Apparatus and method for dispersing particles in a molten material without using a mold

An apparatus for dispersing particles within a molten material in a mold-less casting process, the apparatus comprising:

• a primary electromagnet for generating an AC magnetic field and a secondary electromagnet adjacent to the primary electromagnet for generating an independent DC magnetic field, each of the primary and secondary electromagnets comprising a coil, the coil of the primary electromagnet comprising coil windings having a nonuniform spacing, and at least one of the primary and secondary electromagnets being positioned about a common longitudinal axis;
• a heat source for forming a melt to be exposed to the AC and DC magnetic fields generated by the primary and secondary electromagnets;
• a particle injection device disposed at one or more positions about the common longitudinal axis for injecting particles into the melt during magnetic field exposure,
• wherein the apparatus does not include a mold for containing the melt prior to solidification, the AC magnetic field generated by the primary electromagnets supplying a gradient electromagnetic pressure to contain the melt.