CN101435064B - High sound intensity ultrasonic processing apparatus for metal and alloy solidification and processing method thereof - Google Patents
High sound intensity ultrasonic processing apparatus for metal and alloy solidification and processing method thereof Download PDFInfo
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Abstract
The invention provides an ultrasonic processing device with high sound intensity, which is used for grain refining, degassing and ingredient homogenization when the metal and the alloy are solidified in a high temperature and comprises an ultrasonic generator, a transducer, an amplitude variable rod and a coupling head; wherein, the ultrasonic generator comprises a frequency phase locking tracking module, which is used for automatically carrying out tracking and detection to working frequency of the ultrasonic generator and adjusting matching frequency, thereby the high frequency resonance of the ultrasonic generator and the transducer is achieved. By adopting the frequency phase locking tracking module, the decrease and drift problems of frequency are solved and even in different high-temperature melts, the ultrasonic effect same as that of starting at rated frequency can also be obtained, thus realizing grain refining, degassing and ingredient homogenization when the metal and the alloy are solidified.
Description
Technical field
The present invention relates to a kind of high sound intensity ultrasonic processing apparatus and treatment process thereof, relate in particular to the high sound intensity ultrasonic processing apparatus and the treatment process thereof that when metal and alloy graining, can realize grain refining, degasification and homogenization of composition.
Background technology
When metal and alloy graining, the continuous refinement, degasification that how to realize crystal grain effectively more thoroughly and composition more even, be the hot subject that people study always.This be because; For the solidifying of various metals and alloy; Although the grain-refining agent of each self application and separately degasification method and homogenization of composition method are arranged respectively, still there are problems such as thinning effect is not ideal enough, degasification is not thorough, uneven components to some extent.
For example; As far as aluminium and duraluminum; Although the commercial master alloy grain-refining agent as aluminium titanium boron is arranged at present; But the problem that at least also has following two aspects, the one, these master alloy grain-refining agents can not be used for the grain refining of rafifinal, and the 2nd, these master alloy grain-refining agents can not suppress the solidifying segregation of some alloys completely effectively.
For another example, as far as magnesium and magnesiumalloy, people never find a kind of effect not have various circumscribed master alloys to adapt to various refinement requirements of solidifying crystal grain significantly again.For example, during some magnesium alloy solidification grain refining composition there is strict requirement, thereby the application of some master alloy grain-refining agents is restricted (magnalium like calcic or strontium is an alloy); Some magnesiumalloy (like the magnesium Mn series alloy) just can not use or not have master alloy to come refinement to solidify crystal grain originally; Some magnesiumalloy (like Mg-Zn based alloy), though there is effective master alloy thinning method, cost is higher.
Therefore, the method beyond the master alloy grain-refining agent of seeking to use come effectively or significantly fining metal and alloy solidify crystal grain, just seem particularly urgent and important.
Equally, as far as the degasification or the homogenization of composition problem of these alloys, be necessary that also the means of seeking beyond the conventional art solve in the lump.
In the prior art, to the problems referred to above, the main countermeasure of taking both at home and abroad is that the utilization physical field comes refinement to solidify crystal grain and homogenizing composition.The physical field here mainly is meant electric field, magnetic field and ultrasonic field.It is relatively large that but electricity, magnetic field refinement method are invested, complicated operation, and handiness is not good enough, and effect is limited.In addition, active area in melt or scope also have relative limitation.Ultrasonic field is as a kind of novel physical means, can fining metal and alloy solidify crystal grain, carry out degasification and homogenizing alloying constituent, but the research that utilizes this technology that metal and alloy are handled is also very flourishing.Tracing it to its cause, mainly is because for a long time the short period of time in continuous solidification pattern and the laboratory solidifies pattern and has than big difference in the industrial production reality.When ultrasonic coupling head was in the high-temperature fusant for a long time, significant drift can take place in its resonant frequency, and then caused impedance and frequency not to match, and made that at last the supersound process effect is relatively poor.
Summary of the invention
The present invention proposes in order to address the above problem, and its purpose is to provide a kind of high sound intensity ultrasonic processing apparatus and treatment process thereof that when metal and alloy graining, can realize grain refining, degasification and homogenization of composition.
A kind of high sound intensity ultrasonic processing apparatus provided by the invention; Be used for metal and alloy high-temp melt solidifying field fashionable grain refining, degasification and homogenization of composition; It comprises ultrasonic generator, transverter, horn and coupling head, and wherein, said ultrasonic generator comprises the frequency phase lock tracking module; Matching frequency is followed the tracks of, detects and regulated to operating frequency to said ultrasonic generator automatically, realizes the high-frequency resonance of said ultrasonic generator and transducer system.
A kind of high sound intensity ultrasonic processing method provided by the invention; Grain refining, degasification and homogenization of composition when utilizing above-mentioned high sound intensity ultrasonic processing apparatus that metal and alloy are solidified; Wherein, the useful output of said ultrasonic generator is below the 1000W.
According to formation of the present invention; Through adopting the frequency phase lock tracking module; Solved frequency decline drifting problem; Even in different high-temperature fusants, also can obtain ultrasonic effect identical when starting shooting at the rated frequency place, thus grain refining, degasification and homogenization of composition when realizing metal and alloy graining.
Description of drawings
Fig. 1 is the synoptic diagram of the working order when representing to utilize the high sound intensity ultrasonic processing apparatus that the present invention relates to handle solidified melt.
Fig. 2 a, 2b are the synoptic diagram that is illustrated in the structure of the linear pattern coupling head that uses in the high sound intensity ultrasonic processing apparatus that the present invention relates to and flexure type coupling head.
Fig. 3 is the synoptic diagram that is illustrated in the structure of the coupling head with water-cooled or air cooling structure that uses in the high sound intensity ultrasonic processing apparatus that the present invention relates to.
Fig. 4 a, 4b be expression utilize the high sound intensity ultrasonic processing apparatus that the present invention relates to carry out before the thinning processing to the A356 alloy and handle after the micro-comparison diagram of alloy graining grain size.
Fig. 5 a, 5b be expression utilize the high sound intensity ultrasonic processing apparatus that the present invention relates to carry out before the thinning processing to the AZ31 alloy and handle after the micro-comparison diagram of alloy graining grain size.
Fig. 6 a～6f is that expression utilizes the high sound intensity ultrasonic processing apparatus that the present invention relates to that several kinds of duraluminums are carried out before the degassing processing (Fig. 6 a, 6c, 6d) and handle the alloy macro morphology comparison diagram of (Fig. 6 b, 6d, 6f) afterwards.
Fig. 7 a～7d is that the high sound intensity ultrasonic processing apparatus that expression utilization the present invention relates to carries out the alloy microscopic structure comparison diagram that homogenizing is handled preceding (Fig. 7 a, 7c) and processing back (Fig. 7 b, 7d) to the Al-14Si alloy.
Embodiment
Below, the preferred embodiments that present invention will be described in detail with reference to the accompanying.
Fig. 1 is the synoptic diagram of the working order when representing to utilize the high sound intensity ultrasonic processing apparatus that the present invention relates to handle solidified melt.As shown in the drawing, high sound intensity ultrasonic processing apparatus mainly comprises ultrasonic generator 1, transverter 2, horn 4 and coupling head 5.In addition, also have the water coolant gangway 3 that is used to supply with water coolant, metal and alloy melt 7 are housed in container 6, can measure temperature as the melt of process object through the thermopair 8 that is inserted in the melt 7.This container 6 is set on the support of vessel member 10, and support 9 is used to support high sound intensity ultrasonic processing apparatus.
Ultrasonic generator in the past can only reach a rated frequency place at normal temperatures and obtain best ultrasonic effect; But in high-temperature fusant because temperature raises, acoustic resistance increases and when causing frequency to take place to descend drift significantly, just can not obtain the ideal treatment effect this moment.Therefore, in ultrasonic generator 1 of the present invention, adopt the frequency phase lock tracking technique, guaranteed the high-frequency resonance of radio-frequency generator and transverter.As the phaselock technique of using in the ultrasonic generator, for example can adopt the technology of utilizing phase differential feedback to realize the lock phase, or utilize current feedback to realize the technology etc. of lock phase.
The present invention is through adopting the circuit that the operating frequency of ultrasonic generator 1 is detected, follows the tracks of and regulates matching frequency automatically; After having solved frequency decline drifting problem; Even in different high-temperature fusants; When frequency is drifted about (the rated frequency 20kHz as from design floats to 15kHz) in very wide scope; Also can regulate, and be complementary, thereby obtain ultrasonic effect identical when starting shooting at the rated frequency place with the practical impedance of coupling head 5 in melt 7 through frequency tracking circuit.
Moreover ultrasonic generator in the past generally is designed to non-stop run, but 1 of the ultrasonic generator among the present invention is according to the difference of melt temperature and the difficulty or ease of grain refining, degasification and homogenization of composition, and is designed to continuously and is interrupted two kinds of patterns of work.Transverter in the past often efficiency of conversion is not high, though the rated output of design is very big, actual converted efficient is lower.Moreover, the excessive life-span that also is unfavorable for very much transverter of power.
Adopt among the present invention transverter, optimized transformational structure through Mechanics Calculation, can obtain efficiency of conversion near ideal value, therefore, when under technical scale, using, the useful output of ultrasonic generator only can meet the demands below the 1000W.
For for the horn in the high sound intensity ultrasonic processing apparatus of the present invention 4, adopt solid construction usually.But in this embodiment, different according to the melt of handling, horn 4 both can adopt solid construction in the past, also can adopt hollow structure.When being designed to hollow structure, wherein can feed water or pressurized gas cools off, be used for reducing the temperature and the acoustic resistance effect of horn 4.
Shown in Fig. 2 a, the coupling head that in ultrasonic unit, uses generally is designed to direct rod shape, and this helps processing and economical with materials cost.But the coupling head 5 that in high sound intensity ultrasonic processing apparatus of the present invention, uses can be designed to direct rod shape or bending (comprising bending) according to the particular case of mold or casting roller.Fig. 2 b shows a kind of flexure type coupling head 5, and the bottom of this coupling head 5 forms lower knuckle portion towards a certain direction bending, thereby makes whole coupling head form the flexure type coupling head.In this flexure type coupling head 5, the central axis of the vertical part on top can be in 5 °～60 ° scope, suitably to choose with the angle that central axis became (being bending angle) of lower knuckle portion, preferably 5 °～45 ° scope.Through adopting aforesaid flexure type coupling head 5; Can further bring into play the acoustic streaming effect (promptly in ultrasonic field, forming stabilized uniform liquid-flow on the both macro and micro) of high sound intensity ultrasonic processing apparatus of the present invention, ultrasonic " dead angle " that occurs in the time of can preventing to carry out ultrasonication.
Fig. 3 is the structural representation that is illustrated in the coupling head with water-cooled or air cooling structure 5 that uses in the high sound intensity ultrasonic processing apparatus that the present invention relates to.Coupling head in the past generally is a solid construction; But the coupling head 5 that uses among the present invention can be according to the different hollow structures that are designed to of the melt of handling; The metal hollow structure of complicated shape can wherein flow through water coolant or cooling gas through electron beam technology processing, carries out water-cooled or air cooling; Reduce the temperature of coupling head 5, thereby reduce its acoustic resistance.For example, for aluminium and aluminium alloy melt, coupling head can be designed to hollow water-cooled or air cooling structure.In addition, the material of the coupling head 5 among the present invention can be selected a kind of in the materials such as titanium alloy, niobium alloy, silicon nitride, sintering metal according to the different melt situation for use.
In order to reduce the quantity of coupling head 5 in melt as far as possible; Be beneficial in actual production, operate; The present invention will be according to metal and alloy cast ingot or strand size design coupling head quantity and size; Even but for larger-size D.C.casting blank in the present industry (is the billet of 1200mm, the slab ingot of 1200mm * 400mm like diameter), coupling head quantity also only needs 3～4 and gets final product.
When in industrial production reality, using, as long as coupling head is directly inserted metal and the following certain depth of alloy melt and opens ultrasonic generator and water-cooled or air cooling system.Container (case for example) position and size when the concrete on position of coupling head and the degree of depth will be according to D.C.castings when actual mold size or continuous casting and rolling are confirmed, but must be guaranteed that ultrasonic energy is radiated on the solid-liquid interface of solidifying.
When the high sound intensity ultrasonic processing apparatus of in utilizing the present invention, putting down in writing is handled metal and solidification of Al, can also utilize for example master alloy grain refining method simultaneously.Like this, when these two kinds of diverse ways are used in stack, can further strengthen solidifying the thinning effect of crystal grain.This is because under the high sound intensity ultrasonic field effect that high sound intensity ultrasonic processing apparatus of the present invention produced, and joins the heterogeneous core in the melt through the master alloy grain-refining agent, has obtained more forming core chance.
High sound intensity ultrasonic processing method as utilizing above-mentioned high sound intensity ultrasonic processing apparatus that metal and solidification of Al are handled can have following specific embodiment.
(embodiment 1) is when directly being used for metal and alloy melt sand mold and solidifying situation; Crooked coupling head 5 directly is inserted in the dead head place, and a dead head place settles a coupling head 5, and coupling head inside gets final product for solid construction; Shown in accompanying drawing 1, this moment, the position at container 1 place was equivalent to sand mold.
(embodiment 2) when directly being used for metal and alloy melt D.C.casting, its coupling head quantity is different and different according to the mold size; When being circular mold and diameter during, an available coupling head less than 300mm; When diameter during greater than 300mm but less than 1200mm, get final product with 2～4 coupling heads, coupling head can be on the transverse section uniform distribution; Increase again like diameter, can suitably increase coupling head quantity according to practical situation; When being metal and alloy side's ingot or slab ingot, if cross-section lengths direction size between 300～500mm the time, is selected crooked coupling head for use.
When directly being used for metal and alloy continuous casting and rolling, its coupling head quantity can decide according to preceding case size and dimension of roller (embodiment 3), the general coupling head that 1～3 bending is set in preceding case.
(embodiment 4) are when directly being used for aluminium and aluminium alloy melt D.C.casting; Coupling head 5 can be selected niobium alloy or silicon nitride material for use; Its shape can be direct rod shape, also can be bending (bending angle is suitably chosen from 5 °～60 ° scope, preferably 5 °～45 ° scope); Its inside can be solid construction, also can be hollow structure; Head can be put down, and also can be round.
(embodiment 5) when directly being used for magnesium and magnesiumalloy D.C.casting, coupling head 5 can be selected a kind of material in titanium alloy, niobium alloy or the silicon nitride for use, and its shape can be a direct rod shape; It also can be bending; Head can be flat, also can be roundly, but inside is merely solid construction.
(embodiment 6) are when directly being used for aluminium and duraluminum continuous casting and rolling; Coupling head 5 can be selected niobium alloy or silicon nitride material for use; Its shape can be direct rod shape, also can be bending (bending angle is suitably chosen from 5 °～60 ° scope, preferably 5 °～45 ° scope); Inside can be solid, also can be hollow.
(embodiment 7) are when directly being used for magnesium and magnesiumalloy continuous casting and rolling; Coupling head 5 can be selected titanium alloy, niobium alloy or silicon nitride material for use; Its shape can be direct rod shape; Also can be flexure type (bending angle is suitably chosen, preferably 5 °～45 ° scope) from 5 °～60 ° scope, but inside is merely solid construction.
(embodiment 8) when being used for steel fusant, the material of said coupling head is a sintering metal, but inside is merely solid construction.
Can carry out with reference to each above-mentioned embodiment when directly being used for other metal and alloy melt (like copper alloy, zinc alloy, iron alloy etc.) (embodiment 9).
When high sound intensity ultrasonic processing apparatus of the present invention directly was used for aluminium and aluminum grain refinement, its effect was shown in Fig. 4 a, 4b; When directly being used for magnesium and magnesium alloy grains, its effect is shown in accompanying drawing 5a, 5b; When directly being used for removing the gas of aluminium and aluminium alloy melt, its effect is shown in accompanying drawing 6a～6f; When directly being used for homogenizing al alloy component, minimizing segregation, its effect is shown in accompanying drawing 7a～7d.From above each figure, can see that adopt after the high sound intensity ultrasonic processing apparatus of the present invention, grain refining effect, degassing effect and uniformization effect are very obvious.Wherein, Shown in Fig. 7 a～7d, before utilizing the present invention to handle (Fig. 7-a, 7c), serious solidifying segregation has taken place in primary silicon mutually at the position up and down of ingot casting; Utilize the present invention to handle back (Fig. 7-b, 7d), solidifying segregation does not take place in ingot casting position primary silicon mutually up and down.
Though described principle of the present invention and embodiment to high sound intensity ultrasonic processing apparatus and treatment process above; But; Under above-mentioned guiding of the present invention; Those skilled in the art can carry out various improvement and distortion on the basis of the foregoing description, and these improve or distortion drops in protection scope of the present invention.It will be understood by those skilled in the art that top specific descriptions just in order to explain the object of the invention, are not to be used to limit the present invention.Therefore, thought of the present invention is not limited to above illustrated example, and thought category of the present invention not only comprises the scope of claims record, also comprises with claim being equal to or distortion of equal value.
Claims (10)
1. a high sound intensity ultrasonic processing apparatus is used for metal and alloy high-temp melt solidifying field fashionable grain refining, degasification and homogenization of composition, and it comprises ultrasonic generator, transverter, horn and coupling head, it is characterized in that,
Said ultrasonic generator comprises the frequency phase lock tracking module, and matching frequency is followed the tracks of, detects and regulated to the operating frequency of said ultrasonic generator automatically, realizes the high-frequency resonance of said ultrasonic generator and transducer system;
Said coupling head comprises the top and bend crooked or bending of direct rod shape, and the angle between the central axis on the top of said direct rod shape and the central axis of said bend is 5 °～60 °;
Said horn is a hollow structure, wherein feeds water coolant or pressurized air cools off;
Described coupling head is a hollow structure, wherein feeds water coolant or pressurized air cools off.
2. high sound intensity ultrasonic processing apparatus according to claim 1 is characterized in that,
Angle between the central axis on the top of said coupling head direct rod shape and the central axis of said bend is 5 °～45 °.
3. high sound intensity ultrasonic processing apparatus according to claim 1 and 2 is characterized in that,
The material of described coupling head is different according to melt, selects a certain in titanium alloy, niobium alloy, silicon nitride, the sintering metal for use.
4. high sound intensity ultrasonic processing method utilizes grain refining, degasification and homogenization of composition when like the described high sound intensity ultrasonic processing apparatus in claim i～3 metal and alloy being solidified, it is characterized in that,
The useful output of said ultrasonic generator is below the 1000W.
5. high sound intensity ultrasonic processing method according to claim 4 is characterized in that,
When being used for metal and alloy melt sand mold and solidifying situation, make crooked coupling head directly be inserted in the dead head place, a dead head place settles a coupling head.
6. high sound intensity ultrasonic processing method according to claim 4 is characterized in that,
When being used for metal and alloy melt D.C.casting, said coupling head quantity is different and different according to the mold size; When being circular mold and diameter during, adopt a said coupling head less than 300mm; When diameter during, adopt 2～4 said coupling heads greater than 300mm but less than 1200mm; Coupling head is uniform distribution on the transverse section.
7. high sound intensity ultrasonic processing method according to claim 4 is characterized in that,
When being used for metal and alloy continuous casting and rolling, 1～3 coupling head is set in preceding case.
8. high sound intensity ultrasonic processing method according to claim 4 is characterized in that,
When being used for aluminium and aluminium alloy melt, the material of coupling head is niobium alloy or silicon nitride.
9. high sound intensity ultrasonic processing method according to claim 4 is characterized in that,
When being used for magnesium and magnesium alloy fused mass, the material of coupling head is selected a certain in titanium alloy, niobium alloy or the silicon nitride for use.
10. high sound intensity ultrasonic processing method according to claim 4 is characterized in that,
When being used for steel fusant, the material of said coupling head is a sintering metal.
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| US9382598B2 (en) | 2010-04-09 | 2016-07-05 | Southwire Company, Llc | Ultrasonic device with integrated gas delivery system |
| US9528167B2 (en) | 2013-11-18 | 2016-12-27 | Southwire Company, Llc | Ultrasonic probes with gas outlets for degassing of molten metals |
| EP3583233A4 (en) * | 2017-02-17 | 2020-12-02 | Southwire Company, LLC | Ultrasonic grain refining and degassing procedures and systems for metal casting including enhanced vibrational coupling |
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