Apparatus and method for integrated semi-solid material production and casting

An apparatus for directly producing a component from a semi-solid material comprising:

• a container for receiving a molten material;
• a thermal control means for controlling the temperature of material in said container;
• a mechanical agitating device comprising a primary stirring component and a secondary stirring component acting with said container for stirring material in said container and acting in conjunction with said thermal control means for producing said semi-solid material;
• said thermal controller and said agitating means maintaining said semi-solid material in a substantially isothermal state;
• and
• a die casting means connected to said container for directly casting said semi-solid material into said component prior to complete solidification of said semi-solid material.

A method of directly producing a component from partially solidified material semi-solid material comprising:

• receiving a molten material in a container;
• forming said molten material into a semi-solid material with an agitating means that includes a primary stirring component and a secondary stirring component acting with the container and a thermal controlling means;
• maintaining said semi-solid material in a substantially isothermal state with said agitating means and said thermal controlling means;
• transferring a portion of said semi-solid material directly to a casting apparatus;
• and
• casting said portion of said semi-solid material into said component with said casting apparatus prior to complete solidification of said portion.