Semi-solid material formation within a cold chamber shot sleeve

Abstract

A method and apparatus is disclosed for the preparation of a semi-solid material in a mixing sleeve of a casting apparatus, the semi-solid material formed from a molten material after a mixing and a cooling thereof in the mixing sleeve wherein a handling of the semi-solid material is minimized.

1 . A casting apparatus comprising:
 a mixing sleeve having a mixing sleeve cavity formed therein for receiving a molten material;   a shot sleeve having a shot sleeve cavity; formed therein, the shot sleeve cavity in fluid communication with the mixing sleeve cavity;   an electromagnetic circuit adapted to produce an electromagnetic current (A, B) for mixing the molten material in the mixing sleeve cavity; and   a cooling sleeve disposed adjacent said mixing sleeve, said cooling sleeve causing the molten material in the mixing sleeve cavity to cool as the electromagnetic current (A, B) causes a mixing of the molten material until the molten material forms a semi-solid material.   
     
     
         2 . The apparatus of  claim 1 , further comprising a means for causing the molten material to flow into the mixing sleeve cavity of said mixing sleeve. 
     
     
         3 . The apparatus of  claim 2 , wherein said means for causing the molten material to substantially fill the mixing sleeve cavity is a plunger. 
     
     
         4 . The apparatus of  claim 2 , wherein said means for causing the molten material to substantially fill the mixing sleeve cavity is gravity. 
     
     
         5 . The apparatus of  claim 1 , further comprising a gate for militating against flow of the molten material from the mixing sleeve cavity to the shot sleeve cavity. 
     
     
         6 . The apparatus of  claim 1 , wherein said shot sleeve is substantially linearly aligned with said mixing sleeve. 
     
     
         7 . The apparatus of  claim 6 , wherein said shot sleeve and said mixing sleeve are disposed in one of a vertical orientation, a horizontal orientation, and an angled orientation with respect to horizontal. 
     
     
         8 . The apparatus of  claim 1 , wherein said cooling sleeve is positioned between said mixing sleeve and said electromagnetic circuit. 
     
     
         9 . The apparatus of  claim 1 , further comprising a thermocouple for measuring a temperature of the molten material and the semi-solid material in the mixing sleeve cavity. 
     
     
         10 . The apparatus of  claim 1 , wherein said mixing sleeve has an inlet formed therein. 
     
     
         11 . A casting apparatus comprising:
 a mixing sleeve having a mixing sleeve cavity formed therein for receiving a molten material;   a shot sleeve having a shot sleeve cavity formed therein, the shot sleeve in fluid communication with the mixing sleeve cavity;   a means for causing the molten material to flow into the mixing sleeve cavity of said mixing sleeve;   an electromagnetic circuit positioned adjacent said mixing sleeve, said electromagnetic circuit adapted to produce an electromagnetic current (A, B), for mixing the molten material in the mixing sleeve cavity; and   a cooling sleeve disposed adjacent said mixing sleeve. said cooling sleeve causing the molten material in the mixing sleeve cavity to cool as the electromagnetic current (A, B) causes a mixing of the molten material until the molten material forms a semi-solid material.   
     
     
         12 . The apparatus of  claim 11 , wherein said means for causing the molten material to substantially fill the mixing sleeve cavity is a plunger. 
     
     
         13 . The apparatus of  claim 11 , wherein said means for causing the molten material to substantially fill the mixing sleeve cavity is gravity. 
     
     
         14 . The apparatus of  claim 11 , further comprising a gate for militating against flow of the molten material from flowing from the mixing sleeve to the shot sleeve cavity. 
     
     
         15 . The apparatus of  claim 11 , wherein said shot sleeve is substantially linearly aligned with said mixing sleeve. 
     
     
         16 . The apparatus of  claim 15 , wherein said shot sleeve and said mixing sleeve are disposed in one of a vertical orientation, a horizontal orientation, and an angled orientation with respect to horizontal. 
     
     
         17 . The apparatus of  claim 11 , further comprising a thermocouple for measuring a temperature of the molten material and the semi-solid material in the mixing sleeve cavity. 
     
     
         18 . A method of forming a semi-solid material in a shot sleeve cavity comprising the steps of:
 providing a casting apparatus comprising a mixing sleeve having a mixing sleeve cavity formed therein for receiving a molten material therein, a shot sleeve having a shot sleeve cavity formed therein for receiving a semi-solid material therein, a means for causing the molten material to substantially fill the mixing sleeve cavity, an electromagnetic circuit for producing an electromagnetic current (A, B) for mixing the molten material, and a cooling sleeve;   positioning the electromagnetic circuit and the cooling sleeve adjacent at least a portion of the mixing sleeve;   introducing the molten material into the casting apparatus;   energizing the electromagnetic circuit to produce an electromagnetic current (A, B) in the molten material in the mixing sleeve cavity, wherein the electromagnetic current (A, B) causes a mixing of the molten material; and   causing the cooling sleeve to cool the molten material as the electromagnetic current (A, B) mixes the molten material until the semi-solid material is formed.   
     
     
         19 . The method of  claim 18 , further providing a gate for militating against a flow of the molten material from the mixing sleeve to the shot sleeve cavity. 
     
     
         20 . The method of  claim 18 , wherein the means for causing the molten material to substantially fill the mixing sleeve cavity is one of a plunger and gravity.