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Chill blocks and methods for manufacturing chill blocks

Inactive Publication Date: 2005-01-27
SPX CORP
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0009] The foregoing needs are met, to a great extent, by the present invention, wherein in one aspect an apparatus is provided that in some embodiments allows molten metal to solidify in the passageway formed by a pair of chill blocks, and that provides for efficient manufacturing of objects by die casting methods.

Problems solved by technology

However, if the molten metal does not solidify while in the chill block passageway the molten metal may escape from an end of the chill block passageway.
Some chill blocks known in the art experience problems with the retention of heat.
However, users of copper chill blocks have found that copper degrades rapidly when it comes in contact with aluminum.

Method used

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  • Chill blocks and methods for manufacturing chill blocks
  • Chill blocks and methods for manufacturing chill blocks
  • Chill blocks and methods for manufacturing chill blocks

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second embodiment

[0033] In the present invention, the chill block base 88 is made from a material, for example, copper or a metallic mixture including copper, for example, beryllium copper. A layer having a thickness, of less than about 0.5 inches and preferably ranging from about 0.060 to about 0.090 inches, of a tool steel is applied, for example, by a spraying technique, such as the rapid solidification process developed at the Idaho National Engineering and Environmental Laboratory, to the parting line surface / chill face 90 of the chill block base 88 and around a portion 92, 94 of the sides 96, 98 of the chill block 12. In addition, a layer of tool steel is present on the bottom of the chill block base 88.

third embodiment

[0034] In the present invention, a layer of tool steel is not present on any portion of the sides 96, 98 of the chill block 12.

[0035]FIG. 3 is a flow chart illustrating a preferred embodiment of a new method 102 for manufacturing a chill block. The process of manufacturing a chill block in accordance with the preferred embodiment of the present invention involves applying a layer of a first material, for example tool steel, having a thickness of less than about 0.5 inches and preferably ranging from about 0.060 to about 0.090 inches, on an inside surface of a mold that is a negative of the chill block being formed 104.

[0036] Preferably, a rapid solidification process is utilized to apply the tool steel. A second material, for example, copper or beryllium copper is added on top of the first material, preferably, by the rapid solidification process 106. The tool steel is porous. When the copper metal is added on top of the tool steel, the copper metal fills the pores formed in the to...

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Abstract

A chill block made from copper bonded to tool steel is disclosed. A tool steel layer of the chill block of less than about 0.5 inches thick is present on the parting surface of the chill block or chill block face. A tool steel layer may also be present on a portion of the sides of the chill blocks and / or the bottom of the chill block. Chill blocks in accordance with the present invention allow molten metal to solidify in the passageway formed by a pair of chill blocks, and provide for efficient manufacturing of objects by die casting methods.

Description

FIELD OF THE INVENTION [0001] The present invention relates generally to casting devices. More particularly, the present invention is directed to chill blocks that are manufactured from two metals. BACKGROUND OF THE INVENTION [0002] In die casting, chill blocks are devices utilized in molds. Typically, two tools are utilized to form a mold that will be employed to manufacture a complete object. Each of the tool devices has a cavity that defines the shape of a portion of the object to be cast, and when arranged together define the entire shape of the object to be cast. Each of the tools has a tool passageway leading from the die cavity to the chill blocks. [0003] Chill blocks are positioned in each of the tools and when the chill blocks are arranged together, the chill blocks form a chill block passageway. The tool passageway provided in each tool allows gas in the die cavity to flow from the die cavity to the chill block passageway, when molten metal is injected into a die cavity to...

Claims

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Application Information

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IPC IPC(8): B22D15/04
CPCB22D15/04
Inventor MALTERER, RANDALL
Owner SPX CORP
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