In-situ slurry formation and delivery apparatus and method

Abstract

An embodiment of the presently claimed invention includes an in-situ slurry formation apparatus mounted to die casting machines to convert liquid metal to semi-solid metal (SSM). Thus, there is no need to modify existing machines or change the cell layout to accommodate more space than would otherwise be necessary. These machines also need not be replaced with machines specially designed for SSM. Further, a method for converting molten metal to semi-solid metal includes coupling a conduit to a die casting machine, wherein the conduit comprises an inlet, an outlet and a body disposed between the inlet and the outlet, regulating the conduit's temperature, surrounding the conduit with a housing, inserting molten metal at the inlet, cooling the molten metal to semi-solid metal in the body, and expelling semi-solid metal from the outlet.

1 . An apparatus for converting molten metal to semi-solid metal comprising: 
 a conduit having an inlet and an outlet to transport the molten metal; and    a temperature regulator disposed adjacent the conduit to regulate the temperature of the molten metal; and    a housing surrounding the conduit and the temperature regulator.    
     
     
         2 . The apparatus of  claim 1 , wherein the temperature regulator further comprises a heater, a cooler and a temperature sensor, operably coupled to a controller.  
     
     
         3 . The apparatus of  claim 1 , wherein the temperature regulator further comprises a hot oil system and a temperature sensor operably coupled to a controller.  
     
     
         4 . The apparatus of  claim 3 , wherein the hot oil system is configured to heat and cool the conduit.  
     
     
         5 . The apparatus of  claim 1 , wherein the conduit has a funnel shape.  
     
     
         6 . The apparatus of  claim 5 , wherein the funnel comprises a first end having a first diameter, a second end having a second diameter and a path disposed between the first and second ends, wherein the first diameter is larger than the second diameter, and wherein the path has a non-linear configuration.  
     
     
         7 . The apparatus of  claim 1 , wherein the conduit has a length configured to cool molten metal to semi-solid metal.  
     
     
         8 . The apparatus of  claim 1 , wherein the housing is configured to couple to a die casting machine.  
     
     
         9 . The apparatus of  claim 1 , wherein the conduit further comprises a non-wetting coating on an inside surface of the conduit.  
     
     
         10 . The apparatus of  claim 9 , wherein the non-wetting coating further comprises a tungsten thermal coating, a boron nitride coating or a ceramic coating.  
     
     
         11 . The apparatus of  claim 1 , wherein the outlet is coupled to a die casting machine inlet.  
     
     
         12 . The apparatus of  claim 1 , wherein the apparatus is configured to couple to a high pressure die casting (HPDC) machine.  
     
     
         13 . The apparatus of  claim 1 , wherein the apparatus is configured to couple to a horizontal with vertical shot components (HVSC) die casting machine.  
     
     
         14 . The apparatus of  claim 1 , wherein the apparatus is configured to convert molten metal  206 ,  356 ,  357 ,  380 ,  383 ,  390 , ADC- 12  and  7 XX alloys to semi-solid metal.  
     
     
         15 . The apparatus of  claim 1 , wherein the conduit further comprises a thermally conductive material.  
     
     
         16 . The apparatus of  claim 15 , wherein the conduit further comprises a steel insert with copper and beryllium casings.  
     
     
         17 . The apparatus of  claim 15 , wherein the conduit further comprises tungsten.  
     
     
         18 . A method for converting molten metal to semi-solid metal comprising: 
 coupling a conduit to a die casting machine, wherein the conduit comprises an inlet, an outlet and a body disposed between the inlet and the outlet;    regulating the conduit's temperature;    surrounding the conduit with a housing;    inserting molten metal at the inlet;    cooling the molten metal to semi-solid metal in the body; and    expelling semi-solid metal from the outlet.    
     
     
         19 . The method of  claim 18 , wherein the step of regulating the temperature of the conduit is done through a heater, a cooler and a temperature sensor operably coupled to a controller.  
     
     
         20 . The method of  claim 19 , wherein the step of regulating the temperature of the conduit is done through a hot oil system and a temperature sensor operably coupled to a controller.  
     
     
         21 . The method of  claim 18 , wherein the body has a non-linear configuration.  
     
     
         22 . The method of  claim 18 , wherein the conduit comprises a thermally conductive material.  
     
     
         23 . The method of  claim 18 , wherein the conduit comprises a non-wetting coating to prevent the oxidation of aluminum.  
     
     
         24 . The method of  claim 18 , wherein the conduit has a funnel shape.  
     
     
         25 . A system for converting molten metal to semi-solid metal comprising: 
 means for coupling a conduit to a die casting machine, wherein the conduit comprises an inlet, an outlet and a body disposed between the inlet and the outlet;    means for regulating the conduit's temperature;    means for surrounding the conduit with a housing; and    means for cooling the molten metal to semi-solid metal in the body.    
     
     
         26 . The system of  claim 25 , wherein the means of regulating the temperature of the conduit is done through a heater, a cooler and a temperature sensor operably coupled to a controller.  
     
     
         27 . The system of  claim 25 , wherein the step of regulating the temperature of the conduit is done through a hot oil system and a temperature sensor operably coupled to a controller.  
     
     
         28 . The system of  claim 25 , wherein the body has a non-linear configuration.