CN105149529B - A kind of temperature control type metal casting method - Google Patents
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Abstract
The invention provides a kind of temperature control type metal casting method, comprise the following steps：Step 1：Molten metal in crucible is stirred, reaches that composition is well mixed, uniformity of temperature profile；Step 2：Molten metal in crucible is flowed into uniforming device by mozzle；Step 3：Molten metal is formed by homogenization turbulent flow by the effect of the helical pipe of uniforming device, and in the presence of cooling pipe, the metal temperature of uniforming device outlet is reduced to subsolidus；Step 4：In the presence of stretching device, by the metal continuous drawing of uniforming device outlet into metal strand.Temperature control type metal casting method provided by the invention, the metal casting surface gloss of preparation is high, internal structure is fine and close, grain size is homogeneous, segregation-free and crackle moreover, plasticity is high, quality is high, and saves the energy, simplify technique, production efficiency height.
Description
Technical Field
The invention relates to the technical field of metal casting, in particular to a temperature control type metal casting method.
Background
The metal casting is a technological process of smelting metal into liquid meeting certain requirements, pouring the liquid into a casting mold, cooling, solidifying and cleaning to obtain a casting with a preset shape, size and performance. It plays a significant role in the production of metals. With the increasing variety of metal materials and products, the rapid expansion of application fields, the rapid development of high and new technologies and the increasing improvement of living standard of people, the world faces the current situations of environment deterioration and resource and energy shortage, and the requirements on energy conservation, consumption reduction, short flow, high efficiency, low cost and casting blank quality in the metal casting process are higher and higher.
The casting molds adopted by the prior metal casting mainly comprise a cooling casting mold (called a cold mold for short), a heating casting mold (called a hot mold for short) and a two-phase region casting mold. The cooling casting mold is mostly adopted in large-scale industrialization, namely, circulating water is applied to the periphery of the casting mold for forced cooling, so that the temperature of the casting mold is far lower than the solidus temperature of metal, metal melt is firstly solidified under the quenching action of the casting mold and gradually grows towards the center, and finally, the casting blank with fine isometric crystals, columnar crystals vertical to the surface and coarse isometric crystals in microstructure from the surface to the core part of the casting blank is obtained. The process is easy to form dendritic crystals, and generates the defects of segregation, shrinkage cavity, looseness and the like, thereby influencing the quality of castings. The heating casting mold is to cool the solidified metal forcibly near the outlet of the casting mold, and to establish a high temperature gradient along the casting direction between the solidified metal and the unset melt, so that the solidified metal and the unset melt have a directional solidification condition, and an infinitely long casting blank with a unidirectional solidified continuous columnar crystal or single crystal structure is continuously obtained. The hot continuous casting method can obtain continuous columnar crystals with good surface smoothness, but high energy consumption and low production efficiency. The two-phase zone casting method is characterized in that the temperature of a casting mold is controlled within the temperature range of a solid-liquid two-phase zone of metal, and solidified metal is forcibly cooled near the outlet of the two-phase zone casting mold to obtain a casting blank. The process can move a good casting blank, but cannot be used for casting and forming of pure metal and eutectic alloy, and has the defects of high casting mold heating temperature, high energy consumption, not too fast blank drawing speed and the like. Therefore, the development of the casting equipment and the casting method which have the advantages of energy conservation, high production efficiency and high yield can improve the surface finish and the internal density of the metal casting blank, and has very important significance.
Chinese patent 201310053924.3 provides a gravity casting method of metal mold: after the molten metal is gravity-cast into a metal mold, an extrusion rod is used for vertically and downwards extruding the mold cavity at the position of a mold pouring cup, so that the liquid metal is solidified and flow-formed under pressure, and the solidified metal is subjected to plastic deformation under pressure, so that a casting has no defects of shrinkage cavity, shrinkage porosity and the like, the structure is fine, the mechanical property is improved, the dead head and the machining allowance are reduced, and the metal utilization rate is high. However, the prior art is only suitable for pure metal casting, and for alloy castings, due to the influence of gravity factors, the components in the cast and formed devices are not uniform, and the overall quality of the castings is finally influenced.
Chinese patent 201310140939.3 provides a warm mold casting method, which is characterized in that: heating the casting mold by a heater, or heating the casting mold by utilizing heat conducted by metal melt before entering the casting mold, so that the temperature of the casting mold is kept in a range which is lower than the solidus temperature of metal and higher than the temperature of the cooling casting mold; forcibly cooling the metal by a cooler arranged near the outlet of the casting mold; and drawing the metal casting blank by using a traction mechanism. Although the prior art provides the device for the warm mold casting method, the device has different temperatures in the middle and the periphery of the molten metal during the casting process, so that the crystal grains are not uniform in size, and the strength of the casting is finally affected. It can be seen that this technique also does not completely solve the problem of metal casting quality.
Disclosure of Invention
In order to overcome the problems of high energy consumption, non-compact internal structure of the casting, non-uniform grain size and the like in the casting in the prior art, the invention provides the temperature control type metal casting method.
The invention firstly discloses a temperature control type metal casting device, which comprises a material containing device, a homogenizing device and a stretching device, and is characterized in that: the material containing device comprises a crucible, a crucible top cover, an electromagnetic stirrer and a flow guide pipe; the homogenizing device comprises a spiral pipeline, an internal heat-insulating layer, a cooling pipeline and an external heat-insulating layer; the stretching device comprises a heating device and a traction mechanism; the electromagnetic stirrer coats the periphery of the material containing device; the connection relationship is as follows: the upper end of the homogenizing device is connected with a guide pipe below the material containing device; the stretching device is connected with the lower end of the homogenizing device. The material containing device further comprises a heat conducting rod, the lower end of the heat conducting rod is a spherical surface, and the heat conducting rod is vertically inserted into the central position of the crucible.
The invention also discloses a temperature control type metal casting method, which comprises the following steps:
the method comprises the following steps: stirring the molten metal in the crucible to ensure that the components are uniformly mixed and the temperature is uniformly distributed;
step two: the molten metal in the crucible flows into the homogenizing device through the guide pipe;
step three: the molten metal is formed into uniform turbulence under the action of a spiral pipeline of the homogenizing device, and the temperature of the metal at the outlet of the homogenizing device is reduced to be below a solidus line under the action of a cooling pipeline;
step four: and continuously drawing the metal at the outlet of the homogenizing device into a metal casting blank under the action of a drawing device.
Further, the first step also comprises the step of conducting heat at the center of the crucible out in time through the heat conducting rod.
Further, the fourth step also comprises the step of regulating and controlling the temperature of the prestretched metal through a heating device at the upper part of the traction mechanism.
Further, the stirring mode in the first step is electromagnetic stirring.
Further, the spiral pipeline of the homogenizing device in the third step is of a single-spiral or double-spiral structure.
Further, the tangential force f of the molten metal at the edge of the crucible in the first stepDSatisfy the following relationship
Wherein f isDIs the tangential force of the metal liquid at the edge of the crucible;
d is the diameter of the crucible;
B0the magnetic induction intensity of the molten metal;
σ is the conductivity of the incoming melt;
omega is the angular frequency of the induction coil;
t is the stirring time;
μ is the magnetic permeability.
Further, the relationship between the length L of the spiral pipeline of the homogenizing device in the third step and the included angle θ between the pipeline and the horizontal plane is as follows:
wherein L is the length of the spiral pipeline;
rho is the density of the molten metal;
g is the acceleration of gravity;
zeta is the heat conduction coefficient of the molten metal;
theta is an included angle between the spiral pipeline and the horizontal plane;
t1the temperature of the molten metal at the lower port of the spiral pipeline;
t2the temperature of the molten metal at the upper port of the spiral pipeline;
t is the temperature difference of the metal melt in unit time.
x is the displacement of the molten metal in the x direction in unit time;
y is the displacement of the molten metal in the y direction in unit time;
z is the displacement of the molten metal in the z direction per unit time;
Nithe number of the metal melting liquid in unit time is shown, wherein i is 1,2, 3, … … n.
In an optional embodiment of the present invention, in the first step, the heat conducting rod is a graphite rod or a silicon carbide rod, and is coated with a refractory material layer.
In an optional embodiment of the present invention, in the first step, the heat conducting rod metal rod is a double-layer sleeve, the outer-layer sleeve is a high-melting-point metal pipe, the inner-layer sleeve is a low-melting-point metal pipe, and the circulating water flows in from the inner-layer metal pipe and flows out from the outer-layer metal pipe.
Further, the homogenizing device and the horizontal plane form an inclined included angle, and the included angle is 15-45 degrees, preferably 30 degrees.
Furthermore, the inner wall of the spiral pipeline of the homogenizing device is provided with spiral grains, so that the pipeline is a spiral channel, and the spiral channel can be in a single-spiral structure or a multi-spiral structure, such as a double-spiral structure, a triple-spiral structure and the like.
Compared with the prior art, the invention has the beneficial effects that:
(1) the temperature control type metal casting method provided by the invention adopts electromagnetic stirring to uniformly mix all components of molten metal in the crucible, and transmits the heat in the central area of the crucible out in time through the heat conducting rod, thereby enhancing the heat dissipation in the molten metal, improving the uniformity of temperature field distribution, and utilizing the refinement of metal crystal grains.
(2) According to the temperature control type metal casting method provided by the invention, the spiral pipeline is adopted in the process steps, so that strong turbulence is generated in the metal liquid, the formation of laminar flow is avoided, the purpose of refining crystal grains is further achieved, and the uniform distribution of a temperature field and a component field is realized.
(3) According to the temperature control type metal casting method provided by the invention, the upper part of the traction mechanism is heated, so that the metal casting is in the temperature range with the optimal plasticity during traction, and the influence on the overall performance of the casting due to the occurrence of microcracks inside the metal casting during traction is avoided.
(4) The temperature control type metal casting method provided by the invention can be almost applied to all metal casting forming, such as pure metal and alloy (such as aluminum alloy, copper alloy, titanium alloy, magnesium alloy and the like), can be used for forming metal castings, and can also be used for producing products such as metal wires, bars, strips, pipes, plates and the like.
Drawings
FIG. 1 is a schematic view of a casting apparatus used in the temperature-controlled metal casting method provided by the present invention;
FIG. 2 is a schematic structural view of a heat conductive rod of inventive example 2;
FIG. 3 is a schematic sectional view of a heat conductive rod of inventive example 2;
the reference numerals in fig. 1 illustrate:
a material containing device 100, a homogenizing device 200 and a stretching device 300; the crucible comprises a crucible 1, a crucible top cover 2, an electromagnetic stirrer 3, a heat conducting rod 4, metal liquid 5, a flow guide pipe 6, a spiral pipeline 7, an internal heat insulation layer 8, a cooling pipeline 9, an external heat insulation layer 10, a heating device 11 and a traction mechanism 12;
reference numbers in fig. 2-3 illustrate:
arrows indicate fluid direction, x indicates fluid entry direction, and x indicates fluid exit direction.
Detailed Description
The present invention will be described in further detail with reference to the following drawings and examples. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.
Example 1
As shown in fig. 1, a temperature-controlled metal casting apparatus includes a material containing device 100, a homogenizing device 200, and a stretching device 300; the material containing device 100 comprises a crucible 1, a crucible top cover 2, an electromagnetic stirrer 3 and a flow guide pipe 6; the homogenizing device 200 comprises a spiral pipeline 7, an internal heat-insulating layer 8, a cooling pipeline 9 and an external heat-insulating layer 10; the stretching device 200 comprises a heating device 11 and a traction mechanism 12; the electromagnetic stirrer 3 covers the periphery of the material containing device. In addition, the connection relationship among the material containing device 100, the homogenizing device 200 and the stretching device 300 is as follows: the upper end of the homogenizing device 200 is connected to the draft tube 6 below the material containing device 100, and the stretching device 300 is connected to the lower end of the homogenizing device 200.
The material containing device 100 of the temperature control type metal casting device can also comprise a heat conducting rod 4, wherein the lower end of the heat conducting rod 4 is a spherical surface and is vertically inserted into the central position of the crucible 2. The heat conducting rod 4 is a graphite rod or a silicon carbide rod, and is coated with a refractory material layer.
The heating device 11 covers the upper half part of the traction mechanism 12, and the heating device 11 adopts electromagnetic induction heating.
The homogenizing device 200 has an inclined angle with the horizontal plane, the angle is 15-45 degrees, and specifically, the angle can be 15, 20, 25, 30, 40, 45, and the like. The inner wall of the spiral pipe 7 of the homogenizing device 200 is provided with spiral threads, so that the pipe is a spiral channel, and the spiral channel can be of a single-spiral structure. The crucible 1 and the crucible top cover 2 are made of calcium oxide or magnesium oxide. The internal heat-insulating layer 8 is an alumina ceramic fiber layer, and the external heat-insulating layer 10 is made of refractory material.
The temperature-controlled metal casting device provided by the invention has the advantages that the prepared metal casting has high surface glossiness, compact internal structure, uniform grain size, no segregation and cracks, high plasticity and quality, energy conservation, simplified process and high production efficiency.
Example 2
Referring to the apparatus drawings of fig. 1-3, a temperature controlled metal casting method includes the steps of:
the method comprises the following steps: stirring the molten metal 5 in the crucible 2 to ensure that the components are uniformly mixed and the temperature is uniformly distributed; the heat at the center of the crucible 2 is conducted out in time through the heat conducting rod 4 at the center of the crucible 2;
step two: the molten metal 5 in the crucible 2 flows into the homogenizing device 200 through the draft tube 6;
step three: the molten metal 5 is made into uniform turbulence by the action of the spiral pipeline 7 of the homogenizing device 200, and the temperature of the metal at the outlet of the homogenizing device 200 is reduced to be below a solidus line under the action of the cooling pipeline 9;
step four: the temperature of the pre-stretched metal is regulated and controlled at the upper part of the traction mechanism 12 through a heating device 11; the metal at the outlet of the homogenizing device is continuously drawn into a cast metal strand by the drawing device 300.
Wherein,
the stirring mode in the first step is electromagnetic stirring, the heat conducting rod (4) is a double-layer sleeve, the outer layer sleeve is made of high-melting-point metal, the inner layer sleeve can be made of other low-melting-point metal, and circulating water flows in from the inner layer metal pipeline and flows out from the outer layer metal pipeline.
The spiral pipe 7 of the homogenizing device 200 in the third step is of a single-spiral or double-spiral structure.
In addition, the inventor conducts long-term experiments to provide the tangential force f to the molten metal at the edge of the crucible in the first stepDThe following relationships were obtained by performing the study in combination with mathematical models and mathematical relationship derivation:
wherein f isDIs the tangential force of the molten metal at the edge part of the crucible;
d is the diameter of the crucible;
B0the magnetic induction intensity of the molten metal;
sigma is the conductivity of the molten metal;
omega is the angular frequency of the induction coil;
t is the stirring time;
mu is the magnetic permeability of the molten metal.
The inventor also models the homogenization device (200) in the third step mathematically and deduces the mathematical relationship to obtain the relationship between the length L of the spiral pipeline (7) and the included angle theta between the pipeline and the horizontal plane as follows:
wherein L is the length of the spiral pipeline (7);
rho is the density of the molten metal;
g is the acceleration of gravity;
zeta is the heat conduction coefficient of the molten metal;
theta is an included angle between the spiral pipeline (7) and the horizontal plane;
t1is the temperature of the molten metal at the lower port of the spiral pipeline (7);
t2is the temperature of the molten metal at the upper port of the spiral pipeline (7);
t is the temperature difference of the metal melt in unit time.
x is the displacement of the unit molten metal in the x direction;
y is the displacement of the unit molten metal in the y direction;
z is the displacement of the unit molten metal in the z direction;
Nithe number of the metal melting liquid in unit time is shown, wherein i is 1,2, 3, … … n.
According to the temperature control type metal casting method provided by the invention, the spiral pipeline is adopted, so that strong turbulence is generated in the metal liquid, the formation of laminar flow is avoided, the purpose of refining crystal grains is further achieved, and the uniform distribution of a temperature field and a component field is realized; the upper part of the traction mechanism is heated, so that the metal casting is in the temperature range with the optimal plasticity when in traction, and the influence on the overall performance of the casting caused by the occurrence of microcracks inside the traction is avoided.
The temperature control type metal casting method provided by the invention can be almost applied to all metal casting forming, such as pure metal and alloy (such as aluminum alloy, copper alloy, titanium alloy, magnesium alloy and the like), can be used for forming metal castings, and can also be used for producing products such as metal wires, bars, strips, pipes, plates and the like.
While the foregoing description shows and describes the preferred embodiments of the present invention, it is to be understood that the invention is not limited to the forms disclosed herein, but is not to be construed as excluding other embodiments and is capable of use in various other combinations, modifications, and environments and is capable of changes within the scope of the inventive concept as described herein, commensurate with the above teachings, or the skill or knowledge of the relevant art. And that modifications and variations may be effected by those skilled in the art without departing from the spirit and scope of the invention as defined by the appended claims.
Claims (7)
1. A temperature-controlled metal casting method comprises the following steps:
the method comprises the following steps: stirring the molten metal (5) in the crucible (2) to ensure that the components are uniformly mixed and the temperature is uniformly distributed;
step two: the molten metal (5) in the crucible (2) flows into the homogenizing device (200) through the guide pipe (6);
step three: the molten metal (5) is formed into a uniform turbulent flow by the action of a spiral pipeline (7) of a homogenizing device (200), and the temperature of the metal at the outlet of the homogenizing device (200) is reduced to be below a solidus line under the action of a cooling pipeline (9);
step four: continuously drawing the metal at the outlet of the homogenizing device into a metal casting blank under the action of a drawing device (300);
the first step also comprises the step of conducting heat at the center of the crucible (2) out in time through the heat conducting rod (4).
2. A temperature controlled metal casting method as defined in claim 1, wherein: the fourth step also comprises the temperature regulation of the pre-stretched metal by the heating device (11) at the upper part of the drawing mechanism (12).
3. A temperature controlled metal casting method as defined in claim 1, wherein: and the stirring mode in the first step is electromagnetic stirring.
4. A temperature controlled metal casting method as defined in claim 1, wherein: the spiral pipeline (7) of the homogenizing device (200) in the third step is of a single-spiral or double-spiral structure.
5. A temperature controlled metal casting method as defined in claim 2, wherein: in the first step, the heat conducting rod (4) is a graphite rod or a silicon carbide rod, and a refractory material layer is coated outside the heat conducting rod.
6. A temperature controlled metal casting method as defined in claim 2, wherein: in the first step, the heat conducting rod (4) is a double-layer sleeve, the outer layer sleeve is a high-melting-point metal pipe, the inner layer sleeve is a low-melting-point metal pipe, and circulating water flows in from the inner layer metal pipe and flows out from the outer layer metal pipe.
7. A temperature controlled metal casting method as defined in claim 1, wherein: and in the second step, the homogenizing device (200) forms an inclined included angle with the horizontal plane, and the included angle is 15-45 degrees.
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| CN109524147A (en) * | 2018-12-29 | 2019-03-26 | 厦门十维科技有限公司 | The preparation method of high-conductivity composite material based on graphene |
| CN111618258B (en) * | 2020-06-10 | 2024-09-13 | 南昌大学 | Full-automatic movable semi-solid processing platform |
| CN112108615B (en) * | 2020-09-16 | 2021-11-23 | 江西晶科铝业有限公司 | Aluminum product casting solution conveying system |
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