Casting Device and Casting Method for the Production of Metal Matrix Composite Materials

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This invention describes a casting apparatus and method for efficiently and continuously producing metal matrix composite (MMC) materials. It utilizes a unique design where molten metal is split into two streams that flow around a particle feed chute; solid strengthening particles are then introduced precisely where the streams recombine, promoting effective mixing and embedding of the particles within the molten metal. The design greatly improves homogeneity and reduces problems with oxidation and particle distribution that have limited previous MMC production technologies.

Use CasesContent extracted from patent full text and abstract with AI.

• Manufacturing high-strength, wear-resistant automotive components (e.g., brake rotors, engine parts)
• Producing lightweight yet strong aerospace components, such as structural parts or turbine blades
• Fabricating military-grade parts requiring a combination of metal toughness and reinforcement from ceramic or other particles
• Creating industrial machine tools and components with enhanced durability and service life
• Enabling scalable, cost-effective production of MMC materials for broad commercial and industrial adoption

BenefitsContent extracted from patent full text and abstract with AI.

• Allows continuous production of metal matrix composites with improved quality and homogeneity
• Ensures better distribution and embedment of reinforcing particles within the molten metal
• Minimizes oxidation and contamination by keeping the molten metal covered, even during particle addition
• Reduces the risk of premature solidification and particle clumping thanks to controlled heating and feed systems
• Simplifies operation and maintenance compared to complex batch and vacuum-based systems
• Improves process flexibility and robustness, accommodating various process and product requirements
• Enables lower costs and higher throughput compared to existing MMC production methods

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Patent Abstract

The invention relates to a casting apparatus for producing metal matrix composite materials having a molten material channel which is inclined in a flow direction of the casting apparatus and a flow pathway for a molten metal, and a particle addition device for adding solid particles to the molten metal; and also to a corresponding casting method in which solid particles are added to a molten metal while the molten metal is flowing in a continuous flow down a molten material channel. In the casting apparatus, the particle addition device takes the form of a particle addition duct that extends at least up to a base of the flow pathway and has a particle exit window formed in a duct casing of the particle addition duct. In the casting method, the molten metal flowing down along a flow pathway of the molten material channel is divided into two partial streams which flow around a particle addition duct that projects into and thus divides the flow pathway, and at the point where the partial streams combine again after flowing around the particle addition duct, the solid particles trickle into the confluence of the partial streams via a particle exit window in the particle addition duct located above the flow pathway.