# US 5,881,796 A · Apparatus and method for integrated semi-solid material production and casting > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 5,881,796 A - Document ID: US5881796A - Status: Granted - Kind: A - Application number: 08/733,125 - Filed: 1996-10-17 - Granted: 1999-03-16 - Earliest claimed: 1996-10-17 - Assignees: Semi-Solid Technologies Inc. - Inventors: Stuart B. Brown; Patricio F. Mendez; Christopher S. Rice; Shinya Myojin - Web page: https://patentgrep.com/patent/US5881796A ## CPC - B22D 1/00: Treatment of fused masses in the ladle or the supply runners before casting {(for continuous casting B22D11/10; metallurgical processing, e.g. refining of iron or other metal C21, C22, C25C)} - B22D 17/007: {Semi-solid pressure die casting} - Y10S 164/90: Rheo-casting - B22D: CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES (shaping of plastics or substances in a plastic state B29C; metallurgical processing, selection of substances to be added to metal C21, C22) - Y10S: TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS ## Abstract An apparatus and process is provided for producing semi-solid material and directly casting the semi-solid material into a component wherein the semi-solid material is formed from a molten material and the molten material is introduced into a container. Semi-solid is produced therefrom by agitating, shearing, and thermally controlling the molten material. The semi-solid material is maintained in a substantially isothermal state within the container by appropriate thermal control and thorough three-dimensional mixing. Extending from the container is a means for removing the semi-solid material from the container, including a temperature control mechanism to control the temperature of the semi-solid material within the removing means. ## Claims ### Claim 1 An apparatus for directly producing a component from a semi-solid material comprising: a source of molten material; a container for receiving said molten material; a thermal control means for controlling the temperature of said container; a mechanical agitating device comprising a primary stirring component and a secondary stirring component for three-dimensionally stirring material within said container and acting in conjunction with said thermal control means to produce a substantially isothermal semi-solid material; a means for removing a portion of said semi-solid material from said container, said removing means being thermally controlled; and a casting means directly connected to said removing means for receiving said portion of semi-solid material from said removing means and casting said semi-solid material into a component. ### Claim 2 (depends on 1) The apparatus of claim 1 wherein said primary stirring component includes an arm having a first portion being substantially parallel to a side wall of said container. ### Claim 3 (depends on 2) The apparatus of claim 2 wherein said arm of said primary stirring component includes a second portion being substantially parallel to a bottom wall of said container. ### Claim 4 (depends on 2) The apparatus of claim 2 wherein said secondary stirring component is augur-shaped and promotes mixing of said semi-solid material along an axis of said secondary stirring component. ### Claim 5 (depends on 4) The apparatus of claim 4 wherein said casting means comprises a die casting device. ### Claim 6 (depends on 5) The apparatus of claim 5 wherein said mechanical agitating device is a stainless steel coated with a ceramic. ### Claim 7 (depends on 1) The apparatus of claim 1 wherein said removal means comprises a transfer tube. ### Claim 8 (depends on 7) The apparatus of claim 7 wherein said transfer tube includes an inner insulating layer. ### Claim 9 (depends on 8) The apparatus of claim 8 wherein said transfer tube includes a support tube surrounding said insulating layer and an outer layer surrounding said support tube. ### Claim 10 (depends on 9) The apparatus of claim 9 wherein said transfer tube includes a heating mechanism for maintaining the temperature of said semi-solid material passing through said transfer tube. ### Claim 11 (depends on 10) The apparatus of claim 10 wherein said transfer tube includes a flow control means for regulating a flow of semi-solid material through said transfer tube. ### Claim 12 (depends on 11) The apparatus of claim 11 wherein said transfer flow control means includes a valve that regulates said flow of semi-solid material through said transfer tube such that no more than one tenth of said semi-sold material is removed per a removal cycle. ### Claim 13 (depends on 11) The apparatus of claim 11 wherein said transfer tube extends though a cover in said chamber. ### Claim 14 (depends on 11) The apparatus of claim 11 wherein said transfer tube extends through a side wall in said chamber. ### Claim 15 (depends on 1) The apparatus of claim 1 wherein said casting means includes a die, a ram, and a shot sleeve disposed therebetween, said shot sleeve for receiving said portion of said semi-solid and said ram for forcing said portion into said die to form said component. ### Claim 16 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. ### Claim 17 (depends on 16) The apparatus of claim 16 wherein said primary stirring component includes a portion being substantially parallel to a side wall of said container. ### Claim 18 (depends on 17) The apparatus of claim 17 wherein said secondary stirring component is augur-shaped. ### Claim 19 (depends on 18) The apparatus of claim 18 wherein said casting means comprises a die casting device. ### Claim 20 (depends on 19) The apparatus of claim 19 wherein said mechanical agitating device is a stainless steel coated with a ceramic. ### Claim 21 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.