Die casting system and method

Abstract

A die casting system includes a die having a plurality of die elements that define a die cavity. A charge of material is received in the die cavity. The charge of material may comprises a refractory metal intermetallic composite based material system. The charge of material may also comprise a composite material.

1 . A die casting system, comprising:
 a die having a plurality of die elements that define a die cavity;   a charge of material communicated into said die cavity, wherein said charge of material comprises a refractory metal intermetallic composite based material system.   
     
     
         2 . The die casting system as recited in  claim 1 , comprising a shot tube in fluid communication with said die cavity, and a shot tube plunger moveable within said shot tube to communicate said charge of material into said die cavity. 
     
     
         3 . The die casting system as recited in  claim 1 , wherein a portion of said die casting system includes a highly conductive material. 
     
     
         4 . The die casting system as recited in  claim 3 , wherein said die elements include said highly conductive material. 
     
     
         5 . The die casting system as recited in  claim 3 , wherein said highly conductive material includes a thermal conductivity of at least of at least 310 W/m*K and a melting temperature of at least 960° C. (1760° F.). 
     
     
         6 . The die casting system as recited in  claim 1 , comprising a heating system that selectively heats said die elements. 
     
     
         7 . The die casting system as recited in  claim 1 , comprising a cooling system that selectively cools said die elements. 
     
     
         8 . The die casting system as recited in  claim 7 , wherein said cooling system includes liquid metal cooling. 
     
     
         9 . (canceled) 
     
     
         10 . The die casting system as recited in  claim 1 , wherein said refractory metal intermetallic composite based material system includes niobium silicide (NbSi). 
     
     
         11 . The die casting system as recited in  claim 1 , wherein said refractory metal intermetallic composite based material system includes molybdenum di-silicide (NbSi2). 
     
     
         12 . The die casting system as recited in  claim 1 , wherein said refractory metal intermetallic composite based material system includes a composite material selected from the group consisting of Nb 5 Si 3 +NbO+SiO 2 ; NbSi 2 +Nb 5 Si 3 +SiO 2 ; TaSi 2 +Ta 5 Si 3 +SiO 2 ; W 5 Si 3 +W+SiO 2 ; and WSi 2 +W 5 Si 3 +SiO 2 . 
     
     
         13 - 15 . (canceled) 
     
     
         16 . A die casting system, comprising:
 a die having at least one die elements that defines a die cavity;   a charge of material communicated into said die cavity, wherein said charge of material comprises a composite material selected from the group consisting of niobium silicide, molybdenum di-silicide, Nb 5 Si 3 +NbO+SiO 2 , NbSi 2 +Nb 5 Si 3 +SiO 2 , TaSi 2 +Ta 5 Si 3 +SiO 2 , W 5 Si 3 +W+SiO 2 , and WSi 2 +W 5 Si 3 +SiO 2 .   
     
     
         17 . The die casting system as recited in  claim 16 , wherein said die elements includes a highly conductive material. 
     
     
         18 - 20 . (canceled) 
     
     
         21 . The die casting system as recited in  claim 1 , comprising a vacuum chamber and a vacuum source that applies a vacuum to said vacuum chamber. 
     
     
         22 . The die casting system as recited in  claim 1 , comprising a heating system that selectively heats said plurality of die elements and a cooling system that selectively cools said plurality of die elements. 
     
     
         23 . The die casting system as recited in  claim 22 , wherein said heating system includes a die heater and said cooling system includes liquid metal cooling.