Method and apparatus for friction-based repair of die casting defects

A method of repairing a casting defect in a die-cast part, the method comprising the steps of:

• providing a tool including a mechanical bit, the mechanical bit including a shank and a body extending from the shank in an axial direction;
• actuating the tool to rotate the mechanical bit;
• advancing the mechanical bit in at least one of the axial direction or a radial direction into a void space formed in the die-cast part;
• wherein friction between the mechanical bit and a surface within the void space generates heat to plasticize local die-cast material at the surface to close the casting defect in a vicinity of the surface of the void space, thereby sealing the surface within the void space.

A tool for repairing a casting defect in a die-cast part, the tool comprising:

• a mechanical bit operable by an actuator device, the mechanical bit comprising:
• a shank configured to fit into the actuator device;
• and
• an elongated body extending in an axial direction from the shank;
• wherein the body is configured to generate plasticized local material along a surface defining a void space in a die-cast part, the plasticized local material closing a casting defect formed in the die-cast part.