Die configuration for high temperature diecasting

Abstract

A die casting die includes a shoe comprised of a first material and includes a pocket. An insert is arranged in the pocket. The insert is comprised of a second material that is different from the first material and the insert provides a contoured surface. A coating is on the contoured surface. The coating provides a cast part contour.

What is claimed is: 
     
         1 . A die casting die comprising:
 a shoe comprised of a first material and including a pocket;   an insert arranged in the pocket, the insert comprised of a second material that is different from the first material, and the insert providing a contoured surface; and   a coating on the contoured surface, the coating providing a cast part contour.   
     
     
         2 . The die casting die in  claim 1 , wherein the first material has a thermal conductivity between  12  W·m −1 K −1  and 62 W·m −1 K −1 . 
     
     
         3 . The die casting die in  claim 2 , wherein the first material comprises steel. 
     
     
         4 . The die casting die in  claim 1 , wherein the second material has a thermal conductivity above 350 W·m −1 K −1 . 
     
     
         5 . The die casting die in  claim 4 , wherein the second material comprises copper. 
     
     
         6 . The die casting die in  claim 1 , wherein the coating has a hardness between 36 HRC and 62 HRC. 
     
     
         7 . The die casting die in  claim 6 , wherein the coating comprise at least one of a cobalt chromium alloy, a cobalt alloy, and ceramic. 
     
     
         8 . The die casting die in  claim 1 , wherein the shoe includes at least one passage for circulation of fluid. 
     
     
         9 . A die casting system comprising:
 a first die including a first shoe comprised of a first material, the first shoe including a first pocket, a first insert arranged in the first pocket, the first insert comprised of a second material that is different from the first material, the first insert providing a first contoured surface, and a first coating on the first contoured surface, the first coating providing a first cast part contour;   a second die including a second shoe comprised of the first material, the shoe including a second pocket, a second insert arranged in the second pocket, the second insert comprised of the second material, the second insert providing a second contoured surface, and a second coating on the second contoured surface, the second coating providing a second cast part contour, wherein the first die and the second die are arranged to form a die cavity;   a chamber in fluid communication with the die cavity; and   a plunger for injecting a molten metal through the chamber into the die cavity.   
     
     
         10 . The die casting system in  claim 9 , wherein the first material has a thermal conductivity between 12 W·m −1 K −1  and 62 W·m −1 K −1 . 
     
     
         11 . The die casting system in  claim 10 , wherein the first material comprises steel. 
     
     
         12 . The die casting system in  claim 9 , wherein the second material has a thermal conductivity above 350 W·m −1 K −1 . 
     
     
         13 . The die casting system in  claim 12 , wherein the second material comprises copper. 
     
     
         14 . The die casting system in  claim 9 , wherein the first and second coatings have a hardness between 36 HRC and 62 HRC. 
     
     
         15 . The die casting system in  claim 14 , wherein the first and second coatings comprise at least one of a cobalt chromium alloy, a cobalt alloy, and ceramic. 
     
     
         16 . The die casting system in  claim 9 , wherein at least one shoe contains at least one passage for the circulation of fluid. 
     
     
         17 . The die casting system in  claim 17 , having a multiple of fluid lines attachable to the at least one fluid passage, the multiple of fluid lines connectable to a cooling fluid source for fluid communication between the at least one shoe and the cooling fluid source. 
     
     
         18 . A method for die casting comprising:
 arranging a first die and a second die to form a cavity,
 the first die including a first shoe comprised of a first material, the first shoe including a first pocket, a first insert arranged in the first pocket, the first insert comprised of a second material that is different from the first material, the first insert providing a first contoured surface, and a first coating on the first contoured surface, the first coating providing a first cast part contour, 
 the second die including a second shoe comprised of the first material, the shoe including a second pocket, a second insert arranged in the second pocket, the second insert comprised of the second material, the second insert providing a second contoured surface, and a second coating on the second contoured surface, the second coating providing a second cast part contour; 
   forcing molten metal into the cavity;   retaining the molten metal in the cavity until the molten metal becomes a solidified metal; and   removing the solidified metal from the cavity.   
     
     
         19 . The method of  claim 18 , wherein at least one shoe includes passages for circulation of fluid during the retaining step. 
     
     
         20 . The method of  claim 18 , wherein the second material comprises copper.