Patent ID: 7513962

Claim:
A method for forming a semi-solid metal alloy, comprising: a. superheating a metal alloy above the liquidus temperature of the metal alloy; b. directing the superheated metal alloy into a nucleation reactor having a plurality of intersecting inner channels such that the metal alloy is directed into at least two intersecting inner channels; c. passively mixing the superheated metal alloy via fluid impingement and convection within the nucleation reactor; d. cooling the superheated alloy within the nucleation reactor to a temperature between a solidus temperature and a liquidus temperature of the alloy to form a plurality of nuclei, thereby producing a nucleated alloy; and e. passively mixing the nucleated alloy, via fluid impingement and convection in the nucleation reactor, at a temperature between the solidus temperature and the liquidus temperature of the alloy, without raising the temperature of the alloy to thereby prevent the nuclei from melting, thereby forming the semi-solid metal alloy.