Various embodiments provide apparatus and methods for melting materials and for containing the molten materials within melt zone during melting. Exemplary apparatus may include a vessel configured to receive a material for melting therein; a load induction coil positioned adjacent to the vessel to melt the material therein; and a containment induction coil positioned in line with the load induction coil. The material in the vessel can be heated by operating the load induction coil at a first RF frequency to form a molten material. The containment induction coil can be operated at a second RF frequency to contain the molten material within the load induction coil. Once the desired temperature is achieved and maintained for the molten material, operation of the containment induction coil can be stopped and the molten material can be ejected from the vessel into a mold through an ejection path.

Various embodiments provide apparatus and methods for melting materials and for containing the molten materials within melt zone during melting. Exemplary apparatus may include a vessel configured to receive a material for melting therein; a load induction coil positioned adjacent to the vessel to melt the material therein; and a containment induction coil positioned in line with the load induction coil. The material in the vessel can be heated by operating the load induction coil at a first RF frequency to form a molten material. The containment induction coil can be operated at a second RF frequency to contain the molten material within the load induction coil. Once the desired temperature is achieved and maintained for the molten material, operation of the containment induction coil can be stopped and the molten material can be ejected from the vessel into a mold through an ejection path.

When forming ultra-conductive wire, multi-walled carbon nanotubes (MWCNTs) are dispersed and de-agglomerated in hot metal. The MWCNTs are dispersed in a precursor matrix via mixing and sintering to form precursor material, which is hot-extruded multiple rounds at a predetermined temperature to form a nano-composite material. The nano-composite material is inserted into a metal bar to form a nano-composite billet (306), which is subjected to multiple rounds of hot extrusion to form an ultra-conductive material. The ultra-conductive material is subjected to one or more rounds of hot wire drawing to form an ultra-conductive wire comprising a nano-composite filament.

When forming ultra-conductive wire, multi-walled carbon nanotubes (MWCNTs) are dispersed and de-agglomerated in hot metal. The MWCNTs are dispersed in a precursor matrix via mixing and sintering to form precursor material, which is hot-extruded multiple rounds at a predetermined temperature to form a nano-composite material. The nano-composite material is inserted into a metal bar to form a nano-composite billet (306), which is subjected to multiple rounds of hot extrusion to form an ultra-conductive material. The ultra-conductive material is subjected to one or more rounds of hot wire drawing to form an ultra-conductive wire comprising a nano-composite filament.

Disclosed is an injection tip for injecting liquid metal under pressure, suitable for being inserted between a liquid metal supply conduit and an injection opening of a mould, the injection tip having a tubular in shape, made from electrically insulating refractory material and in that it includes a channel suitable for the flow of liquid metal between a first end referred to as the upstream end, suitable for being connected to the conduit, and a second end, referred to as the downstream end, suitable for being connected to the mould, and an electromagnetic coil, positioned between the ends, the axis of which merges with at least a portion of the axis of the channel. Also disclosed is a casting machine using such a tip and a method for casting metal using the machine.

An apparatus and method for melting and forming metal in a vacuum environment. Metal is melted within a metal-forming apparatus and the molten metal is filled into a mold cavity. A high-level vacuum environment is created in the apparatus by drawing air from the apparatus which is sealed from atmospheric air. This makes it possible to reduce contact with air, which can improve the quality of the metal product.

An apparatus and method for melting and forming metal in a vacuum environment. Metal is melted within a metal-forming apparatus and the molten metal is filled into a mold cavity. A high-level vacuum environment is created in the apparatus by drawing air from the apparatus which is sealed from atmospheric air. This makes it possible to reduce contact with air, which can improve the quality of the metal product.

The present invention is a casting machine for casting parts in a mold out of a metal using a metal feedstock. The machine feeds solid metal feedstock into a processing cylinder formed in a thermally conductive block and a heater elevates the temperature of the feedstock as it passes along the said processing cylinder first and second ends, the first end of the processing cylinder being configured to receive. The feedstock becomes more liquid and is transferred to an injector cylinder formed in the thermally conductive block adjacent the processing cylinder. The injector cylinder has a shooting pot coupled to the second end of the processing cylinder by a passage configured to permit feedstock to pass from the processing cylinder into the shooting pot from where is it injected into a mold.

The present invention is a casting machine for casting parts in a mold out of a metal using a metal feedstock. The machine feeds solid metal feedstock into a processing cylinder formed in a thermally conductive block and a heater elevates the temperature of the feedstock as it passes along the said processing cylinder first and second ends, the first end of the processing cylinder being configured to receive. The feedstock becomes more liquid and is transferred to an injector cylinder formed in the thermally conductive block adjacent the processing cylinder. The injector cylinder has a shooting pot coupled to the second end of the processing cylinder by a passage configured to permit feedstock to pass from the processing cylinder into the shooting pot from where is it injected into a mold.

A die casting insert for producing die casted metal parts from liquid metal. The die casting insert has an outer casing shaped to be fixed in the die block of the die casting apparatus. The die casting insert also has a stopper with a purge opening that is adapted to evacuate contaminants topping the liquid metal as pressure is applied to the liquid metal. The stopper, fitted to mate with the hollow inner cavity of the injection sleeve, is constructed to seal the hollow inner cavity of the injection sleeve except at the purge opening when in a first position; and to permit the flow of the liquid metal into at least one molding cavity when the stopper is in a second position. The die casting insert also has an activation mechanism configured to shift the stopper between the first position and the second position.