A kind of composite electromagnetic that applies stirs the method for preparing semi-solid metal slurry continuously
Technical field
The invention belongs to the semi-solid-state metal processing technique field, specially refer to a kind of composite electromagnetic that applies and stir the method for preparing semi-solid metal slurry continuously.
Background technology
The semisolid Metal Processing notion is proposed at eighties of last century the seventies first by U.S. scientist, the basic principle of this method is to apply vigorous stirring in the liquid metal solidification process, the broken branch primary crystal that is generated and form subsphaeroidal primary crystal and the common alloy pulp that constitutes of remaining liquid phase with non-dendritic structure feature, even this slurry still has good flowability when fraction solid is big under the effect of power, can be delivered directly to former, utilize common process such as rolling, die casting, extruding, die forging to shape.This method has merged casting and Forging Technology characteristics, has advantages such as efficient, energy-saving and environmental protection, high-quality, high finished product rate and nearly end form, therefore, is subjected to the extensive concern of international material circle, has become one of current most active research field.
Semi-solid-state shaping technology mainly comprises two kinds of thixotropic forming and rheological moldings.Thixotropic forming technology is that the semi solid slurry that will prepare is cast as blank earlier, must be through post bake, form processing again, its process controllability is strong, process is stable and easy to operate, it is not too high relatively that stock quality is required, thereby comparatively fast entered suitability for industrialized production, but the technical process relative complex causes cost to increase.Rheological molding technology attempts to save post bake, directly carries out rheological molding processing by the semi solid slurry for preparing, and has characteristics such as production procedure is short, relative cost is low, equipment is simple, is subjected to generally attention both domestic and external in recent years, and development rapidly.Because rheological molding is without the post bake operation, the solidified structure of semi solid slurry and defective are very big to the final products Effect on Performance, therefore the semisolid stock quality have been proposed requirements at the higher level.As seen, no matter be thixotropic forming or rheological molding, all comprise semisolid slurrying and semi-solid-state shaping two parts, wherein, slurrying is the basis of whole process and crucial, the research focus that how to stablize, axle, semi solid slurry tiny, uniform non-dendritic structure such as preparation becomes current semi-solid processing field effectively.
At present, preparation method of semisolid state slurry thereof mainly comprises mechanical mixing method, magnetic field paddling process, spray deposition, double helix shearing method, single roller rotary process, slope cooling method, near liquidus casting etc.Mechanical mixing method is a kind of blank preparation method who occurs the earliest, owing to there are shortcomings such as efficient is low, agitating device material life-span weak point, pollution metal melt, is unfavorable for the heavy industrialization application.The jet deposition rule is that process is too complicated, and cost is higher, the semi solid slurry preparation of only suitable quality requirement higher material.Though the double helix shearing method can be realized continuous slurrying, exist the screw rod operating mode poor, consume high, shortcomings such as the life-span is short, equipment needed thereby is complicated, cost height and restricting its commercial application.Therefore, state such as Japan has proposed to have the process such as single roller rotary process, slope cooling method of characteristics such as simple to operate, that cost is lower in recent years, but adopts the semi solid slurry of these explained hereafter can only be used for producing blank, can't be directly used in rheological molding.Though the near liquidus casting is noticed cast cold and can be obtained the effect of obvious crystal grain thinning, but the pouring temperature that this method requires molten metal is very near the liquidus temperature of this metal, could obtain the globular crystal semi-solid metal slurry, this makes the metal bath temperature controlling become very difficult, and being in molten metal under this state property variation that flows, the practical operation difficulty is very big.Because electromagnetic field has noncontact, energy density height, cleaning and characteristics such as can accurately design and control, in the preparation process of metal material, brought into play enormous function, this also is that electromagnetic agitation prepares semi-solid-state metal blank prevailing reason in actual Application of Semi-Solid Metals Forming, and, can produce the semi solid slurry of high-quality more along with electromagnetic field applies the variation of mode.Adopt electromagnetic agitation method to prepare the existing several patents of technology of used for semi-solid processing blank at home and abroad at present, but their common trait is: inefficiency, power consumption is big, the device structure complexity, the cost of semi solid slurry and blank is higher, make the industrial applications of utilizing electromagnetic stirring method to prepare semi solid slurry or blank make slow progress, the advantage that applies electromagnetic field does not embody fully.The not enough main performance that existing electromagnetic stirring method prepares semi solid slurry and blank technology is: 1) electromagnetic agitation is applied in the pulping chamber outside, because the pulping chamber volume is bigger, inevitable requirement electromagnetic agitation power is very big, cause electromagnetic equipment huge, energy consumption increases, dendrite is slow to non-dendrite transforming process, and crystal grain is thick, and the preparation semi solid slurry time is long, efficient is low; Exist when 2) the pulping chamber volume is big and stir the Distribution of Magnetic Field problem of non-uniform, it is inhomogeneous to make that pulping chamber inner edge portion and heart portion molten metal stir, and occurs limit portion coagulation phenomena early easily; 3) because pulping chamber is close with the mozzle bore, slurry flows and only relies on the gravity effect, and it is discontinuous to cause slurry to flow; When the fraction solid of slurry is high, make semi solid slurry that the effect of the power of shear repeatedly take place owing to lack, the thixotropy of semi solid slurry is not in full use, and viscosity is bigger, and the difficulty that slurry is carried continuously increases; 4) the semi solid slurry technology of stable preparation with ideal solid phase mark is still immature, and slurry can't be directly used in rheological molding.
Summary of the invention
The objective of the invention is to: overcome the deficiencies in the prior art, provide a kind of composite electromagnetic that applies to stir the method for preparing semi-solid metal slurry continuously.Adopt this method can obtain the semi-solid metal slurry of economy, quick, efficient, high-quality, this slurry can be directly used in rheocasting, also can be cast as the blank of certain size, realizes thixotropic forming by post bake.
For achieving the above object, the present invention takes following technical scheme:
A kind of composite electromagnetic that applies stirs the method for preparing semi-solid metal slurry continuously, and this method comprises the steps:
1) over-heat metal liquid that melting is qualified is with in the tundish that is higher than 10~80 ℃ of its liquidus temperatures and continuously waters a preheating, and tundish inner metal liquid body remains constant altitude, wherein, the preheat temperature of tundish is above 0~30 ℃ of the liquidus temperature that exceeds institute's casting metal liquid, simultaneously the metal liquid in the tundish is applied electromagnetic agitation, metal liquid is evenly cooled off in the mode of whole electromagnetic agitation, described metal liquid temperature is on its liquidus temperature within 0~10 ℃ of scope;
2) temperature in the tundish being on its liquidus temperature metal liquid within 0~10 ℃ of scope flows through and is positioned at the mozzle that the tundish bottom connects, simultaneously the metal liquid in the mozzle of flowing through is applied electromagnetic agitation, it is to be undertaken by being located at the outer magnetic stirrer of mozzle that metal liquid in the mozzle of flowing through is applied electromagnetic agitation, this magnetic stirrer is connected with power frequency supply, power of agitator is between 0.1~0.5kW, and mixing speed is at 500~3000rmp; And the intensity of cooling of the thermostat control mozzle outer wall on the employing mozzle outer wall, make the cooling velocity of mozzle inner metal liquid body be controlled at 1~50 ℃/s, will be controlled under the liquidus temperature of institute's casting metal liquid 5~30 ℃ through the temperature of the metal liquid behind the mozzle;
3) enter in the warmer through the metal liquid behind the mozzle, the warmer temperature is controlled under the liquidus temperature of institute's casting metal liquid 10~30 ℃, and temperature retention time is 5~60s;
4) the above-mentioned slurry of handling through insulation can be delivered directly on the conventional formers such as die casting, rolling, die forging and carry out rheological molding, perhaps continuously is poured into and makes the semisolid continuous casting base in the crystallizer.
In the method for the invention, in described step 1), it is to be undertaken by being located at the outer magnetic stirrer of tundish that metal liquid in the tundish is applied electromagnetic agitation, this magnetic stirrer links to each other with a low-frequency power, the power of this magnetic stirrer is 1~10kW, frequency is 1~300Hz, and stir speed (S.S.) is 50~300rpm.This magnetic stirrer is tundish inner metal liquid body to be applied one horizontally rotate magnetic field, the temperature that makes metal liquid on the liquidus temperature that controls to this alloy under the even cooling condition of integral body 0~10 ℃.
In the method for the invention, in described step 2) in, electromagnetic agitation is to apply one in the mozzle outside to horizontally rotate magnetic field, by regulate intensity of cooling and stirring intensity, metal bath become semi solid slurry when going out mozzle with the spherical fraction solid of 10~50% non-dendrite to mozzle inner metal liquid body.
In the method for the invention, the metal bath of deriving through mozzle enters in the warmer of a round cavity under the acting in conjunction of metal liquid static pressure and electromagnetic stirring force, directly be transported to former through the slurry that is incubated processing and carry out semi-solid rheological molding, perhaps enter a heat top that is positioned at crystallizer top and is attached thereto, cast semi-solid blank continuously.
Compared with prior art, the invention has the advantages that:
1. over-heat metal liquid temp and flowability are easy to control.Metal liquid in the tundish is applied electromagnetic agitation, make whole uniform decrease in temperature of over-heat metal liquid in it to liquidus temperature, can solve in the prior art and cause technical barriers such as flowability is poor, practical operation difficulty near liquidus temperature by leaving standstill the preservation and controlling metal liquid merely; Because the magnetic field that horizontally rotates that is applied in the tundish is mainly used to realize uniform decrease in temperature, less demanding to stirring intensity, therefore, required power of agitator is little, energy consumption is low.
2. semi solid slurry prepares fast, the control easily of speed.Apply outside mozzle and horizontally rotate magnetic field and cooling, the metal liquid stream in the mozzle of flowing through can obtain to cool off fast fully, understand at the inner a large amount of forming cores of metal liquid, therefore, the obvious refinement of solidified structure; Because almost be the while forming core, the nucleus size is close, helps the solidified structure homogenising again.Thereby the metal liquid stirring is inhomogeneous, inhomogeneous cooling is even causes the uneven problem of solidified structure because of the pulping chamber size is brought more greatly in the prior art with regard to having solved like this, has also avoided pure dependence intense electromagnetic to stir the problem that equipment is huge He power of agitator is big, stirring efficiency is low, energy consumption is big that realizes the dendrite fragmentation and bring.Because the mozzle size is less, therefore, the electromagnetic stirring equipment volume is little, need not converter plant, and cost of investment is few, and required power of agitator is little, power consumption is low, efficient is high.
3. semi solid slurry has good thixotropic property.Metal liquid in the mozzle is to flow into warmer in a spiral manner under metal liquid static pressure and electromagnetic stirring force acting in conjunction, and forms the semi-solid metal slurry with specific fraction solid.This spiral souring can guarantee that metal bath still has good flowability when reaching higher fraction solid, and enters the metal bath uniformity of temperature profile in the warmer.Therefore, the semi solid slurry that both can realize stablizing, preparation has the ideal solid phase mark has effectively solved again that semi solid slurry tissue odds is even in the prior art, the nodularization degree is low and can not directly carry out the difficult problem of rheological molding.
4. simple, the applied range, practical of pulping equipment.Magnetic stirrer is simple in structure, stirring efficiency is high, energy consumption is low, do not need converter plant.Continuously the semi solid slurry of preparation not only can be used for producing continuous casting billet and is used for thixotropic forming, and can be delivered directly to former, utilizes common process such as rolling, die casting, extruding, die forging to carry out rheological molding.This method both had been suitable for the preparation of semi-solid metal slurry of the spherical or granular primary crystal of acieral, also was suitable for the preparation of the semi-solid metal slurry of non-ferrous metals such as acid bronze alloy, magnesium base alloy, zinc-containing alloy.
Description of drawings
Fig. 1 applies composite electromagnetic to stir preparation semi-solid metal slurry structural representation continuously.
Fig. 2 applies resultant field but the microstructure of the A356 alloy semi solid slurry handled without insulation, and light areas is primary crystal α-A1, and darker regions is the eutectic liquid that solidifies.
Fig. 3 is the microstructure that applies resultant field and the A356 alloy semi solid slurry through being incubated processing, and light areas is primary crystal α-A1, and darker regions is the eutectic liquid that solidifies.
The specific embodiment
As shown in Figure 1, tundish 2 is a bearing container, roof is provided with the import of metal liquid on it, diapire is provided with the outlet of metal liquid under it, this outlet connects mozzle 6, mozzle 6 walls are provided with thermostat 7, in bearing container 2, run through a stopper rod 5 by its upper top to its lower bottom part, the last roof of the top break-through bearing container 2 of stopper rod 5, be slidingly connected with last roof, its handgrip that exposes the stopper rod 5 outside bearing container 2 can be used for operating stopper rod 5 and moves up and down, and the lower end of stopper rod 5 is provided with piston, and this piston cooperates plug to connect with the outlet of the metal liquid of bearing container 2, can control the relative position of outlet of the metal liquid of this piston and bearing container 2 by the handgrip of stopper rod 5, with opening of the outlet of control metal liquid, close and flow.Around bearing container 2 and mozzle 6 outsides, be provided with agitator 3, following agitator 4 respectively, below the outlet of mozzle 6, be provided with warmer 8.
Describe embodiments of the invention in detail below in conjunction with accompanying drawing:
As shown in Figure 1, at first, the A356 alloy liquid (its liquidus temperature is 613 ℃) that melting is qualified continuously is poured into through in the tundish 2 of preheating at 670 ℃, preheat temperature is controlled at about 620 ℃, up-down error is no more than 2 ℃, and guarantees that A356 alloy liquid 1 remains constant altitude in tundish 2.At this moment open power on magnetic stirrer and following magnetic stirrer 4.The magnetic stirrer that powers on links to each other with a low-frequency power, and applying power is 2.0kW, and applying frequency is 30Hz, and stir speed (S.S.) is 150rpm.Following magnetic stirrer 4 links to each other with a power frequency supply, and applying power is 0.3kW, and stir speed (S.S.) is 2000rmp.The magnetic stirrer that powers on produces one and horizontally rotates magnetic field, impels molten metal with the liquidus temperature of the even cooling of whole alr mode near this metal.The temperature of A356 alloy liquid is controlled near 0~2 ℃ of its liquidus temperature in the tundish after treatment.Even the liquid metal of this moment beginning crystallization, because function composite by electromagnetic stirring can not grown by the dendrite mode yet, metal liquid at this moment still has good flowability.Then, A356 alloy liquid 1 in the rotation stopper rod 5 control tundish is derived through mozzle 6, the molten metal flow is controlled by the hoisting depth of regulating stopper rod 5, and the intensity of cooling of mozzle 6 outer walls is controlled by thermostat 7, and the cooling velocity of mozzle inner metal liquid body is 30 ℃/s.Following magnetic stirrer 4 one of generation horizontally rotate magnetic field and help metal liquid stream acquisition cooling fast fully, mix, molten metal is rapid cold excessively, forming core quantity increases considerably, the obvious refinement of solidified structure, through composite electromagnetic stir but the A356 alloy semi solid slurry do not handled through insulation as shown in Figure 2 by the microstructure after quenching.Under molten metal static pressure and electromagnetic stirring force acting in conjunction, be moved into warmer 8 through the A356 of composite electromagnetic stir process molten metal in a spiral manner and be incubated processing when above-mentioned, wherein, the warmer temperature is controlled at 600 ℃, temperature retention time is 15s, and then accompanying drawing 3 is above-mentioned process composite electromagnetic stir process and is incubated the microstructure of handling after back A356 alloy semi solid slurry adopts quenching. Contrast accompanying drawing 2,3 finds that though the semi solid slurry solidified structure of not handling through insulation through the composite electromagnetic stirring obtains obvious refinement and homogenising, crystal grain nodularization roundness is low; And simultaneously through the solidified structure after composite electromagnetic stirring and the insulation processing, the nodularization degree also increases substantially, and the roundness of primary grain is good.