CN100534669C - Vertical semi-continuous light alloy ingot casting process and apparatus with cooperation of power ultrasound wave and low frequency electromagnetic wave - Google Patents
Vertical semi-continuous light alloy ingot casting process and apparatus with cooperation of power ultrasound wave and low frequency electromagnetic wave Download PDFInfo
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- CN100534669C CN100534669C CNB2007100106415A CN200710010641A CN100534669C CN 100534669 C CN100534669 C CN 100534669C CN B2007100106415 A CNB2007100106415 A CN B2007100106415A CN 200710010641 A CN200710010641 A CN 200710010641A CN 100534669 C CN100534669 C CN 100534669C
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Abstract
The present invention is vertical semi-continuous light alloy casting process and apparatus with cooperation of power ultrasonic field and low frequency electromagnetic field. During casting, one low frequency electromagnetic field acting on the surface of metal molt and one power ultrasonic field acting on the crystallizer axis part are applied simultaneously. The present invention can reduce the transverse temperature gradient in casting blank solidification, alter liquid hole shape, raise the homogeneity of the casting blank and raise casting blank quality.
Description
Technical field
The invention belongs to the light-alloy casting technical field, particularly a kind ofly apply the method and apparatus that two kinds of outfields synergies of power ultrasonic and low frequency electromagnetic are carried out the big specification ingot blank of light-alloy vertical semi-continuous casting.
Background technology
Applying the outfield is the highly effective method that changes the metal freezing behavior, as apply electric field, electric current, magnetic field (comprising permanent magnetic field, electromagnetic field, pulse electromagnetic field, combined electric magnetic field etc.), ultrasonic wave when solidifying, mechanical waves etc. all exert an influence to temperature field, flow field, concentration field and the forming core of alloy in the DC casting process and the behavior of solidifying such as grow up.Wherein, applying electromagnetic field is a kind of efficient, economic method that realizes easily.Big quantity research shows that also the nonlinear effect that ultrasonic wave is had has very unique effect to changing the metal freezing behavior in metal bath.The defective that may occur in the DC casting process can be improved or avoid to these means, for slab quality improves the condition of having created.
The engineer Getselev ZN of the pioneer former Soviet Union of the application of electromagnetic field in semi-continuous casting utilizes the magnetic pressure of 500～4000Hz electromagnetic field of high frequency to make melt avoid the once cooling of crystallizer, directly secondary cooling realizes that containerless casting is to improve the aluminium alloy slab surface quality.In addition, also favourable agitating function with electromagnetic field changes the correlative study of metal freezing behavior, wherein, Frenchman Vives etc. utilizes power frequency electromagnetic field to realize the electromagnetic casting of 2024 and 2214 aluminium alloys, has invented electromagnetic agitation crystal grain thinning technology (US4523628).In recent years, Northeastern University utilizes low frequency electromagnetic to have the characteristics of higher penetration depth to develop light-alloy low frequency electromagnetic semi-continuous casting technology and low frequency electromagnetic oscillation semicontinuous casting technology to metal bath.But because electromagnetic field is difficult to the kelvin effect that overcomes in metal bath, even low frequency electromagnetic field, its depth of interaction is also very limited.This seems fairly obvious in the preparation of big specification ingot blank, limited by electromagnetism to change the physical size that metallurgical melt solidifies behavior.
Ultrasonic also is to improve the metal or alloy solidified structure as a kind of mechanical dilatational wave, improves the effective means of the mechanical property of materials.Ultrasonic wave acts on that the microbubble that metal bath produces forms, grows up, the process of pulsation and avalanche, be cavitation effect, have crystal grain thinning, suppress dendrite and promote equiax crystal formation, suppress the alloying element segregation and purify melt remarkable results such as (degasification, slagging-off, purifications).The former Soviet Union has promptly begun the ultrasonic coagulation research of metal in generation nineteen thirty, and the ultrasonic semi-continuous casting technology of having invented the light metal melt.The ultrasonic processing of melt mainly is by immersing luffing bar realization energy transmission in the melt, reaching the effect that changes the behavior of solidifying.Yet, ultrasonic wave is a compressional wave, its effect has very significant directivity, ultrasonic decay in metal bath simultaneously is very serious, make ultrasonic effect mainly concentrate on the near zone at the melt middle part of supersonic source effect, the metal volume of its effect is subjected to certain limitation equally, generally puts on ultrasonic in the solidification liquid core and is difficult to affact near the scull top layer melt.
As seen, electromagnetic field or the ultrasonic finite region that acts on separately: electromagnetic field mainly acts on surf zone, and ultrasonic field mainly acts on the central area.Two kinds of outfields are single to apply the full volumetric effect that all can't realize melt, be difficult to eliminate fully the coarse grain zone and the dendrite district of ingot blank, particularly thick for dendrite prosperity, crystal grain, cause internal stress easily, then difficulty is bigger for the large-scale ingot blank of the material that the crackle tendency is serious.
Summary of the invention
At the big specification ingot blank of light-alloy casting difficulty, be easy to occur crackle and casting flaw such as loose, simultaneously because component segregation, grain structure is thick and unequal problem has limited the performance of material property, even be difficult to satisfy the requirement that practical distortion is produced.The invention provides the production method and the equipment of the vertical semi-continuous casting of the big specification ingot blank of a kind of light-alloy.
This method is utilized low frequency electromagnetic field and power ultrasonic, or the synergy of low frequency electromagnetic oscillation and power ultrasonic, realizes the outfield full volumetric effect in the light-alloy ingot blank vertical semi-continuous casting process.
The big specification ingot blank of the synergistic light-alloy of power ultrasonic that the present invention relates to and low frequency electromagnetic vertical semi-continuous casting technology is to adopt to apply low frequency electromagnetic oscillation field and power ultrasonic field (Fig. 1) simultaneously in the vertical semi-continuous casting process of light-alloy, or low frequency electromagnetic field and power ultrasonic field (Fig. 2), the power ultrasonic field acts on crystallizer axis position by ultrasonic bar, electromagnetic field mainly acts near the metal bath top layer owing to Kelvin effect, adjusting by two kinds of outfield parameters realizes synergy, makes to realize the full volumetric outer field action in the melt solidifying process in the crystallizer.
The equipment that the inventive method adopted comprises the crystallizer of smelting furnace, tundish, 1～2 magnet exciting coil of a configuration, ultrasonic-frequency power supply and transducer system, its concrete configuration is in crystallizer water jacket inside or outside or top dispose one group of magnet exciting coil, and logical with low frequency ac; In crystallizer water jacket inside or outside or top dispose one group and pass to low frequency ac and one group and pass to galvanic two groups of built-in magnet exciting coils, any of two kinds of configurations is all above the crystallizer or be provided with the ultrasonic amplitude transformer that is contained on the traversing carriage simultaneously above tundish and crystallizer in the above.Be equipped with can above the crystallizer or simultaneously above the tundish and the traversing carriage of the ultrasonic amplitude transformer that moves above the crystallizer to carry out three-dimensional by step motor control mobile.Its basic way is melting is finished and through the light-alloy melt after refining and the purified treatment, through flow-control mouth, runner, the tundish (can apply ultrasonic processing) of smelting furnace bottom sides, to enter in the crystallizer through pouring mouth or shunting disk at last.There is one group to pass to low frequency ac and one group and pass to galvanic two groups of magnet exciting coils in the water jacket internal configurations of crystallizer, interaction by DC fields and alternating-current field provides the low frequency electromagnetic oscillation field for melt, in casting process, the ultrasonic amplitude transformer on the support that is fixed in band stepper motor regulating system is inserted in the melt in crystallizer centre to apply ultrasonic wave simultaneously, realize that the low frequency electromagnetic oscillation and the synergy of power ultrasonic cast.During casting, adjust casting speed after, two magnet exciting coils energisings, fill melt in crystallizer, the machine of waiing upon starts casting machine simultaneously, and in the crystallization control device after the liquid level stabilizing, in the ultrasonic amplitude transformer immersed in liquid level of preheating and power, adjusting to predetermined value, finish until casting.
Concrete operations be in the smelting furnace on request component carry out the light-alloy melting; The preheating tundish, and in the dummy bar introducing crystallizer; Open cooling water, and give magnet exciting coil in the crystallizer logical with the alternating current of preset frequency and intensity or the direct current of leading to for another magnet exciting coil simultaneously with predetermined strength; Entering in the tundish via the flow-control mouth through refining and purification and the light-alloy melt that reaches design temperature; And by the liquid level in the flow-control mouth control tundish, by the liquid level in pouring mouth or the shunting disk crystallization control device; Opening casting machine subsequently casts by setting casting speed; Subsequently under the liquid level that inserts through the ultrasonic amplitude transformer of preheating in the crystallizer, open ultrasonic and regulate power to predetermined value; Ingot blank is pulled out until casting by dummy bar and is finished.For magnesium alloy, melt enters tundish and enters in the whole process of crystallizer and all will adopt CO
2+ 5%SF
6Some requisite measures are protected and taked to mist, and the melt secondary pollution that causes with the secondary oxidation of avoiding melt and burning guarantees the quality of melt and carrying out smoothly of casting process.
The present invention is particularly suitable for casting Φ 150mm above round base and the slab of thickness more than 150mm, simultaneously diameter or thickness is also had positive effect less than the raising of the metallurgical quality of the ingot blank of 150mm.Must the luffing bar of configuration more than 2 greater than the ingot blank of 500mm for diameter greater than Φ 500mm or thickness.For the magnesium alloy ingot blank casting, the luffing bar material is the mild steel through specially treated, and its phosphorus content is 0.1～0.8%; For the casting of aluminium alloy ingot blank, the luffing bar is that a kind of high temperature cobalt-base alloys (GH605) or the anti-corrosion nickel-base alloy of a kind of high temperature (GH5K) material are made; Casting die is the crystallizer system that disposes built-in magnet exciting coil, and cover is the straight barrel type metal pattern or is inlaid with graphite annulus and the hot top formula metal pattern of hot top in the crystallizer.
The luffing bar must keep 0.5h～1h through being preheated to uniform temperature before immersing melt, perhaps adopt acetylene to be baked to relevant temperature.In crystallizer, the supersonic frequency that is applied is 18kHz～28kHz, and ultrasound intensity is 3W/cm
2～50W/cm
2, be 5s～180s ultrasonic effective acting time, perhaps applies impulse ultrasound, and frequency is 18kHz～28kHz, and pulsewidth is 10
-4S～10
-1S, ultrasound intensity are 7W/cm
2～80W/cm
2, be 10s～250s ultrasonic effective acting time; Also can apply frequency simultaneously in tundish is 18kHz～28kHz, and the sound intensity is 1W/cm
2～50W/cm
2ultrasonicly carry out the melt preliminary treatment.
The low frequency electromagnetic frequency range that is applied is 1Hz～90Hz, and intensity is 2000AT～40000AT; The low frequency electromagnetic oscillation frequency range that is applied is 1Hz～90Hz, and alternating electromagnetic intensity is 2000AT～40000AT, and static magnetic field strength is 1500AT～30000AT.
Melt temperature in the vertical semi-continuous casting tundish all is controlled at and is higher than 50 ℃～100 ℃ of liquidus temperatures; Casting speed is 20mm/min～300mm/min, should adjust according to the ingot blank trade mark and specification.
Advantage of the present invention: the transverse temperature gradient when greatly reducing casting blank solidification, change liquid cave shape, improve the uniformity that ingot blank solidifies, significantly reduce the dimensional effect of ingot blank casting flaw, greatly improve the internal metallurgical quality and the surface quality of the large-scale ingot blank of vertical semi-continuous casting light-alloy, can obtain gross segregation and significantly reduce, grain refinement, tissue differences reduces, and crackle and defective such as loose significantly suppress the big specification ingot blank that surface quality improves.This technology for the dendrite prosperity, crystal grain is thick, segregation is serious, the tissue coagulation dimensional effect is remarkable, the magnesium alloy or 7075 of big, the easy hot tearing of air content, the aluminium alloy of 7055 high-alloyings such as grade, can realize the smooth production of its high-quality large-scale ingot blank, and significantly improve lumber recovery, simultaneously, some are easily realized the specification and the trade mark of vertical semi-continuous casting, also the raising for its metallurgical quality also provides the space, it is the advanced technologies method that the large-scale ingot blank casting of above casting flaw appears in non-ferrous metal ingot blank, particularly light metal alloy and being easy to.
Description of drawings
Fig. 1 is the vertical semi-continuous casting apparatus structure schematic diagram under power ultrasonic of the present invention and the low frequency electromagnetic oscillation synergy;
Fig. 2 is the vertical semi-continuous casting apparatus structure schematic diagram under power ultrasonic of the present invention and the low frequency electromagnetic synergy;
Fig. 3 is that the sampling point schematic diagram is observed in the metallographic structure on the circular ingot blank cross section in the example;
Fig. 4 is the AZ31 magnesium alloy Φ 200mm ingot blank tissue contrast of traditional DC casting, low frequency electromagnetic oscillation vertical semi-continuous casting and the present invention's method casting shown in Figure 1;
Fig. 5 is the AZ80 magnesium alloy Φ 300mm ingot blank tissue contrast of traditional DC casting, low frequency electromagnetic vertical semi-continuous casting and the present invention's method casting shown in Figure 2;
Fig. 6 is the MA2-1 magnesium alloy Φ 300mm ingot blank tissue contrast of traditional DC casting, low frequency electromagnetic vertical semi-continuous casting and the present invention's method casting shown in Figure 2;
Fig. 7 is the tissue contrast of the Al-11Si binary aluminium alloy Φ 100mm ingot blank of traditional DC casting, low frequency electromagnetic vertical semi-continuous casting and the present invention's method casting shown in Figure 2;
Among the figure: 1 smelting furnace, 2 light-alloy melts, 3 flow-control mouths, 4 ultrasonic amplitude transformers (be fixed in and realize that by stepper motor accurate three-dimensional moves on the support of control), 5 pouring mouths or shunting disk, 6 crystallizers, 7 ingot blanks, 8 dummy bars, 9 magnet exciting coils, 10 tundish, 11 runners.
The specific embodiment
Embodiment 1AZ31 magnesium alloy Φ 200mm ingot blank vertical semi-continuous casting
According to proportioning melting AZ31 magnesium alloy, and it is fire-retardant to realize to add 20ppmBe; Crystallizer is the hot top formula metal pattern that is inlaid with graphite annulus and hot top; Melt is no ultrasonic processing in tundish, applies the synergy of power ultrasonic field and low frequency electromagnetic oscillation field in crystallizer.
The casting technique condition is: casting speed is 100mm/min; Φ 20mm low-carbon steel material ultrasonic amplitude transformer is at 300 ℃ of preheating 1h; Supersonic frequency is 20kHz, and ultrasound intensity is about 6W/cm
2690 ℃ of melt temperatures in the tundish; A-c cycle 30Hz, intensity 4000AT; Direct current intensity 4000AT.
Fig. 4 is that the tissue of the AZ31 magnesium alloy Φ 200mm ingot blank of traditional vertical semi-continuous casting, low frequency electromagnetic oscillation vertical semi-continuous casting and vertical type semi-continuous casting method of the present invention acquisition compares.As seen, the inventive method organize more even, tiny.
Detection shows that under above casting speed and casting temperature, the liquid point depth of three kinds of casting methods is obviously different, and traditional D.C.casting is 120mm, and low frequency electromagnetic oscillation is cast into 90mm, and the present invention is 70mm～80mm; The relative mistake of main alloying element Al: traditional D.C.casting is 16%～20%, and low frequency electromagnetic oscillation is cast into 10%～15%, and the inventive method is cast into 6%～10%.Relatively as seen, the present invention has the most shallow liquid cave, minimum gross segregation.
Embodiment 2:AZ80 magnesium alloy Φ 300mm ingot blank vertical semi-continuous casting
According to proportioning melting AZ80 magnesium alloy, and it is fire-retardant to realize to add 10ppmBe; Crystallizer is the hot top formula metal pattern that is inlaid with graphite annulus and hot top; Melt is no ultrasonic processing in tundish, applies the synergy of power ultrasonic field and low frequency electromagnetic field in crystallizer.
The casting technique condition is: casting speed is 90mm/min; Φ 20mm low-carbon steel material ultrasonic amplitude transformer is at 300 ℃ of preheating 1h; Supersonic frequency is 20kHz, and ultrasound intensity is about 5W/cm
2670 ℃ of melt temperatures in the tundish; A-c cycle 30Hz, intensity 6000AT.
Fig. 5 is that the tissue of the AZ80 magnesium alloy Φ 300mm ingot blank of traditional D.C.casting, low frequency electromagnetic vertical semi-continuous casting and vertical type semi-continuous casting method of the present invention acquisition compares.As seen, the inventive method organize more even, tiny.
Detection shows, the relative mistake of main alloying element Al: traditional D.C.casting is 25%～35%, and low frequency electromagnetic oscillation is cast into 15%～25%, and the inventive method is cast into 12%～15%.Relatively as seen, the present invention has the most shallow liquid cave, minimum gross segregation.
Embodiment 3:MA2-1 magnesium alloy Φ 300mm ingot blank vertical semi-continuous casting
According to proportioning melting MA2-1 (the Russian trade mark is equivalent to AZ41) magnesium alloy, and it is fire-retardant to realize to add 20ppmBe; Cover is for being inlaid with the hot top formula metal pattern of graphite annulus and hot top in the crystallizer; Melt is no ultrasonic preliminary treatment in tundish, applies power ultrasonic and low frequency electromagnetic collaborative in crystallizer.
The casting technique condition is: casting speed is 100mm/min; Φ 20mm low-carbon steel material ultrasonic amplitude transformer is at 300 ℃ of preheating 1h; Supersonic frequency is 20kHz, and ultrasound intensity is about 10W/cm
2680 ℃ of melt temperatures in the tundish; A-c cycle 25Hz, intensity 6000AT.
Fig. 6 is that the tissue of the MA2-1 magnesium alloy Φ 300mm ingot blank of traditional D.C.casting, low frequency electromagnetic vertical semi-continuous casting and vertical type semi-continuous casting method of the present invention acquisition compares.As seen, traditional D.C.casting tissue is mainly thick rosiness crystal grain, and center crystal grain is obviously thicker than limit portion, and the centre grain size reaches 400 μ m～500 μ m; The refinement of low frequency electromagnetic D.C.casting Faxian work the tissue of center and limit portion, it is irregular that grain shape becomes, but the center is still comparatively thick, grain size is 100 μ m～200 μ m; The ingot blank that adopts the present invention to produce is organized then even and tiny, and mean grain size is less than 100 μ m.
Embodiment 4:Al-11Si binary aluminium alloy Φ 100mm ingot blank vertical semi-continuous casting
According to proportioning melting Al-11Si binary aluminium alloy, cover is the duralumin mould in the crystallizer.Apply in the technology of ultrasonic field and the collaborative outer field action of low frequency electromagnetic field at crystallizer, the tundish melt is through ultrasonic preliminary treatment.
The casting technique condition is: casting speed is 120mm/min; Φ 20mm luffing bar (GH605 high temperature Co-base alloy material is made) is at 350 ℃ of preheating 1h; Supersonic frequency is 20kHz, and ultrasound intensity is about 10W/cm
2730 ℃ of melt temperatures in the tundish; A-c cycle 30Hz, intensity 7200AT.Tundish melt treatment supersonic frequency is 20kHz, and ultrasound intensity is about 20W/cm
2
Fig. 7 is that the tissue of the Al-11Si binary hypoeutectic aluminium alloy Φ 100mm ingot blank of traditional D.C.casting, low frequency electromagnetic vertical semi-continuous casting and vertical type semi-continuous casting method of the present invention acquisition compares.As seen, the primary-Al crystal grain in traditional D.C.casting tissue is thick especially and the centre is bigger than limit portion; In the single low frequency electromagnetic casting tissue that applies low frequency electromagnetic field, the primary-obvious refinement of Al crystal grain, but the centre is still thick than limit portion, and grain orientation is obvious; Adopt the ingot blank primary-further refinement of Al crystal grain of low frequency electromagnetic of the present invention and supersonic synergetic effect method (Fig. 2) preparation, the orientation of grain growth also significantly reduces, and the tissue differences of center and limit portion is also very little.
Claims (5)
1. power ultrasonic and the big specification ingot blank of the synergistic light-alloy of low frequency electromagnetic vertical type semi-continuous casting method, its processing step comprises: the light-alloy melt after molten alloy and process refining and the purified treatment, enter in the crystallizer through tundish, the magnet exciting coil of crystallizer configuration is switched on, start in casting machine and the crystallization control device after the liquid level stabilizing, ultrasonic amplitude transformer through preheating is immersed in the crystallizer melt liquid level, maybe will immerse the tundish melt liquid level through the ultrasonic amplitude transformer of preheating, immerse again in the crystallizer melt liquid level, apply ultrasonic wave, it is characterized in that adopting and to apply power ultrasonic and two kinds of big specification ingot blanks of the synergistic light-alloy in outfield of low frequency electromagnetic vertical semi-continuous casting equipment, in casting process, apply low frequency electromagnetic field and power ultrasonic field simultaneously or apply the low frequency electromagnetic oscillation field simultaneously and the power ultrasonic field, the power ultrasonic field action is in crystallizer axis position, electromagnetic field effect is in the metal bath near surface, adjusting by two kinds of outfield parameters realizes synergy, makes to realize in the crystallizer melt solidifying process that the full volumetric outer field action casts.
2, the big specification ingot blank of the synergistic light-alloy of power ultrasonic and low frequency electromagnetic vertical type semi-continuous casting method according to claim 1 is characterized in that described two kinds of outfield parameters are, the supersonic frequency that is applied is 18kHz～28kHz, and ultrasound intensity is 3W/cm
2～50W/cm
2, be 5s～180s ultrasonic effective time, or to apply the impulse ultrasound frequency be 18kHz～28kHz, pulsewidth is 10
-4S～10
-1S, ultrasound intensity are 7W/cm
2～80W/cm
2, the ultrasonication time is 10s～250s; The low frequency electromagnetic frequency range that is applied is 1Hz～90Hz, and intensity is 2000AT～40000AT, and static magnetic field strength is 1500AT～30000AT; Melt temperature in the casting tundish is controlled at and is higher than 50 ℃～100 ℃ of liquidus temperatures, and casting speed is 20mm/min～300mm/min.
3, the used equipment of the big specification ingot blank of the synergistic light-alloy of power ultrasonic and low frequency electromagnetic vertical type semi-continuous casting method according to claim 1, comprise melt stove, tundish, crystallizer, it is characterized in that in crystallizer water jacket inside or outside or top dispose one group of magnet exciting coil, and logical with low frequency ac; Or in crystallizer water jacket inside or outside or top dispose one group and pass to low frequency ac and one group and pass to galvanic two groups of built-in magnet exciting coils, any of two kinds of configurations is all above the crystallizer or be provided with the ultrasonic amplitude transformer that is contained on the traversing carriage simultaneously above tundish and crystallizer in the above.
4, the used equipment of the big specification ingot blank of the synergistic light-alloy of power ultrasonic as claimed in claim 3 and low frequency electromagnetic vertical type semi-continuous casting method, it is characterized in that described be equipped with can above the crystallizer or the traversing carriage of the ultrasonic amplitude transformer that above tundish and crystallizer, moves simultaneously to carry out three-dimensional by step motor control mobile.
5, as claim 3 or 4 described power ultrasonics and the used equipment of the big specification ingot blank of the synergistic light-alloy of low frequency electromagnetic vertical type semi-continuous casting method, it is characterized in that must the ultrasonic amplitude transformer of configuration more than 2 greater than the ingot blank of 500mm greater than Ф 500mm or thickness when casting diameter.
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