Described herein are techniques for improving the grain structure of a metal product by applying ultrasonic energy to a continuously cast metal product at a position downstream from the casting region and allowing the ultrasonic energy to propagate through the metal product to the solidification region. At the solidification region, the ultrasonic energy can interact with the growing metal grains, such as to deagglomerate and disperse nucleating particles and to disrupt and fragment dendrites as they grow, which can promote additional nucleation and result in smaller grain sizes.

Disclosed herein are metal matrix composites and methods of making and use thereof. For example, disclosed herein are methods of making a metal matrix composite comprising a metal matrix reinforced by a high entropy alloy. The methods comprise mixing a first powder and a second powder to form a powder mixture, wherein the first powder comprises a plurality of particles comprising a metal and the second powder comprises a plurality of particles comprising a high entropy alloy. The methods further comprise compacting the powder mixture to form a pellet and adding the pellet to a molten metal, the molten metal comprising the metal in a molten state, thereby melting the pellet to form a molten mixture. The methods further comprise subjecting the molten mixture to an ultrasonic treatment and casting the ultrasonic treated mixture to form the metal matrix composite.

Disclosed herein are metal matrix composites and methods of making and use thereof. For example, disclosed herein are methods of making a metal matrix composite comprising a metal matrix reinforced by a high entropy alloy. The methods comprise mixing a first powder and a second powder to form a powder mixture, wherein the first powder comprises a plurality of particles comprising a metal and the second powder comprises a plurality of particles comprising a high entropy alloy. The methods further comprise compacting the powder mixture to form a pellet and adding the pellet to a molten metal, the molten metal comprising the metal in a molten state, thereby melting the pellet to form a molten mixture. The methods further comprise subjecting the molten mixture to an ultrasonic treatment and casting the ultrasonic treated mixture to form the metal matrix composite.

A manufacturing method for a cast bar and tube made of a magnesium alloy, includes steps of preparing a manufacturing device; depressurizing a vacuum chamber through a depressurization device; heating a vicinity of an opening of a hollow tube; inserting the opening of the hollow tube into a molten metal; switching a valve member to be open; introducing the molten metal into a cylindrical part, and filling the cylindrical part with the molten metal; cooling the hollow tube; and continuously vibrating the hollow tube until completing solidification of the molten metal in the cylindrical part.

A molten metal processing device including an assembly mounted on the casting wheel, including at least one vibrational energy source which supplies vibrational energy to molten metal cast in the casting wheel while the molten metal in the casting wheel is cooled, and a support device holding the vibrational energy source. An associated method for forming a metal product which provides molten metal into a containment structure included as a part of a casting mill, cools the molten metal in the containment structure, and couples vibrational energy into the molten metal in the containment structure.

Provided is a high-quality semi-solid slurry manufacturing apparatus and method using optimized process parameters, and a component molding apparatus including the semi-solid slurry manufacturing apparatus, and particularly, a high-quality semi-solid slurry manufacturing apparatus and method using optimized process parameters, which can optimize process parameters for manufacturing a semi-solid slurry such that a fine slurry structure and uniform spheroidized particles are obtained and can obtain high-quality products by increasing convenience and productivity of the apparatus, and a component molding apparatus including the semi-solid slurry manufacturing apparatus.

A semi-continuous casting equipment for thin-walled alloy castings with equal outer diameter, optimized by synergistic action of traveling magnetic fields and ultrasonic wave, includes: a melting and insulation device, a heat insulation panel, a traveling magnetic field generator and a water-cooled crystallizer sequentially positioned on a working platform; an outer mold positioned on the water-cooled crystallizer and sleeved the traveling magnetic field generator; a mold core inside the outer mold defining a casting cavity; a bottom plate below the mold core capable of sliding against and along an inner side of the outer mold; two position control units supported by the working platform; an ultrasonic limit baffle moveably engaged with the position control units; an ultrasonic wave generator affixed on the ultrasonic limit baffle and extended to the casting cavity; a motion system controlling up and down movement of the bottom plate and the position control units through a gear transmission mechanism.

A semi-continuous casting equipment for thin-walled alloy castings with equal outer diameter, optimized by synergistic action of traveling magnetic fields and ultrasonic wave, includes: a melting and insulation device, a heat insulation panel, a traveling magnetic field generator and a water-cooled crystallizer sequentially positioned on a working platform; an outer mold positioned on the water-cooled crystallizer and sleeved the traveling magnetic field generator; a mold core inside the outer mold defining a casting cavity; a bottom plate below the mold core capable of sliding against and along an inner side of the outer mold; two position control units supported by the working platform; an ultrasonic limit baffle moveably engaged with the position control units; an ultrasonic wave generator affixed on the ultrasonic limit baffle and extended to the casting cavity; a motion system controlling up and down movement of the bottom plate and the position control units through a gear transmission mechanism.

A molten metal conveyor having a receptor plate in contact with molten metal during transport of the molten metal. The receptor plate extends from an entrance where molten metal enters onto the receptor plate to an exit where molten metal exits the receptor plate. The molten metal conveyor has at least one vibrational energy source which supplies vibrational energy directly to the receptor plate in contact with molten metal. A corresponding method for forming a metal product includes providing molten metal onto a molten conveyor; cooling the molten metal by control of a cooling medium flowing through a cooling passage in the or attached to the conveyor; and coupling vibrational energy directly into a receptor plate in contact with the molten metal on the conveyor.

A ladle, process, and system for casting an aluminum-based alloy includes a casting ladle. The casting ladle includes a cup and the cup defines an opening. The ladle also includes an ultrasonic transducer including an end immersed in the cup, wherein the cup exhibits a first depth and the ultrasonic transducer is immersed in the cup at a second depth in a range of 5 percent to 100 percent of the first depth. An aluminum-based alloy melt is introduced into an opening of a casting ladle, an ultrasonic transducer immersed in the aluminum-based alloy melt is activated, and the aluminum-based alloy melt is transferred onto a casting surface.