Apparatus and method for integrated semi-solid material production and casting

Abstract

An apparatus and process is provided for producing semi-solid material and directly casting the semi-solid material into a component wherein the semi-solid material is formed from a molten material and the molten material is introduced into a container. Semi-solid is produced therefrom by agitating, shearing, and thermally controlling the molten material. The semi-solid material is maintained in a substantially isothermal state within the container by appropriate thermal control and thorough three-dimensional mixing. Extending from the container is a means for removing the semi-solid material from the container, including a temperature control mechanism to control the temperature of the semi-solid material within the removing means.

We claim:  
     
         1 . An apparatus for directly producing a component from a semi-solid material comprising: 
 a source of molten material;    a container for receiving said molten material;    a thermal control means for controlling the temperature of said container;    an agitation means for stirring material within said container acting in conjunction with said thermal control means to produce a substantially isotropic semi-solid material;    a means for removing a portion of said semi-solid material from said container, said removing means being thermally controlled; and    a casting means directly connected to said removing means for receiving said portion of semi-solid material from said removing means and casting said semi-solid material into a component.    
     
     
         2 . The apparatus of  claim 1  wherein said agitating means is an electromagnetic stirring device.  
     
     
         3 . The apparatus of  claim 1  wherein said agitation means comprises a mechanical agitating device immersed in said semi-solid material.  
     
     
         4 . The apparatus of  claim 3  wherein said mechanical agitating device comprises a primary stirring component and a secondary stirring component.  
     
     
         5 . The apparatus of  claim 4  wherein said primary stirring component includes an arm having a first portion being substantially parallel to a side wall of said container.  
     
     
         6 . The apparatus of  claim 5  wherein said arm of said primary stirring component includes a second portion being substantially parallel to a bottom wall of said container.  
     
     
         7 . The apparatus of  claim 5  wherein said secondary stirring component is augur-shaped and promotes mixing of said semi-solid material along an axis of said secondary stirring component.  
     
     
         8 . The apparatus of  claim 7  wherein said casting means comprises a die casting device.  
     
     
         9 . The apparatus of  claim 8  wherein said mechanical agitating device is a stainless steel coated with a ceramic.  
     
     
         10  The apparatus of  claim 1  wherein said semi-solid material comprises aluminum or an alloy thereof.  
     
     
         11 . The apparatus of  claim 1  wherein said semi-solid material comprises steel or an alloy thereof.  
     
     
         12 . The apparatus of  claim 1  wherein said semi-solid material comprises magnesium or an alloy thereof.  
     
     
         13 . The apparatus of  claim 1  wherein said removal means comprises a transfer tube.  
     
     
         14 . The apparatus of  claim 13  wherein said transfer tube includes an inner insulating layer.  
     
     
         15 . The apparatus of  claim 14  wherein said transfer tube includes a support tube surrounding said insulating layer and an outer layer surrounding said support tube.  
     
     
         16 . The apparatus of  claim 15  wherein said transfer tube includes a heating mechanism for maintaining the temperature of said semi-solid material passing through said transfer tube.  
     
     
         17 . The apparatus of  claim 16  wherein said transfer tube includes a flow control means for regulating a flow of semi-solid material through said transfer tube.  
     
     
         18 . The apparatus of  claim 17  wherein said transfer flow control means regulates said flow of semi-solid material through said transfer tube such that no more than one tenth of said semi-sold material is removed per a removal cycle.  
     
     
         19 . The apparatus of  claim 17  wherein said transfer tube extends though a cover in said chamber.  
     
     
         20 . The apparatus of  claim 17  wherein said transfer tube extends through a side wall in said chamber.  
     
     
         21 . The apparatus of  claim 1  wherein said casting means includes a die, a ram, and a shot sleeve disposed therebetween, said shot sleeve for receiving said portion of said semi-solid and said ram for forcing said portion into said die to form said component.  
     
     
         22 . An apparatus for directly producing a component from a semi-solid material comprising: 
 a source of semi-solid material;    a container for receiving said semi-solid material;    a thermal control means for controlling the temperature of said semi-solid material;    an agitating means acting with said container for stirring said semi-solid material in said container;    said thermal controller and said agitating means maintaining said semi-solid material in a substantially isothermal state; and    a die casting device connected to said container for directly casting said semisolid material into a component prior to solidification of said semi-solid material.    
     
     
         23 . The apparatus of  claim 22  wherein said agitating means is an electromagnetic stirring device.  
     
     
         24 . The apparatus of  claim 22  wherein said agitation means comprises a mechanical agitating device immersed in said semi-solid material.  
     
     
         25 . The apparatus of  claim 24  wherein said mechanical agitating device comprises a primary stirring component and a secondary stirring component.  
     
     
         26 . The apparatus of  claim 25  wherein said primary stirring component includes a portion being substantially parallel to a side wall of said container.  
     
     
         27 . The apparatus of  claim 26  wherein said secondary stirring component is augur-shaped.  
     
     
         28 . The apparatus of  claim 27  wherein said casting means comprises a die casting device.  
     
     
         29 . The apparatus of  claim 28  wherein said mechanical agitating device is a stainless steel coated with a ceramic.  
     
     
         30 . A method of directly producing a component from partially solidified material semi-solid material comprising: 
 receiving a molten material in a container;    forming said molten material into a semi-solid material with an agitating means and a thermal controlling means;    maintaining said semi-solid material in a substantially isothermal state with said agitating means and said thermal controlling means;    transferring a portion of said semi-solid material directly to a casting apparatus; and    casting said portion of said semi-solid material into a component prior to complete solidification of said portion.