Apparatus for processing a liquid alloy

Abstract

An apparatus for producing solid alloy components from its liquid state are provided. A molten alloy is rapidly cooled using a chill to temperatures below the thermosolutal transition temperature of the alloy. Finite-amplitude acoustic vibration is applied on the chill to shake off dendrites that form on the chill surface, to stir the slurry containing the fragments of dendrites, and to shake off slurry material that sticks on the surface of the chill as the chill is separating from the slurry. The slurry is then immediately poured into a chamber of a forming machine or a mold cavity shaped into solid components.

What is claimed is: 
     
         1 . An apparatus for production of a slurry containing a small fraction of non-dendritic solid crystals from its liquid alloy for subsequent forming into solid alloy components, comprising:
 a vessel or a trough for containing a quantity of liquid alloy and for pouring the alloy into another chamber of a forming apparatus or a mold cavity;   a chill having a bottom surface with a shape and size complementary to that of the liquid alloy;   a plurality of a small-amplitude vibrator coupled to the chill for producing non-dendritic solid crystals in the liquid alloy and for shaking of the liquid alloy or the slurry that sticks on the surfaces of the chill while it is separating from the slurry;   means for controllably contacting a top surface of the liquid alloy with the chill, and maintaining the bottom surface of the chill in a substantial contact with the top surface of the liquid alloy, and vibrating the chill,   whereby the slurry containing a small fraction of non-dendritic solid crystals is formed from the liquid alloy while the top surface of the liquid alloy remains quiescent.   
     
     
         2 . The apparatus of  claim 1 , wherein the said vessel or the said trough is made of ceramic materials or steel protected with a layer of coating to prevent the steel from reacting to the liquid alloy. 
     
     
         3 . The apparatus of  claim 1 , wherein the vessel is a ladle used for a casting process including HPDC process. 
     
     
         4 . The apparatus of  claim 1 , wherein the small-amplitude vibrator is an acoustic vibrator with a frequency in the range of 500 to 500,000 Hz and power of 100 watts to 60,000 watts. 
     
     
         5 . The apparatus of  claim 1 , wherein the chill is made of a material having high thermal conductivity and thermal capacity for effective cooling the liquid metal. 
     
     
         6 . The apparatus of  claim 1 , wherein the chill consists of a plurality of metallic sonotrode. 
     
     
         7 . The apparatus of  claim 1 , wherein the chill consists of a plurality of metallic sonotrode containing at least one sonotrode surrounded by a block of metal chill. 
     
     
         8 . The apparatus of  claim 1 , where in the chill has a total volume and a total surface area comparable to that of the liquid alloy in said vessel or trough. 
     
     
         9 . The apparatus of  claim 1 , wherein the chill can be cooled internally or externally to enhance its cooling capability and to maintain its desired temperatures using a fluid including compressed air, water, cooling oil, ionic liquid, or liquid metallic alloy. 
     
     
         10 . The apparatus of  claim 1 , wherein the chill is made of a titanium alloy. 
     
     
         11 . The apparatus of  claim 1 , wherein the chill is made of steel or cast iron. 
     
     
         12 . The apparatus of  claim 1 , wherein the chill is made of niobium alloys.