Disclosed is an inspection cup for inspecting an impurity in molten metal for die casting. The inspection cup for inspecting an impurity in molten metal for die casting according to an exemplary embodiment of the present disclosure is configured to detect an impurity contained in the molten aluminum and includes a cup body having a molten metal accommodation portion capable of accommodating a predetermined amount of molten aluminum, and the molten metal accommodation portion is shaped such that a cross-sectional area thereof gradually decreases from an upper end toward a lower end.

Disclosed is an inspection cup for inspecting an impurity in molten metal for die casting. The inspection cup for inspecting an impurity in molten metal for die casting according to an exemplary embodiment of the present disclosure is configured to detect an impurity contained in the molten aluminum and includes a cup body having a molten metal accommodation portion capable of accommodating a predetermined amount of molten aluminum, and the molten metal accommodation portion is shaped such that a cross-sectional area thereof gradually decreases from an upper end toward a lower end.

Raw material feed into an electric arc furnace (“EAF”) is melted into heated liquid metal at a controlled temperature with impurities and inclusions removed as a separate liquid slag layer. The heated liquid metal is removed from the EAF into a passively heatable ladle wherein it is moved into a refining station where they are placed into a inductively heated refining holding vessel and wherein vacuum oxygen decarburization is applied to remove carbon, hydrogen, oxygen, nitrogen and other undesirable impurities from the liquid metal. The ladle and liquid metal is then transferred to a refining station/gas atomizer having a controlled vacuum and inert atmosphere wherein the liquid metal is poured from an inductively heated atomizing holder vessel into a heated tundish at a controlled rate wherein high pressure inert gas is applied through a nozzle to create a spray of metal droplets forming spherical shapes as the droplets that cool and fall into a bottom formed in the chamber. Spherical powder comprising the droplets are removed from the chamber through screen and blenders and then classified by size.

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.

An assembly and method for producing powder are provided. The assembly includes a melting chamber, an atomizing vessel, and a powder processing device. The melting chamber includes a crucible, a tundish, and a filtering device. The crucible is arranged for melting a material. The crucible and tundish are configured for providing a flow path for the melted material from the crucible into the tundish. The filtering device is arranged in the flow path. The tundish is connected to an atomizing nozzle. The atomizing nozzle is configured to direct molten material from the tundish towards and into the atomizing vessel. The atomizing vessel comprises an outlet which is configured to extract solidified, atomized particles of the formerly molten material from the atomizing vessel. The powder processing device includes one or more separation units which are arranged for outputting one or more powders from the atomized particles.

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.

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 tilting melting hearth system (10) includes a tilting melting hearth (12) for melting a metal (14) into a molten metal (16) and a central processing unit (CPU) (18) for controlling the tilting melting hearth (12) having an automated hearth tilting program (20) configured to select a hearth tilt profile based on a weight (66A) of the molten metal (16) in the tilting melting hearth (12). The tilting melting hearth system (10) can also include an atomization die (38) in flow communication with the tilting melting hearth (12) for receiving a stream of molten metal (40) and generating a metal powder (42), or a casting die (46) for generating a casting (48) of the metal (14). The tilting melting hearth system (10) can be used to perform a method for recycling scrap metal by automatically determining the weight of the molten metal (16) in the tilting melting hearth (12).

A tilting melting hearth system (10) includes a tilting melting hearth (12) for melting a metal (14) into a molten metal (16) and a central processing unit (CPU) (18) for controlling the tilting melting hearth (12) having an automated hearth tilting program (20) configured to select a hearth tilt profile based on a weight (66A) of the molten metal (16) in the tilting melting hearth (12). The tilting melting hearth system (10) can also include an atomization die (38) in flow communication with the tilting melting hearth (12) for receiving a stream of molten metal (40) and generating a metal powder (42), or a casting die (46) for generating a casting (48) of the metal (14). The tilting melting hearth system (10) can be used to perform a method for recycling scrap metal by automatically determining the weight of the molten metal (16) in the tilting melting hearth (12).