Metal-molding system and process for making foamed alloy

Disclosed is: (i) a metal injection-molding system, (ii) a metal injection-molding system including a combining chamber, (iii) a metal injection-molding system including a first injection mechanism and a second injection mechanism, (iv) a metal injection-molding system including a first injection mechanism being co-operable with a second injection mechanism, (v) a mold of a metal injection-molding system, and (vi) a method of a metal injection-molding system.

TECHNICAL FIELD

The present invention generally relates to, but is not limited to, molding systems, and more specifically the present invention relates to, but is not limited to, (i) a metal injection-molding system, (ii) a metal injection-molding system including a combining chamber, (iii) a metal injection-molding system including a first injection mechanism and a second injection mechanism, (iv) a metal injection-molding system including a first injection mechanism being co-operable with a second injection mechanism, (v) a mold of a metal injection-molding system, and (vi) a method of a metal injection-molding system.

BACKGROUND

U.S. Pat. No. 5,865,237 (Inventor: SCHORGHUBER et al; Published: 1999, Feb. 2) discloses production of molded foamed metal parts, in which a compacted powder metallurgical preform is foamed by heating in a chamber and the foam charge is injected into a mold.

U.S. Pat. No. 5,972,285 (Inventor: KNOTT; Published: 1999, Oct. 26) discloses a foamed metal especially aluminum body production from a compacted mixture of metal powder and magnesium hydride blowing agent.

U.S. Pat. No. 6,733,722 (Inventor: SINGER et al; Published: 2004, May 11) discloses production of a molded body from a foamed metal that includes feeding two powders in non-compact form to an extruder, injecting powder mixture into the mold and releasing the pressure so that the mold is completely filled with foamed metal.

PCT Patent Number WO/04108976A2 (Inventor: KÖRNER et al; Published: 2004, Dec. 16) discloses foamed metal molding production, that includes adding foaming agent to molten metal after leaving supply vessel and before entry into a mold cavity. Also disclosed is a method for producing a metal foam body, whereby a molten metal is prepared and introduced into a reservoir, and the molten metal is injected into a mold cavity surrounded by a mold, via a line connecting the reservoir to the mold. The aim is to create a foam structure only in the core of the metal foam body. To this end, a blowing agent is added to the metal melt, once it has left the reservoir and before it enters the mold cavity.

U.S. Pat. No. 6,866,084 (Inventor: ASHOLT et al; Published: 2005, Mar. 15) discloses a method and means for producing molded bodies of a metal foam, in particular an aluminum foam. The method involves the use of mold having a cavity and at least one entrance opening. The mold is filled with a metal foam in a manner where the entrance opening of the mold is submerged into a metal melt and the melt is caused to foam inside the mold and fill its cavity.

U.S. Pat. No. 6,840,301 (Inventor: NICHOL et al; Published: 2005, Jan. 11) discloses aluminum article casting that involves releasing pressure in a bath, after filling a molten aluminum foam produced by passing gas bubbles through the molten aluminum, to remove the article from the die cavity.

U.S. Pat. No. 6,915,834 (Inventor: KNOTT et al; Published: 2005, Jul. 12) discloses production of a metal foam that includes inserting the molten metal into a mold hollow chamber, and foaming with a propellant which is solid at room temperature. Also disclosed is a process for producing a metal foam and to a metal body produced using the process. The object is achieved by a process for producing the metal foam by adding a blowing agent to a metal melt, wherein the metal melt is: (i) introduced into the die cavity of a metal die-casting machine, and is (ii) foamed using a blowing agent, which releases gases and is solid at room temperature.

U.S. Pat. No. 6,998,535 (Inventor: NICHOL; Published: 2006, Feb. 14) discloses a method for casting articles from a metal foam, a molten metal bath and a foam-forming means. The foam is drawn into a ladle, within a heated chamber, which transports a foam sample to a mold. The ladle deposits the foam sample into the mold and the mold is closed. Once cooled and hardened the formed article is removed. The system includes a molten metal bath, a heated foam collecting chamber, a ladle for drawing a sample of the foam and for transporting the sample to a mold.

PCT Patent Application Number WO/06021082 (Inventor: KILLINGBECK et al; Published: 2006, May 04) discloses a casting apparatus for casting metal foam article from foam of molten metal. The apparatus includes a gas injection nozzle connected to a gas supply. The nozzle is positioned below a mold cavity opening. A flow generating mechanism causes a molten metal to flow.

U.S. Pat. No. 7,175,689 (Inventor: DOBESBERGER et al; Published: 2007, Feb. 13) discloses a process for producing a lightweight molded part, comprising introducing a gas into a particle-containing, molten metal to produce a metal foam having voids with a monomodal distribution of their dimensions, introducing the metal foam into a casting die and compressing it therein essentially under all-round pressure; and the molded part made by this process.

U.S. Pat. No. 7,195,662 (Inventor: DOBESBERGER et al; Published: 2007, Mar. 27) discloses a device for feeding gas in a melt of foamable metal by means of at least one pipe for producing metal foam. The gas insertion pipe projects inwardly into the melt and at the projecting end has a gas outlet having a cross-sectional area of 0.006 to 0.2 millimeters (mm) squared, and a pipe face area of less than 4.0 mm squared. A flowable metal foam has gas bubbles defined by walls of a liquid metal matrix with solid reinforcing particles, and the diameter of the largest gas bubbles divided by that of the smallest gas bubbles is less than 2.5.

A technical article (Title: METALLIC FOAMS—ULTRA LIGHT MATERIALS FOR STRUCTURAL APPLICATIONS; Author: FRANTIEK SIMANCIK; Technical Journal Name: INZYNIERIA MATERIALOWA Nr. 5/2001; Pages: 823 to 828) discloses, in the Abstract, the following: metallic foams are relatively unknown structural materials, however with enormous future potential for applications where lightweight combined with high stiffness and acceptable manufacturing costs are of prime interest The performance of metallic foams, in particular those made of aluminum, in various prototypes, such as foamed panels, sandwiches, complex 3-D-parts, foamed hollow profiles as well as castings with foamed cores, has been discussed with respect to the expected and achieved goals. The important contributions of aluminum foam to the improvement of the products properties are highlighted and most promising utilization is suggested.

A technical article (Title: PRODUCTION AND PROPERTIES OF FOAMED MAGNESIUM; Authors: Fr.-W. BACH, 0. BORMAUN, P. WILK, R. KUCHARSKI; Journal Title: CELLULAR METALS AND POLYMERS 2004, pages 77 to 80, edited by R. F. Singer; C. Körner, V. Altstadt, Fragezeichenverlag, Furth, Long ISBN number 8585858585) discloses, in the Abstract, results from the priority program “Cellular Metals” of the Deutsche Forschungsgemeinschaft (DFG SPP 1075). Two processes for the production of foams and sponges basing on magnesium are presented and discussed concerning their producibility and their applications. The powder metallurgical route for the production of metallic foams basing on aluminum is well examined since some decades but foamed parts basing on magnesium could not be produced yet. The discussion of the foamability of magnesium alloys leads to a sintering process which enhances the foamability at the beginning of the foaming process and finally leads to foamed magnesium cylinders with 40 mm in diameter. Relatively easy in the production but appropriate only for small open cell sponges is the infiltration process using salt grains as place holder. The molten magnesium is forced by vacuum to infiltrate the salt grains which are dissolved in sodium hydroxide solution after machining. A method which applies mechanical vibration for grain fining of the bulk material and improving the infiltration process is adopted.

SUMMARY

According to a first aspect of the present invention, there is provided a metal injection-molding system, including a combining chamber configured to: (i) receive a molten-metallic alloy and a spacing agent being injectable under pressure into the combining chamber, the molten-metallic alloy and the spacing agent combinable, at least in part, under pressure in the combining chamber, and (ii) convey, under pressure, the molten-metallic alloy and the spacing agent toward a mold, the molten-metallic alloy combined with the spacing agent being solidifiably formable into a molded-foamed-metallic article in the mold.

According to a second aspect of the present invention, there is provided a metal injection-molding system, including a first injection mechanism configured to process a molten-metallic alloy, and a second injection mechanism configured to process a spacing agent, the first injection mechanism and the second injection mechanism configured to couple to a combining chamber configured to: (i) receive a molten-metallic alloy and a spacing agent being injectable under pressure into the combining chamber, the molten-metallic alloy and the spacing agent combining, at least in part, under pressure in the combining chamber, and (ii) convey, under pressure, the molten-metallic alloy and the spacing agent to a mold, the molten-metallic alloy combined with the spacing agent being solidifiably formable into a molded-foamed-metallic article in the mold.

According to a third aspect of the present invention, there is provided a metal injection-molding system, including a first injection mechanism configured to process a molten-metallic alloy, the first injection mechanism being co-operable with a second injection mechanism configured to process a spacing agent, the first injection mechanism and the second injection mechanism configured to couple to a combining chamber configured to: (i) receive a molten-metallic alloy and a spacing agent being injectable under pressure into the combining chamber, the molten-metallic alloy and the spacing agent combining, at least in part, under pressure in the combining chamber, and (ii) convey, under pressure, the molten-metallic alloy and the spacing agent to a mold, the molten-metallic alloy combined with the spacing agent being solidifiably formable into a molded-foamed-metallic article in the mold.

According to a fourth aspect of the present invention, there is provided a metal injection-molding system, including a first injection mechanism configured to process a molten-metallic alloy, a second injection mechanism configured to process a spacing agent, a stationary platen configured to support a stationary mold portion of a mold, a movable platen configured to move relative to the stationary platen, and configured to support a movable mold portion of the mold, the stationary mold portion and the movable mold portion forming a mold cavity once the movable platen is made to move toward the stationary platen sufficiently enough as to abut the stationary mold portion against the movable mold portion, the stationary mold portion defining a mold gate leading to the mold cavity, a clamping mechanism coupled to the stationary platen and the movable platen, and configured to apply a clamp tonnage between the stationary platen and the movable platen, and a combining chamber configured to: (i) receive a molten-metallic alloy and a spacing agent being injectable under pressure into the combining chamber, the molten-metallic alloy and the spacing agent combining, at least in part, under pressure in the combining chamber, and (ii) convey, under pressure, the molten-metallic alloy and the spacing agent to a mold, the molten-metallic alloy combined with the spacing agent being solidifiably formable into a molded-foamed-metallic article in the mold.

According to a fifth aspect of the present invention, there is provided a method of a metal injection-molding system, including: (i) receiving, in a combining chamber, a molten-metallic alloy and a spacing agent being injectable under pressure into the combining chamber, the molten-metallic alloy and the spacing agent combining, at least in part, under pressure in the combining chamber, and (ii) conveying, under pressure, the molten-metallic alloy and the spacing agent to a mold, the molten-metallic alloy combined with the spacing agent being solidifiably formable into a molded-foamed-metallic article in the mold.

According to a sixth aspect of the present invention, there is provided a metal injection-molding process, including injecting, under pressure, a molten-metallic alloy and a spacing agent into a mold, the molten-metallic alloy combined with the spacing agent being solidifiably formable into a molded-foamed-metallic article in the mold.

According to a seventh aspect of the present invention, there is provided a metal injection-molding process, including: (i) a receiving operation, including receiving a solidified molten-metallic alloy and a spacing agent, (ii) a heating operation, including heating the solidified molten-metallic alloy associated with the receiving operation above a solidus temperature of the solidified molten-metallic alloy, the solidified molten-metallic alloy becoming a molten-metallic alloy, (iii) a combining operation, including combining the molten-metallic alloy associated with the heating operation with the spacing agent associated with the receiving operation, and (iv) an injecting operation, including injecting, under pressure, the molten-metallic alloy and the spacing agent into a mold, the molten-metallic alloy combined with the spacing agent being solidifiably formable into a molded-foamed-metallic article in the mold.

According to an eighth aspect of the present invention, there is provided a metal injection-molding system, including: (i) receiving means configured to implement a receiving operation, including receiving a solidified molten-metallic alloy and a spacing agent, (ii) heating means configured to implement a heating operation, including heating the solidified molten-metallic alloy associated with the receiving operation above a solidus temperature of the solidified molten-metallic alloy, the solidified molten-metallic alloy becoming a molten-metallic alloy, (iii) combining means configured to implement a combining operation, including combining the molten-metallic alloy associated with the heating operation with the spacing agent associated with the receiving operation, and (iv) injection means configured to implement an injecting operation, including injecting, under pressure, the molten-metallic alloy and the spacing agent into a mold, the molten-metallic alloy and the spacing agent into a mold, the molten-metallic alloy combined with the spacing agent being solidifiably formable into a molded-foamed-metallic article in the mold.

A technical effect, amongst other technical effects, of the aspects of the present invention is improved operation of a molding system for manufacturing articles molded of metallic alloys.

The drawings are not necessarily to scale and are sometimes illustrated by phantom lines, diagrammatic representations and fragmentary views. In certain instances, details that are not necessary for an understanding of the embodiments or that render other details difficult to perceive may have been omitted.

REFERENCE NUMERALS USED IN THE DRAWINGS

The following is a listing of the elements designated to each reference numeral used in the drawings:

a material input,2

first injection mechanism,110

second injection mechanism,114

DETAILED DESCRIPTION OF THE NON-LIMITING EMBODIMENTS

FIG. 1depicts the schematic representation of the metal injection-molding system100(hereafter referred to as the “system100”) according to the first non-limiting embodiment. Preferably, the system100includes a metal-injection molding system101. The system100may include some components that are known to persons skilled in the art, and these known components will not be described here; these known components are described, at least in part, in the following text books (by way of example): (i) “Injection Molding Handbook” by Osswald/Turng/Gramann (ISBN: 3-446-21669-2; publisher: Hanser), (ii) “Injection Molding Handbook” by Rosato and Rosato (ISBN: 0-412-99381-3; publisher: Chapman & Hill), and/or (iii) “Injection Molding Systems”3rdEdition by Johannaber (ISBN 3-446-17733-7).

According to the first non-limiting embodiment, the system100includes a first injection mechanism110(hereafter referred to as the “mechanism110”) that is configured to process a molten-metallic alloy112(hereafter referred to as the “alloy112”). The system100also includes a second injection mechanism114(hereafter referred to as the “mechanism114”) that is configured to process a spacing agent116. The combination of the alloy112and the spacing agent116will be, from time to time, referred to as the “inputs” for the sake of simplifying the detailed description. Once the spacing agent116is combined with the alloy112, the alloy112and the spacing agent116may solidify (in a mold104) into a molded-foamed-metallic article124(hereafter referred to as the “article124”). According to non-limiting variants, the spacing agent116includes any one of (for example, but not limited to): (i) a gas, (ii) a non-reactive solid being non-reactive with the alloy112, and/or (iii) a reactive solid being reactive with the alloy112. Examples of the spacing agent116are described in technical articles, titled: (i) METALLIC FOAMS—ULTRA LIGHT MATERIALS FOR STRUCTURAL APPLICATIONS; Author: FRANTIEK SIMANCIK; Technical Journal Name: INZYNIERIA MATERIALOWA Nr. 5/2001, and (ii) PRODUCTION AND PROPERTIES OF FOAMED MAGNESIUM; Authors: Fr.-W. BACH, 0. BORMAUN, P. WILK, R. KUCHARSKI; Journal Title: CELLULAR METALS AND POLYMERS 2004; edited by R. F. Singer; C. Körner, V. Altstadt, Fragezeiche). The spacing agent116may also be called a foaming agent, in that by combining the spacing agent116with the alloy112, an article may be molded to form a molded-foamed-metallic article, which includes “spaces” primarily located in the solidified alloy of the molded article; the spaces in the molded article may also be called “voids” or the spaces may contain a material that is lighter (in weight and/or density) than (the weight and/or density of) the solidified alloy. According to a non-limiting variant, the spacing agent116includes hollow-sphere structures that are made of a material being different than the alloy112. The hollow-sphere structures do not (for the most part) melt in the alloy112. The hollow-sphere structures may be pre-produced by different techniques. It is possible to manufacture hollow spheres with: (i) a diameter in a range from about 1 to about 10 millimeters (mm), and/or (ii) a mantle thicknesses from about 20 to about 50 micrometers (μm). The hollow-sphere structures may be manufactured in principle by sintering, soldering and/or sticking. Hollow-sphere structures on iron basis are producible in a far density range, from about 0.2 to 1.5 grams per cubic centimeter (g/cm3). The operational areas lie for example in lightweight construction, in heat and acoustic noise insulation, as crash absorber or carrier material for functional applications, etc. Details regarding the hollow spheres may be obtained from Dr.-Ing. Guenter Stephani at the Fraunhofer-Institut für Fertigungstechnik und Angewandte Materialforschung, Institutsteil Dresden IFAM-DD, Winterbergstr. 28, 01277 Dresden, Germany.

There are several options (but not limited thereto) available for manufacturing the article124: (i) injecting a mixture of a flowable alloy (either a molten, liquid metal or a semisolid metal) and a gas (which is an example of a spacing agent116) into a mold, and the mixture solidifies in the mold to form the foamed alloy, (ii) injecting a mixture of a flowable alloy (either a molten, liquid metal or a semisolid metal) and a space holder (which is an example of a spacing agent116), in which examples of the space holder are: organic granules and/or inorganic granules which may remain in the solidified metallic foamed alloy or may be removed from the solidified metallic foamed alloy by a thermal treatment and/or a chemical treatment, (iii) injecting a mixture of a flowable alloy (either a molten, liquid metal or a semisolid metal) and hollow spheres (which is an example of a spacing agent116), and/or (iv) injecting a mixture of a flowable alloy (either a molten, liquid metal or a semisolid metal) and a blowing agent (which is an example of a spacing agent116), in which the blowing agent decomposes under the influence of heat and releases gas which propels the foaming process. Under option (iv), the blowing agent is mixed with a parent material, the blowing agent and the parent material are activated by heat so as to create foam responsive to the blowing agent experiencing a drop in pressure. In other words, the blowing agent and the parent material must be mixed, heated, injected, etc while under pressure to stop the blowing agent and the parent material from foaming until the blowing agent and the parent material are (preferably, completely) inside a mold cavity, where the blowing agent and the parent material experience a reduction in pressure due to the larger volume of the mold cavity (when compared to the melt channels, etc) and consequently the blowing agent and the parent material “foam” within the confines of the molded part and (preferably) not foam elsewhere in the melt conduit. In fact in some processes, a mold-clamp force is reduced to allow the mold to partially blow open thereby further reducing the pressure resisting foaming.

The mechanism110and the mechanism114each include: (i) respective reciprocating screws (not depicted inFIG. 1, but depicted inFIG. 6andFIG. 7, by way of example) that are mounted in respective barrels (depicted but not numbered) of the mechanism110and the mechanism114, and (ii) respective hoppers (depicted but not numbered) that are attached to feed throats (depicted but not numbered) of their respective barrels. The hopper associated with mechanism110is to receive solidified particles (sometimes called “chips” or “blocks”) of the alloy112. The hopper (that is, a receiving mechanism) associated with the mechanism114is to receive the spacing agent116.

The system100also includes: (i) a stationary platen102, and (ii) a movable platen103. The stationary platen102is configured to support a stationary mold portion108of the mold104. The movable platen103is configured to: (i) move relative to the stationary platen102(by use of a stroking actuator that is not depicted, but is known), and (ii) support a movable mold portion106of the mold104. The mold104is usually supplied separately from the system100. It is understood that the mold104is a component that wears down over time and is to be replaced as may be required. The mold104has a mold body111that includes: (i) the stationary mold portion108, and (ii) the movable mold portion106, which in combination define a mold cavity109once the movable platen103is made to move toward the stationary platen102sufficiently enough as to abut the stationary mold portion108against the movable mold portion106. The mold body111is used to moldably manufacture the article124. The stationary mold portion108defines a mold gate107that leads to the mold cavity109. The system100also includes a clamping mechanism105that is coupled to: (i) the stationary platen102(via tie bars199), and (ii) the movable platen103. Specifically, the tie bars199are: (i) connected to the stationary platen102, and (ii) extend to the movable platen103. The tie bars199are lockably engageable and disengageable to the movable platen103by locking mechanisms (not depicted) that are known to those skilled in the art (and therefore will not be described in the detailed description). The movable platen103may be used to house or support the locking mechanisms at respective corners of the movable platen103. The tie bars199assist in coupling the clamping mechanism105to the stationary platen102when the locking mechanisms lock the tie bars199to the movable platen103. Once the platens102,103are stroked so as to close the mold104, the locking mechanisms are engaged, the clamping mechanism105may then be engaged so as to apply a clamp tonnage (also called a clamping force) to the platens102,103and in this manner the clamp tonnage may be applied to the mold104; since the process of applying clamp tonnage is known to those skilled in the art, the process is not further described in the detailed description. It will be appreciated that the tie bars199will not be depicted in the remaining FIGS. for the sake of simplifying the remaining FIGS and the description associated with the remaining FIGS.

The system100also includes a combining chamber200(hereafter referred to as the “chamber200”). The combining chamber200is configured to receive the alloy112and the spacing agent116. The alloy112and the spacing agent116are injectable under pressure into the combining chamber200. The alloy112and the spacing agent116are combinable, at least in part, under pressure in the combining chamber200. The combining chamber200is also configured to convey, under pressure, the alloy112and the spacing agent116toward a mold104. The alloy112combined with the spacing agent116are solidifiably formable into a molded-foamed-metallic article124in the mold104. It will be appreciated that the system100and the chamber200may be supplied or sold separately or sold integrated.

According to a non-limiting variant, the chamber200is configured to: (i) receive the alloy112that is injectable under pressure from the mechanism110, and (ii) receive the spacing agent116that is injectable under pressure from the mechanism114so that, in effect, the alloy112and the spacing agent116combine, at least in part (under pressure), to form a combined alloy122in the chamber200. The combined alloy122is a combination of the alloy112and the spacing agent116. It is understood that the combined alloy122is not necessarily a combination of two alloys per se (that is, the combined alloy122may be a combination of several alloys or just one alloy; the combined alloy includes at least one alloy combined with at least one spacing agent). The combined alloy122may be referred to as an output alloy, but is hereafter referred to as the “alloy122”. The chamber200is also configured to: (iii) communicate, under pressure, the alloy122to the mold gate107that leads to the mold cavity109that is defined by the mold104once the platens102,103are stroked together so as to close the mold104. The alloy112and the spacing agent116may be collectively referred to a “plurality of inputs” or the “inputs”, in that at least two or more inputs may be combined in the chamber200. Preferably (but not essential) the chamber200includes a mixing element (not depicted) that is used to improve the mixing (or combining) of the alloy112with the spacing agent116in the chamber200.

The alloy112and spacing agent116are introduced into the mechanism110and the mechanism114, respectively. Once the alloy112is introduced (in the form of solid chips, etc) to the mechanism110, the mechanism110converts the alloy112primarily into a thixotropic state (sometimes referred to as the “semi-solid state”) so that the alloy112contains a mixture of liquid and solid particles of globular shape, etc. Alternatively, the mechanism110may convert the alloy112primarily into the liquid state. It is understood that the mechanism110may condition or process the alloy112so that the alloy112may exist primarily in: (i) the liquid state, or (ii) the semi-solid state.

A technical effect of this arrangement is that the alloy122may be manufactured having desired (or predetermined) characteristics (or attributes) that are associated with the alloy112and with the spacing agent116. After combining or mixing the alloy112with the spacing agent116, the alloy122is created. The alloy122solidifies in the mold cavity109and is formed into the article124. The article124is removable from the mold104after: (i) the clamping mechanism105has ceased applying the clamp tonnage between the movable platen103and the stationary platen102(this includes application of a mold-break force to the mold104by usage of a mold-break actuator, which is known to those skilled in the art and not depicted), and (ii) the movable platen103has been moved away from the stationary platen102so as to separate the stationary mold portion108from the movable mold portion106. The article124may be: (i) ejected from the mold104by ejection mechanisms (not depicted, but known to those skilled in the art), or (ii) may be removed by a robot (not depicted, but known to those skilled in the art).

According to non-limiting variants, the chamber200includes a combining valve118. The combining valve118is configured to: (i) couple to the mechanism110, and (ii) couple to the mechanism114. The chamber200also includes a conduit120that is configured to: (i) couple to the combining valve118, and (ii) couple to the mold gate107of the mold104. The combining valve118is operable between: (i) a non-flow state, and (ii) a flow state. In the non-flow state, the combining valve118is configured to: (i) not receive the alloy112from the mechanism110, and (ii) not receive the spacing agent116from the mechanism114. In the flow state, the combining valve118is configured to: (i) receive the alloy112from the mechanism110, and (ii) receive the spacing agent116from the mechanism114. The alloy112and the spacing agent116combine, at least in part, to form the alloy122in the combining valve118. The conduit120is configured to: (i) receive the alloy122from the combining valve118, and (ii) communicate the alloy122to the mold gate107of the mold104.

FIG. 2depicts the schematic representation of the system100according to the second non-limiting embodiment. According to the second non-limiting embodiment, the chamber200includes a combining valve218that is configured to: (i) couple to the mechanism110, and (ii) couple to the mechanism114. The chamber200also includes a channel208that is configured to couple to the combining valve218. The chamber200also includes a shooting pot valve202that is configured to couple to the channel208. The chamber200also includes a shooting pot204that is configured to couple to the shooting pot valve202. The shooting pot204includes a plunger206that is movable in the shooting pot204. The chamber200also includes a conduit120that is configured to couple to: (i) the shooting pot valve202, and (ii) the mold gate107of the mold104. The combining valve218is operable between a non-flow state, and a flow state. In the non-flow state, the combining valve218is configured to: (i) not receive the alloy112from the mechanism110, and (ii) not receive the spacing agent116from the mechanism114. In the flow state, the combining valve218is configured to: (i) receive the alloy112from the mechanism110, and (ii) receive the spacing agent116from the mechanism114. The alloy112and the spacing agent116combine, at least in part, to form the alloy122in the combining valve218. The channel208is configured to receive the alloy122from the combining valve218. The shooting pot valve202is operable between a first valve state, and a second valve state. In the first valve state, the shooting pot valve202is configured to not receive the alloy122from the channel208. In the second valve state, the shooting pot valve202is configured to receive the alloy122from the channel208. The shooting pot204is configured to receive the alloy122from the shooting pot valve202once the shooting pot valve202is placed in the second valve state. The shooting pot valve202is configured to disconnect the channel208from the shooting pot204once the shooting pot valve202is placed in the first valve state. The conduit120is configured to: (i) receive the alloy122from shooting pot valve202once the shooting pot valve202is placed in the first valve state, and (ii) communicate the alloy122to the mold gate107of the mold104.

FIG. 3depicts the schematic representation of the system100according to the third non-limiting embodiment. According to the third non-limiting embodiment, the chamber200includes a combining valve318that is configured to: (i) couple to the mechanism110, (ii) couple to the mechanism114, and (iii) couple to a shooting pot204. The chamber200also includes a conduit120that is coupled to: (i) the combining valve318, and (ii) the mold gate107of the mold104. The combining valve318is operable between a first state, and a second state. In the first state, the combining valve318is configured to: (i) receive the alloy112from the mechanism110, (ii) receive the spacing agent116from the mechanism114(the alloy112and the spacing agent116combine, at least in part, to form the alloy122in the combining valve318), and (iii) transmit the alloy122to a shooting pot204. In the second state, the combining valve318is configured to: (i) not receive the alloy112from the mechanism110, (ii) not receive the spacing agent116from the mechanism114, and (iii) permit the shooting pot204to shoot the alloy122back into the combining valve318. The conduit120is configured to: (i) communicate the alloy122, under pressure, from the combining valve318to the mold gate107once the combining valve318is placed in the second state.

FIG. 4depicts the schematic representation of the system100according to the fourth non-limiting embodiment. According to the fourth non-limiting embodiment, the chamber200includes a combining valve418that is configured to: (i) couple to the mechanism110, (ii) couple to the mechanism114, and (iii) couple to the mold gate107of the mold104. The combining valve418is operable between a first state, and a second state. In the first state, the combining valve418is configured to: (i) receive the alloy112from the mechanism110, (ii) receive the spacing agent116from the mechanism114(the alloy112and the spacing agent116combine, at least in part, in the combining valve418so as to form the alloy122), and (iii) communicate the alloy122to the mold gate107of the mold104. In the second state, the combining valve418is configured to: (i) not receive the alloy112from the mechanism110, and (ii) not receive the spacing agent116from the mechanism114.

FIG. 5depicts the schematic representation of the system100according to the fifth non-limiting embodiment. According to the fifth non-limiting embodiment, the chamber200includes a hot runner402. The hot runner402includes a manifold404. The manifold404is configured to support: (i) switching valve408and switching valve428, (ii) a shooting pot412and a shooting pot432, and (iii) a combining valve418. The shooting pot412and the shooting pot432may collectively be known as the “shooting pots412,432”. The switching valve408and the switching valve428may collectively be known as the “switching valves408,428”. The switching valve408and the switching valve428are coupled (via conduits406,426respectively) to the mechanism110and the mechanism114(respectively) so as to receive the alloy112and spacing agent116from the mechanism110and the mechanism114respectively (that is, once the nozzle190and the nozzle192of the mechanism110and the mechanism114, respectively, are made to contact the conduits406,426respectively). Preferably, the nozzles190,192are maintained in contact (during operation of the system100) with their respective conduits406,426. The nozzles190,192are depicted offset from the conduits406,426respectively for illustration purposes. The shooting pot412and the shooting pot432are coupled to the switching valve408and the switching valve428respectively (preferably via conduits). The combining valve418is coupled to the shooting pot412and the shooting pot432(via conduits410,430) and is also coupled to the mold gate107(via a conduit420). A hot-runner nozzle (not depicted in this non-limiting embodiment) may be inserted in the conduit420if so required to control the release of molding material (that is the alloy122) into the mold cavity109of the mold104. According to a non-limiting variant, the switching valve408and switching valve428are “on/off” valves that are switchable (or operable) between a non-flow state and a flow state. According to another non-limiting variant, the switching valve408and the switching valve428are “on/off/variable-flow” valves that are switchable (or operable) between: (i) a non-flow state, (ii) a full-flow state and (iii) a partial-flow state. According to yet another non-limiting variant, the combining valve418is an “on/off” valve that is switchable (or operable) between: (i) a non-flow state, and (ii) a flow state. According to yet another non-limiting variant, the combining valve418is an “on/off/variable-flow” valve that is switchable (or operable) between: (i) a non-flow state, (ii) a full-flow state, and (iii) a partial-flow state.

The shooting pot412and the shooting pot432, include: (i) a pressure chamber414and a pressure chamber434respectively, (ii) an accumulation chamber416and an accumulation chamber436respectively, and (iii) a piston417and a piston437respectively that are each slidably movable within their respective accumulation chambers416,436. The pressure chamber414and the pressure chamber434may collectively be known as the “pressure chambers414,434”. The pressure chambers414,434are fillable with a pressurizable fluid, such as compressed air, or can be actuated by a remote drive not shown. If hydraulic oil is used, care must be used because the temperatures needed for processing metal alloys may cause hydraulic oil to ignite. It will be appreciated that the shooting pot412and the shooting pot432may be actuated by electrical actuators (not depicted), etc. In operation, initially the combining valve418, the switching valve408and the switching valve428are placed in the non-flow state. The pressure chamber414and the pressure chamber434are de-pressurized so as to permit respective pistons417,437to retract (that is, to be movable). The mechanism110and the mechanism114are configured to process and prepare the alloy112and spacing agent116, respectively. After the mechanism110and the mechanism114are each ready to inject or shoot the alloy112and the spacing agent116respectively, the combining valve418remains in the non-flow state, and the switching valve408and the switching valve428are placed in the flow state, and then the mechanisms110,114inject the alloy112and the spacing agent116, respectively, into the conduits406,426respectively so that (in effect) the alloy112and spacing agent116may be injected, under pressure, into the accumulation chambers416,436of the shooting pots412,432respectively; as a result, the pistons417,437are moved into the pressure chambers414,434respectively so as to displace the pressurizable fluid out from the pressure chambers414,434respectively. Once the mechanism110and the mechanism114have completed their injection cycle, the switching valve408and the switching valve428are placed in the non-flow state, the combining valve418is placed in the flow state (either full-flow or partial flow, etc, as may be required to achieve a desired combination of the alloy112and spacing agent116), and the pressure chambers414,434are pressurized (that is, filled with the pressurizable fluid); as a result, the pistons417,437are moved into their respective accumulation chambers416,436respectively so as to inject or push the alloy112and the spacing agent116respectively into the combining valve418. Then the alloy112and spacing agent116become combined, at least in part in the combining valve418, to form the alloy122. The alloy122then is pushed, under pressure, through the conduit420into the mold gate107. The combining valve418may be used or arranged so that a desired ratio of the alloy112and spacing agent116may be realized. The switching valve408and the switching valve428may be used so as to permit a desired amount of flow of the alloy112and of the spacing agent116into the accumulation chambers416,436respectively (as may be required). It will be appreciated that a single drop (that is, the conduit420) is depicted, and that the non-limiting embodiment may be modified to operate with a plurality of drops that: (i) all lead into a single mold cavity (as depicted), or (ii) lead into separate mold cavities (not depicted).

FIG. 6depicts the schematic representation of the system100according to the sixth non-limiting embodiment. According to the sixth non-limiting embodiment, the manifold404is configured to support: (i) the shooting pot412and the shooting pot432, and (iii) the combining valve418. The shooting pots412,432are coupled to the mechanisms110,114(respectively) so as to receive the inputs from the mechanisms110,114respectively. The combining valve418is coupled to: (i) the shooting pots412,432, and (ii) the mold gate107. The switching valves408,428of the fifth non-limiting embodiment are not used in the sixth non-limiting embodiment. In operation, the combining valve418is operated in the non-flow state, and the mechanism110and the mechanism114accumulate their respective shots of alloys and then inject the alloy112and spacing agent116respectively into the accumulation chambers416,436(so that in effect, the shots of the alloy112and the spacing agent116are transferred into the accumulation chambers416,436). Once the shots are received in the accumulation chambers416,436, (i) screws292,294of the mechanisms110,114respectively (the screws292,294are equipped with non-return valves) maintain their positions so as to prevent flow of the alloy112and the spacing agent116back into the mechanisms110,114respectively, and (ii) the combining valve418is placed in the flow state. The pressure chamber414and the pressure chamber434are pressurized so as to move their respective pistons417,437into the accumulation chambers416,436respectively so as to inject or push the alloy112and the spacing agent116from the accumulation chambers416,436respectively into the combining valve418. A hot-runner nozzle (not depicted) may be inserted in the conduit420if so required to control the release of molding material into the mold cavity109of the mold104. It will be appreciated that a single drop (that is, conduit420) is depicted, and that the non-limiting embodiment may be modified to operate with a plurality of drops that lead into the mold cavity109(or that lead into separate mold cavities (not depicted).

FIG. 7depicts the schematic representation of the system100according to the seventh non-limiting embodiment. According to the seventh non-limiting embodiment, the mold104defines the mold cavity109and the mold cavity509. The mold cavities109,509may be known collectively as mold cavities109,509. Associated with each of the mold cavities109,509is the mold gate107and a mold gate507, respectively, that each lead to the mold cavity109and the mold cavity509respectively. The manifold404supports the nozzles504,506(sometimes referred to as “hot-runner nozzles”) that are coupled (via conduit502) to the combining valve418, and also coupled to respective mold gates107,507. In operation, the alloy112and spacing agent116combine to form the alloy122(at least in part) in the combining valve418, the conduit502, and the nozzles504,506.

FIG. 8depicts the schematic representation of the metal injection-molding process10(hereafter referred to as the “process10”) according to the eighth non-limiting embodiment. Generally, the process10includes injecting, under pressure, the alloy112and the spacing agent116into the mold104. According to a non-limiting variant, the process10includes: (i) a receiving operation12, (ii) a heating operation14, (iii) a combining operation16and (iv) an injecting operation18. The receiving operation12includes receiving a solidified-metallic alloy113and the spacing agent116. The heating operation14includes heating the solidified-metallic alloy113associated with the receiving operation12above a solidus temperature of the solidified-metallic alloy113so that the solidified-metallic alloy113may become the alloy112. The combining operation16includes combining the alloy112associated with the heating operation14with the spacing agent116associated with the receiving operation12. The injecting operation18includes injecting, under pressure, the alloy112and the spacing agent116into the mold104. At a minimum, the alloy112is heated above a solidus temperature of the alloy112but below a liquidus temperature of the alloy112(so that the alloy112may exist in a semi-solid state). Optionally, the alloy112is heated above a liquidus temperature of the alloy112(so that the alloy112exists primarily in a liquid state). The alloy112includes an AZ91D alloy, and the liquidus temperature of the AZ91D alloy is nominally 595 degrees Centigrade (° C.). The alloy112includes a zinc alloy. According to non-limiting variants: (i) the alloy112includes a magnesium alloy, and/or (ii) an aluminum alloy. A material input2is used by the process10, and the material input includes at least the alloy112and/or the spacing agent116. The article124is made by the process10. The system100ofFIG. 1is operable according to the process10ofFIG. 8.

FIG. 9depicts a schematic representation of the metal injection-molding system500operable according to the process10ofFIG. 8. The metal injection-molding system500includes: (i) receiving means512, (ii) heating means514, (iii) combining means516and (iv) injection means518. The receiving means512is configured to implement a receiving operation12including receiving the solidified-metallic alloy113and the spacing agent116. The heating means514is configured to implement a heating operation14including heating the solidified-metallic alloy113associated with the receiving operation12above the solidus temperature of the solidified-metallic alloy113so that the solidified-metallic alloy113may become (or may be transformed into) the alloy112. The combining means516is configured to implement a combining operation16, including combining the alloy112associated with the heating operation14with the spacing agent116associated with the receiving operation12. The injection means518is configured to implement an injecting operation18, including injecting, under pressure, alloy112and the spacing agent116into the mold104.

The description of the non-limiting embodiments provides examples of the present invention, and these examples do not limit the scope of the present invention. It is understood that the scope of the present invention is limited by the claims. The non-limiting embodiments described above may be adapted for specific conditions and/or functions, and may be further extended to a variety of other applications that are within the scope of the present invention. Having thus described the non-limiting embodiments, it will be apparent that modifications and enhancements are possible without departing from the concepts as described. It is to be understood that the non-limiting embodiments illustrate the aspects of the invention. Reference herein to details of the illustrated embodiments is not intended to limit the scope of the claims. The claims themselves recite those features regarded as essential to the present invention. Preferable embodiments of the present invention are subject of the dependent claims. Therefore, what is to be protected by way of letters patent are limited only by the scope of the following claims: