Metal casting method and apparatus, and metal material manufacturing method and apparatus

Abstract

A casting method includes the steps of cooling a molten metal to form a metal slurry containing a solid phase, cooling the metal slurry to form a solid metal material and heating the metal material to a semi-melted metal material and supplying it into a mold. A casting apparatus includes a first device for cooling a molten metal to form a metal slurry containing a solid phase and a second device for cooling the metal slurry to form a solid metal material. The metal material is then heated to a semi-melted state and the resultant metal material is poured into a mold. A method for manufacturing a metal material being heated to a semi-melted state and then supplied into a mold, includes the steps of cooling a molten metal to form a metal slurry containing a solid phase and cooling the metal slurry to form a solid metal material. An apparatus for manufacturing a metal material being heated to a semi-melted state and then supplied into a mold, includes a first device for cooling a molten metal to form a metal slurry containing a solid phase and a second device for cooling the slurry to form a solid metal material.

What is claimed is:  
     
         1 . A casting method comprising a first step of cooling a molten metal to form a metal slurry containing a solid phase, a second step of cooling the metal slurry to form a solid metal material, and a third step of heating the metal material to a semi-melted metal material and supplying it into a mold.  
     
     
         2 . The casting method according to    claim 1   , wherein the second step includes continuously forming metal materials from the metal slurry and cutting the metal materials to a predetermined length.  
     
     
         3 . A casting apparatus comprising first means for cooling a molten metal to form a metal slurry containing a solid phase and second means for cooling the metal slurry to form a solid metal material, wherein the metal material is then heated to a semi-melted state and the resultant metal material is poured into a mold.  
     
     
         4 . The casting apparatus according to    claim 3   , wherein the second means forms metal materials continuously from the metal slurry and includes a cutting unit for cutting the metal materials to a predetermined length.  
     
     
         5 . The casting apparatus according to    claim 4   , wherein the cutting unit can move along an advancing direction of the metal materials and cut the metal materials when a velocity of the cutting unit relative to the metal materials becomes zero.  
     
     
         6 . A method for manufacturing a metal material being heated to a semi-melted state and then supplied into a mold, comprising a first step of cooling a molten metal to form a metal slurry containing a solid phase and a second step of cooling the metal slurry to form a solid metal material.  
     
     
         7 . The method according to    claim 6   , wherein the second step includes continuously solidifying the metal slurry into solid metal materials and cutting the metal materials to a predetermined length.  
     
     
         8 . An apparatus for manufacturing a metal material being heated to a semi-melted state and then supplied into a mold, comprising first means for cooling a molten metal to form a metal slurry containing a solid phase and second means for cooling the slurry to form a solid metal material.  
     
     
         9 . The apparatus according to    claim 8   , wherein the second means can solidify the metal slurry continuously into solid metal materials and includes a cutting unit for cutting the solid metal materials to a predetermined length.  
     
     
         10 . The casting apparatus according to    claim 9   , wherein the cutting unit can move along an advancing direction of the metal materials and cut the metal materials when a velocity of the cutting unit relative to the metal materials becomes zero.