Continuous alloy feedstock production mold

Abstract

Embodiments herein relate to a process for semi-continuous or continuous production of a solid object from a molten metal, with the potential of being a cleaner and less expensive alternative to complicated split mold processes currently used. The embodiments can be used to perform multiple melt/pour cycles without breaking vacuum, with the system only opened to remove the solid object via an air lock, e.g., a separate chamber or load lock, which will be periodically opened to remove feedstock without breaking the vacuum of the process chamber. Embodiments also relate to an apparatus for semi-continuous or continuous production of a solid object from a molten metal.

What is claimed: 
     
         1 . A method comprising:
 filling a metal alloy into a cavity of a rotating mold,   cooling a molten metal alloy to form a solid object comprising a bulk solidifying amorphous alloy,   rotating the rotating mold along a horizontal axis of revolution; and   ejecting the solid object using a device located within the rotating mold.   
     
     
         2 . The method of  claim 1 , further comprising maintaining the metal alloy in the rotating mold in a form of the molten metal alloy at a temperature near or above a melting temperature (Tm) of the molten metal alloy so as to prevent formation of crystals of the metal alloy, wherein the molten metal alloy has a composition that forms a bulk solidifying amorphous alloy at a cooling rate of 1000 degree C. or less. 
     
     
         3 . The method of  claim 1 , wherein the cooling is at a cooling rate such that a time-temperature profile during the cooling does not traverse through a region bounding a crystalline region of the metal alloy in a time-temperature-transformation (TTT) diagram. 
     
     
         4 . The method of  claim 1 , wherein the rotating mold comprises an integrated cooling channel within the rotating mold, wherein the cooling channel is configured to allow a coolant to flow through the cooling channel 
     
     
         5 . The method of  claim 1 , wherein the rotating mold contains a plurality of cavities for forming a plurality of objects. 
     
     
         6 . The method of  claim 1 , further comprising induction heating the metal alloy in the rotating mold, wherein the rotating mold is substantially electromagnetically transparent. 
     
     
         7 . The method of  claim 1 , further comprising preheating the rotating mold. 
     
     
         8 . The method of  claim 1 , wherein the filling the metal alloy into the rotating mold comprises filling the molten metal alloy. 
     
     
         9 . The method of  claim 1 , wherein the filling the metal alloy into the rotating mold comprises filling a powder form of the metal alloy. 
     
     
         10 . The method of  claim 9 , wherein the powder form of the metal alloy is heated to form the molten metal alloy in situ in the rotating mold. 
     
     
         11 . The method of  claim 10 , wherein the powder form of the metal alloy is heated by induction heating using an induction coil, and wherein the cooling the molten metal alloy comprises in situ cooling using a cooling channel in the rotating mold. 
     
     
         12 . The method of  claim 1 , wherein the device comprises a piston or a striker. 
     
     
         13 . The method of  claim 12 , wherein the piston or striker is actuated by gravity. 
     
     
         14 . The method of  claim 1 , wherein the solid object is an ingot, a feedstock or a part. 
     
     
         15 . The method of  claim 1 , wherein the method is carried out in a process chamber under vacuum. 
     
     
         16 . The method of  claim 15 , wherein the ejecting comprises transferring the solid object from the rotating mold to atmospheric pressure via a separate chamber or load lock without breaking the vacuum of the process chamber. 
     
     
         17 . An apparatus comprising a rotating mold comprising a plurality of cavities configured to hold a molten metal and cool the molten alloy at a cooling rate to form a solid object comprising a bulk-solidifying amorphous alloy, and a device to eject the solid object from the cavity. 
     
     
         18 . The apparatus of  claim 17 , wherein the cooling rate is such that a time-temperature profile during cooling does not traverse through a region bounding a crystalline region of the metal alloy in a time-temperature-transformation (TTT) diagram of the metal alloy. 
     
     
         19 . The apparatus of  claim 17 , wherein the device comprises a piston or a striker. 
     
     
         20 . The apparatus of  claim 19 , wherein the piston or striker is actuated by gravity. 
     
     
         21 . The apparatus of  claim 17 , wherein the rotating mold comprises an integrated cooling channel within the rotating mold, wherein the cooling channel is configured to allow a coolant to flow through the cooling channel. 
     
     
         22 . The apparatus of  claim 17 , wherein the rotating mold contains a plurality of cavities for forming a plurality of objects. 
     
     
         23 . The apparatus of  claim 17 , further comprising an induction for induction heating the metal alloy in the rotating mold, wherein the rotating mold is substantially electromagnetically transparent.