Die casting of component having integral seal

Abstract

A method of die casting a component having an integral seal includes defining a first portion of a die cavity of a die to include an open cell structure. A second portion of the die is defined without the open cell structure. Molten metal is injected into the die cavity, and the molten metal is solidified within the die cavity to form the component having the integral seal.

1 . A method of die casting a component with an integral seal, comprising the step of:
 (a) defining a first portion of a die cavity of a die to include an open cell structure;   (b) defining a second portion of the die cavity without the open cell structure;   (c) injecting molten metal into the die cavity;   (d) solidifying the molten metal within the die cavity to form the component with the integral seal.   
     
     
         2 . The method as recited in  claim 1 , wherein said step (a) includes:
 positioning an insert that defines the open cell structure within the first portion of the die cavity.   
     
     
         3 . The method as recited in  claim 2 , wherein said step (d) includes:
 locally bonding the insert with the component to provide the component with the integral seal.   
     
     
         4 . The method as recited in  claim 2 , wherein the insert is a honeycomb abradeable seal. 
     
     
         5 . (canceled) 
     
     
         6 . (canceled) 
     
     
         7 . The method as recited in  claim 1 , wherein said step (c) includes:
 melting an ingot of material to prepare the molten metal;   communicating the molten metal into a shot tube; and   injecting the molten metal into the die cavity with a shot tube plunger.   
     
     
         8 . The method as recited in  claim 1 , wherein the component is a seal having an integral honeycomb abradeable seal. 
     
     
         9 . The method as recited in  claim 1 , comprising the step of:
 (e) positioning the die within a vacuum chamber.   
     
     
         10 . The method as recited in  claim 1 , wherein the first portion and the second portion of the die cavity are openings within the die, and the first portion defines the integral seal and the second portion defines the component. 
     
     
         11 - 15 . (canceled) 
     
     
         16 . The method as recited in  claim 1 , wherein the open cell structure establishes walls having openings between the walls. 
     
     
         17 . The method as recited in  claim 1 , wherein the component and the integral seal are formed together within the die cavity. 
     
     
         18 . The method as recited in  claim 1 , wherein said step (a) includes:
 positioning an insert that is a honeycomb seal made of a nickel alloy within the first portion of the die cavity.   
     
     
         19 . A method of die casting a component with an integral seal, comprising:
 positioning an insert within a portion of a die cavity of a die, wherein the insert defines an open cell structure having walls with openings extending between the walls;   injecting molten metal into the die cavity; and   solidifying the molten metal within the die cavity to overcast the component against the insert to establish the integral seal on the component.