Die casting of component having integral seal

Abstract

A method of die casting a component with an integral sea according to an exemplary aspect of the present disclosure includes, among other things, defining a first portion of a die cavity of a die to include an open cell structure and defining a second portion of the die cavity without the open cell structure. The first portion is located within an opening formed in a first die element of the die and the second portion is located within a void formed in a second die element of the die. The method further includes injecting molten metal into the die cavity and solidifying the molten metal within the die cavity to form the component with the integral seal.

What is claimed is: 
     
         1 . A method of die casting a component with an integral seal, comprising:
 defining a first portion of a die cavity of a die to include an open cell structure, the first portion located within an opening formed in a first die element of the die;   defining a second portion of the die cavity without the open cell structure, the second portion located within a void formed in a second die element of the die;   injecting molten metal into the die cavity; and   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 defining the first portion of the die cavity 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 defining the second portion of the die cavity 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 abradable seal. 
     
     
         5 . The method as recited in  claim 1 , wherein defining the first portion of the die cavity includes:
 pre-defining the open cell structure in the first portion of the die cavity.   
     
     
         6 . The method as recited in  claim 5 , wherein defining the first portion of the die cavity includes:
 forming honeycomb design features within the first portion of the die cavity.   
     
     
         7 . The method as recited in  claim 1 , wherein injecting the molten metal 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 abradable seal. 
     
     
         9 . The method as recited in  claim 1 , comprising:
 positioning the die within a vacuum chamber.   
     
     
         10 . The method as recited in  claim 1 , wherein the first portion defines the integral seal and the second portion defines the component.