Acoustic rotary liquid processor for processing semisolid materials

Abstract

An acoustic rotary liquid processor coupled with high-intensity ultrasonic vibration, rotary stirring, and melt surface stabilizing is described. The processor can be used for the preparation of slurry containing a small fraction of non-dendritic solid particles for semi-solid material processing.

What is claimed is: 
     
         1 . A method of processing a liquid material for preparation of semi-solid slurry, the method comprising:
 preparing a bath of liquid material;   preparing elongated articles including
 an elongated baffle plate and a rotary ultrasonic vibrator; and 
   submerging the elongated articles into the bath of liquid material for a predetermined duration and removing the elongated articles out of the bath after the semi-solid slurry containing a predetermined fraction of non-dendritic solid has been obtained.   
     
     
         2 . The method of  claim 1 , wherein said liquid material is a material being heated up to predetermined temperatures above its melting temperature. 
     
     
         3 . The method of  claim 1 , wherein the liquid material is an aluminum alloy at temperatures above its liquidus temperature. 
     
     
         4 . The method of  claim 1 , wherein the rotary ultrasonic vibrator rotates at a rate in a range between about 60 rounds per min. to about 2,000 rounds per min. 
     
     
         5 . The method of  claim 1 , wherein the rotary ultrasonic vibrator operates at a frequency in a range between 15,000 Hz to 400,000 Hz with the intensity of vibration high enough to generate cavitations in the liquid bath adjacent to the tip of the second end of the elongated sonotrode or the elongated sonotrode rotor. 
     
     
         6 . The method of  claim 1 , wherein said elongated sonotrode rotor is made of steel, titanium alloy, niobium alloy, or ceramic materials including sialon. 
     
     
         7 . The method of  claim 1 , wherein the elongated baffle plate is coupled to ultrasonic vibrations.