Shot tube plunger for a die casting system

Abstract

A shot tube plunger for a die casting system includes a first face, an opposing second face and an outer surface disposed between said first face and said opposing second face. A channel circumferentially extends about the outer surface. The channel is operable to receive a portion of a charge of material introduced into the die casting system.

1 . A die casting system, comprising:
 a shot tube plunger having a first face, an opposing second face, and an outer surface disposed between said first face and said opposing second face, wherein a channel circumferentially extends about said outer surface, said channel operable to receive a portion of a charge of material introduced into the die casting system; and   an engagement member that extends from said first face to establish a contact area for the charge of material to bond to.   
     
     
         2 . The system as recited in  claim 1 , wherein said channel includes a circumferential groove that extends radially inward from said outer surface. 
     
     
         3 . (canceled) 
     
     
         4 . The system as recited in  claim 1 , wherein said engagement member is a recess. 
     
     
         5 . The system as recited in  claim 1 , wherein said engagement member is a protrusion. 
     
     
         6 . The system as recited in  claim 1 , comprising a shaft, wherein said second face includes an attachment member that removably attaches said shot tube plunger to said shaft. 
     
     
         7 . The system as recited in  claim 6 , wherein said attachment member includes one of a recess and a protrusion and said shaft includes the other of said recess and said protrusion. 
     
     
         8 . The system as recited in  claim 1 , wherein said shot tube plunger includes a disposable piston head and said channel extends circumferentially about said disposable piston head. 
     
     
         9 . A die casting system, comprising:
 a die including a plurality of die components that define a die cavity;   a shot tube in fluid communication with said die cavity;   a shot tube plunger moveable within said shot tube to communicate a charge of material into said die cavity; and   a disposable piston head removably attached to said shot tube plunger, wherein said disposable piston head includes a first face and an opposing second face, and said first face includes an engagement member that contacts a portion of said charge of material and said opposing second face includes an attachment member that removably attaches said disposable piston head to said shot tube plunger.   
     
     
         10 . The system as recited in  claim 9 , wherein said disposable piston head includes an outer surface having a channel that circumferentially extends about said outer surface. 
     
     
         11 . The system as recited in  claim 9 , wherein said engagement member includes one of a recess and a protrusion. 
     
     
         12 . The system as recited in  claim 9 , wherein said attachment member includes one of a recess and a protrusion and said shot tube plunger includes the other of said recess and said protrusion to removably attach said disposable piston head to said shot tube plunger. 
     
     
         13 . A method of die casting a component with a die casting system, comprising the steps of:
 (a) removably attaching a disposable piston head to a shot tube plunger of the die casting system;   (b) injecting a charge of material through a shot tube and into a die cavity of the die casting system with the shot tube plunger and attached disposable piston head; and   (c) capturing a portion of the charge of material in a channel that circumferentially extends about an outer surface of the disposable piston head such that the portion of the charge of material captured within the channel avoids contact with the shot tube during the step of injecting the charge of material.   
     
     
         14 . The method as recited  13 , comprising the steps of:
 (d) solidifying the charge of material to form the component; and   (e) removing the component from the die cavity with the disposable piston head still attached to the component.   
     
     
         15 . The method as recited  14 , comprising the step of:
 (f) removing the disposable piston head from the component; and   (g) disposing of the disposable piston head.   
     
     
         16 . The method as recited in  claim 13 , wherein the disposable piston head includes a first face that faces the charge of material, the first face including a recess, and wherein said step (c) includes:
 capturing a portion of the charge of material within the recess.   
     
     
         17 . The system as recited in  claim 9 , wherein at least a portion of said die and said shot tube are disposed within a vacuum chamber. 
     
     
         18 . The system as recited in  claim 9 , wherein a portion of said charge of material is received within a circumferential channel of said disposable piston head, wherein said portion of said charge of material within said circumferential channel avoids contact with said shot tube. 
     
     
         19 . The system as recited in  claim 1 , wherein said engagement feature includes at least one recess that extends from said first face in direction toward said opposing second face. 
     
     
         20 . The system as recited in  claim 19 , wherein said at least one recess includes one of a truncated triangular configuration and a T-shaped configuration. 
     
     
         21 . A die casting system, comprising:
 a shot tube plunger having a first face, an opposing second face, and an outer surface disposed between said first face and said opposing second face;   an engagement member that extends from said first face to establish a contact area for a charge of material to bond to;   an attachment member disposed on said opposing second face, wherein said attachment member is isolated from contact with said charge of material; and   a channel that circumferentially extends about said outer surface, wherein said channel receives a portion of said charge of material such that said portion is entirely spaced from said outer surface of said shot tube plunger.