EP1132162A1 - Metal casting method and apparatus - Google Patents
Metal casting method and apparatus Download PDFInfo
- Publication number
- EP1132162A1 EP1132162A1 EP01301973A EP01301973A EP1132162A1 EP 1132162 A1 EP1132162 A1 EP 1132162A1 EP 01301973 A EP01301973 A EP 01301973A EP 01301973 A EP01301973 A EP 01301973A EP 1132162 A1 EP1132162 A1 EP 1132162A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- metal
- metal material
- slurry
- semi
- solid
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
- B22D17/007—Semi-solid pressure die casting
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/12—Making non-ferrous alloys by processing in a semi-solid state, e.g. holding the alloy in the solid-liquid phase
Abstract
Description
- This invention relates to a method and apparatus for casting metals including alloys and to a method and apparatus of manufacturing metal materials using a casting apparatus or injection molding machine, and more particularly, this invention relates to a metal casting method and apparatus and a metal material manufacturing method and apparatus, wherein semi-melted and semi-solid metal thixotropy is effectively utilized for each method and apparatus.
- Thixo-casting (semi-melted casting) and rheocasting (semi-solid casting) are known as casting methods utilizing thixotropy, or low viscosity and high fluidity, of a semi-melted and semi-solid metal. These casting methods are implemented by using a semi-melted and semi-solid metal slurry containing a mixture of liquid-phase metal and solid-phase metal.
- In thixo-casing, a solid metal is heated to form a semi-melted metal slurry and the slurry is then supplied into a mold. In rheocasting, after a solid metal is perfectly melted, the molten metal is cooled to form a semi-solid slurry containing granular crystals and the slurry is then poured into a mold.
- In the two casting methods, mold filling is improved because it is possible to conduct casting using a metal exhibiting a high solid-phase ratio and low viscosity. These methods further have the advantages of enabling (1) a higher yield, (2) molding of large-sized products, (3) suppression of shrinkage cavity formation and improvement in mechanical strength, and (4) molding of thinner products. In addition, the service life of a mold is prolonged owing to a decreased heat load on the mold.
- In the above casting procedures, it is necessary that ultrafine, uniform non-dendrite crystals (desirably spherical crystals) exist in a semi-melted semi-solid metal in order to effectively utilize the thixotropy of a semi-melted metal and the fluidity of a semi-solid metal. However, if the solid metal is simply heated to a semi-melted state or the melted metal is simply cooled to a semi-solid state, almost all metal crystals become dendrite crystals in the semi-melted and semi-solid metal. For this reason, it is impossible to attain sufficient thixotropy of the semi-melted metal and sufficient fluidity of the semi-solid metal.
- Therefore, in thixo-molding, a screw extruder is generally used in an injection-molding machine, and a solid metal in the extruder barrel is successively heated while applying a shearing force to the metal to obtain a semi-melted state metal slurry.
- However, since a screw extruder is complicated in structure and expensive, the cost to establish casting equipment having the screw extruder is very high. Moreover, since the metal slurry produced in the extruder barrel is supplied directly into a mold, it is impossible to confirm whether or not the metal crystals have become complete non-dendrite crystals. Furthermore, it is necessary to use molded metal chips as a solid metal to be supplied into the barrel, making the material cost very expensive.
- In rheocasting disclosed in JP-A-HEI 10-34307, for example, a molten metal is subjected to refrigeration in a holding furnace by contact with a cooling body to obtain a half-melted metal in which a solid phase and a liquid phase coexist. The half-melted metal is further cooled in a holding vessel while maintaining the coexisting state, thereby forming a metal slurry.
- In the prior art rheocasting, the molten metal yields many crystal nuclei when it undergoes refrigeration. The crystals become spherical in the vessel, and a desired metal slurry can be produced without use of an expensive extruder generally used in thixo-casting. Moreover, the material cost increase can be controlled, as a metal ingot can be charged into the holding furnace as it is. In addition, since it is easy to confirm whether or not the metal slurry has non-dendrite crystals, a casting procedure effectively utilizing the fluidity of semi-solid metal can be implemented.
- However, when a real mass production system is constructed by the rheocasting, a large number of holding vessels must be installed between the cooling body and the mold to hold the metal slurry. At the same time, the process that refrigerates the molten metal and the process that supplies the metal slurry into the mold need to be linked by using the large number of holding vessels, thus requiring extremely complicated control. Moreover, it is necessary to accurately control the temperature of the metal slurry in the holding vessels before pouring the slurry into the mold, making the control even more complicated.
- In view of the above problems, the present invention has been accomplished, and one object thereof is to provide a metal casting method and apparatus and a metal material manufacturing method and apparatus that can reduce their operation costs and material costs and effectively utilize thixotropy without need of complicated control.
- To attain the above object, the present invention provides a casting method comprising a first step of cooling a molten metal to form a metal slurry containing a solid phase, a second step of cooling the metal slurry to form a solid metal material, and a third step of heating the metal material to a semi-melted metal material and supplying it into a mold. In this method, the second step preferably includes continuously forming metal materials from the metal slurry and cutting the metal materials to a predetermined length.
- This invention further provides a casting apparatus comprising first means for cooling a molten metal to form a metal slurry containing a solid phase and second means for cooling the metal slurry to form a solid metal material. The metal material is then heated to a semi-melted state and the resultant metal material is poured into a mold. In this apparatus, the second means preferably forms metal materials continuously from the metal slurry and includes a cutting unit for cutting the metal materials to a predetermined length. Moreover, the cutting unit can preferably move along the advancing direction of the metal material and cut the metal material when its velocity relative to the metal material becomes zero.
- This invention further provide a metal material manufacturing method that produces a metal material being heated to a semi-melted state and then supplied into a mold and comprises a first step of cooling a molten metal to form a metal slurry containing a solid phase and a second step of cooling the metal slurry to form a solid metal material. In this method, the second step preferably includes continuously solidifying the metal slurry into solid metal materials and cutting the metal materials to a predetermined length.
- This invention further provides a metal material manufacturing apparatus that produces a metal material being heated to a semi-melted state and then supplied into a mold and comprises first means for cooling a molten metal to form a metal slurry containing a solid phase and second means for cooling the slurry to form a solid metal material. In this apparatus, the second means can preferably solidify the metal slurry continuously into solid metal materials and includes a cutting unit for cutting the solid metal materials to a predetermined length.
- It has been found that when a metal slurry containing non-dendrite crystals is cooled rapidly into a solid metal material, thixotropy is potentially maintained in the solid metal material and that when the solid material is heated into a metal slurry in a semi-melted state again, the metal slurry exhibits thixotropic properties. Therefore, a metal slurry excelling in fluidity and containing non-dendrite crystals can easily be produced, without need of complicated control, by rapidly cooling a molten metal into a metal slurry containing non-dendrite crystals in the first step, cooling the slurry into a solid metal material in the second step, and heating the metal material into a semi-melted state. The metal slurry thus produced can be supplied into a mold.
- The above and other objects, advantages and features of the invention will become apparent from the detailed description of the invention with reference to the accompanying drawings, in which:-
- FIG. 1 is a schematic cross section showing one embodiment of a casting apparatus according to this invention,
- FIG. 2(a) is a vertical cross section showing first means of the casting apparatus of FIG. 1 for cooling a molten metal to form a metal slurry,
- FIG. 2(b) is a lateral cross section showing the first means of FIG. 2(a),
- FIG. 3(a) is a cross section showing second means of the casting apparatus of FIG. 1 for producing a metal material from the metal slurry,
- FIG. 3(b) is an enlarged cross section taken along line 3-3 of FIG. 3(a),
- FIG. 4 is an enlarged cross section taken along line 4-4 in the FIG. 1,
- FIG. 5 is a schematic view showing a sequence of processes for cutting a metal material with a cutting unit of the casting apparatus of FIG. 1, and
- FIG. 6 is a schematic view showing a sequence of processes for supplying metal materials into a mold of the casting apparatus of FIG. 1.
-
- As a result of inventors' earnest researches and studies to solve the above problems, it has been confirmed that when a metal slurry containing non-dendrite crystals is cooled rapidly, thixotropy is potentially maintained after the metal slurry is solidified into a metal material and that if the metal material is heated to the semi-melted state again, the semi-melted metal material exhibits thixotropic properties for about one hour. This invention has been perfected by utilizing the characteristics of a metal slurry containing non-dendrite crystals that a solid metal material into which the metal slurry is heated and which is heated to a semi-melted state can show thixotropy.
- This invention will be described in detail with reference to the accompanying drawings. FIG. 1 shows one embodiment of a casting apparatus according to the invention. This casting apparatus is for casting desired products using magnesium alloy (AZ91D) and has a melting pot 1.
- The melting pot 1 is covered at its periphery and heated by a melting heater 2 to hold the magnesium alloy in a melted condition or liquid-phase temperature state. The melting pot 1 has at its bottom a
gate 3 for a molten material. Thegate 3 is for pouring downward molten magnesium alloy stored in the melting pot 1. Thegate 3 is bent like a crank and has a switching valve 4 in the middle. The switching valve 4 has aslidable valve plunger 5 to open and shut thegate 3 and a valve cylinder 6 to slide thevalve plunger 5. - As first means for producing a metal slurry containing a solid phase, a
cooling unit 10 is placed near the lower area of the melting pot 1. As shown in FIGs. 2(a) and 2(b), thecooling unit 10 has a plurality ofguide recesses 11 formed on its surface and a coolingwater circulating passage 12 therein. Thecooling unit 10 is inclined so the guide recesses 11 face the lower open end of thegate 3.Reference number 13 in FIG. 1 represents a cover block that communicates with the lower open end of thegate 3 and has a predetermined space between it and the surface of thecooling unit 10. - As second means for cooling the metal slurry into a solid metal material, a
reservoir 20 having arapid cooling unit 22, a pair offeed rollers cutting unit 40 are set in the casting apparatus. - The
reservoir 20 is open at its top and is set in position below thecooling unit 10. Amaterial forming passage 21 has a circular section and is attached to thereservoir 20. Thematerial forming passage 21 is located at the lower part of thereservoir 20, extends horizontally and is open to the side wall of thereservoir 20. Therapid cooling unit 22 is set at the end of thepassage 21. As shown in FIG. 3(a), therapid cooling unit 22 comprises aring jacket 23 surrounding thepassage 21 and a spoutingnozzle 24 open toward the axial center of thering jacket 23. - The
feed rollers recesses material forming passage 21. The distance between the feed recesses 30a and 31a is maintained equal to the inside diameter of thepassage 21. Each feed roller is coupled with a rotary actuator (not shown) so that thetop feed roller 30 rotates clockwise while thebottom feed roller 31 rotates counterclockwise, as shown in FIG. 3(a). - As shown in FIG. 1, the cutting
unit 40 comprises amain body 41, a fixeddamper 42A, amovable clamper 42B and a pair of feed-outrollers - The
main body 41 of the cuttingunit 40 is movably held by aguide rod 46 and reciprocates horizontally along the axial direction of thematerial forming passage 21 on an extension area of thepassage 21. Aretraction cylinder 47 is placed between themain body 41 and a fixed frame F. Theretraction cylinder 47 serves as an actuator for allowing themain body 41 to move when an external force acts on themain body 41 in the direction away from thereservoir 20 and causing themain body 41 to return back to a position near thereservoir 20 when theretraction cylinder 47 is operated to extend. - As shown in Fig. 3(b), the fixed
clamper 42A andmovable clamper 42B are block members having clamp through-holes slits holes material forming passage 21. Theslits holes holes Tapered surfaces slits slits tapered surfaces 50A and 508 are inclined so that their widths increase gradually toward the outside. The rod through-holes 51A and 51B are parallel to each other and havehemispheric dent portions - Clamping
hydraulic cylinders hydraulic cylinders dampers - The clamping
hydraulic cylinders clamp pieces 55 into the rod through-holes 51A and 51B and held by thedampers clamp pieces 56 are attached to thedent portions clamp pieces dent portions slits dampers dent portions hydraulic cylinders holes - The unclamping
cylinders slits dampers bracket 57. Anexpansion rod 58 is located between the piston rods 54aA and 54aB of the unclampinghydraulic cylinders tapered surfaces slits expansion rod 58 is a columnar part attached to thetapered 50B. When the unclampingsurfaces 50A adhydraulic cylinders expansion rod 58 spreads theslits clampers tapered surfaces holes - The fixed clamper 42A adjusts the axis of the clamp through-
hole 49A to coincide with the axis of thematerial forming passage 21 and is fixed onto themain body 41 of the cuttingunit 40 along the vertical above part of theslit 48A. - On the other hand, the
movable clamper 42B is set on acutting cylinder 59 along the vertical below part of theslit 48B so that its end facing thereservoir 20 abuts on the fixeddamper 42A. - The cutting
cylinder 59 and itscylinder body 59b are set on themain body 41 of the cuttingunit 40 so that itspiston rod 59a is directed vertically downward, and moves themovable clamper 42B in a vertical direction relative to the fixeddamper 42A. When the cuttingcylinder 59 retracts to its maximum position, themovable damper 42B stops at its uppermost position so that the axis of the damp through-hole 49B coincides with the axis of thematerial forming passage 21 or so that the clamp through-hole 49B coincides with the damp through-hole 49A of the fixeddamper 42A. Conversely, when the cuttingcylinder 59 extends to its maximum position, themovable clamper 42B descends to its extreme position and stops at a position where the clamp through-hole 49B deviates completely from the damp through-hole 49A of the fixeddamper 42A. - The feed-out
rollers roller bracket 60 extending from themovable clamper 42B. The feed-outrollers recesses 44a and 45a on their circumferences, and the radius of curvature of each feed-out recess is substantially the same as the inside diameter of thematerial forming passage 21. The interval between the feed-outrecesses 44a and 45a is secured to coincide with the inside diameter of thematerial forming passage 21. The feed-outrollers roller 44 rotates clockwise, while the lower feed-outroller 45 rotates counterclockwise. -
Reference numeral 61 in FIG. 1 denotes a guide block that connects between thecover block 13 and thereservoir 20. - As shown in FIG. 1, an
injection apparatus 70 is set in the casting apparatus. Theinjection apparatus 70 supplies heated semi-melted metal into amold 90 and has aheating chamber 71. Theheating chamber 71 has a substantially sealed space covered by aheater 72. Anoutlet nozzle 73 provided on the upper end of theheating chamber 71 is connected to asprue 91 of themold 90 through anauxiliary nozzle 74. - A
suction rod 75 and apre-heating barrel 76 are set on theheating chamber 71. - The
suction rod 75 is a movable columnar part in the upper end wall of theheating chamber 71. It is connected to a suction cylinder 77 and moved into or out of theheating chamber 71 by the suction cylinder 77. - The pre-heating
barrel 76 is a cylindrical part extending horizontally from the side wall of theheating chamber 71. The distal end of thepre-heating barrel 76 has substantially the same inside diameter as thematerial forming passage 21 of thereservoir 20. The inside diameter of the proximal end of thebarrel 76 adjacent to theheating chamber 71 is slightly larger than the distal end inside diameter, and these ends are connected by a part with a tapered inside diameter. As shown in FIG. 4, amaterial intake hole 78 is set at the distal end of thepre-heating barrel 76, and ashoot board 79 is connected to thematerial intake hole 78. - A pre-heater 80 is set around the proximal end of the
pre-heating barrel 76, and aplunger 81 is set at the distal end of thepre-heating barrel 76. - The pre-heater 80 surrounds the pre-heating
barrel 76 and heats the pre-heatingbarrel 76, and is set to have a slightly lower temperature than theheater 72 of theheating chamber 71. - The
plunger 81 is a cylindrical part having a size fitted into the distal end of thepre-heating barrel 76. A push-out cylinder 82 is connected to theplunger 81 in order to move theplunger 81 forward and backward inside of thepre-heating barrel 76. - In the casting apparatus, magnesium alloy ingots are first introduced into the melting pot 1, and the melting heater 2 is turned on. With the melted magnesium alloy held in the melting pot 1, cooling water is circulated in the
cooling unit 10 and then supplied into therapid cooling unit 22 to establish a standby state. In this operation, theretraction cylinder 47 in the cuttingunit 40 is operated to extend and themain body 41 of the cuttingunit 40 is located near thereservoir 20. Simultaneously, the cuttingcylinder 59 is operated to retract, and themovable damper 42B is stopped at the highest location. Unclamping oil pressure is then applied to the unclampinghydraulic cylinders hydraulic cylinders damper 42A andmovable clamper 42B spread the inside diameters of the clamp through-holes feed rollers rollers - If the valve cylinder 6 retracts and the
valve plunger 5 is moved backward in the standby state, thegate 3 for the molten material is opened and a molten magnesium alloy M1 stored in the melting pot 1 is poured onto the coolingunit 10 through the gate 3 (Arrow A in FIG. 1). - The magnesium alloy M1 poured onto the
inclined cooling unit 10 flows along theguide recess 11 of the coolingunit 10 downward (Arrow B in FIG. 1) and is then held in thereservoir 20. During the above operation, the molten magnesium alloy M1 flowing onto the coolingunit 10 is suitably cooled by the coolingunit 10 and becomes a metal slurry M2 with many nuclei crystallized out therein. These crystal nuclei then grow to become finely grained and uniformly spherical crystals. The metal slurry M2 may thus be sufficiently fluid without use of an expensive extruder, thereby greatly decreasing the equipment cost. Moreover, as a metal ingot can be supplied into the melting pot 1 without conducting any pre-treatment, the material cost can be reduced. - The metal slurry M2 stored in the
reservoir 20 is continuously discharged through thematerial forming passage 21. At the same time, the metal slurry M2 passing through thepassage 21 is cooled by the cooling water flowing in thering jacket 23 in therapid cooling unit 22 and rapidly cooled by the cooling water supplied from the spoutingnozzle 24, and perfectly solidified as a columnar-rod metal material M3. In this operation, perfectly solidified metal material M3 is produced by rapidly cooling a metal slurry with perfect thixotropy, and therefore potentially retains the thixotropy itself. This can easily be confirmed by observing the crystal structure in the metal material M3. - The metal material M3 discharged from the
reservoir 20 is supplied to the cuttingunit 40 by thefeed rollers holes movable dampers rollers - During the above operation, the rotation of the
feed rollers - When the number of rotations of the
feed rollers hydraulic cylinders hydraulic cylinders holes movable clampers clampers main body 41 of the cuttingunit 40 moves together with the metal material M3 along theguide rod 46 while theretraction cylinder 47 retracts, the relative velocity between thedampers - The cutting
cylinder 59 is then operated to extend, and themovable clamper 42B is gradually moved downward relative to the fixeddamper 42A. As result, as shown in FIG. 5(b), a shearing stress acts between part of the metal material M3 that has passed through the fixeddamper 42A and part of the metal material M3 before passing through the fixeddamper 42A. The metal material M3 is then sheared, with the parts as the boundary. - As shown in FIG. 5(c), when the cutting
cylinder 59 extends to its maximum position and the metal material M3 has been sheared, the oil pressure that acts upon the clamping and unclampinghydraulic cylinders movable damper 42B is suitably switched. Themovable clamper 42B increases the diameter of the clamp through-hole 49B. At the same time, the feed-outrollers movable damper 42B and discharge it onto a carrying conveyor 100 (FIG. 1). - When the sheared metal material M3 has been discharged onto the carrying conveyor, as shown in FIG. 5(d), the feed-out
rollers cylinder 59 and fixeddamper 42A are returned to their respective standby positions. Theretraction cylinder 47 is then operated to extend, and theunit body 41 is also returned to its standby position. - By repeating the above operation, the metal materials M3 of the pre-fixed length are continuously discharged onto the carrying conveyor 100.
- In the above cutting process, since the cutting
unit 40 cuts a metal material M3 when the relative velocity thereof to the metal material M3 becomes zero, continuous cutting is possible without interrupting the formation of metal material M3. - As shown in FIG. 4, the metal materials M3 thus produced are successively passed through the
shoot board 79 and dropped into the pre-heatingbarrel 76 from thematerial intake hole 78. As shown in FIG. 6(a), both the pre-heater 80 and theheater 72 of theheating chamber 71 are operated in order just when one piece of the metal material M3 has been dropped into the pre-heatingbarrel 76. - The metal material M3 that has been dropped into the pre-heating
barrel 76 is supplied into theheating chamber 71 by the reciprocating movement of theplunger 81 and held therein in a semi-melted condition as shown in FIG. 6(b). - According to the casting apparatus, the metal material M3 in the
pre-heating barrel 76 is heated by the pre-heater 80, so it is possible to obtain a semi-melted magnesium alloy M4 immediately when the metal material M3 reaches theheating chamber 71. Since the inside diameter of the distal end of thepre-heating barrel 76 is the same as the outside diameter of the metal material M3, the distal end is closed by the metal material M3 not semi-melted to prevent the semi-melted magnesium alloy M4 in theheating chamber 71 from flowing backward. - As shown in FIG. 6(c), when a necessary volume of semi-melted magnesium alloy M4 is stored in the
heating chamber 71, the extending action of the feed-outcylinder 82 allows theplunger 81 to advance. At the same time, thesuction rod 75 is moved into theheating chamber 71 by the extending action of the suction cylinder 77. As a result, the semi-melted magnesium alloy M2 stored in theheating chamber 71 is supplied into themold 90 through theoutlet nozzle 73 andauxiliary nozzle 74 and molded into a desired shape. - The semi-melted alloy M4 supplied into the
mold 90 is obtained by heating the metal material M3 that potentially has thixotropy, and is able to exhibit thixotropy again when molded into a desired shape. Therefore, the casting successfully utilizing thixotropy can be ensured. In other words, the casting using magnesium alloy having low viscosity and a high solid-phase ratio can be conducted. The filling ability of themold 90 and the yield are therefore improved and the casting rate is increased. Therefore, it is possible to manufacture large-sized products, suppress the shrinkage cavity formation, improve the mechanical strength and manufacture thin products, thus creating many new advantages. Furthermore, the thermal load on themold 90 can be reduced to prolong the service life of the mold. - Moreover, the casting apparatus is designed so that the metal slurry M2 is solidified to form a metal material M3 that is then heated to form a semi-melted metal material that is then supplied into the
mold 90. It is therefore unnecessary to couple thecooling unit 10 which cools the molten metal M1 and theinjection apparatus 70 together or to accurately control the temperature of the metal material M3. This eliminates the need for complicated control, and it is possible to easily carry out casting that effectively utilizes thixotropy. Moreover, it is possible to handle the solidified metal material M3 as a small billet, which may lead to more convenient handling procedures. - After the termination of supplying the semi-melted magnesium alloy M4 into the
mold 90, the push-out cylinder 82 retracts, the suction cylinder 77 retracts and the level of the molten metal in theheating chamber 71 decreases as shown in FIG. 6(d). This prevents the semi-melted magnesium alloy M4 from being solidified in theoutlet nozzle 73 andauxiliary nozzle 74. - The above actions are then repeated to mass-produce desired products using the
mold 90. - Moreover, in the above embodiment, the casting apparatus manufactures products from magnesium alloy, but it can also manufacture products from aluminum, aluminum alloy and other metals and alloys.
- Furthermore, in the above embodiment, the cutting unit is used to cut the metal material for easier handling, but this is not always necessary. In the absence of the cutting unit, it may be adopted to heat the produced metal material to a semi-melted state and supply the semi-melted metal material into the mold. Furthermore, the cross section of the produced metal material need not be circular.
- As has been described in the foregoing, this invention helps reduction of the operation and material costs, because it does not require use of an expensive extruder normally used in thixo-casting and because metal blocks can be used without any pretreatment. Moreover, the formed metal slurry is solidified, so it is not necessary to couple the metal slurry forming process and its supply to the mold, eliminating the need to accurately control the temperature of the solidified metal slurry. It is also possible to perform casting that effectively utilizes thixotropy.
Claims (10)
- A casting method comprising a first step of cooling a molten metal to form a metal slurry containing a solid phase, a second step of cooling the metal slurry to form a solid metal material, and a third step of heating the metal material to a semi-melted metal material and supplying it into a mold.
- The casting method according to claim 1, characterized in that the second step includes continuously forming metal materials from the metal slurry and cutting the metal materials to a predetermined length.
- A casting apparatus comprising first means for cooling a molten metal to form a metal slurry containing a solid phase and second means for cooling the metal slurry to form a solid metal material, wherein the metal material is then heated to a semi-melted state and the resultant metal material is poured into a mold.
- The casting apparatus according to claim 3, characterized in that the second means forms metal materials continuously from the metal slurry and includes a cutting unit for cutting the metal materials to a predetermined length.
- The casting apparatus according to claim 4, characterized in that the cutting unit can move along an advancing direction of the metal materials and cut the metal materials when a velocity of the cutting unit relative to the metal materials becomes zero.
- A method for manufacturing a metal material being heated to a semi-melted state and then supplied into a mold, comprising a first step of cooling a molten metal to form a metal slurry containing a solid phase and a second step of cooling the metal slurry to form a solid metal material.
- The method according to claim 6, characterized in that the second step includes continuously solidifying the metal slurry into solid metal materials and cutting the metal materials to a predetermined length.
- An apparatus for manufacturing a metal material being heated to a semi-melted state and then supplied into a mold, comprising first means for cooling a molten metal to form a metal slurry containing a solid phase and second means for cooling the slurry to form a solid metal material.
- The apparatus according to claim 8, characterized in that the second means can solidify the metal slurry continuously into solid metal materials and includes a cutting unit for cutting the solid metal materials to a predetermined length.
- The casting apparatus according to claim 9, characterized in that the cutting unit can move along an advancing direction of the metal materials and cut the metal materials when a velocity of the cutting unit relative to the metal materials becomes zero.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP2000062924A JP4195767B2 (en) | 2000-03-08 | 2000-03-08 | Casting method, casting equipment, metal material manufacturing method and metal material manufacturing apparatus |
JP2000062924 | 2000-03-08 |
Publications (2)
Publication Number | Publication Date |
---|---|
EP1132162A1 true EP1132162A1 (en) | 2001-09-12 |
EP1132162B1 EP1132162B1 (en) | 2005-08-31 |
Family
ID=18582873
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP01301973A Expired - Lifetime EP1132162B1 (en) | 2000-03-08 | 2001-03-05 | Metal casting method and apparatus |
Country Status (6)
Country | Link |
---|---|
US (1) | US20010020526A1 (en) |
EP (1) | EP1132162B1 (en) |
JP (1) | JP4195767B2 (en) |
AU (1) | AU783639B2 (en) |
CA (1) | CA2339398C (en) |
DE (1) | DE60112980T2 (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US7343959B2 (en) | 2003-07-11 | 2008-03-18 | Nissei Plastic Industrial Co., Ltd. | Pressure casting method of magnesium alloy and metal products thereof |
Families Citing this family (14)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE10157349A1 (en) * | 2001-11-22 | 2003-06-12 | Demag Ergotech Gmbh | Device and method for casting metallic materials |
JP3503898B1 (en) * | 2003-03-07 | 2004-03-08 | 権田金属工業株式会社 | Method and apparatus for manufacturing magnesium metal sheet |
KR100559636B1 (en) * | 2003-12-31 | 2006-03-10 | 현대자동차주식회사 | Manufacturing method of magnesium alloy extruding members for seat frame and magnesium alloy |
US7331372B2 (en) | 2004-02-25 | 2008-02-19 | Nissei Plastic Industrial Co., Ltd. | Method for melting metallic raw material in metal molding apparatus |
CN100389908C (en) * | 2004-02-25 | 2008-05-28 | 日精树脂工业株式会社 | Production method for metallic material in metal forming machine |
JP4009601B2 (en) * | 2004-02-27 | 2007-11-21 | 日精樹脂工業株式会社 | Low melting point metal alloy forming method |
JP4289613B2 (en) * | 2004-02-27 | 2009-07-01 | 日精樹脂工業株式会社 | Low melting point metal alloy forming method |
JP4051350B2 (en) * | 2004-03-05 | 2008-02-20 | 日精樹脂工業株式会社 | Low melting point metal alloy forming method |
JP2007046071A (en) * | 2005-08-05 | 2007-02-22 | Chuo Kosan Kk | Mg ALLOY, AND CASTING METHOD OR FORGING METHOD OF THE SAME |
JP4051393B2 (en) * | 2007-06-13 | 2008-02-20 | 日精樹脂工業株式会社 | Low melting point metal alloy forming method |
CN102000784B (en) * | 2010-11-17 | 2012-10-31 | 昆明理工大学 | Method for controlling large-scale nodular iron cast coagulation tissue |
CN102773413A (en) * | 2012-07-24 | 2012-11-14 | 江苏万里活塞轴瓦有限公司 | Temperature controllable semi-solid touch deforming mold |
CN106825483A (en) * | 2017-03-21 | 2017-06-13 | 昆明理工大学 | A kind of method and device for preparing semi solid slurry |
CN106944599B (en) * | 2017-04-21 | 2022-06-14 | 苏州金澄精密铸造有限公司 | Pulping machine for semi-solid pulping and semi-solid pulping method |
Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP0701002A1 (en) * | 1994-09-09 | 1996-03-13 | Ube Industries, Ltd. | Process for moulding aluminium- or magnesiumalloys in semi-solidified state |
US5571346A (en) * | 1995-04-14 | 1996-11-05 | Northwest Aluminum Company | Casting, thermal transforming and semi-solid forming aluminum alloys |
EP0745694A1 (en) * | 1995-05-29 | 1996-12-04 | Ube Industries, Ltd. | Method and apparatus for shaping semisolid metals |
EP0903193A1 (en) * | 1996-11-28 | 1999-03-24 | Ube Industries, Ltd. | Apparatus for producing metal to be semimolten-molded |
EP0931607A1 (en) * | 1997-12-20 | 1999-07-28 | Ahresty Corporation | Method of producing semi-solid metal slurries |
Family Cites Families (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
IT1243100B (en) * | 1990-04-12 | 1994-05-24 | Stampal Spa | PROCEDURE AND RELATED EQUIPMENT FOR INDIRECT CASTING OF BILLETS WITH METALLIC ALLOY IN THE SEMI-LIQUID OR PASTY STATE |
JP3248942B2 (en) * | 1992-03-24 | 2002-01-21 | ティーディーケイ株式会社 | Cooling roll, method for manufacturing permanent magnet material, permanent magnet material, and permanent magnet material powder |
-
2000
- 2000-03-08 JP JP2000062924A patent/JP4195767B2/en not_active Expired - Fee Related
-
2001
- 2001-03-05 DE DE60112980T patent/DE60112980T2/en not_active Expired - Lifetime
- 2001-03-05 CA CA002339398A patent/CA2339398C/en not_active Expired - Fee Related
- 2001-03-05 EP EP01301973A patent/EP1132162B1/en not_active Expired - Lifetime
- 2001-03-07 US US09/799,561 patent/US20010020526A1/en not_active Abandoned
- 2001-03-08 AU AU26421/01A patent/AU783639B2/en not_active Ceased
Patent Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP0701002A1 (en) * | 1994-09-09 | 1996-03-13 | Ube Industries, Ltd. | Process for moulding aluminium- or magnesiumalloys in semi-solidified state |
US5571346A (en) * | 1995-04-14 | 1996-11-05 | Northwest Aluminum Company | Casting, thermal transforming and semi-solid forming aluminum alloys |
EP0745694A1 (en) * | 1995-05-29 | 1996-12-04 | Ube Industries, Ltd. | Method and apparatus for shaping semisolid metals |
EP0903193A1 (en) * | 1996-11-28 | 1999-03-24 | Ube Industries, Ltd. | Apparatus for producing metal to be semimolten-molded |
EP0931607A1 (en) * | 1997-12-20 | 1999-07-28 | Ahresty Corporation | Method of producing semi-solid metal slurries |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US7343959B2 (en) | 2003-07-11 | 2008-03-18 | Nissei Plastic Industrial Co., Ltd. | Pressure casting method of magnesium alloy and metal products thereof |
Also Published As
Publication number | Publication date |
---|---|
JP4195767B2 (en) | 2008-12-10 |
AU783639B2 (en) | 2005-11-17 |
CA2339398A1 (en) | 2001-09-08 |
US20010020526A1 (en) | 2001-09-13 |
DE60112980D1 (en) | 2005-10-06 |
AU2642101A (en) | 2001-09-13 |
DE60112980T2 (en) | 2006-06-14 |
EP1132162B1 (en) | 2005-08-31 |
JP2001252759A (en) | 2001-09-18 |
CA2339398C (en) | 2009-08-04 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
EP1132162B1 (en) | Metal casting method and apparatus | |
US10118219B2 (en) | Semisolid casting/forging apparatus and method as well as a cast and forged product | |
US5979535A (en) | Methods for semi-melting injection molding | |
US5346184A (en) | Method and apparatus for rapidly solidified ingot production | |
EP0859677B1 (en) | Apparatus for processing semisolid thixotropic metallic slurries | |
US7051784B2 (en) | Method of producing semi-solid metal slurries | |
EP1292411B1 (en) | Production of on-demand semi-solid material for castings | |
EP0931607B1 (en) | Method of preparing a shot of semi-solid metal | |
JP2004538153A (en) | Apparatus and method for producing slurry material without agitation for use in semi-solid molding | |
US20140014288A1 (en) | Device for casting | |
AU2001261796A1 (en) | Production of on-demand semi-solid material for castings | |
US7469738B2 (en) | Process for injection molding semi-solid alloys | |
US10384262B2 (en) | Die-casting apparatus, die-casting method, and diecast article | |
US6901991B2 (en) | Semi-solid molding apparatus and method | |
US20020011321A1 (en) | Method of producing semi-solid metal slurries | |
EP2106867B1 (en) | Device for casting | |
JP4509343B2 (en) | Semi-molten metal forging method and forging apparatus | |
Schwam et al. | Optimization of Squeeze Casting for Aluminum Alloy Parts | |
US20030226651A1 (en) | Low-velocity die-casting | |
EP1787740A2 (en) | In-situ semi solid metal slurry formation and delivery apparatus and method |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
PUAI | Public reference made under article 153(3) epc to a published international application that has entered the european phase |
Free format text: ORIGINAL CODE: 0009012 |
|
AK | Designated contracting states |
Kind code of ref document: A1 Designated state(s): AT BE CH CY DE DK ES FI FR GB GR IE IT LI LU MC NL PT SE TR Kind code of ref document: A1 Designated state(s): DE FR GB IT |
|
AX | Request for extension of the european patent |
Free format text: AL;LT;LV;MK;RO;SI |
|
RIN1 | Information on inventor provided before grant (corrected) |
Inventor name: MIYAZAKI, KEIICHI Inventor name: MOTEGI, TETSUICHI Inventor name: YOSHIWARA, KIYOTAKA Inventor name: TEZUKA, YOSHOMOTO |
|
17P | Request for examination filed |
Effective date: 20020104 |
|
RIN1 | Information on inventor provided before grant (corrected) |
Inventor name: TEZUKA, YOSHITOMO Inventor name: YOSHIHARA, KIYOTAKA Inventor name: MIYAZAKI, KIICHI Inventor name: MOTEGI, TETSUICHI |
|
R17P | Request for examination filed (corrected) |
Effective date: 20011229 |
|
AKX | Designation fees paid |
Free format text: DE FR GB IT |
|
GRAP | Despatch of communication of intention to grant a patent |
Free format text: ORIGINAL CODE: EPIDOSNIGR1 |
|
GRAS | Grant fee paid |
Free format text: ORIGINAL CODE: EPIDOSNIGR3 |
|
RAP1 | Party data changed (applicant data changed or rights of an application transferred) |
Owner name: TEZUKA, YOSHITOMO Owner name: MIYAZAKI, KIICHI Owner name: YOSHIHARA, KIYOTAKA Owner name: MOTEGI, TETSUICHI Owner name: SEIKO IDEA CENTER CO.,LTD. |
|
GRAL | Information related to payment of fee for publishing/printing deleted |
Free format text: ORIGINAL CODE: EPIDOSDIGR3 |
|
GRAS | Grant fee paid |
Free format text: ORIGINAL CODE: EPIDOSNIGR3 |
|
GRAA | (expected) grant |
Free format text: ORIGINAL CODE: 0009210 |
|
AK | Designated contracting states |
Kind code of ref document: B1 Designated state(s): DE FR GB IT |
|
REG | Reference to a national code |
Ref country code: GB Ref legal event code: FG4D |
|
REF | Corresponds to: |
Ref document number: 60112980 Country of ref document: DE Date of ref document: 20051006 Kind code of ref document: P |
|
ET | Fr: translation filed | ||
PLBE | No opposition filed within time limit |
Free format text: ORIGINAL CODE: 0009261 |
|
STAA | Information on the status of an ep patent application or granted ep patent |
Free format text: STATUS: NO OPPOSITION FILED WITHIN TIME LIMIT |
|
26N | No opposition filed |
Effective date: 20060601 |
|
PGFP | Annual fee paid to national office [announced via postgrant information from national office to epo] |
Ref country code: FR Payment date: 20110404 Year of fee payment: 11 Ref country code: IT Payment date: 20110325 Year of fee payment: 11 |
|
PGFP | Annual fee paid to national office [announced via postgrant information from national office to epo] |
Ref country code: GB Payment date: 20110321 Year of fee payment: 11 |
|
GBPC | Gb: european patent ceased through non-payment of renewal fee |
Effective date: 20120305 |
|
REG | Reference to a national code |
Ref country code: FR Ref legal event code: ST Effective date: 20121130 |
|
PG25 | Lapsed in a contracting state [announced via postgrant information from national office to epo] |
Ref country code: GB Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES Effective date: 20120305 Ref country code: FR Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES Effective date: 20120402 |
|
PG25 | Lapsed in a contracting state [announced via postgrant information from national office to epo] |
Ref country code: IT Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES Effective date: 20120305 |
|
PGFP | Annual fee paid to national office [announced via postgrant information from national office to epo] |
Ref country code: DE Payment date: 20130321 Year of fee payment: 13 |
|
REG | Reference to a national code |
Ref country code: DE Ref legal event code: R119 Ref document number: 60112980 Country of ref document: DE |
|
REG | Reference to a national code |
Ref country code: DE Ref legal event code: R119 Ref document number: 60112980 Country of ref document: DE Effective date: 20141001 |
|
PG25 | Lapsed in a contracting state [announced via postgrant information from national office to epo] |
Ref country code: DE Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES Effective date: 20141001 |