Apparatus and method for high pressure extrusion with molten aluminum

1. A molten metal supply system comprising:

(a) a molten metal supply source; and

(b) a plurality of molten metal injectors comprising at least a first molten metal injector, and at least a second molten metal injector,

wherein the first molten metal injector is configured to alternate between being:

in a first instance, in fluid communication with the molten metal supply source, and

in a second instance, in fluid communication with the second molten metal injector and a downstream process,

wherein the second molten metal injector is configured to alternate between being:

in a first instance, in fluid communication with the first molten metal injector and the downstream process and

in a second instance, in fluid communication with the downstream process,

wherein each of the injectors comprises:

an injector housing configured to contain molten metal and a piston that is reciprocally operable within the injector housing;

wherein the piston of each injector housing is moveable through a return stroke and a forward stroke,

wherein the return stroke allows the molten metal to be received into the injector housing; and

wherein the forward stroke displaces the molten metal from the injector housing:

wherein the system is configured such that the forward stroke of the first molten metal injector simultaneously feeds the molten metal to both ( 1 ) the housing of the second molten metal injector and (ii) the downstream process, and

wherein the system is configured such that the forward stroke of the second molten metal injector feeds the molten metal into the downstream process; and

(c) a process control cylinder having:

a process control cylinder housing in gaseous communication with the second molten metal injector, the process control cylinder housing configured to contain a gas, and

a process control cylinder piston, wherein the process control cylinder piston is reciprocally operable within the process control cylinder housing, wherein the process control cylinder piston is movable through a forward stroke and a return stroke,

wherein the system is configured to control the exit speed of a product of the downstream process via the process control cylinder piston;

wherein the return stroke of the process control cylinder piston decreases the amount of pressure applied to the gas in the process control cylinder housing, which decreases the velocity of the forward stroke of the second molten metal injector, which decreases the exit speed of the product of the downstream process,

wherein the forward stroke of the process control cylinder piston increases the amount of pressure applied to the gas in the second housing, which increases the exit speed of the product of the downstream process.

2. The molten metal supply system according to claim 1 , wherein the forward stroke of each of the first and second molten metal injectors feed the molten metal to the downstream process at a rate to maintain continuous operation.

3. The molten metal supply system according to claim 1 , wherein each of the injectors is in gas communication with at least one adjacent injector.

4. The molten metal supply system according to claim 3 , further comprising a plurality of gas valves comprising at least a first gas valve positioned between the first molten metal injector and the second molten metal injector and a second gas valve positioned adjacent the first molten metal injector, each of the gas valves being in gaseous communication with at least one of the injectors wherein:

prior to the second molten metal injector completing the forward stroke the first gas valve is opened, during the return stroke of the second molten metal injector the first gas valve is closed;

during a displacement stroke of the first molten metal injector each of the first and second gas valves are closed; and

when the first molten metal injector completes the down stroke the second gas valve is opened, during the return stroke of the first molten metal injector each of the first and second gas valves are closed.

5. The molten metal supply system according to claim 1 , further comprising a gas pad located between the piston and the molten metal in the first molten metal injector.

6. The molten metal supply system according to claim 5 , wherein the gas pad is argon or other suitable gas.

7. A molten metal supply system according to claim 1 , wherein the molten metal supply system further comprises:

a plurality of check valves comprising at least a first check valve positioned between the first molten metal injector and the molten metal supply source and a second check valve positioned between the first and second molten metal injectors;

wherein the first check valve is open and the second cheek valve is closed during the return stroke of the first molten metal injector, the first check valve is closed and the second check valve is open during a displacement stroke of the first molten metal injector and during the return stroke of the second molten metal injector, the second cheek valve is closed during the forward stroke of the second molten metal injector, the first and second molten metal injectors being synchronized to move in substantially opposite directions.

8. The molten metal supply system according to claim 1 , wherein the downstream process is an extrusion mold.