Tool and method for direct squeeze casting

Abstract

A casting tool for a direct squeeze casting process that includes a cast mold tool with a contoured internal passage for better die thermal management. This enables the use of a grey cast iron mold material. A durable mold surface may also be formed through a nodular cast iron reaction with a Magnesium addition in either sand core or sand core coating.

What is claimed is: 
     
         1 . A casting tool for a direct squeeze casting process, the tool comprising a cast tool including a contoured internal passage. 
     
     
         2 . The tool of  claim 1 , wherein the contoured internal passage forms a thermal management passage for the direct squeeze casting process. 
     
     
         3 . The tool of  claim 1 , wherein the contoured internal passage forms a venting passage for the direct squeeze casting process. 
     
     
         4 . The tool of  claim 1 , wherein the contoured internal passage forms one of a runner and gate passage for the direct squeeze casting process. 
     
     
         5 . The tool of  claim 1 , wherein the tool comprises a gray iron material. 
     
     
         6 . The tool of  claim 1 , further comprising a mold surface having transition layers with a ductile and compacted graphite structure. 
     
     
         7 . The tool of  claim 1 , further comprising a mold surface comprising a pressure sensitive die coating. 
     
     
         8 . 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 receives 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, and wherein one of the top mold and the bottom mold comprises a casting including a contoured internal passage.   
     
     
         9 . The system of  claim 8 , wherein the contoured internal passage forms a thermal management passage. 
     
     
         10 . The system of  claim 8 , wherein the contoured internal passage forms a venting passage. 
     
     
         11 . The system of  claim 8 , wherein the contoured internal passage forms a gate passage. 
     
     
         12 . The system of  claim 8 , wherein the casting comprises a gray iron material. 
     
     
         13 . A direct squeeze casting method comprising:
 providing a cast mold tool that includes a contoured internal passage;   pouring molten metal into an interior cavity defined by the cast molded tool; and   exerting pressure on the molten metal to form a structural cast component.   
     
     
         14 . The method of  claim 13 , further comprising flowing a thermal management liquid through the contoured internal passage. 
     
     
         15 . The method of  claim 13 , further comprising venting the mold through the contoured internal passage. 
     
     
         16 . The method of  claim 13 , wherein pouring the molten metal comprises pouring the molten metal through a gate passage that is formed by the contoured internal passage. 
     
     
         17 . The method of  claim 13 , wherein the cast mold tool comprises a gray iron material. 
     
     
         18 . The method of  claim 13 , forming a ductile and compacted graphite structure in the structural cast component through contact with transition layers in a surface in the cast mold tool. 
     
     
         19 . The method of  claim 13 , wherein the cast mold tool comprises a pressure sensitive die coating.