Patent Abstract:
An apparatus for molding a metal material. The apparatus includes a vessel with portions defining a passageway through the vessel. An inlet is located toward one end and a member or agitation means is located within the passageway. A plurality of heaters are located a length of the vessel. The first of the heaters is located immediately downstream of the inlet and is a low frequency induction coil heater whereby the temperature gradient through the vessel&#39;s sidewall is minimized.

Full Description:
FIELD OF THE INVENTION  
         [0001]    The present invention generally relates to metal molding and casting machines. More specifically, the invention relates to a metal molding machine adapted for quicker heat up times, faster cycle times and reduced thermal stresses in the machine.  
         BACKGROUND OF THE INVENTION  
         [0002]    This invention relates to an apparatus for molding metals into articles of manufacture. More specifically, the present invention relates to an apparatus of the above type configured to increase thermal efficiency and increase through-put while decreasing thermal gradients and the resultant stresses.  
           [0003]    Metal compositions having dendritic structures at ambient temperatures conventionally have been melted and then subjected to high pressure die casting procedures. These conventional die casting procedures are limited in that they suffer from porosity, melt loss, contamination, excessive scrap, high energy consumption, lengthy duty cycles, limited die life, and restricted die configurations. Furthermore, conventional processing promotes formation of a variety of microstructural defects, such as porosity, that require subsequent, secondary processing of the articles and also result in use of conservative engineering designs with respect to mechanical properties.  
           [0004]    Processes are known for forming these metal compositions such that their microstructures, when in the semi-solid state, consist of rounded or spherical, degenerate dendritic particles surrounded by a continuous liquid phase. This is opposed to the classical equilibrium microstructure of dendrites surrounded by a continuous liquid phase. These new structures exhibit non-Newtonian viscosity, an inverse relationship between viscosity and rate of shear, and the materials themselves are known as thixotropic materials  
           [0005]    While there are various specific techniques for forming thixotropic materials, one technique, an injection molding technique, delivers the alloy in an “as cast” state. With this technique, the feed material is fed into a reciprocating screw injection unit where it is externally heated and mechanically sheared by the action of a rotating screw. As the material is processed by the screw, it is moved forward within the barrel. The combination of partial melting and simultaneous shearing produces a slurry of the alloy containing discrete degenerate dendritic spherical particles, or in other words, a semisolid state of material and exhibiting thixotropic properties. The thixotropic slurry is delivered by the screw to an accumulation zone in the barrel which is located between the extruder nozzle and the screw tip. As the slurry is delivered into this accumulation zone, the screw is simultaneously withdrawn in a direction away from the unit&#39;s nozzle to control the amount of slurry corresponding to a shot and to limit the pressure build-up between the nozzle and the screw tip. The slurry is prevented from leaking or drooling from the nozzle tip by controlled solidification of a solid metal plug in the nozzle or by other sealing mechanisms. Once the appropriate amount of slurry for the production of the article has been accumulated in the accumulation zone, the screw is rapidly driven forward (developing sufficient pressure to force the solid metal plug, if necessary, out of the nozzle and into a receiver) thereby allowing the slurry to be injecting into the die cavity so as to form the desired solid article. Sealing the nozzle provides protection to the slurry from oxidation or the formation of oxide on the interior wall of the nozzle that would otherwise be carried into the finished, molded part. This sealing further seals the die cavity on the injection side facilitating the use of vacuum to evacuate the die cavity and further enhance the complexity and quality of parts so molded.  
           [0006]    In the above technique, generally all of the heating of the material occurs in the barrel of the machine. Material enters at one section of the barrel while at a “cold” temperature and is then advanced through a series of heating zones where the temperature of the material is rapidly and, at least initially, progressively raised. The heating elements themselves are typically resistance or ceramic band heaters. As a result, a thermal gradient exists both through the thickness of the barrel as well as along the length of the barrel. As further discussed below, the thermal gradient through the barrel thickness is undesirable.  
           [0007]    Typical barrel constructions of a molding machine for thixotropic materials have seen the barrels formed as long (up to 110 inches) and thick (outside diameters of up to 11 inches with 3 to 4 inch thick walls) monolithic cylinders. As the size and through-put capacities of these machines have increased, the length and thicknesses of the barrels have correspondingly increased. This has led to increased thermal gradients throughout the barrels and previously unforeseen and unanticipated consequences. Additionally, the primary material, wrought alloy  718  (having a limiting composition of: nickel (plus cobalt), 50.00-55.00%; chromium, 17.00-21.00%; iron, bal.; columbium (plus tantalum) 4.75-5.50%; molybdenum, 2.80-3.30%; titanium, 0.65-1.15%; aluminum, 0.20-0.80; cobalt, 1.00 max.; carbon, 0.08 max.; manganese, 0.35 max.; silicon, 0.35 max.; phosphorus, 0.015 max.; sulfur, 0.015 max.; boron, 0.006 max.; copper, 0.30 max.) used in constructing these barrels has previously been in short supply.  
           [0008]    Since the nickel content of the alloy  718  is subject to be corroded by molten magnesium, currently the most commonly used thixotropic material, more recent barrel designs included a sleeve or liner of a magnesium resistant material to prevent the magnesium from attacking the alloy  718 . Several such materials are Stellite  12  (nominally 30 Cr, 8.3W and 1.4C; Stoody-Doloro-Stellite Corp), PM 0.80 alloy (nominally 0.8C, 27.81 Cr, 4.11W and bal. Co. with 0.66N) and Nb-based alloys (such as Nb-30Ti-20W). Obviously, the coefficients of expansion of the barrel and the liner must be compatible to one another for proper working of the machine.  
           [0009]    Reviews of failed barrels has yielded information that barrels fail often as a result of the thermal stress and more particularly thermal shock in the cold section or end of the barrels. As used herein, the cold section or end of a barrel is that section or end where the material first enters into the barrel. It is in this section that the most intense thermal gradients are seen, particularly in the intermediate temperature region of the cold section, which is located downstream of the feed throat.  
           [0010]    During use of a thixotropic material molding machine as described above, the solid material feedstock, which has been seen in pellet and chip forms, is fed into the barrel while at ambient temperatures, approximately 75° F. Being long and thick, the barrels of these machines are, by their very nature, thermally inefficient for heating a material introduced therein. With the influx of “cold” feedstock, the adjacent region of the barrel is significantly cooled on its interior surface. The exterior surface of this region, however, is not substantially affected or cooled by the feedstock because the positioning of the heaters is directly thereabout. A significant thermal gradient, measured across the barrel&#39;s thickness, is resultingly induced in this region of the barrel. Likewise, a greater thermal gradient is also induced along the barrel&#39;s length. In this intermediate temperatures region of the barrel where the highest thermal gradients has been found to develop, the barrel is heated more intensely as the heaters cycle “off” less frequently.  
           [0011]    Preheating of the barrel prior to production operation has also been long, up to three (3) hours. For example, a barrel having a 0.5 inch thick shrunk fit Stellite liner in a 1.85 inch thick alloy  718  shell, after normal preheating with ceramic band heaters for twenty minutes, the barrel will obtain an external temperature of about 700° F ( 1200 ° F. is required for operation and molding of AZ91 D magnesium alloy). At that same point in time, the thermal gradient through the barrel thickness is about 400° F. The barrel cannot be heated more intensely, and therefore faster, because of the generating of greater thermal gradients and stresses which can crack the barrel. Full preheating therefore requires about three (3) hours.  
           [0012]    Prior metal processing machines have employed resistance type heaters. This heating technique generates the thermal energy within the resistance heater itself, which then must be transferred from the resistance heater to the barrel and other components of the machine. This means that the energy flow from the resistance heater to the part is maximized by a suitably large temperature differential. To accelerate this thermal transfer, one must obtain higher temperature differentials to overcome the thermal interface between the resistance heater (contact integrity) and the barrel, outer diameter through the barrel radial thickness, then into the feedstock and finally into the screw. Therefore, the energy level that is generated at the outside surface of the barrel, has to be high enough to sufficiently accelerate the energy flow to get uniform heating of the barrel, which therefore slows down the process and causes thermal fatigue of the barrel. Additionally, these resistance heaters, because of the thermal cycling they undergo, are also highly subject to thermal fatigue and frequent replacement. Another major problem is that the resistance heaters cannot couple thermal energy directly in the screw. As a result there are substantial thermal criteria in this arrangement which impact productivity and response to the thermal dynamics of handling incoming cold feedstock.  
           [0013]    Within the barrel, a screw rotates, shearing the feedstock and moving it longitudinally through the various heating zones of the barrel. This causes the feedstock&#39;s temperature to rise and equilibriate at the desired level when it reaches the hot or shot end of the barrel. At the hot end of the barrel, the processed material exhibits temperatures generally in the range of 1050°-1100° F. The maximum temperature to which the barrel is subjected is near  1300 ° F. (for magnesium processing). As the feedstock is heated and moved through the barrel, the material is converted into a semisolid state where it develops its thixotropic properties.  
           [0014]    Once a sufficient amount of material is accumulated in the hot section of the barrel and the material exhibits its thixotropic properties, the material is injected into a die cavity having a shape conforming to the shape of the desired article of manufacture. Additional feedstock is then introduced into the cold section of the barrel, lowering the temperature of the interior barrel surface, upon the ejection of the material from the barrel.  
           [0015]    As the above discussion demonstrates, the interior surface of the barrel, particularly in the intermediate temperature region of the barrel, experiences a cycling of its temperature during operation of the injection metal molding machine. This thermal gradient between the interior and exterior surfaces of the barrel is dependent on barrel design, but has been seen to be as great as  227 ° F. during production operation.  
           [0016]    Because of the significant cycling of the thermal gradient in the barrel, the barrel experiences thermal fatigue and shock. This has been found to cause cracking in the barrel and in the barrel liner in as little time as 30 hours. Once the barrel liner has become cracked, magnesium can penetrate the liner and attack the barrel. Both the cracking of the barrel and the attacking of the barrel by magnesium will contribute to the premature failure of the barrels. Molding machines can also operate in the all liquid state to inject good quality parts; but with the same needs for faster cycles and lower thermal stresses on the barrel as described above. As a variation, such machines can use a plunger rather than a screw for the injection stroke.  
           [0017]    From the above it is evident that there exists a need for an improved construction, particularly one which decreases preheating times, decreases operation cycle times and decrease thermal gradients through the barrel thickness.  
           [0018]    It is therefore a principle object of the present invention to fulfill that need by providing for an improved construction that optimizes heat transfer to and through-put of material being processed.  
           [0019]    Another object of the present invention is to provide a construction decreasing preheating time  
           [0020]    A further object of the present invention is to provide a construction that reduces thermal fatigue and shock in the barrel by reducing the thermal gradient through.  
         SUMMARY OF THE INVENTION  
         [0021]    The above and other objects are accomplished in the present invention by providing a novel construction where suitable frequency induction heaters are strategically positioned along at least a portion of the length of the barrel. As a result the machine experiences a decrease in the thermal gradient through the thickness of the barrel and a decrease in the cycle time for each successive shot. The coils of the suitable frequency induction heaters generate the optimum power density electromagnetic flux field to induce an electric current that flows within the barrel, liner, processed material and screw. This induced electric current directly heats the barrel, liner, processed material and screw by I 2 R joule) heat generation. By specifying the location, power density and frequency of these induction heaters, it has become possible to decrease the temperature gradient through the various sections of the barrel and while also directly heating the screw and the feedstock. As a result, the temperature gradient through the barrel thickness can be a low as 0° F. after preheating, before the introduction of feedstock or during the holding time between successive shots. Contrarily, resistance heaters can heat only the outer of the barrel surface and then must conduct the heat to the material being processed. The power transferred is simply determined by the wall thickness and surface temperature. With induction, the heat is generated internally to the barrel and screw and the thermal stresses substantially reduced accordingly.  
           [0022]    Induction electromagnetic heating generates an alternating flux field which induces an electric current to flow within the operational components of the machine (barrel, screw, and even feedstock). This current generates internal heat within these components based on the induced levels of current (power density) and the inherent electrical resistivity of the particular component. The thermal profile can be adjusted based on power density and frequency and can be programmed to provide the optimum thermal gradient to enhance productivity and process quality.  
           [0023]    According to the present invention, the induction coils or heaters are appropriately spaced along the length of the barrel to create the desired temperature gradient along the length of the barrel for optimum melting. The present machine was designed to have a higher power density near the cold end of the machine (the feedstock inlet of the machine) to directly heat and bring the material up to temperature as rapidly as possible. In other words, the material can be heated without requiring conductive heat transfer from the heater itself and through another body or material. The heat input is then profiled along the barrel length to provide the proper power distribution to continue to add energy to the material as it is fed and moved through the barrel. In this manner it is possible to prevent liquid metal from returning to the feed throat through which the feedstock is introduced into the barrel. By limiting liquid metal at the feed throat, the present invention prevents the freezing of such liquid metal, and therefore plugging of the feed throat upon the introduction of feedstock into the barrel. Furthermore, the screw and feedstock itself can be preferentially heated to melt any solid metal plugs, should they form.  
           [0024]    The present invention requires the use of suitable low frequency induction heaters. As used herein and based on existing component geometries (barrel, screw, feedstock), the term low frequency induction heaters denotes induction heaters operating at less than 1000 Hz. One preferred frequency range is greater than 0 to 400 Hz. In one construction, the preferred frequency was about 60 Hz. The precise frequency will be dependant upon the specific component criteria and material properties of the machine within which it is employed.  
           [0025]    By way of a comparative example, a 245 ton injection metal molding machine, manufactured by Japan Steel Works, with conventional ceramic band heaters on a barrel having a 0.5 inch shrunk fit Stellite liner in a 1.85 inch alloy  718  shell, in processing magnesium alloy AZ91D required 32 to 47 seconds to mold a standard 4 bar tensile molding weighing 326 grams.  
           [0026]    A machine according to the principles of the present invention, provided with suitable induction heating coils in zones  1  and  2  of the barrel length, enabled the production of the 4 bar tensile molding on a 16 to 20 second cycle time (a 56% decrease). This production cycle was maintained for several hours without incident. The machine ran quieter and screw retraction was smoother and quicker requiring only 5 seconds (versus 11 seconds for the 245 ton JSW machine having ceramic heaters). In addition, and as seen in the attached tables, the microstructure of the 4 bar tensile molding was refined by this invention, making for more thixotrophy and fluidity and therefore better mold filling. The α-solid phase was refined by the vigorous and fast action afforded by the influence of the low frequency heating and the resultant hot screw. As seen in the table, there is a reduction in the area, perimeter, width and height of the α-solid phase. The decrease in size and increase in roundness improved the fluidity mentioned above since fluidity is inversely proportional to the diameter times the surface area of α.  
           [0027]    As utilized above, induction heaters were placed along the initial length of the barrel. Two power sources were utilized for the inductors and both were 60 Hz160 KVA.  
           [0028]    With utilization of the present invention, one preferred construction of the barrel (and liner) employs non-magnetic materials. The utilization of non-magnetic materials allows for deeper penetration by the inductive heater. It has additionally been found that the position of the screw is critical during the preheating stage. Preferably the screw is retracted during heat up, prior to feeding of the feedstock for operation, to prevent overheating of the first feedstock at the feed throat. The screw can be moved forward to enable melting of any plugs that may occur during operation. This concept substantially reduces, and possibly eliminates, thermal fatigue problems of both the barrel and the other operational components. The inductor coil design and electromagnetic coupling techniques, as well as axial position, can program the desired thermal profiles to optimize the process quality as well as the productivity objectives. The present invention can therefore provide more accurate process control and faster response time since the thermal energy is generated directly within the mechanical hardware itself.  
           [0029]    Additional benefits, advantages and objects of the present invention will become more readily apparent to those skilled in the technology from a reading of the following description and claims and from a review of the drawings appended hereto.  
         BRIEF DECRIPTION OF THE DRAWINGS  
         [0030]    [0030]FIG. 1 is a diagrammatic illustration of a semisolid metal injection molding machine according to the present invention.  
           [0031]    [0031]FIG. 2A is a temperature profile table and graph for the initial two zones of a barrel and screw (no molding alloy present) heated according to the principles of the present invention.  
           [0032]    [0032]FIG. 2B is a plot of the data seen in FIG. 2A.  
           [0033]    [0033]FIGS. 3, 4 and  5  are thermal contour models for the initial two zones of a two piece barrel, according to U.S. Pat. No. 6,059,012 (hereby incorporated by reference), (of alloy  718 ) and screw (of steel  2888 ) during preheating, at full preheat and during production, respectively.  
           [0034]    [0034]FIG. 6 is a thermal contour model for the initial two zones of a two piece barrel (of steel  2888 ), according to U.S. Pat. No. 6,059,012 (hereby incorporated by reference), heated in accordance with the principles of the present invention.  
           [0035]    [0035]FIG. 7 is a chart which shows a comparative of the benefits of low frequency inductive heating over ceramic band heaters with barrel and liner stresses during preheating.  
           [0036]    [0036]FIG. 8 is a chart which shows a comparison of the benefits of low frequency inductive heating on a particle size.  
           [0037]    [0037]FIG. 9 is a diagrammatic illustration of a second embodiment of the present invention.  
           [0038]    [0038]FIG. 10 is an illustration of two induction coil heaters mounted to a barrel adjacent to the barrel inlet.  
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0039]    Referring now to the drawings, a machine or apparatus for processing a metal material into a thixotropic state or molten state and molding the material to form molded, die cast, or articles for forging according to the present invention is generally illustrated in FIG. 1 and designated at  10 . Unlike typical die casting or forging machines, the present invention is adapted to use a solid state feedstock of a metal or metal alloy (hereinafter just “alloy”). This eliminates the use of a melting furnace, in die casting processes, along with the environmental and safety limitations associated therewith. The present invention is illustrated as accepting feedstock in a chipped or pelletized form. These feedstock forms are preferred, but other forms may be used. The apparatus  10  transforms the solid state feedstock into a semisolid, thixotropic slurry or liquid which is then formed into an article of manufacture by either injection molding or die casting.  
         [0040]    The apparatus  10 , which is generally shown in FIG. 1, includes a barrel  12  coupled to a mold  17 ,  19 . As more fully discussed below, the barrel  12  includes a liner  13 , a cold section or inlet section  14 , and a hot section or shot section  15  and an outlet nozzle  30 . An inlet  18  located in the cold section  14  and an outlet  20  located in the hot section  15 . The inlet  18  is adapted to receive the alloy feedstock (shown in phantom) in a solid particulate, pelletized or chip form from a feed hopper  22 . Preferably the feedstock is provided in the chip form and is of a size within the range of 5-18 mesh.  
         [0041]    In the illustrated example, the inlet section  14  occupies approximately one half of the overall length of the barrel  12  and is constructed as a separate section. It should be noted that the inlet and shot sections  14  and  15  could be unitarily constructed and that the inlet section  14  can occupy more or less than one half of the overall barrel length. These are factors design criteria which will depend on the specifics of individual machines.  
         [0042]    One group of alloys which are suitable for use in the apparatus  10  of the present invention includes magnesium alloys. However, the present invention should not be interpreted as being so limited. It is believed that any metal or metal alloy which is capable of being processed into a thixotropic state will find utility with the present invention, in particular Al, Zn, Ti and Cu based alloys.  
         [0043]    At the bottom of the feed hopper  22 , the feedstock is discharged, either gravitationally or by other means, through an outlet  32  into a volumetric feeder  38  or other feeder. A feed auger (not shown) is located within the feeder  38  and is rotationally driven by a suitable drive mechanism  40 , such as an electric motor. Rotation of the auger within the feeder  38  advances the feedstock at a predetermined rate for delivery into the barrel  12  through a transfer conduit or feed throat  42  and the inlet  18 .  
         [0044]    Once received in the barrel  12 , induction coils  23  heat the feedstock in the initial zones, zones  1  and  2 , of the barrel  12  to a predetermined temperature (based on the material being processed) so that the material is brought into its two-phase region. By way of examples, for AZ91D, the temperature in zone  1  is typically in the range of 900-1000° F. and in zone  2  is typically in the range of 1080-1130° F. For AM60, the temperature in zone  1  is in the range of 950-1050° F. and in zone  2  is in the range of 1100-1160° F. In this two-phase region with the temperature of the feedstock in the barrel  12  between the solidus and liquidus temperatures of the alloy, the feedstock partially melts and is in an equilibrium state having both solid and liquid phases. Alternatively, and depending on the desired characteristics of the resultant article of manufacture, the material may be heated into an all liquid state.  
         [0045]    Temperature control is provided with the induction coils  23  in order to achieve this intended purpose. As illustrated, the induction coils  23  are representatively shown in FIG. 1 and consist of induction low frequency heaters, presently 60 Hz. The induction coils  23  are located along the two initial zones of the barrel  12 , at specific positions and spacings to achieve the desired heating profile of the barrel, feedstock and screw.  
         [0046]    As mentioned above, the induction coils  23  generate an alternating flux field that induces a current in the work piece that is equal and opposite to the inducing current. The current in the work piece generates joule (I 2 R) heating and the depth of heating is governed by the properties of the work piece according to the following equation:  
         delta=1.983*( rho/mu /frequency) 1/2    
         [0047]    Delta is defined as the depth (in inches) at which the current has decreased to I/e of the current at the surface and therefore the volumetric power generation is I/e 2  of the surface value. Further, delta is the depth at which the product I 2  of the fully integrated current generated in the work and R the resistance of the work piece will equal the total integrated power generation. “[R]ho” is the material resistivity in micro-ohm cm. “[M]u” is the relative permeability of the material (non magnetic materials having mu=1). Finally, frequency is in Hertz.  
         [0048]    By the proper selection of the materials, the physical dimensions and the frequency the equipment can be designed to minimize the through wall temperature gradient, and therefore, minimize the thermal stresses. Additionally, the heat generated can be optimized in the internally located member or screw. For example, the exterior wall of the barrel, may be thinner, of a material with high electrical resistivity, and non-magnetic to allow the magnetic field to pass through to the internal screw that may be manufactured of a material with magnetic properties. The barrel may be constructed of more than one material to provide the mechanical strength desired in addition to controlling the wall temperature distribution, power distribution between the wall and the screw or other results as may be desired for particular materials and machine design. In fact, the coil could be encased within the barrel wall to further reduce any temperature differential to the inner diameter if desired. Although the initial or proving equipment was optimized at 60 Hz, various frequency can be applied based upon the desired equipment configuration and desired thermal profiles. Further, the frequency can be varied during the metal processing or the heat cycle to distribute the heat as desired either preferentially to the screw or preferentially to the barrel, for example, between the preheat portion of the cycle and the production portion of the cycle, or varied depending upon the power distribution desired for various production rates or various production material melting temperature profile requirements. Also the frequency may vary between the first coil and subsequent coils to accomplish a desired heating/melting/temperature differential result. Generally, smaller equipment would have higher frequencies and larger equipment lower frequencies. For example, while a barrel with a 2 inch thick wall may provide optimum performance with a frequency of 60 Hz, a 3 inch thick wall may provide optimum performance with a frequency of 26 Hz. Additional considerations may be optimization of the barrel, screw, heated length and frequency to optimize the electromagnetic stirring within the semi-solid or molten material for improved material properties.  
         [0049]    The power system  73  for the coils, in the case of 50 or 60 Hz, may be single phase directly from the line with suitable power control, power factor correction and voltage matching components. The power source may also be an inverter that would present a balance three (or multiple) phase high power factor load to the line and produce the desired single phase secondary power at the desired frequency required for the particular application. There may be one or several inverters from one DC source. The power level is generally controlled by thermocouple feedback  74  but may be controlled from any desired feedback parameter such as from a suitable smart sensor control technique.  
         [0050]    Seen in FIG. 10 is one representative example of the location and placement of the inductive coils  23 . A 245 ton JSW machine, as outlined above, with a one-piece barrel (6.7 inch outer diameter) was provided with two inductive coils on the cold section of the barrel. The first induction coil, the coil closest to the feed throat  42 , includes eleven turns with a gap spacing of about 0.2 inches relative to one another. Generally, overlying the above first four turns are three additional larger diameter (approximately 10.8 inch O.D.) turns of equidistant spacing (gap spacing of about 0.3 inches). Total length of the first induction coil is about 5.5 inches and its location on the barrel is about 6-7 inches from the centerline of the feedthroat  42 . Additionally, a 2 inch wide plastic collar is located between the feed throat and the first induction coil. Power at a steady state to the first induction coil is generally in the range of 15-20 kW and the set temperature is generally in the range of 950-970° F.  
         [0051]    The second induction coil is approximately 10 inches in length and spaced about 3.5 inches from the first induction coil. A first set of coils includes a total of sixteen turns spaced relative to one another with a gap spacing of about 0.4 inches. Overlying the more closely spaced turns are four additional, larger diameter (approximately 10.8 inch O.D.) turns. These turns are equidistantly spaced with a gap spacing of about 0.3 inches. Downstream of the second induction coil is located another, 2 inch wide plastic collar. Power at steady state to the second induction coil is approximately 20-28 kW and the set temperature is 1130° F.  
         [0052]    In the above system, two power supplies  75  and  77  (designated in FIG. 1) were utilized. The system, however, could be energized with one or more power supplies, depending on the equipment design, the material being processed, etc.  
         [0053]    Utilizing these induction coils  23  generally seen in FIG. 10, above with AZ91D, a cycle time of 20 seconds and less has been achievable. Equipped with band heaters, the same 245 ton machine operates at a cycle time of 32 to 47 seconds. The present invention accordingly results in at least a 37% reduction in cycle time for molding a four bar tensile molding as per ASTM B 557-94.  
         [0054]    Referring now to the chart of FIG. 2A, an initial test inductor coil  23  represented in zone  1  contained six turns while a second test inductor coil  23  represented in zone  2  contains ten turns. Through the use of these test inductor coils  23 , in less than 45 minutes it is seen that the barrel  12  is heated for AZ91D, to its desired temperature of about 950° F (measurement taken at point  2  in zone  1 ) and about 1000° F (measurement taken at point  5  in zone  2 ). This temperature verses time data is graphically illustrated in FIG. 2B for points  3  through  7 , those points or locations for which target temperatures are established.  
         [0055]    The remaining length of the barrel  12  may be heated with conventional resistance or ceramic band heaters  24  or alternatively with additional induction coils  23 . Temperature control means in the form of induction coils  23 , ceramic band or other heaters  24  may also be placed about the nozzle  30  to aid in controlling its temperature and readily permit the formation of a critically sized solid plug of the alloy in the nozzle  30 . The plug prevents the drooling of the semi-solid alloy from the barrel  12  or the back flowing of air (oxygen) or other contaminant into the protective internal atmosphere (typically argon) of the apparatus  10 . Such a plug also facilitates evacuation of the mold  16  when desired, e.g. for vacuum assisted molding.  
         [0056]    The apparatus may also include a stationary platen  16  and moveable platen  11 , each having respectively attached thereto a stationary mold half  19  and a moveable mold half  17 . Mold halves include interior surfaces which combine to define a mold cavity  100  in the shape of the article being molded. Connecting the mold cavity to the nozzle  30  are a runner (which may be hot runners), gate and sprue, generally designated at  102 . Operation of the mold  16  is otherwise conventional and therefore is not being described in greater detail herein.  
         [0057]    In the present embodiment, a reciprocating screw  26  is positioned in the barrel  12  and is rotated by an appropriate drive mechanism  44 , such as an electric motor, so that vanes  28  on the screw  26  subject the alloy to shearing forces and move the alloy through the barrel  12  toward the outlet  20 . The shearing action conditions the alloy into a thixotropic slurry consisting of spherulites of rounded degenerate dendritic structures surrounded by a liquid phase. Alternatively, the alloy can be processed into an all liquid phase.  
         [0058]    During operation of the apparatus  10 , the induction coils  23  are turned on to thoroughly heat the barrel  12  and the screw  26  to the proper temperature or temperature profile along its length. Additionally, the band or resistance heaters  24  are also turned on. Generally, for forming thin section parts, a high temperature profile is desired, for forming mixed thin and thick section parts a medium temperature profile is desired and for forming thick section parts a low temperature profile is desired. Once thoroughly heated, the system controller  34  then actuates the drive mechanism  40  of the feeder  38  causing the auger within the feeder  38  to rotate. This auger conveys the feedstock from the feed hopper  22  to the feed throat  42  and into the barrel  12  through its inlet  18 . If desired, preheating of the feedstock is performed in either the feed hopper  22 , feeder  38  or feed throat  42  indicated at  74 .  
         [0059]    In the barrel  12 , the feedstock is engaged by the rotating screw  26  which is being rotated by the drive mechanism  44  that was actuated by the controller  34 . Within the bore  46  of the barrel  12 , the feedstock is conveyed and subjected to shearing by the vanes  28  on the screw  26 . As the feedstock passes through the initial zones of barrel  12 , the feedstock is directly heated by the induction coils  23  and indirectly heated by the barrel  12  and screw  26  and further heated by the shearing action to the desired temperature between its solidus and liquidus temperatures. In this temperature range, the solid state feedstock is transformed into a semisolid state comprised of the liquid phase of some of its constituents in which is disposed a solid phase of the remainder of its constituents. The rotation of the screw  26  and vanes  28  continues to induce shear into the semisolid alloy, at a rate sufficient to prevent dendritic growth with respect to the solid particles thereby creating a thixotropic slurry.  
         [0060]    The slurry is advanced through the barrel  12  until an appropriate amount of the slurry has collected in the fore section  21  (accumulation region) of the barrel  12 , beyond the tip  27  of the screw  26 . The screw rotation is interrupted by the controller  34  which then signals an actuator  36  to advance the screw  26 . A non-return valve  31  prevents the material from flowing rearward toward the inlet  18  during advancement of the screw  26 . If desired, the shot charge in the fore section  21  of the barrel  12  may be compacted at a relatively slow speed to squeeze or force excess gas, including the protective gas of the atmosphere, out of the charge of slurry. Thereafter, the velocity of the screw  26  is rapidly increased raising the pressure to a level sufficient to blow or force the plug from the nozzle  30  into a sprue cavity designed to catch it and force the alloy through a nozzle  30  associated with the outlet  20  and into the mold  16 . As the instantaneous pressure drops, the velocity increases to a programmed level, typically in the range of 40 to 120 inches/second in the case of magnesium alloys. When the screw  26  reaches the position corresponding to a full mold cavity, the pressure again begins to rise at which time the controller  34  ceases advancement of the screw  26  and begins retraction at which time it resumes rotation and processing of the next charge for molding. The controller  34  permits a wide choice of velocity profiles in which the pressure/velocity relationship can be varied by position during the shot cycle (which may be as short as 25 milliseconds or as long as 200 milliseconds).  
         [0061]    Once the screw  26  stops advancing and the mold is filled, a portion of the material located within the nozzle  30  at its tip solidifies as a solid plug. The plug seals the interior of barrel  12  and allows the mold  16  to be opened for removal of the molded article.  
         [0062]    During the molding of the next article, advancement of the screw  26  will cause the plug to be forced out of the nozzle  30  and into the sprue cavity which is designed to catch and receive the plug without interfering with the flowing of the slurry through the gate and runner system  102  into the mold cavity  100 . After molding, the plug is retained with the solidified material of the gate and runner system  102 , trimmed from the article during a subsequent step and returned to recycling.  
         [0063]    Seen in FIGS. 3, 4 and  5  are thermal contour models for the first part of a two-piece barrel (alloy  718 ). Such a two-piece barrel and screw construction is disclosed in U.S. Pat. No. 6,059,012 which is herein incorporated by reference. This first part or cold section of the barrel  12 ′ includes the first two heating zones (zones  1  and  2 ) of the barrel  12 ′. During initial preheating (FIG. 3), through use of the inductive coils  23 ′ it is possible for the screw  26 ′ to be heated before the barrel and for the screw  26 ′ at least through the vanes  28 ′, to heat the barrel  12 ′ allowing the barrel  12 ′ to be heated from the inside out. Initially, heat is seen as being concentrated at the center portion of the screw  26 ′ within this section of the barrel  12 ′ and as being conducted through the vanes  28 ′ to the center portion of this part of the barrel  12 ′.  
         [0064]    At full preheat, FIG. 4, heat is concentrated, or spread over a greater axial length, internally of the barrel  12 ′. This provides a greater amount of the heat for actual use in heating the feedstock instead of heating the barrel  12 ′ itself. Additionally, there is no temperature gradient through the barrel.  
         [0065]    During production, the introduced feedstock extracts a significant amount of heat from the screw  26 ′ since the feedstock circumferentially surrounds the screw  26 ′. The barrel  12 ′ temperature remains steady without the large thermal gradients through sections of the barrel  12 ′ thickness as previously occurred. Additionally, as the feedstock moves longitudinally within the barrel  12 ′ and the barrel  12 ′ becomes heated, the thermal profile of the barrel  12 ′ exhibits a greater temperature progressing toward the hot end or section of the barrel  12 ′. A significant amount of heat remains available in the barrel  12 ′.  
         [0066]    If the material of the barrel  12 ′ is changed from the superalloy to steel  2888 , it is noted that a increased temperature gradient develops in the barrel  12 ′ during production operation. This is presented in FIG. 6.  
         [0067]    The chart of FIG. 7 shows a comparative of the benefits of low frequency inductive heating over ceramic band heaters with barrel and liner stresses during preheating. Similarly, the chart of FIG. 8 shows a comparison of the benefits of low frequency inductive heating on a particle size.  
         [0068]    In another embodiment seen in FIG. 9, the apparatus  100  is a two stage machine having a first stage  102 , where the alloy is initially processed and a second stage  104 , where the processed alloy is caused to be forced into a mold. Since various components of the apparatus  100  of the second embodiment are the same as those in the prior embodiment, only the first and second stages  102 ,  104  need be and are illustrated in FIG. 9.  
         [0069]    The first stage  102  generally include the barrel  106  within which is located a screw  108  is rotated by an appropriate drive mechanism so as to impart shear to the feedstock received into the barrel  102  through the inlet  110 . Located along the length of the barrel  106  are a series of inductive coils  112 . As discussed in connection with the prior embodiment, the inductive coils  112  induce heating of the barrel  106 , screw  108  and the feedstock. The action of the sheering and the imparting of heat to the feedstock results in the feedstock being processed into a molten or semisolid state, or alternatively, a full liquid state. Continued rotation of the screw  108 , longitudinally moves the material through the barrel  106  away from the inlet  110 .  
         [0070]    The processed material is transferred from the first stage  102  through a transfer coupling  114  to the second stage  104 . The transfer coupling  114  includes a passageway defined therethrough which may be lined by a liner  116  and which terminates at a valve  118 . Additionally, resistance or ceramic band heaters  120  are placed about the length of the transfer coupling  114 .  
         [0071]    While illustrated in FIG. 9 as having a parallel barrel  106  and shot sleeve  112  arrangement, it is noted that orientation of the barrel  106  may be non-parallel to the shot sleeve  112 . Additionally, the feedstock may be gravitationally fed through the barrel  106  and may be sheared by mechanisms other than a screw  108 , such as by paddles, a tortuous path or a non-contact electro-magnetic method or other method.  
         [0072]    The second stage  104  includes a second barrel or shot sleeve  112  (which may also be lined) within which is disposed a piston or plunger  124 . This second stage  104  may further, but not necessarily, include additional heaters  120  to provide heat input so as to maintain the processed material at the appropriate temperature once it has been received into the passageway  126  of the shot sleeve  122 . Upon the appropriate amount of material being received into the passageway  126  of the second stage  104 , an actuation mechanism  128  coupled to the plunger  124  is advanced. Upon advancement of the plunger  124 , the material is forced out of the shot sleeve  122 , the valve  118  preventing back flow up through the transfer coupling  114 , through a nozzle  130  and into the mold assembly (not shown).  
         [0073]    In substantially all other respects the apparatus  100  of the second embodiment operates in the same manner and fashion as the apparatus  10  of the first embodiment. For this reason, further discussion regarding the operation of this second embodiment need not be presented herein.  
         [0074]    While described with particular reference to a reciprocating screw style of semisolid metal injection molding machine, it is readily understood that the present invention will have application to other styles of metal molding machines, including two-stage (barrel and shot sleeve) semisolid metal injection molding machines and even to machines for molding or casting materials in non-thixotropic states.

Technology Classification (CPC): 8