Ultrasound assisted shot chamber for die casting applications

A method for producing a semi-solid material directly from its liquid material in a shot chamber in a cold chamber die casting machine for making castings, comprising the steps of:

• embedding at least one sonotrode in a shot plate or the shot plate and a plunger with one tip of each sonotrode in direct contact with the liquid material to be introduced in the shot chamber;
• preparing the liquid material and pouring the liquid material into the shot chamber at a temperature slightly higher than its liquidus temperature;
• transmitting ultrasonic vibration through said at least one sonotrode to the liquid material immediately as the liquid material is being introduced into the shot chamber wherein the tip of the sonotrode is in direct contact with the liquid material with intensity of ultrasonic vibration at the tip of each sonotrode capable of creating cavitation in the liquid material adjacent to the tip of the sonotrode;
• and
• forcing slurry formed from the liquid material to fill die cavity using the plunger while ultrasonic vibration is applied to the slurry in the shot chamber to further break up dendrites and to make dendritic fragments globular.