Filtration system for magnesium recycling and purification

Abstract

Magnesium alloys are heated to a molten state in preparation for hot-working thereof, for example, die-casting. The presence of inclusions within the magnesium alloys results in metallurgical defects therein and will adversely affect the quality of the castings produced from the magnesium alloys. An embodiment of the invention processes the magnesium melt containing impurities through a non-reactive filter under an environment filled with protective gas for substantially purifying the magnesium melt and to reduce the presence of inclusions in castings formed therefrom.

1 . A filtration system for magnesium recycling and purification, the filtration system comprising: 
 a fast chamber for containing magnesium melt the magnesium melt containing impurities ad the first chamber enclosing the magnesium melt containing impurities therein; and    a second chamber for receiving purified magnesia melt, the second chamber enclosing the purified magnesium melt therein and the first and second chambers respectively separating the magnesium melt containing impurities and the purified magnesium melt from the atmosphere,    wherein sad first and second chambers have disposed therebetween a filter, the filter being a silicon-free medium, and each of the first chamber and the second chamber for further containing and enclosing protective gases therein.    
   
   
       2 . The filtration system as in  claim 1 , the second chamber being in fluid communication with the first chamber and the filter for substantially removing the impurities from the magnesium melt flowing from the first chamber into the second chamber.  
   
   
       3 . The filtration system as in  claim 1 , further comprising; 
 a heating apparatus integrated with the first and second chambers for maintaining the magnesium melt contained in the first and second chambers in a molten state.    
   
   
       4 . The filtration system as in  claim 1 , further comprising. 
 a filter adapter disposed between the first chamber and the second chamber, the filter being removably coupled to the filter adapter and the filter adapter for positioning the filter to interface the first chamber and the second chamber.    
   
   
       5 . The filtration system as in  claim 1 , the filter comprising one of steel or ceramic material.  
   
   
       6 . The filtration system as in  claim 5 , the filter further comprises at least one material selected from a group consisting of Al 2 O 3 , MgO, AlPO 4  and Mg 3 (PO 4 ) 2 .  
   
   
       7 . The filtration system as m  claim 1 , the filter comprising an array of at least one aperture.  
   
   
       8 . The filtration system as in  claim 7 , each of the at least one aperture being shaped and dimension for preventing passage of a panicle having a size greater than 5 microns therethrough.  
   
   
       9 . The filtration system as in  claim 7 , each pair adjacent apertures being spaced apart a distance of 5 to 250 microns.  
   
   
       10 . The filtration system as in  claim 1 , further comprising a temperature control system for regulating temperature of the magnesium melt within the first chamber and the second chamber.  
   
   
       11 . The filtration system as in  claim 10 , the temperature control system, comprising: 
 a controller, the heating apparatus being electrically connected to the controller;    a first thermocouple being electrically connected to the controller and being disposed within the first chamber for transducing temperature of the magnesium melt therein into first temperature signals; and    a second thermocouple being electrically connected to the controller and being disposed within the second chamber for transducing temperature of the filtered magnesium melt therein into second temperature signals,    wherein the first temperature signals and the second temperature signals are transmitted to the controller, the controller having a control function for controlling the heating apparatus and thereby maintaining the magnesium melt in a molten state and preventing overheating of the magnesium melt.    
   
   
       12 . The filtration system as in  claim 1 , further comprising a gas feed system for introducing a protective gas in to the first and second chambers.  
   
   
       13 . The filtration system as in  claim 1 , further comprising a step of: 
 an extractor for extracting the magnesium melt from the second chamber, the extractor being extending from within the second chamber to a die-casting assembly, the extractor for providing the extracted magnesium melt to the die-casting assembly.    
   
   
       14 . A filtration method for magnesium recycling and purification, comprising the steps of: 
 receiving magnesium melt into a first chamber, the magnesium melt containing impurities within the first chamber containing impurities and the first chamber enclosing the magnesium melt containing impurities therein;    providing a second chamber, the second chamber being in fluid communication with the first chamber, the second chamber enclosing the purified magnesium melt herein and the first and second chambers respectively separating the magnesium melt containing impurities and the purified magnesium melt from the atmosphere; and    substantially removing the impurities from the magnesium melt flowing from the first chamber into the second chamber using a filter, the filter being disposed between the first chamber and the second chamber, each of the first chamber and the second chamber for further containing and enclosing protective gases therein, and the filter including a silicon-free medium.    
   
   
       15 . The filtration method as in  claim 14 , ether comprising a step of: 
 providing a heating apparatus integrated with the first and second chambers for maintaining the magnesium melt contained in the first and second chambers in a molten state.    
   
   
       16 . The filtration method as in  claim 14 , the filter comprising one of steel or ceramic material.  
   
   
       17 . The filtration method as in  claim 15 , further comprising a step of providing a temperature control system for regulation temperature of the magnesium melt within the first chamber and the second chamber.  
   
   
       18 . The filtration method as in  claim 17 , the temperature control system comprising: 
 a controller, the heating apparatus being electrically connected to the controller;    a first thermocouple being electrically connected to the controller and being disposed within the first chamber for transducing temperature of the magnesium melt therein into first temperature signals; and    a second thermocouple being electrically connected to the controller and being disposed within the second chamber for transducing temperature of the filtered magnesium melt therein into second temperature signals,    wherein the first temperature signals and the second temperature signals are transmitted to the controller, the controller having a control fraction for controlling the heating apparatus and thereby maintaining the magnesium melt in a molten state and preventing overheating of the magnesium melt.    
   
   
       19 . The filtration method as in  claim 14 , further comprising a step of: 
 extracting the magnesium melt from the second chamber by an extractor, the extractor extending from within the second chamber to a die-casting assembly, the extractor for providing the extracted magnesium melt to the die-casting assembly.    
   
   
       20 . A filtration method for magnesium recycling and purification, comprising the steps of: 
 receiving magnesium into a first chamber, the magnesium within the first chamber containing impurities, the first chamber enclosing the magnesium melt containing impurities therein and the magnesium being one of a magnesium melt or solid magnesium ingot;    providing a second chamber, the second chamber being in fluid communication with the first chamber, the second chamber enclosing the purified magnesium melt therein and the fist and second chambers respectively separating the magnesium melt containing impurities and the purified magnesium melt from the atmosphere;    heating the magnesium contained in the fist chamber by a heating apparatus for melting the magnesium and for maintaining the magnesium melt in a molten state, and the magnesium melt in the first chamber thereby flowing into the second chamber; and    substantially removing the impurities from the magnesium melt flowing from the first chamber into the second chamber using a filter, the filter being disposed between the first chamber and the second chamber, each of the first chamber and the second chamber for further containing and enclosing protective gases therein, and the filter including a silicon-free medium.