Semi-solid material formation within a cold chamber shot sleeve
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.