Mazda Motor Corporation

Semiconductor Energy Laboratory Co., Ltd.

Yukio Yamamoto

Makoto Fujita

Kazuo Sakamoto

Yukihiro Sugimoto

Nobuo Sakate

Kyoso Ishida

Shoji Hirabara

Nobuyuki Oda

Satoshi Nanba

Mitsugi Fukahori

Seiji Nomura

Katsunori Hanakawa

Katsuya Ohuchi

Kazuyuki Yoshimoto

Katsuya Nishiguchi

Ryoji Abe

Motoyasu Asakawa

Hiroshi Kodama

Shunzo Takasuga

Yukiyoshi Fukuda

Akihiro Nakano

Shinya Shibata

Fuminori Ishimura

Toshio Miyatani

Masashi Yoritaka

Kyousou Ishida

Norio Kodama

Fujio Ueoka

In a semi-molten metal injection molding method of producing a thin molded product by injecting a semi-molten metal M of a magnesium alloy, in a semi-melting state, into a cavity of a mold through a product gate, characterized in that it is made possible to obtain a high-quality thin molded product by maintaining satisfactory fluidity of the semi-molten metal M. A grain size of the solid fraction in the melt M is set to not more than 0.13 times the average thickness of the product portion of the thin molded product and a molten metal velocity at the product gate is set to not less than 30 m/s and, moreover, a solid fraction Fs (%) of the semi-molten metal M and a grain size D (&mgr;m) of the solid phase of the semi-molten metal M are set so as to define the relationship Fs&times;D&lE;1500.

Method and apparatus for semi-molten metal injection molding

In a semi-solid alloy including a large amount of a liquid phase portion, that is, semi-solid alloy with less than 50% of solid phase rate, there is a tendency for a solid phase portion to concentrate into the central portion in the direction of thickness, that is the internal portion. In order to enhance corrosion resistance at a portion where high corrosion resistance is particularly required in parts molded by semi-solid injection, the above tendency is utilized. By utilizing the tendency, a layer consisting of a liquid phase portion is partially formed at the semi-solid state on a surface portion where high corrosion resistance is required.

Parts formed by injection molding and manufacturing method thereof

When a seat ( ) (FIG. A) on which a wax layer ( ) is formed via a melting reaction layer ( ) is brought into contact with a head ( ) and heated and pressed in this state, a melting reaction layer ( ) forms below the wax layer (FIG. B). When electric current application and pressing are continued from this state, a wax which has not reacted in the wax layer ( ) in the formation of the melting reaction layer ( ) is discharged from between the melting reaction layers ( ) and ( ). When electrical current application and pressing are further continued from this state, the two melting reaction layers ( ) and ( ) diffuse each other. The result is that a ternary alloy bonding layer ( ) containing Fe, Al, and Zn, which constitute the melting reaction layers ( ) and ( ) is formed between the seat ( ) and the head ( ) (FIG. D).

Metal welding method and metal bonding structure

An automobile bodyshell frame structure includes a generally elongated first panel member, and a generally elongated second panel member having opposite side edge portions connected to the first panel member to define a hollow between the first and second panel members. A filler is disposed within a portion of a cross-section of the hollow between the first and second panel members. This filler is provided on an inner surface of one of the first and second panel members and has an average compressive strength equal to or greater than 4 Pa and/or a maximum bending strength equal to or greater than 10 MPa.

Automobile bodyshell frame structure

In a semi-molten metal injection molding method of producing a thick molded article by injecting a semi-molten melt M of a magnesium alloy, in a semi-melting state, into a cavity of a mold through a product gate characterized in that it is made possible to obtain a high-quality thick molded article free from internal defects. A solid fraction of the semi-molten melt M is set to not less than 10%, and more preferably within a range of 40 to 80%. A sectional area Sg of a product gate portion of the thick molded article corresponding to the product gate is set to not less than 0.1 times a sectional area Sp in the vicinity of the product gate in the product portion corresponding to the cavity Furthermore, a product gate velocity Vg mm/s of the semi-molten melt M, a sectional area Sg mm of the product gate portion of the thick molded article and a volume Vp mm of the product portion are set so as to satisfy the following relationships: Vg&lE;8.0&times;10 ; and, Vg&times;Sg/Vp&gE;10.

In order to provide a die structure for injection molding of a light alloy free from gas defects, and a method of molding a light alloy parts using the die, the die structure is used for converting a light alloy into a semi-molten state, wherein a solid phase and a liquid phase coexist, or a molten state at a temperature just above a melting point and injecting the molten metal into an interior cavity portion, and S /S of a gate sectional area S with respect to a maximum sectional area S of the cavity of the mold which area is almost perpendicular to the flowing direction of the melt therein is set in a range of 0.06 to 0.5.

Mold structure for injection molding of a light alloy and method of injection molding a light alloy using the same

A light metal alloy material has excellent plastic workability. The method of producing the light metal alloy material comprises a light metal as a matrix, which is injection-molded at a solid phase proportion of not more than 20%. The injection molded material has a limiting upsetting rate of not more than 70% and excellent moldability. This injection molded material can be molded into a final molded article by means of single-step forging.

Method of producing light metal alloy material for plastic working and plastic-worked product

In a semi-molten metal injection molding method of producing a thick molded article by injecting a semi-molten melt M of a magnesium alloy, in a semi-melting state, into a cavity,of a mold,through a product gate,, characterized in that it is made possible to obtain a high-quality thick molded article free from internal defects. A solid fraction of the semi-molten melt M is set to not less than 10%, and more preferably within a range of 40 to 80%. A sectional area Sg of a product gate portion of the thick molded article corresponding to the product gate,is set to not less than 0.1 times a sectional area Sp in the vicinity of the product gate,in the product portion corresponding to the cavity,. Furthermore, a product gate velocity Vg mm/s of the semi-molten melt M, a sectional area Sg mm,of the product gate portion of the thick molded article and a volume Vp mm,of the product portion are set so as to satisfy the following relationships: Vg&lE;8.0&times;10,; and, Vg&times;Sg/Vp&gE;10.

Material characteristics that a foamed filler material (s) to be filled in a frame cross section (fr) should have are discussed. By using a material complying with the characteristics, the energy absorbability of the frame (fr) is effectively enhanced. In a frame structure (fr) for vehicle bodies in which a filler material is filled in at least part of the cross section of a frame, the filler material is set to a mean compressive strength of not less than 4 MPa and/or a maximum bending strength of not less than 10 MPa. More particularly, the filler material is set to a mean compressive strength of not less than 5 MPa and/or a maximum bending strength of 60 MPa.

Frame structure for vehicle body

The present invention provides a method for joining two metal members into a joined metal member. The method comprise steps of; applying a brazing material having a higher melting point than both the members on the surface of a first metal member and heating them to form a brazing material on said surface and a braze-diffusion layer under the brazing material in the surface area of the first member; and, then, pressing the first and another second metal members between which the brazing material is interposed during heating at a higher temperature than said melting point of the brazing material to squeeze the molten brazing material out between both the contact surfaces of both the metal members, therefor the two metal members being joined by the braze diffusion layers formed in both the surfaces into the joined metal member. Particularly, the first metal member may comprise an iron-based alloy and the second metal members may comprise an aluminum-based alloy, and the brazing material may be zinc-containing material such as Zn&mdash;Al eutectic alloy.

Joined metal member and a method and an apparatus for fabricating the same

The film boiling state of a refrigerant is maintained for a time longer than in the prior art by t to lower the nuclear boiling start temperature to a temperature at which the material proof strength of a work exceeds thermal stress, thereby lowering the cooling rate of the work. In addition, by controlling the cooling rate in hardening, the film boiling state of the refrigerant is maintained to a temperature at which the material proof strength exceeds thermal stress, thereby cooling the work at a temperature equal to or higher than the critical cooling rate of the work.

Light-alloy casting heat treatment method

A method is provided for producing a preform structure which is used in a composite aluminium or aluminium alloy component in which a base metal of an aluminium or aluminium alloy is reinforced with reinforcing materials. A slurry is prepared by mixing reinforcing materials including ceramic particles and first whiskers with burning-away powders and liquid. Liquid components contained in the slurry are filtered to provide a dehydrated structure. Thereafter a preform structure is produced by sintering the ceramic particles with the first whiskers after burning the burning-away powders in the dehydrated structure.

Preform structures, composite aluminium or aluminium alloy components

This invention is to provide a magnesium alloy cast material capable of manufacturing a wheel, a large-sized forged piece such as wheel having properties equivalent to those of aluminum molten forged member, directly from the state of continuous cast material. The magnesium alloy cast material is a nearly intermediate alloy composition between conventional AZ61 alloy and AZ80 alloy, comprising Al: 6.2 to 7.6 wt. %, Mn: 0.15 to 0.4 wt. %, Zn: 0.4 to 0.8 wt. % and Mg: balance, and casting by defining the mean crystal grain size under 200 .mu.m. The forgeability is excellent, and when forged, a forged piece superior in mechanical properties and corrosion resistance to the aluminum molten forged member can be manufactured.

Magnesium alloy cast material for plastic processing, magnesium alloy

A metallic porous product is produced by applying a slurry of a mixture of skeleton constituent metal particles and property modifying particles to an inflammable porous foam, burning the inflammable porous foam having open pores by heat to provide a metallic skeleton structure, and sintering the metallic skeleton structure.

Metallic porous product and composite product thereof and method of

A method for preparing a light metal or light metal alloy composite product, wherein (a) an aqueous slurry containing water, a reinforcement powder, a metal powder and an alumina sol binder is prepared; (b) a preform is prepared from the slurry; (c) the preform is sintered; and (d) the sintered preform is impregnated with a melt of a light metal or a light metal alloy to produce a light metal or a light metal alloy based composite product.

Growing community of inventors

Hiroshima, Japan

Yukio Yamamoto