Controlled pressure casting

• US 8,899,624 B2
• Filed: 08/30/2010
• Issued: 12/02/2014
• Est. Priority Date: 05/19/2005
• Status: Active Grant

• Current Assignee: Magna International Incorporated
• Original Assignee: Magna International Incorporated
• Inventors: Kotagiri, Seetarama S., Skszek, Timothy W., Horton, Frank A., Kiselis, Gregory P.
• Primary Examiner(s): TO, TOAN C
• Application Number:
  US12/871,329
• Publication Number:
  US 20110012320A1
• Time in Patent Office: 1,555 Days
• Field of Search: 280/781, 280/93.511, 280/93.512, 164/111, 164/112, 164/120
• US Class Current: 280/781
• CPC Class Codes: B22D 19/16 for making compound objects cast of two or more different metals, e.g. for making rolls for rolling mills casting compound ingots B22D7/02
• CPC Class Codes: B60B 35/06 cranked
• CPC Class Codes: B60G 2206/11 the arm being a radius or track or torque or steering rod or stabiliser end link
• CPC Class Codes: B60G 2206/60 Subframe construction
• CPC Class Codes: B60G 2206/8101 by casting
• CPC Class Codes: B60G 3/02 with a single pivoted arm
• CPC Class Codes: B60K 5/12 Arrangement of engine supports supports comprising both a plastic spring and a fluid damper F16F13/06
• CPC Class Codes: B60R 19/03 characterised by material, e.g. composite B60R19/18 takes precedence
• CPC Class Codes: B60R 19/34 destroyed upon impact, e.g. one-shot type
• CPC Class Codes: B62D 21/03 transverse members providing body support
• CPC Class Codes: B62D 21/11 with resilient means for suspension , e.g. of wheels or engine; sub-frames for mounting engine or suspensions
• CPC Class Codes: Y10T 428/12292 Workpiece with longitudinal passageway or stopweld material [e.g., for tubular stock, etc.]
• CPC Class Codes: Y10T 428/12972 Containing 0.01-1.7% carbon [i.e., steel]

Abstract

A method of forming metal castings, including positioning a first end of a structural member in a first mold cavity and a second end of the structural member in a second mold cavity. The first and second mold cavities being fluidly coupled to a reservoir of molten metal. Applying a main pressure to the molten metal in the reservoir to force the molten metal into the first mold cavity and the second mold cavity. Then, applying a first auxiliary pressure to the first mold cavity and a second auxiliary pressure to the second mold cavity to densify the casting formed in the first mold cavity and the second mold cavity. Also, a method for casting including maintaining a main pressure at or less than an initial, mold-filling pressure after first and second mold cavities have been filled. Additionally, a method for detecting whether a first mold cavity is sufficiently filled with molten metal by monitoring a moveable element.

Claims

1. A composite casting comprising:

a steel member;

an end cap fastened to an end portion of the steel member, wherein the end cap has a flange having one of a circular and a non-circular configuration and the flange has notches for providing a mechanical interlock surface; and

a cast coupling member cast about the end portion of the steel member including the end cap, thereby positively and rigidly locking and securing said cast coupling member to said steel member.

2. The composite casting as defined in claim 1, wherein the steel member is a tubular member.

3. The composite casting as defined in claim 1 wherein the steel member is made from high strength steel.

4. A composite casting comprising:

a steel member;

an end cap fastened to an end portion of the steel member, wherein the end cap has a flange having a polygonal shape for providing a mechanical interlock surface; and

a cast coupling member cast about the end portion of the steel member including the end cap, thereby positively and rigidly locking and securing said cast coupling member to said steel member.

5. A composite casting comprising:

a steel member;

an end cap fastened to an end portion of the steel member, wherein the end cap has a flange having a polygonal shape including an outwardly extending member; and

a cast coupling member cast about the end portion of the steel member including the end cap, thereby positively and rigidly locking and securing said cast coupling member to said steel member.

6. A composite casting comprising:

a steel member, wherein the steel member is a tubular member;

an end cap fastened to an open portion of the steel member, wherein said end cap about which a cast coupling member is casted is a mid portion of said tubular member and said mid portion includes a section having a non-circular cross-section; and

a cast coupling member cast about the end cap of said steel member by casting-in-place aluminum about said end cap, thereby positively and rigidly securing said coupling member to said steel member.

7. A composite casting, comprising:

a steel member, wherein the steel member is a tubular member;

an end cap welded to an end portion of the steel member; and

a cast coupling member cast about the end portion of the steel member including the end cap, thereby positively and rigidly securing the cast coupling member to the steel member; and

wherein the end cap has a flange having one of a circular and a non-circular configuation.

8. The composite casting as defined in claim 7 wherein the flange has notches for providing a mechanical interlock surface.

9. A composite casting, comprising:

a steel member, wherein the steel member is a tubular member;

an end cap welded to an end portion of the steel member;

a cast coupling member cast about the end portion of the steel member including the end cap, thereby positively and rigidly securing the cast coupling member to the steel member; and

wherein the end cap has a flange having a polygonal shape for providing a mechanical interlock surface.