Counter piston central injection die casting

Abstract

The die casting system can use a counter piston to enable central injection of large or multi-cavity parts. The die casting system can include a shot piston disposed on the injection side and a counter piston disposed on the ejector side. The counter piston can move between a sealing position to seal the liquid in the shot sleeve during the injection and low-velocity injection phases and an open position to admit liquid into the casting cavity during the cavity injection phase.

Description

[Technical Field]

[0001] [CROSS-REFERENCE TO RELATED APPLICATIONS] This application claims priority to U.S. Provisional Patent Application No. 63 / 403,236, filed September 1, 2022, the entire contents of which are incorporated by reference in their entirety for all purposes.

[0002] This application relates to die casting machines and processes that use counter-pistons. More particularly, the die casting machines or processes use counter-pistons to enable central injection die casting of large and / or multi-cavity parts. [Background technology]

[0003] Die casting is a manufacturing process in which molten metal is poured or forced into a mold, also known as a die. The larger the die-cast part, the larger the die-casting machine required, and the larger the die-casting machine, the greater the clamping force required. Additionally, the larger the die-cast part, the longer the flow length of the molten metal required. The castability of a given part is limited by the maximum allowable flow length.

[0004] Traditional die casting methods often use horizontal cold chamber machines with biscuit and runner systems, which require large clamping forces and higher material costs. Molten metal flows into the chamber or cavity primarily through pressure from one side. Therefore, traditional die casting methods have limited design control over the flow of molten metal during the filling process. This can prevent a biscuit from being attached to the casting cavity, as the molten metal may spill or flow into the cavity too quickly during the injection and low-speed phases. Such traditional die casting methods can result in a limited die casting process window, high energy loss due to low material yield, and ineffective consolidation pressure. When it comes to casting large and / or multi-cavity parts, current die casting technology remains limited and unpredictable. Summary of the Invention [Means for solving the problem]

[0005] The present disclosure relates generally to die casting machines and processes that use counter-pistons. More specifically, various embodiments of the present disclosure relate to die casting machines or processes that use counter-pistons to enable central injection of large cast parts and / or multi-cavity parts.

[0006] One aspect is directed to a die casting machine having an ejector side and an injection side. The counter piston die casting machine can include a counter piston disposed on the ejector side, a shot piston disposed on the injection side, and a shot sleeve configured to receive the shot piston and a liquid.

[0007] In a variation of the above embodiment, the counter piston is movable between a first position and a second position.

[0008] In a variation of the above embodiment, when the counter piston is in the first position, liquid is allowed to flow from the shot sleeve to the casting cavity.

[0009] In a variation of the above embodiment, when the counter piston is in the second position, liquid is prevented from flowing from the shot sleeve to the casting cavity.

[0010] In a variation of the above embodiment, the shot sleeve is separated from the casting cavity by the counter piston when the counter piston is in the second position.

[0011] In a variation of the above embodiment, the counter piston is provided with a tapered edge on the side facing the shot sleeve for creating a pressure seal with the tapered edge of the shot sleeve on the side facing the counter piston.

[0012] In a variation of the above aspect, the counter piston has an uneven surface facing the shot sleeve, the uneven surface being configured to form a corresponding uneven surface on the cast part.

[0013] In a variation of the above embodiment, the counter-piston is further movable to a third position.

[0014] In a variation of the above embodiment, when the counter piston is in the third position, the counter piston is disengaged from the counter piston sleeve for cleaning and lubrication.

[0015] In a variation of the above aspect, the shot sleeve includes a pour hole configured to allow liquid to enter the shot sleeve.

[0016] In a variation of the above aspect, the shot sleeve includes a vent port configured to allow air to exit the shot sleeve.

[0017] In a variation of the above aspect, the counter piston is connected to a drive cylinder, the drive cylinder being configured to control the movement of the counter piston.

[0018] Another aspect is directed to a die casting process using a counter piston, the process including moving the counter piston into at least partial contact with a shot sleeve to prevent liquid from flowing through the shot sleeve into a casting cavity, the process may further include sliding the shot piston within the shot sleeve to remove air from the interior of the shot sleeve, and moving the counter piston away from the shot sleeve to allow liquid to enter the casting cavity.

[0019] A variation of the above aspect further includes moving the counter piston from the counter piston sleeve for cleaning and lubrication.

[0020] A variation of the above embodiment further includes injecting liquid into the shot sleeve through a pour hole on the shot sleeve.

[0021] In a variation of the above aspect, removing air from within the shot sleeve includes removing air from the shot sleeve through a vent port on the shot sleeve.

[0022] Another aspect is directed to a die casting machine configured to control the flow of molten metal into a casting cavity during a third stage. The die casting machine may include a housing, a shot sleeve, a shot piston, and a counter piston. The shot sleeve may be slidably disposed within the housing and form a receptacle configured to receive the molten metal and gas during the first stage. The shot piston may be configured to slide within the shot sleeve to remove the gas from the receptacle during the second stage, leaving behind the molten metal. The counter piston may be slidably disposed within the housing to prevent molten metal from entering the casting cavity during the first and second stages, while allowing the molten metal to enter the casting cavity during the third stage.

[0023] In a variation of the above embodiment, the counter piston is provided with a tapered edge on the side facing the shot sleeve for creating a pressure seal with the tapered edge of the shot sleeve on the side facing the counter piston. [Brief explanation of the drawings]

[0024] The present disclosure will now be described with reference to the accompanying drawings, in which like reference numerals refer to like elements.

[0025] [Figure 1A] 1 is an exemplary front view of a full shot of conventional die casting. FIG.

[0026] [Figure 1B] FIG. 1 is an exemplary front view of a central injection die casting concept according to an embodiment of the present disclosure.

[0027] [Figure 2A] FIG. 1 is a cross-sectional side view of a counter-piston die-casting machine according to a preferred embodiment of the present disclosure during the injection stage, taken along the central longitudinal axis of the counter-piston die-casting machine.

[0028] [Figure 2B] 2B is a cross-sectional side view of the counter-piston die-casting machine of FIG. 2A taken along the central longitudinal axis of the counter-piston die-casting machine at the low-velocity injection stage.

[0029] [Figure 2C] 2B is a cross-sectional side view of the counter-piston die-casting machine of FIG. 2A taken along the central longitudinal axis of the counter-piston die-casting machine in the filling stage.

[0030] [Figure 2D] 2B is a cross-sectional side view of the counter piston die casting machine of FIG. 2A taken along the central longitudinal axis of the counter piston die casting machine during the solidification stage.

[0031] [Figure 3A] FIG. 10 is an exemplary cross-sectional view of another embodiment of a counter-piston die casting machine according to the present disclosure.

[0032] [Figure 3B] FIG. 3B is an exemplary top view of the counter-piston die casting machine of FIG. 3A.

[0033] [Figure 4A] FIG. 1 is a cross-sectional side view of another embodiment of a counter-piston die-casting machine according to the present disclosure in the low-velocity injection stage, taken along the central longitudinal axis of the counter-piston die-casting machine.

[0034] [Figure 4B]4B is a cross-sectional side view of the counter piston die casting machine of FIG. 4A taken along the central longitudinal axis of the counter piston die casting machine at the solidification stage.

[0035] [Figure 4C] FIG. 10 is a cross-sectional side view of another embodiment of a counter-piston die-casting machine according to the present disclosure in a sealing stage, taken along the central longitudinal axis of the counter-piston die-casting machine.

[0036] [Figure 4D] 4D is a cross-sectional side view of the counter piston die casting machine of FIG. 4C at the solidification stage, taken along the central longitudinal axis of the counter piston die casting machine.

[0037] [Figure 5] FIG. 10 is a perspective end view of a shot sleeve of another embodiment of a counter-piston die casting machine according to the present disclosure.

[0038] [Figure 6A] FIG. 10 is a perspective end view of a shot block of another embodiment of a counter-piston die casting machine according to the present disclosure.

[0039] [Figure 6B] FIG. 6B is a perspective view of an end face of a shot sleeve of the counter-piston die casting machine of FIG. 6A.

[0040] [Figure 7A] FIG. 1 is a cross-sectional side view of an assembled counter piston with a counter piston sleeve and a shot sleeve according to the present disclosure taken along the central longitudinal axis of the counter piston die casting machine and showing the counter piston in an extended position.

[0041] [Figure 7B] FIG. 7B is a perspective view of an end face of a shot sleeve of the counter-piston die casting machine of FIG. 7A.

[0042] [Figure 8] FIG. 10 shows an assembled counter piston with a counter piston sleeve and a shot sleeve, with the assembled counter piston connected to a motion control system.

[0043] [Figure 9] FIG. 10 is a cross-sectional side view of the ejector main insert and counter piston assembly with air blowing channels during the die opening stage. DETAILED DESCRIPTION OF THE INVENTION

[0044] Generally described, one or more aspects of the present disclosure relate to die casting machines and processes that use counter-pistons. In particular embodiments, the present disclosure relates to die casting machines or processes that use counter-pistons to enable center injection die casting of large and / or multi-cavity parts.

[0045] Die casting of large casting parts requires a long metal flow length. To shorten the metal flow length, two existing center injection methods exist. One method is center shot die casting with a three-plate die configuration. The three-plate die configuration, which includes an additional center plate, an additional die opening stroke, an additional runner removal step, and additional heat concentration in the middle plate, can be complex and costly.

[0046] water Conventional die casting using a flat cold die casting machine The mold is shown in Figure 1A. The horizontal cold die casting machine 10 may have a biscuit 11, one or more runners 12, one or more gates 13, one or more casting cavities (or cast parts) 14, one or more overflows 15, and one or more vents 16. To shorten the metal flow length Conventional possible Method for casting parts to Large opening in By requiring the biscuit and runner to be centered in the casting. Runner teeth , biscuits of It must be attached to the upper part, so that、 Runner is longer and the injection This leads to inefficiencies in the system, resulting in uneven flow distribution across the cavity and limiting the operating window of the die casting process (e.g., the castable size of the cast part). To Bi-Run Na The excess metal in the area is removed from the casting. Quality part It cannot be, Therefore, simply scaling and / or adapting existing die casting technology to die cast large parts (e.g., vehicle chassis) is not a practical economic solution.

[0047] A counter-piston die casting system according to the present disclosure can solve one or more of the problems described above. For example, in certain embodiments, the use of a counter-piston to exercise control over the flow of molten metal allows for direct injection of molten metal into a die cavity. As shown in FIG. 1B, the counter-piston die casting system 20 can eliminate (or significantly shorten) the runner while also allowing the biscuit 24 to be part of the die-cast product, reducing production costs. By using a counter-piston, the counter-piston die casting system provides control over the flow of molten metal, ensuring a uniform flow of molten metal, thereby enabling predictable and repeatable casting of large parts. In some embodiments, the counter-piston central injection die casting methods disclosed herein can reduce the required clamp tons of the die casting machine (e.g., by about 15-30%), increase material yield (e.g., by about 90% compared to about 60% for conventional die casting methods), widen the die casting operating window due to shorter molten metal fill distance, and achieve better die casting quality due to better consolidation pressure effectiveness compared to conventional die casting.

[0048] 2A-2D illustrate an exemplary embodiment of a die casting machine 100 according to the present disclosure. In certain embodiments, the die casting machine 100 may include a shot piston 101 from an injection side A and a counter piston 106 from an ejector side B. In certain embodiments, at the injection side A, the die casting machine 100 may include a machine platen 103 and a cover die 104 attached to the machine platen 103. In certain embodiments, a shot sleeve 102 may be positioned inside the cover die 104 and / or the machine platen 103 and configured to receive molten metal 119. The shot piston 101 may be configured to be movable within the shot sleeve 102 between a first position and a second position. In some embodiments, the first position may be at an end of the shot sleeve 102 adjacent to the injection side A, and the second position of the shot piston 101 may be at an end of the shot sleeve 102 adjacent to the ejector side B. In some embodiments, the shot sleeve 102 may include a vent port 117 that allows air to escape and a pour hole 118 that allows molten metal 119 to enter. The space between the cover die and the ejector main insert may define a casting cavity 116 configured to receive the molten metal 119 to form the cast part.

[0049] In certain embodiments, at ejector side B, the die casting machine 100 may include an ejector main insert 105 (or ejection die) and / or an ejector holder block 114 attached to the ejector main insert 105. The ejector main insert 105 may include a counter piston sleeve 115 configured to receive and retain a counter piston 106. The counter piston 106 may be configured to be movable between a sealed position and an open position. In some embodiments, the counter piston 106, when in the sealed position, may be configured to contact and seal against the shot sleeve 102 at the ejector side B of the shot sleeve 102. In other embodiments, the sealed position of the counter piston 106 may be further toward injection side A than the open position of the counter piston 106. When in the open position, the counter piston 106 may be configured not to contact the shot sleeve 102, such that the shot sleeve 102 is not sealed by the counter piston 106 but is instead open to the casting cavity 116. In some embodiments, the counter piston 106, when in the open position, may be fully received by the counter piston sleeve 115. In other embodiments, the counter piston 106 may be at least partially received by the counter piston sleeve 115.

[0050] In some embodiments, the die casting machine 100 may further include, on the ejector side B, an ejector platen 110 and an ejector back plate 111 attached to the ejector platen 110. In some embodiments, one or more ejector control bars 109 may be positioned inside the ejector platen 110 and / or the ejector back plate 111. The ejector control bars 109 may be attached to the ejector plate 112 and configured to push or pull the ejector plate 112. The die casting machine 100 may further include one or more counter piston support blocks 107 positioned between the ejector main insert 105 (and / or the ejector holder block 114) and the ejector platen 110 (and / or the ejector back plate 111), as shown in FIG. 2A . The ejector plate 112 can be configured to be movable relative to the counter piston support block 107 within the space between the ejector main insert 105 (and / or ejector holder block 114) and the ejector platen 110 (and / or ejector back plate 111). One or more ejector pins 113 can be attached to the ejector plate 112 at one end and positioned inside the ejector main insert 105 (and / or ejector holder block 114) at the other end.

[0051] 2A, during the injection phase, molten metal 119 may be injected into the shot sleeve 102 through the pour hole 118 with the shot piston 101 in a first position. In some embodiments, the first position of the shot piston 101 may be positioned further toward the injection side A than the pour hole 118.

[0052] During the low-speed injection phase, as shown in FIG. 2B , the molten metal 119 may be gently pushed by the shot piston 101 toward the casting cavity 116 on the ejector side B. In some embodiments, air within the shot sleeve 102 may escape and be removed from the shot sleeve 102 through the vent port 117 during the low-speed injection phase. The counter piston 106 may remain in a sealing position during the low-speed injection phase. As shown in FIG. 2B , when the counter piston 115 is in the sealing position (e.g., against the end face of the shot sleeve 102), it can seal the opening of the shot sleeve 102 facing the casting cavity 116, thereby creating two separate air chambers, one within the casting cavity 116 and the other within the shot sleeve. The two separate air chambers can help achieve a high vacuum level within the die cavity without allowing the molten metal 119 to enter.

[0053] 2C shows the die casting machine 100 in a filling stage in which molten metal 119 can enter the casting cavity 116. During the filling stage, the counter piston 106 can be in an open position, and the casting cavity 116 can be unobstructed by the counter piston 106. In some embodiments, the filling stage can begin and the counter piston 106 can move to the open position after the shot piston 101 has moved toward ejector side B and passed through the vent port 117 to reach its second position, thereby removing substantially all of the air within the shot sleeve 102 through the vent port 117.

[0054] 2D shows the die casting machine 100 in a solidification stage, where the casting cavity 116 may be substantially filled with molten metal 119. During the solidification stage, the shot piston 101 may reach its second position and push and maintain the molten metal 119 inside the casting cavity 116, while the counter piston 106 may remain in an open position. The molten metal 119 may cool during the solidification stage to form a cast part in the casting cavity 116.

[0055] During the die casting process, runners and biscuit sections are used to guide the flow of molten metal before it enters the casting cavity to achieve specific qualities or characteristics (e.g., temperature, flow rate, etc.). In some embodiments, the runners and biscuit sections can be eliminated or shortened by using the counter-piston die casting process according to the present disclosure compared to conventional die casting processes. With the help of the counter-piston, the flow of molten metal can be controlled by pressure from both sides, i.e., the shot piston and the counter piston. With improved flow control, the size of any runner and biscuit section can be designed (e.g., shortened) without adversely affecting the desired quality and characteristics of the molten metal.

[0056] In some embodiments, the biscuit and runner shapes can also be configured to be part of the cast shape to reduce waste in the runner and biscuit system. Using a counter piston, the counter piston die casting process can allow the injection point to be located at any desired location because the flow of molten metal can be controlled by both the counter piston and the shot piston. Therefore, it is possible to configure the biscuit and runner to be part of the cast shape, or at least reduce material waste by reducing the size of the biscuit and runner.

[0057] 3A-3B show an example of a counter piston die casting process with a shot piston 201 and a counter piston 206. The counter piston die casting process can be configured to include a runner 213 and a biscuit 214 as part of a cast part 211 with a possible gating location 212, as shown in FIG. 3A. In some embodiments, the minimum biscuit thickness can be equal to or greater than the required cast part thickness at that location. In some embodiments, for example, a sturdy structure having a thickness greater than 5 mm and / or having reinforcing ribs can be cast with a counter piston die casting process without a runner.

[0058] The counter-piston die casting process according to the present disclosure may also include a seal or vent slot design configured to seal the molten metal 119 within the shot sleeve 102 prior to the cavity filling stage. In some embodiments, the seal design may be a conical surface pressure seal 121 and / or a compound face seal, as shown in FIGS. 2A-2B . In some embodiments, the conical surface pressure seal 121 is disposed between a tapered edge of the counter-piston 106 and a tapered edge of the shot sleeve 102. In some embodiments, the seal design may be a cylindrical surface mating seal 321, as shown in FIGS. 4A-4D . In some embodiments, the cylindrical surface mating seal 321 is disposed between a straight edge of the counter-piston 306 and the inner surface of the shot sleeve 302 (see FIG. 4A ).

[0059] A counter piston 106 having a conical surface pressing seal 121 may be advantageous over a cylindrical surface mating seal 321 because the conical surface pressing seal 121 can reach its sealing position within a shorter distance from its open position (see FIGS. 2A and 4A). A counter piston 106 having a conical surface pressing seal 121 may also be more tolerant of misalignment between the central axis of the shot sleeve 102 and the central axis of the counter piston 106. A counter piston 306 having a cylindrical surface mating seal 321 may be advantageous in that the casting cavity 316 may have an ejector side (e.g., the side of the casting cavity 416 facing ejector side B) that is not restricted by the tapered edge of the conical surface pressing seal 121. With the cylindrical surface mating seal 321, in some embodiments, the ejector side of the casting cavity 316 may be configured to be flat, as shown in FIG. 4B. In some embodiments, the ejector side of the casting cavity 316 can be configured to be irregular (e.g., angled) with a cylindrical surface mating seal, as shown in Figure 4D. Correspondingly, the shot piston 401 can also have an irregular ejector side (e.g., the side of the shot piston 401 facing ejector side B) and a biscuit with an irregular profile, as shown in Figures 4C-4D.

[0060] The counter-piston die casting system may also include a gating design including a gate notch or ridge disposed on the end face of the shot sleeve (e.g., the face of the shot sleeve facing the casting cavity). The gate notch or ridge can be configured to form a desired pattern on the casting cavity / part. The gate notch or ridge can have a size (e.g., width and thickness) and location around the biscuit. The size and location can be configured according to the intended casting design. FIG. 5 shows an end face 51 of a shot sleeve 50 having multiple gate notches 52. The shot sleeve 50 may also include a face-fitting seal 53 (e.g., a press seal face or front face) disposed on the inner surface of the shot sleeve 50. In some embodiments, the multiple gate notches 52 can be distributed around the circular end face 51, as shown in FIG. 5.

[0061] In some embodiments, the counter piston die casting system may further include one or more notches or ridges disposed on the end face of the counter piston (e.g., the face of the counter piston facing the casting cavity). The one or more notches or ridges on the counter piston may be configured to cooperate with one or more gate notches or ridges on the shot sleeve to function as a conventional fixed shot distributor (e.g., a shot block or shot sprue). The one or more notches or ridges on the counter piston and the one or more gate notches or ridges on the shot sleeve may be combined to regulate the flow of molten metal, preferably in a specific manner (e.g., in a specific direction or at a specific flow rate), to form a desired pattern on the casting cavity / part, as shown in Figures 6A-6B. Figure 6B shows the end face 61 of the shot sleeve 61 with a gate notch 62 and a face-fitting seal 63 (e.g., a press seal face or front face). 6A shows an end face 67 of a counter piston 66 having a ridge 65 disposed thereon and configured to cooperate with the gate notch 62. The counter piston 66 may also include a face-fitting seal 65 (e.g., a press seal face or front face) disposed thereon and configured to cooperate with the face-fitting seal 63.

[0062] One embodiment of a counter piston die casting system using a vent slot 716 to facilitate sealing between a shot sleeve 702 and a counter piston 706 is shown in FIGS. 7A-7B. As shown in FIG. 7B, a shot sleeve 702 having an end face 721 and a plurality of sprue notches 722 can include a vent slot 716 disposed in the end face 721. FIG. 7A illustrates that the shot sleeve 702 can be configured to contact the counter piston 706 so that only a lower portion of the end face 721 of the shot sleeve 702 is sealed, and the shot sleeve 702 can be configured to communicate with the casting cavity or ambient air for venting purposes. When a conventional venting process (e.g., no vent port in the shot sleeve, as shown in FIGS. 2A-2D ) is used, it can be advantageous to include the vent slot 716 in the sealing design.

[0063] The counter piston and / or counter piston sleeve for the counter piston die casting system according to the present disclosure may have a structural design similar to that of a conventional solid-shot piston and / or shot sleeve. For example, the mating clearance between the counter piston and the counter piston sleeve may be maintained within a similar range to that between a conventional solid-shot piston and a shot sleeve. The counter piston die casting system may also employ thermal control methods similar to those of conventional die casting systems, but with tighter control to maintain a more uniform shape of the counter piston end face for sealing purposes. In some embodiments, internal cooling may be implemented using the counter piston and its sleeve, for example, using 3D printing. The expected life of the counter piston may be much longer than that of a conventional solid-shot piston because the counter piston can have a shorter travel stroke and a lower travel speed.

[0064] In some embodiments, the position of the counter piston can be controlled by a drive cylinder 108 in the ejector box, as shown in FIGS. 2A-2D. The drive cylinder 108 can apply pressure to properly seal the surfaces between the counter piston 106 and the shot sleeve 102. In some embodiments, the drive cylinder 108 can also control the movement of the counter piston 106 based on the timing requirements of the die casting process. In other embodiments, the movement of the counter piston 806 can be controlled by a circuit 800 (e.g., a hydraulic circuit), as shown in FIG. 8. In some embodiments, the hydraulic circuit 800 can include a two-position servo valve, a pressure release valve, a drive motor, and an oil tank. In some embodiments, the die casting system can further include a die casting machine control system that sends signals to control the servo valve.

[0065] In some embodiments, the counter-piston die-casting system may include a die-opening stage in which the solidified cast part can be removed from the casting cavity. As shown in FIG. 9 , the counter-piston 906 can move from the counter-piston sleeve 915 in a third position toward injection side A to eject the solidified cast part from the casting cavity 916 during the die-opening stage. In some embodiments, the counter-piston die-casting system may include one or more air-blow channels 925 configured to blow air and clean debris, if any, from a counter-piston pocket 926 disposed between the counter-piston 906 and the counter-piston sleeve 915. In some embodiments, the one or more air-blow channels 925 may be disposed in a surface of the ejector main insert 905 (e.g., the surface facing the counter-piston). In other embodiments, the one or more air-blow channels 925 may be disposed in one or more shock absorber plates 924 attached to a surface of the ejector main insert 905 (e.g., the surface facing the counter-piston). In some embodiments, one or more air blowing channels 925 can be implemented in one or more shock absorber plates 924 by one or more built-in air nozzles. During the die opening stage, after cleaning the counter piston (e.g., air blowing cleaning), an external oil spray can also be applied to the counter piston for lubrication.

[0066] The foregoing disclosure is not intended to limit the disclosure to the precise form or particular field of use disclosed. Accordingly, various alternative embodiments and / or modifications to the disclosure, whether expressly described or implied herein, are contemplated as possible in light of the present disclosure. While embodiments of the present disclosure have been described in this manner, those skilled in the art will recognize that changes can be made in form and detail without departing from the scope of the present disclosure. Accordingly, the present disclosure is limited only by the claims.

[0067] In the foregoing specification, the present disclosure has been described with reference to specific embodiments. However, as those skilled in the art will understand, the various embodiments disclosed herein can be modified or otherwise implemented in various other ways without departing from the spirit and scope of the present disclosure. Accordingly, this description should be considered illustrative and is for the purpose of teaching those skilled in the art how to make and use various embodiments of the disclosed counter piston die casting system or process. It should be understood that the forms of the disclosure shown and described herein should be construed as representative embodiments. Equivalent elements, materials, processes, or steps may be substituted for those typically shown and described herein. Furthermore, certain features of the present disclosure can be utilized independently of the use of other features, as will all become apparent to those skilled in the art after having the benefit of this description of the present disclosure. The terms "including," "comprising," "incorporating," "consisting of," "having," "being," and the like, used to describe and claim the present disclosure, are intended to be construed in a non-exclusive manner, i.e., allowing for the presence of items, components, or elements not expressly recited. References to the singular should also be construed to relate to the plural.

[0068] Furthermore, the various embodiments disclosed herein should be construed in an exemplary and explanatory sense and in no way as limiting the present disclosure. All joint references (e.g., attached, fixed, coupled, connected, etc.) are used solely to aid the reader's understanding of the present disclosure and do not create any limitations with respect to the position, orientation, or use of the systems and / or methods disclosed herein, among other things. Accordingly, joint references, if present, should be interpreted broadly. Furthermore, such joint references do not necessarily imply that two elements are directly connected to one another. Furthermore, all numerical terms, such as, but not limited to, "first," "second," "third," "primary," "secondary," "main," or any other conventional and / or numerical term, should also be construed solely as identifiers to aid the reader's understanding of the various elements, embodiments, variations, and / or modifications of the present disclosure, and in particular do not create any limitations with respect to the order or preference of any element, embodiment, variation, and / or modification relative to or over another element, embodiment, variation, and / or modification.

[0069] It will also be understood that one or more of the elements shown in the drawings / figures may also be implemented in a more separate or integrated manner, or may be removed or rendered inoperable in certain cases, as may be useful depending on the particular application.

Claims

1. A die casting machine having an ejector side and an injection side, a counter piston disposed on the ejector side; a shot piston disposed on the injection side; a shot sleeve configured to receive the shot piston and a liquid; A die casting machine comprising:

2. 2. The die casting machine of claim 1, wherein the counter piston is movable between a first position and a second position.

3. 3. The die casting machine of claim 2, wherein when the counter piston is in the first position, the liquid is allowed to flow from the shot sleeve to the casting cavity.

4. 3. The die casting machine of claim 2, wherein when the counter piston is in the second position, the liquid is prevented from flowing from the shot sleeve to the casting cavity.

5. 3. The die casting machine of claim 2, wherein the shot sleeve is separated from the casting cavity by the counter piston when the counter piston is in the second position.

6. 6. The die casting machine of claim 5, wherein the counter piston includes a tapered edge on a side facing the shot sleeve for creating a pressure seal with the tapered edge of the shot sleeve on a side facing the counter piston.

7. the counter piston has an uneven surface facing the shot sleeve; The die casting machine of claim 1 , wherein the uneven surface is configured to form a corresponding uneven surface on the cast component.

8. The die casting machine of claim 2 , wherein the counter piston is further movable to a third position.

9. 9. The die casting machine of claim 8, wherein when the counter piston is in the third position, the counter piston is disengaged from the counter piston sleeve for cleaning and lubrication.

10. 10. The die casting machine of claim 1, wherein the shot sleeve includes a pour hole configured to allow the liquid to enter the shot sleeve.

11. 10. The die casting machine of claim 1, wherein the shot sleeve includes a vent port configured to allow air to exit the shot sleeve.

12. 2. The die casting machine of claim 1, wherein the counter piston is connected to a drive cylinder, the drive cylinder configured to control movement of the counter piston.

13. 1. A die casting process using a counter piston, comprising: moving the counter piston into at least partial contact with the shot sleeve to prevent liquid from flowing through the shot sleeve into the casting cavity; sliding a shot piston within the shot sleeve to remove air from within the shot sleeve; moving the counter piston away from the shot sleeve to allow the liquid to enter the casting cavity; Including die casting process.

14. 14. The die casting machine of claim 13, further comprising the step of moving the counter piston from the counter piston sleeve for cleaning and lubrication.

15. The die casting machine of claim 13 further comprising the step of injecting the liquid into the shot sleeve through a pour hole on the shot sleeve.

16. 14. The die casting machine of claim 13, wherein removing air from inside the shot sleeve comprises removing air from the shot sleeve through a vent port on the shot sleeve.

17. 1. A die casting machine configured to control the flow of molten metal into a casting cavity during a third stage, comprising: Housing and a shot sleeve slidably disposed within the housing and forming a receptacle, a shot sleeve, the receptacle configured to receive the molten metal and gas during a first stage; a shot piston configured to slide within the shot sleeve to remove the gas from the receptacle during a second stage, leaving the molten metal; a counter piston slidably disposed within the housing for preventing the molten metal from entering the casting cavity during the first and second stages while allowing the molten metal to enter the casting cavity during the third stage; A die casting machine comprising:

18. 18. The die casting machine of claim 17, wherein the counter piston includes a tapered edge on a side facing the shot sleeve for creating a pressure seal with the tapered edge of the shot sleeve on a side facing the counter piston.

19. 18. The die casting machine of claim 17, wherein the counter piston has an uneven surface facing the shot sleeve, the uneven surface configured to form a corresponding uneven surface on the cast component.

20. 18. The die casting machine of claim 17, wherein the counter piston is connected to a drive cylinder, the drive cylinder configured to control movement of the counter piston.

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