Smart insert pin and method of using same for die casting of ultra-large castings for a vehicle

Abstract

A system and method of using a smart insert pin for making a casting for a vehicle, in which the casting includes a boss having internal threads. The system includes a mold and an insert pin insertable into the mold. The mold includes a portion of a mold cavity defining a boss shaped cavity and a bore in communication with the boss shaped cavity. The insert pin includes a first portion having external threads and a second portion extending from the first portion. The second portion of the insert pin is insertable into the bore with the first portion extending into the portion of the mold cavity defining the boss shaped cavity. The mold cavity is fill with a molten metal. The molten metal is cooled into a solidified casting. The insert pin is unfastened from the casting leaving a cast boss with an internal threaded bore.

1 . A system for casting a vehicle component, comprising:
 an insert pin comprising a first portion having external threads and a second portion extending from the first portion; and   a mold comprising an interior surface defining a mold cavity and a bore in communication with the mold cavity; and   wherein the second portion of the insert pin is receivable in the bore such that the first portion of the insert pin extends into the mold cavity.   
     
     
         2 . The system of  claim 1 , wherein the first portion of the insert pin includes a distal end, and wherein the external threads taper from a first thread depth to a second thread depth lesser than the first thread depth in a direction toward the distal end. 
     
     
         3 . The system of  claim 2 , wherein the second thread depth is 50% to 75% of the first thread depth. 
     
     
         4 . The system of  claim 1 , wherein a portion of the mold cavity defines a boss shaped cavity, and the first portion of the insert pin extends into the boss shaped cavity. 
     
     
         5 . The system of  claim 1 , wherein the first portion of the insert pin includes a nitride coating. 
     
     
         6 . The system of  claim 1 , wherein the second portion of the insert pin includes an end surface defining a key pocket having a predetermined shape. 
     
     
         7 . The system of  claim 1 , further comprising a sleeve having internal threads fastenable onto the external threads of the first portion of the insert pin. 
     
     
         8 . The system of  claim 7 , wherein the sleeve includes an external surface defining at least one of an indent, a protrusion, and a spine. 
     
     
         9 . The system of  claim 1 , wherein:
 the insert pin further comprises a collar integrally connecting the first portion and the second portion, wherein the collar includes an annular surface facing toward the second portion;   the mold further comprises an annular seat surface surrounding the bore opening and facing the mold cavity, wherein the annular seat surface cooperates with the annular surface of the collar to limit the insertion of the insert pin into the bore from the mold cavity; and   the bore is configured to receive an application of a vacuum sufficient to fix the second portion of the insert pin in the bore.   
     
     
         10 . The system of  claim 1 , where:
 the insert pin includes an annular shoulder facing the first portion;   the bore includes an interior opening and an exterior opening; and   the mold further comprises an interior annular surface in the bore facing toward the exterior opening and configured to abut the annular shoulder of the insert pin in response to the insert pin received in the bore from the exterior opening.   
     
     
         11 . A die casting system, comprising:
 a mold comprising an interior surface defining a boss shaped cavity and a bore in communication with the boss shaped cavity; and   an insert pin comprising a first portion having external threads and a second portion extending from the first portion, wherein the second portion is receivable in the bore such that the first portion extends into boss shaped cavity.   
     
     
         12 . The die casting system of  claim 11 , wherein:
 the insert pin includes an annular shoulder facing the first portion;   the bore comprises an interior opening in direct communication with the boss shaped cavity and an exterior opening opposite the interior opening;   the mold further comprises an interior annular surface in the bore facing the exterior opening;   a sealing plate for selectively sealing the exterior opening of the bore; and   a biasing member disposed in the bore, wherein the biasing member urges the insert pin, when received in the bore, in a direction toward the interior opening such that the annular shoulder of the insert pin abuts the interior annular surface of the bore.   
     
     
         13 . The die casting system of  claim 11 , wherein:
 the insert pin further includes a collar integrally connecting the first portion and the second portion, wherein the collar includes an annular surface facing toward the second portion; and   the interior surface of the mold further defines an annular seat surface surrounding the bore opening, wherein the annular seat surface cooperates with annular surface of the collar to limit the insertion of the insert pin into the bore from the boss shaped cavity.   
     
     
         14 . The die casting system of  claim 11 , wherein the first portion of the insert pin includes a nitride coating comprising at least one of Titanium Nitride (TiN), Titanium Aluminum Nitride (TiAlN), Titanium Carbonitriden (TiCN), and Aluminum Titanium Nitride (AlTiN). 
     
     
         15 . The die casting system of  claim 11 , further comprising a metallic sleeve having internal threads complementary to the external threads of the first portion of the insert pin such that the metallic sleeve is fastenable to the first portion of the insert pin, wherein the metallic sleeve includes an exterior surface comprising a coating of at least one of a Zinc (Zn), a Nickel (Ni), and an Al-12% Si eutectic alloy. 
     
     
         16 . A method of casting a vehicle component, comprising:
 providing a mold having an interior surface defining a mold cavity and a bore having an interior opening in direct communication with the mold cavity;   providing an insert pin having a first portion and a second portion, wherein the first portion includes external threads;   inserting the second portion of the insert pin into the bore such that first portion extends into the mold cavity;   filling the mold cavity with a molten metal;   cooling the molten metal to form a solidified casting; and   unscrewing the insert pin from the solidified casting to remove the insert pin from the solidified casting.   
     
     
         17 . The method of  claim 16 , wherein:
 the mold cavity includes a portion defining a boss shaped cavity; and   the first portion extends into the boss shaped cavity.   
     
     
         18 . The method of  claim 16 , further comprising cooling the molten metal to about 300° C. to 500° C. to form the solidified casting and unscrewing the insert pin at about 300° C. to 500° C. 
     
     
         19 . The method of  claim 16 , wherein the first portion of the insert pin includes a distal end, and the external threads taper from a first thread depth to a second thread depth, wherein the second thread depth is 50% to 75% of the first thread depth. 
     
     
         20 . The method of  claim 16 , further comprising fastening a sleeve having internal threads onto the first portion of the insert pin before filling the mold cavity with a molten metal, wherein the sleeve includes an outer surface having a duck tail shaped texture to join the sleeve to the solidified casting.