Direct squeeze casting

Abstract

A casting system includes a pour cup, a plurality of runners that receive molten metal from the pouring cup, a top mold and a bottom mold that receive the molten metal from the plurality of runners, and a plurality of slides positioned within the top mold and the bottom mold. The positioning of the plurality of slides applies direct pressure on the molten metal in the top mold and the bottom mold to form a cast structural component.

What is claimed is: 
     
         1 . A casting system comprising:
 a pour cup;   a plurality of runners that receive molten metal from the pouring cup;   a top mold and a bottom mold that receive the molten metal from the plurality of runners; and   a plurality of slides positioned within the top mold and the bottom mold,   wherein positioning of the plurality of slides applies direct pressure on the molten metal in the top mold and the bottom mold to form a structural component.   
     
     
         2 . The casting system of  claim 1  wherein the pour cup is a gravity pour cup. 
     
     
         3 . The casting system of  claim 1  wherein the pour cup is a tilt pour cup. 
     
     
         4 . The casting system of  claim 1  wherein interior surfaces of the top mold and the bottom mold have a pressure sensitive coating. 
     
     
         5 . The casting system of  claim 1  wherein the pour cup introduces the molten metal to the plurality of runners with a pour velocity of less than 100 cm/sec. 
     
     
         6 . The casting system of  claim 1  wherein the plurality of slides is four slides. 
     
     
         7 . The casting system of  claim 7  wherein each slide is an insert that reciprocates along a respective channel. 
     
     
         8 . The casting system of  claim 1  wherein the pour cup introduces molten metal to the runners so that the molten metal flows into the mold quiescently without turbulence. 
     
     
         9 . The casting system of  claim 1  wherein the applied pressure is between about 60 psi and about 3000 psi. 
     
     
         10 . An apparatus to form a mechanical component comprising:
 a first mold;   a second mold, the first mold and the second mold being configured to receive molten metal;   a plurality of slides positioned within the top mold and the bottom mold, wherein positioning of the plurality of slides applies direct pressure on the molten metal in the top mold and the bottom mold to form a mechanical component.   
     
     
         11 . The apparatus of  claim 10  wherein interior surfaces of the first mold and the second mold have a pressure sensitive coating. 
     
     
         12 . The apparatus of  claim 10  wherein the plurality of slides is four slides. 
     
     
         13 . The apparatus of  claim 12  wherein each slide is an insert that reciprocates along a respective channel. 
     
     
         14 . The apparatus of  claim 10  wherein the applied pressure is between about 60 psi and about 3000 psi. 
     
     
         15 . A method of casting a mechanical component, the method comprising:
 pouring molten metal into an interior cavity defined by a first mold and a second mold; and   exerting pressure on the molten metal to form a structural cast component.   
     
     
         16 . The method of  claim 15  wherein interior surfaces of the first mold and the second mold are have a pressure sensitive coating. 
     
     
         17 . The method of  claim 15  wherein the molten metal pours into the interior cavity with a velocity of less than 100 cm/sec. 
     
     
         18 . The method of  claim 15  wherein the molten metal flows into the interior cavity quiescently without turbulence. 
     
     
         19 . The method of  claim 15  wherein the applied pressure is between about 60 psi and about 3000 psi. 
     
     
         20 . The method of  claim 15  wherein the applied pressure is produced by a plurality of slides positioned in the first mold and the second mold. 
     
     
         21 . The method of  claim 20  wherein the slides move outwards along respective channels to accommodate an overfill volume, and wherein the slides move inward to compensate for metal shrinkage as the molten metal transitions to a solid, while the positioning of the slides maintain the desired pressure on the solidifying casting. 
     
     
         22 . The method of  claim 20  wherein the slides are configured to move to apply direct pressure to the molten metal as it solidifies, and wherein pressure is applied and controlled with use of one or more pressure punches applied to regions of interest of the solidifying casting, the slides and the one or more pressure punches operating simultaneously or independently of each other.