MXPA99003086A - Apparatus and method for integrated semi-solid material production and casting - Google Patents

Abstract

An apparatus and process are provided for producing semi-solid material and directly casting the semi-solid material into a component wherein the semi-solid material is formed from a molten material and the molten material is introduced into a container. Semi-solid is produced therefrom by agitating, shearing, and thermally controlling the molten material. The semi-solid material is maintained in a substantially isothermal state within the container by appropriate thermal control and thorough three-dimensional mixing. Extending from the container is a means for removing the semi-solid material from the container, including a temperature control mechanism to control the temperature of the semi-solid material within the removing means.

Description

APPARATUS AND METHOD FOR THE PRODUCTION AND LAYING OF INTEGRATED SEMI-SOLID MATERIAL This application is claimed for the benefit of the co-pending provisional application "Apparatus and Method for Integrated Semi-Solid Material Production and Casting", filed on October 4, 1996 (proxy number 0097701-0006, Express Mail No. EH408038515US, serial number not yet known). A related application entitled "Apparatus and Method for Semi-Solid Material Production", filed on October 4, 1996 (proxy number 0097701-0005, Express Mail No. EH408038921, series number not yet known) and is incorporated herein by reference.

TECHNICAL FIELD The present invention relates generally to the production and supply of a slurry of semi-solid material for use in material-forming processes. In particular, the invention relates to an apparatus for producing a slurry of substantially non-dendritic semi-solid material and providing the semi-solid directly to a die casting apparatus.

BACKGROUND OF THE INVENTION Slurry casting is a process in which a molten material is subjected to vigorous agitation as it undergoes solidification. During normal solidification processes (ie, not reocolated), dendritic structures are formed within the solidifying material. In geometrical terms, a dendritic structure is a solidified particle in the shape of an elongated rod type that has transverse branches. Vigorous agitation of materials, especially metals, during solidification eliminates at least some of the dendritic structures. Said agitation cuts the tips of the solidified dendritic structures, thus reducing the dendrite formation. The resultant material slurry is a solid-liquid composition, composed of relatively fine, non-dendritic solid particles in a liquid matrix (hereinafter referred to as a semi-solid material). In the molding step, it is well known that the components made of the semi-solid material have great advantages over conventional melt-forming processes. These benefits derive, in large part, from reduced thermal requirements for the handling of solid material. A material in a semi-solid state is at a lower temperature than the same material in a liquid state. In addition, the heat content of the material in the semi-solid form is much lower. In this way, less energy is required, less heat needs to be removed, and coaming equipment or molds are used to form semi-solid components that have a longer life.

In addition, and perhaps very importantly, the casting equipment can process more material in a given amount of time since the cooling cycle is reduced. Other benefits of the use of semi-solid materials include more uniform cooling, a more homogeneous composition, fewer voids and porosities in the resulting component. The prior art contains many methods and apparatus used in the formation of semi-solid materials. For example, there are two basic methods for effecting vigorous agitation. One method is mechanical agitation. This method is illustrated in the patent of E.U.A. 3,951,651 to Mehrabian et al., Which discloses rotating blades within a rotating crucible. The second method of agitation is achieved with electromagnetic agitation. An example of this method is described in the patent of E.U.A. No. 4,229,210 to Winter et al., Which is incorporated herein by reference. Winter and others describe using either AC induction or pulsed DC magnetic fields to produce the indirect agitation of the semi-solid. However, once the semi-solid material is formed, virtually all of the methods of the prior art then include a solidification and reheating step. This so-called double processing causes the solidification of the semi-solid material to an ingot. One of many examples of double processing is described in the U.S. patent. 4, 771,818 to Kenney. The solid ingot resulting from the double processing is easily stored or transported for further processing. After solidification, the ingot must be reheated so that the material returns to obtain the semi-solid properties and advantages discussed above. The reheated ingot is then subjected to manipulation such as casting or die casting to form a component. In addition, to modify the material properties of the semi-solid, double processing requires additional steps of cooling and reheating. For reasons of efficiency and material handling costs, it may be absolutely desirable to eliminate the solidification and reheating step that dual processing demands. The patent of E.U.A. No. 3,902,544 to Flemings et al., Incorporated herein by reference, describes a semi-solid formation process integrated with a co-process. This process does not include a solidification step in double processing. However, there are numerous difficulties with the process described by Flemings and others. First and most importantly, Flemings and others require multiple zones including a melting zone and a stirring zone, which are integrally connected and require extremely accurate temperature control. In addition, in order to produce the semi-solid material, there is a flow of material through the integrally connected zones. The semi-solid material is produced through a combination of material flow and temperature gradient in the zone of agitation. In this way, the calibration of the required temperature gradient with the (possibly and variably) flowing material is exceedingly difficult. Second, the process of Flemings et al. Describes a means of individual agitation. Exact and complete agitation is necessary to maximize the semi-solid characteristics described above. Third, the process of Flemings et al. Lacks effective transfer means and regulation of flow from the agitation zone to a casting apparatus. The additional difficulties with the Flemings process and the improvements on these will be evident from the following detailed description. A principal object of the present invention is to provide an apparatus and process for integrating the formation of semi-solid material with the casting of the semi-solid material, while avoiding a step of solidification and reheating. A further object of the present invention is to provide a more efficient and cost effective die casting process for use with the formation of semi-solid material. Another object of the present invention is to provide the formation of semi-solid material suitable for direct straining to a component. A further object of the present invention is to provide a formation of semi-solid material with improved agitation. Still another object of the present invention is to provide an apparatus for forming semi-solid material integrated with a casting device for casting the semi-solid material directly to a component.

COMPENDIUM OF THE INVENTION The present invention provides a method and an apparatus for producing a component directly from a semi-solid material comprising a source of molten material, a container for receiving the molten material, thermal control means mounted to the container for controlling the temperature of the container, a means of agitation for stirring the material, and a casting device directly connected to the container. The agitation means and the thermal control means act together to produce a substantially isotropic semi-solid material in the container. A thermally insulated medium for removing the semi-solid material from the container directly provides the semi-solid material to the casting device, which casts the semi-solid material to a component.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a schematic front section view of a semi-solid production apparatus according to the present invention. Figure 2 is a schematic side sectional view of the apparatus of Figure 1.

Figure 3 is a side sectional view of removal means according to the present invention. Figure 4 is a schematic sectional view of the apparatus of Figure 1 integrated with a semi-solid coining apparatus according to the present invention. Figure 5 is a schematic side sectional view of the apparatus of Figure 1 showing an alternative embodiment of the present invention. Figure 6 is a schematic side sectional view of the apparatus of Figure 1 showing an alternative embodiment of the present invention.

DESCRIPTION OF THE PREFERRED MODALITIES In Figure 1, there is shown an apparatus for producing semi-solid material generally with the reference number 10. Separated from the apparatus 10 is a source of molten material 11, generally any material that can be processed to a solid material 50 is suitable for use with this apparatus 10. The molten material 11 can be a pure metal such as aluminum or magnesium, a metal alloy such as an alloy of steel or aluminum A356, or a mixture of metal-ceramic particles such as aluminum and Silicium carbide. The apparatus 10 includes a cylindrical chamber 12, a primary rotor 14, a secondary rotor 16 and a chamber cover 18. The chamber 12 has an internal bottom wall 20 and a cylindrical internal side wall 22, which are preferably made of a material refractory. The chamber 12 has an outer support layer 24 preferably made of steel. The upper part of the chamber 12 is covered by a chamber cover 18. The chamber cover 18 similarly has an insulated refractory layer. The thermal control system 30 comprises heating segments 32 and heating segments 34. The heating and cooling segments 32, 34 are mounted to, or embedded within, the outer layer 24 of the chamber 12. The heating and cooling segments 32, 34 can be oriented in many ways, but as shown, the heating and cooling segments 32, 34 are interleaved around the circumference of the chamber 12. The heating and cooling segments 32, 34 are also mounted to the cover of chamber 18. Individual heating and cooling segments 32, 34 can independently add and / or remove heat, thereby improving the temperature control capability of the contents of chamber 12. Primary rotor 14 has a rotor end 42 and an arrow 44, which extends upwardly from the rotor end 42. The primary rotor shaft 44 extends through the chamber lid 18. The rotor end 42 is immersed in and completely surrounded by the chamber 12. As shown in Figure 1. the rotor end 42 has L-shaped blades 43, preferably two of these blades are 180 degrees apart, extending from the bottom of the rotor end 42. The L-shaped blades 43 have two portions, one of which is parallel to the inner side wall 22 and the other being parallel to the inner bottom wall 20. The blades 43 with L shape, when they rotate, they cut dendrites that tend to form on the inner side wall 42 and the lower wall 20 of the chamber 12. Furthermore, the rotation of the blades 43 promotes the mixing of the material within the horizontal planes. Other geometries of the blades 43 (eg, T-shaped) should be effective as long as the gap between the inner side wall 22 of the chamber and the blades 43 is small. It is desirable that this gap be smaller than 5.08 cm. In addition, to promote further cutting, the gap between the lower chamber portion 20 and the blades 43 must also be less than 5.08 cm. A typical rotation speed of the cutting rotor 14 is about 30 rpm. The secondary rotor 16 has a rotor end 48 and an arrow 46 extending from the rotor end 48. The shape of the rotor end 48 must be designed to promote vertical mixing of the semi-solid material 50 and improve cutting of the semi material -solid 50. The rotor end 48 preferably has the shape of an auger or screw shape, but many other shapes, such as blades inclined relative to the horizontal plane, will also work in a similar manner. The arrow 46 extends upwardly from the bit-shaped rotor end 48. Depending on the rotational direction of the secondary rotor 16, the material in the chamber 12 is forced to move either in an upward or downward direction. A typical rotation speed of the secondary rotor 16 is 300 rpm. The primary rotor 14 and the secondary rotor 16 are oriented relative to the chamber 12 and one another in order to improve both cutting and three-dimensional agitation of the semi-solid material 50. In Figure 1, it is seen that the rotor primary 14 rotates around the secondary rotor 16. The secondary rotor 16 rotates within a predominantly horizontal mixing action of the primary rotor 14. This configuration promotes complete three-dimensional mixing of the semi-solid material 50. Although Figure 1 illustrates a plurality of rotors , an individual rotor can be used that provides the proper cutting and mixing properties. Said single rotor should offer both cutting and mixing, the mixing being three dimensional so that the semi-solid material 50 in the container 12 can be maintained at a substantially uniform temperature. The environment of the semi-solid material in which the rotors 14, 16 are submerged, is quite hard. The rotors 14, 16 are exposed to a very high temperature, usually corrosive conditions, and considerable physical force. By converting these conditions, the preferred composition of the rotors 14, 16 is a corrosion and heat resistant alloy of stainless steel type with a high temperature MgZr03 ceramic coating.

Other materials resistant to high temperatures are also suitable, such as an over-coating coated with AI2O3. A frame 56 is mounted to the chamber lid 18. The frame 56 supports a primary drive motor 58 and a secondary drive motor 60. The respective motors 58, 60 are mechanically coupled to the arrows 44, 46 of the respective rotors. , 16. As shown in Figure 1, the primary motor 58 is coupled to the primary rotor shaft 44 through a pair of reduction gears 62 and 64. The primary bull shaft 44 is supported in the frame 56 a Through bearing shells 56. Similarly, the secondary rotor shaft 46 is supported on the frame 56 through a bearing bushing 68. Both motors 58, 60 can be connected to the rotors via reduction or step gear for improve the transmission of energy and / or torque. An alternative to the mechanical agitation described above is electromagnetic agitation. An example of electromagnetic stirring is found in the U.S.A. No. 4,229,210 to Winter et al. Electromagnetic agitation can effect the three-dimensional, isotropic, desired cutting and mixing properties desired in the present invention. The molten material 11 can be supplied to the chamber 12 in a number of different ways. In one embodiment, the molten material 11 is supplied through a hole 70 in the chamber cover 18. Alternatively, the molten material 11 can be supplied through a hole in the side wall 22 (not shown) and / or through of a hole in the bottom wall 20. The semi-solid material 50 is formed from the molten material 11 after agitation through the primary rotor 14 and the secondary rotor 16, and proper cooling of the thermal control system 30. After an initial start cycle, the process is semi-continuous, whereby a semi-solid material 50 is removed from the chamber 12, and the molten material 11 is added. However, the rotors 14, 16 and the thermal control system 30 they keep the semi-solid material 50 in a substantially isothermal state. In addition to controlling the temperature of the chamber 12 thus maintaining the semi-solid material 50 in a substantially isotropic state, the thermal control system 30 is also instrumental in starting and stopping the apparatus 10. During the start, the thermal control system the chamber 12 and its contents must be brought to the appropriate temperature to receive the molten material 11. The chamber 12 may have a large amount of solidified semi-solid material or solidified material (previously melted) remaining from the previous operation. The thermal control system 30 must be capable of supplying sufficient energy to remelter the solidified material. Similarly, when the apparatus 10 is stopped, it may be desirable for the thermal control system 30 to heat the semi-solid material 50 in order to completely drain the chamber 12. Another stopping procedure may cause careful cooling of the semi-solid material. 50 in the solid state. As shown in Figure 2, the removal of the semi-solid material 50 formed in the chamber 12 is preferably done through a removal tube 72. A detailed view of the removal tube 72 is shown in Figure 3. The tube 72 has a cylindrical inner wall 74, which is in contact with the removed semi-solid material 50. The inner wall 74 is preferably a refractory material. A support wall 76 is sandwiched between the inner wall 74 and the outer wall 78. The support wall 76 is made of a material such as cast iron, capable of supporting the inner wall 74 and the semi-solid material 50 contained in the same The outer layer 78 provides the insulation of the removal tube 72 and the semi-solid material 50. The removal tube 72 also protects the semi-solid material 50 from being contaminated by the ambient atmosphere. Without such protection, an oxide could be formed on the outside of the semi-solid material and interspersed with any of the components made from it. Provided around the removal tube is a heater 80 to keep the semi-solid material 50 at the desired temperature. In Figure 2, the removal port 72 extends from the apparatus 10 through the chamber cover 18. The one alternative preferred embodiment, the removal port 72 extends from the side wall of chamber 22, which has a outlet port 112 as shown in Figure 5. Alternatively, Figure 5 also shows a removal port 73 extending from the lower wall 20, which has an exit hole 113. In any case, as described above, the The removal port includes a heater 80 for maintaining the isotropic state of the semi-solid material 50 that is to be removed. The flow of semi-solid material 50 through port 72 can be achieved through any number of methods. A vacuum can be applied to the removal port 72, thus sucking the semi-solid material out of the chamber 12. Gravity can be used as illustrated in Figure 5 on port 73. Other transfer methods using media Mechanicals, such as submerged pistons, helical rotors or other positive displacement actuators, which produce a controlled rate of transfer of the semi-solid material 50, are also effective. To further regulate the flow of the semi-solid material 50 out of the chamber 12 through any of the removal ports described above, a valve 83 is provided on the port 72. The valve 83 can be a single-compound or other valve liquid flow regulation device. It may be desirable to heat the valve 83 so that the semi-solid material 50 is maintained at the desired temperature and plugging is prevented. The regulation of the flow can also be crudely effected through local solidification. Instead of a valve 83, a heater / cooler (not shown) can locally solidify the semi-solid material 50 in port 72 thus stopping the flow. Subsequently, the heater / cooler can reheat the material to resume the flow. This procedure could normally be part of a start or stop cycle, and is not necessarily part of the isothermal semi-solid material process described above. Another way to transfer the semi-solid material 50, which provides the inherent flow control, uses a bucket 114 as illustrated in Figure 6. Bucket 114 removes e! semi-solid material 50 of the chamber 12, while a heater 82, which is mounted to the bucket 114, maintains the temperature of the semi-solid material 50 that is being removed. A bucket cup 115 of the bucket 114 is attached to a bucket driver 115. The cup 115 can rotate to empty its contents, and the actuator 116 moves the bucket in the horizontal and vertical directions. To help maintain the appropriate temperature conditions within the chamber 12, the transfer of semi-solid material 50 can occur in successive cycles. During each cycle, the flow regulation described above allows a described amount of semi-solid material 50 to be removed. The amount of semi-solid material removed during each cycle should be small relative to the material remaining in chamber 12. In this way, the change in thermal mass within chamber 12 during the removal cycles is small. In a typical cycle, less than 10% of the semi-solid material 50 is removed within the chamber. Turning now to Figure 4, a die colander 84 is directly attached to the removal tube 72 extending from the apparatus 10. The die colander 84 includes a ram 86, a trigger sleeve 88 and a die 90. The removal tube 72 supplies the semi-solid material 50 directly to the firing sleeve 88 through an opening in the firing sleeve 92. The firing sleeve 88 has two open ends 94., 96. The firing sleeve is positioned between, the open ends 94, 96 facing the die 90 and the ram 86. The ram 86 is connected to a piston 98, which is pneumatically driven by a pneumatic impeller 100. When driven , the ram 86 forces the semi-solid material 50 to the die 90. The semi-solid material 50 enters the die chamber 102 through a die chamber inlet 104 within the die 90. The die 90 includes two halves 106, 108, which are separated to expose a die cast component 110, which is removed after cooling. The casting device 84 can be any suitable device for forming a component from the semi-solid material 50. Suitable casting devices include a mold, a die die assembly as described in US Patent Specification. 5,187,719, or other commonly known die casting mechanisms. The die colander 84 is not limited to a vertical configuration relative to the apparatus 10 as shown in Figure 4. The die colander can be positioned relative to the apparatus 10 in any number of orientations. For example, the die colander 84 may be below the apparatus 10, so that gravity aids the transfer of the semi-solid material 50 through the transfer tube 72 (not shown). Or instead of a vertical orientation, the die colander 84 can lie horizontally relative to the apparatus 10 (not shown). In Figures 2 and 4, the removal tube 72 extends from the apparatus 10 through the chamber cover 18. In an alternative preferred embodiment, the removal tube 72 extends from the side wall of chamber 22, which it has an exit port 112 as shown in Figure 5. Alternatively, Figure 5 also shows a removal tube 73 extending from the lower layer 20, which has an exit port 113. In any case, as described above , the removal tube 72 is directly connected to the die casting device 84. In another preferred embodiment, the chamber side wall 22 is directly adjacent to the die casting device 84 (not shown) eliminating the need for the tube transfer 72. The output port 112 directly feeds the firing sleeve 88 with the semi-solid material 50. The component 110 is formed as described above. Although not required, it may be desirable to keep the entire apparatus 10 in a controlled environment (not shown). Oxides are easily formed on the outer layers of molten materials and semi-solid materials. Pollutants other than oxides can also enter molten material and semi-solid material. In an inert environment, such as one of nitrogen or argon, the formation of oxide could be reduced or eliminated. The inert environment can also result in some contaminants in the semi-solid material. However, it may be more economical to limit the controlled environment to discrete portions of the apparatus 10 such as the supply of molten material 11 to the chamber 12. Another discrete and economical portion for environmental control may be the removal port 72 (or the bucket). 114). In the removal port 72, the semi-solid material 50 no longer undergoes agitation and the material will soon be cast to a component. In this way, any oxide layer that is formed in this stage will not be dispersed through the material by mixing in the container 12. Rather, the oxides will be concentrated on the outer layers of the semi-solid material. Therefore, to reduce both oxide formation and to reduce high concentration oxide cavities, a controlled nitrogen environment (or other suitable and economical environment) at the removal port 72 stage could be advantageous. The following is an example of the process of the apparatus described above after completing the start cycle. The molten aluminum at a temperature of about 677 ° C is emptied into the chamber 12 which already contains a large amount of semi-solid material. The primary rotor 14 rotates at about 30 rpm and shakes and cuts the aluminum in a direction corresponding to the clockwise The secondary rotor 16 rotates at approximately 300 rpm and forces the aluminum upwards and / or downwards, while also cutting the aluminum The combined effect of the two rotors 14, 16 conscientiously shakes and cuts the aluminum in three dimensions The thermal control system 30 maintains the temperature of the aluminum at approximately 600 ° C, so that dendritic structures are formed The rotors 14, 16 cut the dendritic structures as they are formed. Since the thermal control system maintains the temperature of the semi-solid aluminum at approximately 600 ° C, the rotors 14, 16 continuously mix the semi-solid aluminum maintaining the temperature Within the substantially uniform material The solid particle size produced by this particular process is typically in the range of 50 to 200 microns and the percentage by volume of solids suspended in the semi-solid aluminum is approximately 20%. The semi-solid aluminum is transferred from chamber 12 to firing sleeve 88 of die die 84 through transfer tube 72 The removal port heater 80 also maintains the semi-solid aluminum at approximately 600 ° C. The ram 86 in the strainer 84 is driven through the pneumatic impeller 100 and the semi-solid aluminum is forced into the die 90 and the component 110. When component 110 and die 90 are cooled to approximately 400 ° C, the component is removed. Although what are considered to be the preferred embodiments of the invention have been described herein, other modifications thereof will be apparent to those skilled in the art from the teaching herein. Therefore, it is desired to ensure in the appended claims that all these modifications fall within the true spirit and scope of the invention. Accordingly, what is desired to be ensured by the granted United States patent is the invention as defined and differentiated in the following claims.

Claims (30)

1. - An apparatus for directly producing a component from a semi-solid material, comprising: a source of semi-solid material; a container for receiving the molten material; a thermal control means for controlling the temperature of the container; a stirring means for stirring the material within the container by acting together with the thermal control means to produce a substantially isotropic semi-solid material; means for removing a portion of the semi-solid material from the container, said means for removing being thermally controlled; and casting means directly connected to the removal means for receiving the portion of the semi-solid material from the removal means and casting the semi-solid material to a component.

2. The apparatus according to claim 1, wherein the agitation means is an electromagnetic agitation device.

3. The apparatus according to claim 1, wherein the agitation means comprises a mechanical agitation device immersed in the semi-solid material.

4. The apparatus according to claim 3, wherein the mechanical agitation device comprises a primary agitation component and a secondary agitation component.

5. The apparatus according to claim 4, wherein the primary agitating component includes an arm having a first portion being substantially parallel to the side wall of the container.

6. The apparatus according to claim 5, wherein the arm of the primary agitating component includes a second portion that is substantially parallel to the lower wall of the container.

7. The apparatus according to claim 5, wherein the secondary agitation component is a bit-shaped component and promotes agitation of the semi-solid material along the axis of the secondary agitation component.

8. The apparatus according to claim 7, wherein the casting means comprises a die casting device.

9. The apparatus according to claim 8, wherein the mechanical agitation device is stainless steel coated with a ceramic.

10. The apparatus according to claim 1, wherein the semi-solid material comprises aluminum or an alloy thereof.

11. The apparatus according to claim 1, wherein the semi-solid material comprises steel or an alloy thereof. 127.

The apparatus according to claim 1, wherein the semi-solid material comprises magnesium or an alloy thereof.

13. The apparatus according to claim 1, wherein the removal means comprise a transfer tube.

14. The apparatus according to claim 13, wherein the transfer tube includes an internal insulating layer.

15. The apparatus according to claim 14, wherein the transfer tube includes a support tube that surrounds the insulating layer and an outer layer surrounding the support tube.

16. The apparatus according to claim 15, wherein the transfer tube includes a heating mechanism for maintaining the temperature of the semi-solid material passing through the transfer tube.

17. The apparatus according to claim 16, wherein the transfer tube includes flow control means for regulating a flow of semi-solid material through the transfer tube.

18. The apparatus according to claim 17, wherein the transfer flow control means regulate said flow of the semi-solid material through the transfer tube, so that no more than one-tenth of the semi-solid material is used. Solid is removed by cycle of removal.

19. The apparatus according to claim 17, wherein the transfer tube extends through a cover in the chamber

20. - The apparatus according to claim 17, wherein the transfer tube extends through a side wall in the chamber.

21. The apparatus according to claim 1, wherein the casting means includes a die, a ram, and a firing sleeve disposed therebetween, the firing sleeve for receiving the portion of the semi-solid material and the ram for forcing the portion toward the die to form said component .

22. The apparatus for directly producing a component from a semi-solid material, comprising: a source of semi-solid material; a container for receiving the semi-solid material; thermal control means for controlling the temperature of the semi-solid material; a stirring means acting with the container for stirring the semi-solid material in the container; the means of thermal control and of agitation keeping the semi-solid material in a substantially isothermal state; and a die casting device connected to the container for directly casting the semi-solid material to a component prior to solidification of said semi-solid material.

23. The apparatus according to claim 22, wherein the agitation means is an electromagnetic agitation device.

24. The apparatus according to claim 22, wherein the agitation means comprise a mechanical agitation device immersed in the semi-solid material.

25. The apparatus according to claim 24, wherein the mechanical agitation device comprises a primary agitation component and a secondary agitation component.

26. The apparatus according to claim 25, wherein the primary agitating component includes a portion that is substantially parallel to a side wall of the container.

27. The apparatus according to claim 26, wherein the secondary agitation component has a bit shape.

28. The apparatus according to claim 27, wherein the casting means comprises a die casting device.

29. - The apparatus according to claim 28, wherein the mechanical agitation device is a stainless steel coated with a ceramic.

30. A method for directly producing a component from a partially solidified material comprising: receiving a molten material in a container; forming the molten material to a semi-solid material with agitation means and thermal control means; maintaining the semi-solid material in a substantially isothermal state with the stirring means and the control means; transferring a portion of the semi-solid material directly to a casting apparatus; and pouring the portion of a semi-solid material to a component before completing the solidification of said portion.