Advanced Feed System for Semi Solid Casting

Abstract

A feed system for introducing semi-solid metal alloy to a die casting machine includes a first chamber for receiving a metal alloy billet and for preparing the semi-solid metal alloy billet. The first chamber includes heaters and a cutting system. The metal alloy billet is heated by the heaters and cut by the cutting system into predetermined lengths to form semi-solid metal alloy portions. The feed system also includes a second chamber connected to the first chamber by a passage to receive the semi-solid metal alloy portions. The second chamber includes a door that opens and closes the passage and a plunger system that introduces the semi-solid metal portions to a die cast machine. An atmosphere control system is in fluid communication with the first chamber and the second chamber. The atmosphere control system removes oxygen from the feed system. A method using the feed system is also provided.

1 . A feed system for semi-solid metal casting, the system comprising:
 a first chamber for receiving a metal alloy billet, the first chamber including heaters and a cutting system, the metal alloy billet being heated by the heaters and cut by the cutting system into predetermined lengths to form semi-solid metal alloy portions;   a second chamber connected to the first chamber by a passage to receive the semi-solid metal alloy portions, the second chamber including a door that opens and closes the passage and a plunger system that introduces the semi-solid metal portions to a die cast machine; and   an atmosphere control system for removing oxygen from the feed system, the atmosphere control system being in fluid communication with the first chamber and the second chamber, the atmosphere control system including an inert gas purging system that introduces an inert gas into the first chamber via inlet port and then into the second chamber via the passage.   
     
     
         2 . The feed system of  claim 1  wherein the plunger system includes a plunger that pushes the semi-solid metal into the die cast machine. 
     
     
         3 . The feed system of  claim 2  wherein the plunger is positionable in a first position such that the second chamber receives the semi-solid metal and a second position in which the door is closed. 
     
     
         4 . The feed system of  claim 3  wherein the plunger system further includes a sheath that operates as the door, the sheath moving with the plunger. 
     
     
         5 . The feed system of  claim 4  wherein the plunger system further includes a biasing member that acts to move the sheath towards the die cast machine. 
     
     
         6 . The feed system of  claim 3  wherein the plunger system further includes a hydraulic system for moving the plunger. 
     
     
         7 . (canceled) 
     
     
         8 . The feed system of  claim 1  wherein inert gas is introduced into the second chamber. 
     
     
         9 . The feed system of  claim 1  wherein the metal alloy billet comprises an alloy with a freezing range. 
     
     
         10 . The feed system of  claim 1  wherein the metal alloy billet comprises an aluminum alloy. 
     
     
         11 . The feed system of  claim 10  wherein the aluminum alloy comprises aluminum and a component selected from the group consisting of copper, magnesium, manganese, silicon, zinc, and combinations. 
     
     
         12 . The feed system of  claim 10  wherein the aluminum alloy comprises aluminum and silicon. 
     
     
         13 . The feed system of  claim 10  wherein the metal alloy billet comprises a component selected from the group consisting of magnesium alloys, tin alloys, zinc alloys, and copper alloys. 
     
     
         14 . A feed system for semi-solid metal casting, the system comprising:
 a first chamber for receiving an alloy billet, the first chamber including heaters and a cutting system, wherein the alloy billet is heated by the heaters and cut by the cutting system into predetermined lengths to form semi-solid metal portions,   a gas purging system providing a positive pressure of an inert gas to the first chamber; and   a second chamber connected to the first chamber by a passage, the second chamber including a door that opens and closes the passage and a plunger system that introduces the semi-solid metal portions to a die cast machine.   
     
     
         15 . A method of feeding alloy billet to a die cast machine, the method comprising:
 introducing the alloy billet into a first chamber including heaters and a cutting system;   heating the alloy billet in a first chamber under a substantially oxygen free environment to a temperature at which the alloy billet is a semi-solid;   cutting the alloy billet in the first chamber into semi-solid metal alloy portions having a predetermined length;   introducing the semi-solid metal alloy portions into a second chamber through a passage between the first and second chamber, the second chamber including a door that opens and closes the passage and a plunger system; and   introducing the semi-solid metal alloy portions into the die cast machine by the plunger system.   
     
     
         16 . The method of  claim 15  wherein inert gas is introduced into the second chamber. 
     
     
         17 . The method of  claim 15  wherein the alloy billet comprises an alloy with a freezing range. 
     
     
         18 . The method of  claim 17  wherein the alloy billet comprises an aluminum alloy. 
     
     
         19 . The method of  claim 18  wherein the aluminum alloy comprises aluminum and a component selected from the group consisting of copper, magnesium, manganese, silicon, zinc, and combinations. 
     
     
         20 . The method of  claim 18  wherein the aluminum alloy comprises aluminum and silicon.