	US 11,969,783 B2
	Method for improving high-pressure die casting shot sleeve by additive manufacturing metal matrix composite insert
Randy S. Beals, Grand Ledge, MI (US)
Assigned to MAGNA INTERNATIONAL INC., Aurora (CA)
Appl. No. 17/054,274
Filed by MAGNA INTERNATIONAL INC., Aurora (CA)
PCT Filed May 10, 2019, PCT No. PCT/US2019/031667 § 371(c)(1), (2) Date Nov. 10, 2020, PCT Pub. No. WO2019/217781, PCT Pub. Date Nov. 14, 2019.
Claims priority of provisional application 62/670,064, filed on May 11, 2018.
Prior Publication US 2021/0245240 A1, Aug. 12, 2021
Int. Cl. B22D 17/20 (2006.01); B22F 5/10 (2006.01); B22F 7/02 (2006.01); B22F 10/22 (2021.01); B22F 10/28 (2021.01); B33Y 10/00 (2015.01); B33Y 80/00 (2015.01); B22F 10/50 (2021.01)

CPC B22D 17/2023 (2013.01) [B22F 5/106 (2013.01); B22F 7/02 (2013.01); B22F 10/22 (2021.01); B22F 10/28 (2021.01); B33Y 10/00 (2014.12); B33Y 80/00 (2014.12); B22F 10/50 (2021.01); B22F 2998/10 (2013.01)]

17 Claims

1. An insert for a shot sleeve of a die casting apparatus, the insert comprising:

a base layer including metal;

an inner layer including ceramic;

at least one middle layer between the base layer and the inner layer;

the at least one middle layer including metal in an amount greater than an amount of metal in the inner layer and less than an amount of the metal in the base layer; and

the at least one middle layer including ceramic in an amount less than an amount of the ceramic in the inner layer and greater than an amount of ceramic in the base layer,

wherein the metal of the base layer and the metal of the at least one middle layer includes steel; the metal of the at least one middle layer further includes an alloy of chromium, iron, and molybdenum; and the ceramic of the at least one middle layer and the ceramic of the inner layer includes zirconium oxide.

4. A shot sleeve, comprising:

a body extending circumferentially around a center axis and longitudinally from a first end to a second end;

the body presenting a body inner surface and a body outer surface;

the body including a pouring hole;

an insert located opposite the pouring hole;

the insert comprising a base layer, an inner layer, and at least one middle layer between the base layer and the inner layer;

the inner layer presenting an insert inner surface adjacent the body inner surface;

the base layer including metal;

the inner layer including ceramic;

the at least one middle layer including metal in an amount greater than an amount of metal in the inner layer and less than an amount of the metal in the base layer; and

the at least one middle layer including ceramic in an amount less than an amount of the ceramic in the inner layer and greater than an amount of ceramic in the base layer;

wherein the metal of the base layer and the metal of the at least one middle layer includes steel;

the metal of the at least one middle layer further includes an alloy of chromium, iron, and molybdenum; and

the ceramic of the at least one middle layer and the ceramic of the inner layer includes zirconium oxide.

8. A method of manufacturing an insert for a shot sleeve of a die casting apparatus, comprising the steps of:

forming a base layer including metal;

forming at least one middle layer on the base layer;

forming an inner layer including ceramic on the at least one middle layer, the at least one middle layer including metal in an amount greater than an amount of metal in the inner layer, and the at least one middle layer including ceramic in an amount less than an amount of the ceramic in the inner layer; and

the steps of forming the base layer, the at least one middle layer, and the inner layer including an additive manufacturing process;

11. A method of manufacturing a shot sleeve of a die casting apparatus, comprising the steps of:

manufacturing an insert by an additive manufacturing process, the additive manufacturing process including:

forming a base layer including metal;

forming at least one middle layer on the base layer;

coupling the insert to a body of a shot sleeve extending circumferentially around a center axis and including a pouring hole; and

wherein the insert is disposed opposite the pouring hole.

13. A method of manufacturing a component for a vehicle, the method comprising the steps of:

pouring molten aluminum or aluminum alloy into a shot sleeve coupled to a cavity of a die casting apparatus, the shot sleeve including: a body extending circumferentially around a center axis and longitudinally from a first end to a second end; the body presenting a body inner surface and a body outer surface; the body including a pouring hole; an insert located opposite the pouring hole; the insert comprising a base layer, an inner layer, and at least one middle layer between the base layer and the inner layer; the inner layer presenting an insert inner surface adjacent the body inner surface; the base layer including metal; the inner layer including ceramic; the at least one middle layer including metal in an amount greater than an amount of metal in the inner layer; and the at least one middle layer including ceramic in an amount less than an amount of the ceramic in the inner layer;

forming the molten aluminum or aluminum alloy in the cavity of the die casting apparatus.