Method and apparatus for preheating and distributing ingots

Abstract

A method and apparatus for preheating and distributing magnesium ingots used in magnesium die casting wherein the heating efficiency is improved thus reducing the energy required to heat the ingots to a temperature varying between 150° C.-350° C. prior to charging into a molten magnesium bath. A housing comprising a ceiling, a floor, side walls extending from the floor to the ceiling for defining a chamber which is divided into at least a storage area and a heating area, and means for moving the ingots from one side to another as well as out to the molten magnesium bath are provided. The apparatus of the invention is adapted to be securely positioned directly atop of a melting furnace whereby the heat generated by said furnace is used to preheat the ingots located within the apparatus prior to charging.

Description

FIELD OF THE INVENTION [0001] The present invention relates generally to the magnesium die casting industry and, more specifically, to methods and apparatus for ultimately improving the overall energy-efficiency of the magnesium die casting process. BACKGROUND OF THE INVENTION [0002] Generally, transferring semiliquid die casting technology to mass production present more than a few difficulties. Most importantly, there is the difficulty in ensuring that the die casting machinery has a continuous supply of ingots within a suitable temperature range. Such a continuous supply within the suitable temperature range is necessary in order to prevent problems linked to the quality of the die casting. Temperatures and minimum temperature variations are critical as well as other process variable parameters such as metal level in the molten bath and consistent metal pour to meet the unique properties of a magnesium melt operation. [0003] Traditionally, furnaces for melting ingots tend to be e...

AI Technical Summary

Benefits of technology

[0006] It is a first object of the present invention to provide a safe and energy efficient method and apparatus for preheating and charging ingots into a molten bath.

[0009] It is an object of the present invention to provide a method for maintaining the metal bath within a pre-determined volume level and selected temperature preferably within a range of + / −8° C. in order to ensure a consistent quality in the metal.

Problems solved by technology

Generally, transferring semiliquid die casting technology to mass production present more than a few difficulties.

Most importantly, there is the difficulty in ensuring that the die casting machinery has a continuous supply of ingots within a suitable temperature range.

Traditionally, furnaces for melting ingots tend to be extremely inefficient especially when the furnace is designed to handle ingots of various sizes.

As a result, excessive heat up energy is required to bring the ingots to the needed homogenizing temperature thus decreasing the overall performance of the furnace.

Not only are furnaces inefficient in their use of energy but they also generate high levels of radiant energy which goes to waste.

This method, and other similar ones, does not allow for heat control and provides no method for the determination of the ingot temperature.

Furthermore, the operator is placed in a situation of close contact with the molten bath which is unsafe and unhealthy because, amongst other things, of exposure to the gases being released from the furnace.

Also, it is extremely dangerous since requirements that an ingot never be introduced into a molten metal bath until it is above 150° C. is not being followed.

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