Dispensing apparatus and method

• US 20030230835A1
• Filed: 06/13/2002
• Published: 12/18/2003
• Est. Priority Date: 06/13/2002
• Status: Active Grant

• Current Assignee: Alotech, Ltd.
• Original Assignee: Alotech, Ltd.
• Inventors: Campbell, John, Grassi, John R.
• Granted Patent: US 6,841,120 B2
• Time in Patent Office: Days
• US Class Current: 266/239
• CPC Class Codes: B22D 18/04 Low pressure casting, i.e. making use of pressures up to a few bars to fill the mould
• CPC Class Codes: B22D 39/02 having means for controlling the amount of molten metal by volume
• CPC Class Codes: C22B 21/0084 melting and handling molten aluminium C22B21/02, C22B21/04 and C22B21/06 take precedence
• CPC Class Codes: F27D 3/14 Charging or discharging liquid or molten material

Abstract

An apparatus for dispensing a molten material from a reservoir of molten material includes a dispensing chamber in communication with the reservoir and a first valve adapted to regulate communication of the dispensing chamber with the reservoir. A riser communicates with the dispensing chamber for dispensing the molten material, and a second valve is adapted to regulate communication of the riser with the dispensing chamber. Also disclosed is a method for reducing the inclusion of oxides in a casting of a molten metal.

Claims

1. An apparatus for dispensing a molten material from a reservoir of molten material, said apparatus comprising:

a dispensing chamber in communication with said reservoir;

a first valve adapted to regulate communication of said dispensing chamber with said reservoir;

a pressure variation means in communication with said dispensing chamber;

a riser communicating with said dispensing chamber for dispensing the molten material; and

a second valve adapted to regulate communication of said dispensing chamber with said riser.

2. The apparatus of claim 1, wherein the molten material can be maintained in said riser at a level above the level of the molten material in said dispensing chamber through coordinated activation of said first valve, said second valve and said pressure variation means.

3. The apparatus of claim 1, wherein said pressure variation means comprises a valve through which a vacuum may be applied or a pressurized gas may be introduced into said dispensing chamber.

4. The apparatus of claim 3, wherein said pressurized gas is an inert gas.

5. The apparatus of claim 4, wherein said inert gas is selected from the group consisting of air and carbon dioxide, admixed with up to about 5% by volume of sulfur hexafluoride or other more environmentally friendly passivating gas.

6. The apparatus of claim 1, wherein said second valve cooperates with an end of said riser to regulate communication of said dispensing chamber with said riser.

7. The apparatus of claim 1, wherein said dispensing chamber is made from a material selected from the group consisting of iron, mild steel, and ferritic stainless steel.

8. The apparatus of claim 1, wherein said dispensing chamber is made from a refractory material selected from the group consisting of clay/graphite refractory materials, clay/silicon carbide refractory materials, clay/fused silica materials, silicon carbide-based ceramics, silicon nitride-based ceramics, related ceramics such as sialon, and fused silica-based refractories that have been converted to a mixture of corundum and aluminum

9. The apparatus of claim 1, further comprising a heater located adjacent said riser for heating said riser.

10. The apparatus of claim 9, further comprising a layer of insulation material positioned radially outwardly of said heater for retarding an outflow of heat from said riser.

11. The apparatus of claim 1, wherein at least one of said first and second valves comprise a stopper-rod that cooperates with a valve seat.

12. The apparatus of claim 11, further comprising a ball of refractory material positioned between said stopper rod and said valve seat.

13. A pump for dispensing a melt from a reservoir of melt, said pump comprising:

a dispensing chamber in communication with said reservoir;

a first melt valve adapted to regulate communication of said dispensing chamber with said reservoir;

a riser communicating with said dispensing chamber for dispensing the melt;

a second melt valve cooperating with said riser to regulate communication of said riser with said dispensing chamber;

a gas reservoir; and

a gas valve for regulating a flow of gas into and out of said dispensing chamber, whereby the melt can be maintained in said riser at a level above the level of the melt in said dispensing chamber.

14. The apparatus of claim 13, further comprising a second gas valve, spaced from said first gas valve, in communication with said dispensing chamber.

15. The apparatus of claim 13, wherein said first melt valve is closable by means of a stopper-rod which cooperates with a valve seat defined on a wall of said dispensing chamber.

16. The apparatus of claim 15, wherein the said second melt valve is closable by means of stopper-rod which cooperates with a valve seat disposed on an opening of said riser.

17. The apparatus of claim 13, further comprising a ball of refractory material positioned between a rod connected to said dispensing chamber and a valve seat defined on a wall of said dispensing chamber.

18. The apparatus of claim 13, wherein said dispensing chamber is made from a refractory material selected from the group consisting of clay/graphite refractory materials, clay/silicon carbide refractory materials, clay/fused silica materials, silicon carbide-based materials, and silicon nitride-nitride-based or related ceramic materials such as sialon, particularly fused-silica-based refractories that have been converted to a mixture of corundum and aluminum.

19. The apparatus of claim 13, wherein the melt is selected from the group consisting of aluminum-based and magnesium-based alloys.

20. The apparatus of claim 13, wherein said dispensing chamber is made from a material selected from the group consisting of iron, mild steel and ferrite steel.

21. The apparatus of claim 13, wherein said riser is located externally of the dispensing chamber.

22. The apparatus of claim 13, wherein said riser is provided with an upwardly directed opening.

23. The apparatus of claim 13, wherein said second valve comprises a hemispherical stop valve supported and actuated by one or more rods and designed to engage with a conical seating at a base of the riser to form a seal when said second valve is closed.

24. The apparatus of claim 13, further comprising a heater for heating said riser.

25. An apparatus for continuously dispensing a molten material from a reservoir of molten material, said apparatus comprising:

at least two dispensing chambers in communication with said reservoir;

a first set of valves adapted to regulate communication of each of said two dispensing chambers with said reservoir, each of said dispensing chambers having at least one of said first set of valves;

at least one riser communicating with said at least two dispensing chambers for dispensing said molten material; and

a second set of valves adapted to regulate communication of said at least one riser with said at least two dispensing chambers, wherein the molten material can be maintained in said at least one riser at a level above the level of the molten material in said at least two dispensing chambers.

26. The apparatus of claim 25, wherein the molten material can be maintained in said at least one riser above the level of the molten material in said at least two dispensing chambers through coordinated activation of said first set of valves and said second set of valves.

27. The apparatus of claim 25, further comprising at least one pressure variation means communicating with at least one of said at least two dispensing chambers.

28. The apparatus of claim 25, further comprising a heater for heating said at least one riser.

29. A method for reducing the inclusion of oxides in a casting of a molten metal, comprising the steps of:

a) providing a reservoir of a molten metal, a dispensing chamber communicating with said reservoir and a riser communicating with said dispensing chamber;

b) flowing the molten metal from said reservoir into said dispensing chamber;

c) flowing the molten metal from said dispensing chamber into said riser;

d) discharging the molten metal from said riser;

e) terminating the step of discharging;

f) holding the molten metal at a predetermined level in said riser, said predetermined level being above a level of the molten metal in said dispensing chamber; and

g) heating said riser adjacent said predetermined level.

30. The method according to claim 29, wherein the step of discharging the molten metal from said dispensing chamber comprises the subsidiary step of pressurizing said dispensing chamber to a desired pressure.

31. The method according to claim 30, further comprising the step of monitoring a pressure in said dispensing chamber.

32. The method according to claim 30, wherein the step of pressurizing the dispensing chamber comprises the subsidiary step of contacting the molten metal with a pressurized gas.

33. The method according to claim 29, wherein the step of holding the molten metal at a predetermined level in said riser comprises the subsidiary step of maintaining the molten metal in said riser at a level higher than the level of the molten metal in said reservoir.

34. The method according to claim 29, further comprising the steps of:

h) flowing additional molten metal from said reservoir into said dispensing chamber; and

i) repeating steps c) through f), whereby a continuous cycle of operations of filling said dispensing chamber and discharging molten metal from said riser is conducted.

35. The method according to claim 29, further comprising the step of urging the molten metal upwards in said riser between steps c) and d).

36. A method for reducing the inclusion of oxides in a casting of molten metal, comprising the steps of:

a) providing a reservoir of a molten metal, a dispensing chamber communicating with said reservoir and a riser communicating with said dispensing chamber;

b) flowing the molten metal from said reservoir into said dispensing chamber;

c) flowing the metal from said dispensing chamber into said riser;

d) urging the molten metal upwards in said riser to an upper opening in said riser;

e) discharging the molten metal from said riser;

f.) terminating the step of discharging;

g) holding the molten metal at a predetermined level in said riser, said predetermined level being above a level of the molten metal in said dispensing chamber; and

h) heating said riser adjacent said predetermined level.

37. The method according to claim 36, wherein the step of discharging the molten metal from said riser comprises the subsidiary step of pressurizing said dispensing chamber to a desired pressure.

38. The method according to claim 37, wherein the step of pressurizing said dispensing chamber comprises the subsidiary steps of:

preventing communication of said dispensing chamber with said reservoir;

admitting a gas into said dispensing chamber above the level of the molten metal held in said dispensing chamber; and

urging the molten metal in said dispensing chamber to enter said riser.

39. The method according to claim 38, further comprising the step of monitoring a gas pressure in said dispensing chamber.

40. The method according to claim 36, further comprising the steps of:

j) flowing additional molten metal from said reservoir into said dispensing chamber; and

k) repeating steps c) through h), whereby a continuous cycle of operations of filling said dispensing chamber and discharging molten metal from said riser is conducted.

41. The method according to claim 36, wherein the step of flowing the liquid metal from said reservoir to said dispensing chamber comprises the subsidiary step of selectively communicating said dispensing chamber with said reservoir.

42. The method according to claim 36, further comprising the step of retarding a loss of heat from said riser.