Apparatus and process for casting metal parts

Inventors: Alexander Mokre (Linz, AT); Zsolt Molnar (Györ, HU)

Assignee: Nemak, S.A.B. de C.V.

B22C9/088 B22D18/04

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Quick Facts

Patent No.: US 12686048
App. No.: 19/121,350
Granted: Jul 21, 2026
Kind: B2

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Abstract

An improved apparatus for casting metal parts. The apparatus is contemplated as including at least one mold cavity formed by at least one at least partly surrounding cavity wall, a system of sprues, runners and/or ingates defining at least one flow channel for filling the at least one mold cavity with molten metal, at least one riser insert arranged at least partly inside at least one riser cavity of at least one riser. The at least one riser insert comprises at least one insert cavity for receiving molten metal at least partially from the at least one mold cavity and at least one the insert cavity at least partly surrounding riser insert wall, wherein the at least one riser insert is configured to at least partly decelerate the solidification of the molten metal received by the at least one insert cavity.

Claims (26)

1 . An apparatus for low pressure die casting of metal, comprising:

at least one mold cavity defined by at least one at least partly surrounding cavity wall;

a system of sprues, runners and/or ingates defining at least one flow channel for filling the at least one mold cavity with molten metal;

at least one riser insert configured to be arranged at least partly inside at least one riser cavity of at least one riser, the at least one riser insert comprising at least one insert cavity for receiving the molten metal at least partly from the at least one mold cavity, and at least one insert cavity at least partly surrounded by a riser insert wall, the at least one riser insert being configured to at least partly decelerate solidification of the molten metal received by the at least one insert cavity; and

at least one heating insert for at least partly heating the molten metal received by the at least one insert cavity, wherein the at least one heating insert is arranged at least partly inside the at least one riser cavity.

2 . The apparatus of claim 1 , wherein the at least one riser insert wall has a thickness of less than 5 cm.

3 . The apparatus of claim 1 , wherein the at least one riser insert wall has a thickness of less than 3 cm.

4 . The apparatus of claim 1 , wherein the at least one riser insert wall has a thickness of less than 1.5 cm.

5 . The apparatus of claim 1 , wherein the at least one riser comprises at least one insulator for insulating the molten metal received by the at least one insert cavity.

6 . The apparatus of claim 5 , wherein the at least one insulator comprises at least one air gap arranged between the riser insert wall and a riser wall of the at least one riser.

7 . The apparatus of claim 5 , wherein the at least one insulator comprises one or more materials selected from the group of: rock wool, stone wool, glass wool, and ceramic, and combinations thereof.

8 . The apparatus of claim 1 , wherein the at least one heating insert is arranged at least partly inside at least one protection element.

9 . The apparatus of claim 1 , wherein the at least one heating insert comprises one or more of: a burner, an electric heating cartridge, an inductive heating element, or combinations thereof.

10 . The apparatus of claim 1 , further comprising at least one holding element at least partly positioned between the at least one riser insert and the at least one heating insert, and at least partly positioned inside the riser cavity.

11 . The apparatus of claim 1 , wherein the at least one riser insert comprises one or more centering pins for aligning, fixating, or aligning and fixating the at least one riser insert inside the at least one riser cavity.

12 . The apparatus of claim 1 , wherein the at least one riser insert comprises at least one venting hole for ventilating the molten metal received by the at least one insert cavity.

13 . The apparatus of claim 1 , wherein the at least one riser insert is in fluid connection with at least one riser neck for receiving the molten metal at least partially from the at least one mold cavity.

14 . A process for low pressure die casting of metal parts, the process comprising the steps of:

providing an apparatus comprising:

at least one mold cavity defined by at least one at least partly surrounding cavity wall;

a system of sprues, runners and/or ingates defining at least one flow channel for filling the at least one mold cavity with molten metal;

at least one riser insert configured to be arranged at least partly inside at least one riser cavity of at least one riser, the at least one riser insert comprising at least one insert cavity for receiving the molten metal at least partly from the at least one mold cavity, and at least one insert cavity at least partly surrounded by a riser insert wall, the at least one riser insert being configured to at least partially decelerate solidification of the molten metal received by the at least one insert cavity; and

filling the at least one mold cavity of the apparatus with the molten metal via the least one flow channel;

receiving the molten metal within the at least insert cavity at least partly from the at least one mold cavity; and

at least partly decelerating the solidification of the molten metal received within the at least one insert cavity via operation of the at least one heating insert.