with clad material.

Method of making blanks and clad parts

A manifold for a heat exchanger is formed by placing a blank having a siamesed pair of tubular passages supported by a first mandrel into a die cavity which receives the blank and defines at least one riser channel extending from the cavity. Each riser channel includes a core such that when a punch forces the blank into the die cavity, the blank is formed as desired and a portion of the blank is forged into the riser channel and around the core. The portion of the sidewall of the blank adjacent to the tubular risers is thickened such that the sidewall of the resulting manifold is substantially uniform after forging. After forging, the blank is removed from the die and the first mandrel is removed. The manifold is completed by inserting a second mandrel including holes in substantial alignment with the tubular risers and forcing punches into the tubular risers to remove the remaining material which separates the risers from the passages. The cores include sharp forming edges between terminal end surfaces and forming surfaces extending around the cores to define the forming heads. Recesses, depressions, patterns of grooves or the like are formed in the end surfaces of the cores. The cores include forming heads with the remainder of the cores and/or riser channels being relieved to facilitate removal of the risers from the riser channels. The riser channels and/or cores can be shaped to form defined distal ends on the tubular risers.

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Decatur, IN, United States of America

John P Waggoner