CN110076305B - Electromagnetic semi-continuous casting method for non-ferrous metal and alloy thereof - Google Patents
Electromagnetic semi-continuous casting method for non-ferrous metal and alloy thereof Download PDFInfo
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- CN110076305B CN110076305B CN201910454986.2A CN201910454986A CN110076305B CN 110076305 B CN110076305 B CN 110076305B CN 201910454986 A CN201910454986 A CN 201910454986A CN 110076305 B CN110076305 B CN 110076305B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
- B22D11/04—Continuous casting of metals, i.e. casting in indefinite lengths into open-ended moulds
- B22D11/055—Cooling the moulds
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
- B22D11/04—Continuous casting of metals, i.e. casting in indefinite lengths into open-ended moulds
- B22D11/057—Manufacturing or calibrating the moulds
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
- B22D11/04—Continuous casting of metals, i.e. casting in indefinite lengths into open-ended moulds
- B22D11/059—Mould materials or platings
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
- B22D11/10—Supplying or treating molten metal
- B22D11/11—Treating the molten metal
- B22D11/114—Treating the molten metal by using agitating or vibrating means
- B22D11/115—Treating the molten metal by using agitating or vibrating means by using magnetic fields
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
- B22D11/12—Accessories for subsequent treating or working cast stock in situ
- B22D11/124—Accessories for subsequent treating or working cast stock in situ for cooling
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Abstract
A non-ferrous metal and its alloy electromagnetism semi-continuous casting method, adopt non-ferrous metal and its alloy electromagnetism semi-continuous casting device, the lateral wall of the copper inner race of the device is equipped with or not equipped with the strengthening rib, when equipped with the strengthening rib, the strengthening rib and copper inner race are an organic whole structure, the strengthening rib is made up of multiple ring bodies, or made up of multirow arc-shaped body, or made up of multiple ring bodies and multiple cylindrical body and form the latticed; the method comprises the following steps: (1) introducing cooling water, and introducing the metal melt into a crystallizer; (2) alternating current or pulse current is respectively introduced into the two groups of excitation coils through a power supply to respectively form magnetic fields, the phase difference is 90 degrees, and the formed phase difference magnetic fields act on the metal melt; (3) and (5) casting. The method has strong applicability to different alloys and has positive effect on the uniform distribution of the magnetic field in the metal melt; no other impurities are introduced and the metal melt is not polluted; the assembly is simple and easy to maintain.
Description
Technical Field
The invention belongs to the field of metal material preparation, and particularly relates to an electromagnetic semi-continuous casting method for nonferrous metals and alloys thereof.
Background
Semi-continuous casting is the main method for preparing metal ingots in the current industrial production; the traditional direct water-cooling semi-continuous casting (traditional DC method) is that molten metal melt is uniformly introduced into a crystallizer, a layer of firm solidified shell is formed under the action of water cooling the crystallizer, then a dummy bar head drives the solidified part to move downwards at a certain speed, when the solidified part is separated from the crystallizer, the solidified layer of an ingot is slowly moved towards the center and is completely solidified and crystallized, and the ingot is also continuously solidified and formed in the crystallizer along with the continuous inflow of the metal melt into the crystallizer; the method improves the labor productivity, improves the labor conditions, increases the length of the ingot blank, and reduces the geometric loss of head cutting and tail cutting; however, the cast ingot produced by the traditional semi-continuous casting has the defects of coarse grains, serious segregation, poor surface quality of the cast ingot and the like, so that the loss rate of the material is greatly increased.
In order to solve various problems existing in the traditional DC method, a novel semi-continuous casting technology is developed at home and abroad, wherein the novel semi-continuous casting technology mainly comprises short groove casting, hot top casting, air slip and air curtain casting, low liquid level semi-continuous casting, outfield auxiliary casting and the like, and the outfield effect is most obvious when the outfield is applied in the metal solidification process; the applied external field mainly comprises an electromagnetic field and an ultrasonic field at present, but the method of applying the ultrasonic field has limited action range due to larger attenuation of ultrasonic in the melt, and the ultrasonic rod directly acts on the melt to cause pollution and other problems, so that the method cannot be applied to industrial production in a large scale; the electromagnetic casting technology has a series of advantages of non-contact, no pollution, obvious solidification structure refinement and the like, and is widely accepted in the industry.
The basic principle of the electromagnetic casting technology is that alternating current is introduced into an excitation coil to generate an alternating magnetic field, the alternating magnetic field penetrates through an inner sleeve of a crystallizer to act on a metal melt, induced current is generated in the metal melt, the induced current and the alternating magnetic field act to generate electromagnetic force to play a role in stirring the melt, and a flow field, a temperature field and a solute field of the melt are homogenized, so that crystal grains of an ingot are refined, and the surface quality of the ingot is improved. However, this technique has certain requirements on the crystallizer: (1) the magnetic permeability of the crystallizer is good so as to ensure the electromagnetic pressure required by the soft contact of the surface of the cast ingot; (2) the crystallizer has good cooling effect to ensure that a solidified blank shell with certain thickness is formed in the melt in the crystallizer, and accidents such as leakage and the like are avoided; (3) the mold has a certain strength, especially a yield strength, because a large thermal stress is generated under a large temperature gradient, and deformation and thermal stress cracks are easily generated, which causes damage to the mold.
At present, the copper inner sleeve can basically meet the requirements of good cooling effect and strength, but because the copper has high shielding property on a magnetic field, an alternating magnetic field generated by an excitation coil has larger loss when passing through the copper inner sleeve of the crystallizer, so that the electromagnetic utilization rate is greatly reduced, and the stirring effect of the electromagnetic field on a melt is poorer; in order to improve the magnetic permeability of the mold, researchers have developed slit-type electromagnetic continuous casting molds. The crystallizer cuts a plurality of gaps uniformly on the upper part of the crystallizer wall along a certain direction, so that an electromagnetic field can directly act on a melt through the gaps, thereby reducing the shielding effect of the crystallizer wall on the magnetic field. The cutting slits have various forms, such as equal cutting slits, unequal cutting slits, through body cutting slits, non-through body cutting slits, oblique cutting slits and the like.
Chinese patents CN200710190961, CN200920266196.3, CN02265157.8, etc. show that the provision of a certain number of slits on the inner jacket of the crystallizer can increase the magnetic field strength in the crystallizer, so as to greatly increase the magnetic permeability of the crystallizer. However, the slit-type crystallizer has a great defect due to the existence of the slit: (1) the distribution of the magnetic field in the melt becomes more complex, the difference of the electromagnetic force borne by the melt at the joint cutting position and the non-joint cutting position is larger, and the difference easily causes the surface quality of the cast ingot to be poor, thereby influencing the metallurgical quality of the cast ingot; (2) the existence of the cutting seam damages the integrity of the crystallizer, so that the strength of the crystallizer is greatly reduced, and an unstable factor is brought to actual production; (3) the kerfs enable every metal sheet layer of the wall of the crystallizer to be mutually independent, in the continuous casting process, the crystallizer can generate thermal expansion and cold contraction effects under the action of high temperature, and the kerfs have the tendency of being compressed or expanded, so that the cooling water loop is difficult to design.
In view of the drawbacks of the slit-type mold, many researchers have focused on seamless electromagnetic casting molds. The seamless crystallizer can be divided into two design forms, one is a sectional seamless crystallizer and the other is an integral seamless crystallizer. Chinese patent 201811273062.4 provides a high-permeability magnetic soft-contact two-section copper alloy crystallizer, wherein the upper part adopts high-permeability magnetic copper alloy to increase permeability, the lower part adopts pure copper material, the thickness of the wall of the crystallizer is 20 mm-30 mm, and the joint of the upper half part and the lower half part adopts pure copper TIG welding, but the crystallizer has the difficulty of smooth connection of the joint of the two materials and easily brings serious defects to cast ingots due to the difference of thermophysical properties; the integral seamless soft contact crystallizer is formed by filling high-resistivity powder between high-conductivity copper or copper alloy and processing the powder into a whole through hot isostatic pressing and sintering; the strength of the crystallizer is improved, but the problem of greatly improving the magnetic permeability is still not solved.
Disclosure of Invention
Aiming at various problems of the existing electromagnetic semi-continuous casting, such as strength reduction caused by the existence of a kerf in an inner sleeve of a crystallizer, easy surface quality deterioration caused by complicated magnetic field distribution in a melt, limited action range of an electromagnetic field in the melt, low utilization rate of the magnetic field and the like, the invention provides a non-ferrous metal and alloy electromagnetic semi-continuous casting method thereof.
The electromagnetic semi-continuous casting method for the nonferrous metal and the alloy thereof adopts a nonferrous metal and alloy electromagnetic semi-continuous casting device, and the device comprises a crystallizer and an excitation coil system; the crystallizer consists of an upper cover plate, a crystallizer shell, a copper inner sleeve and a crystallizer water sealing plate, wherein the upper part of the crystallizer shell is provided with a cooling water inlet, and the bottom of the copper inner sleeve is provided with two cooling water spray holes; the excitation coil system is fixed in a cooling water tank between the crystallizer shell and the copper inner sleeve and consists of a fixing bolt, a coil pressing plate, a coil supporting block and an excitation coil; the outer side wall of the copper inner sleeve is provided with or not provided with a reinforcing rib, when the reinforcing rib is arranged, the reinforcing rib and the copper inner sleeve are of an integrated structure, and the reinforcing rib consists of a plurality of ring bodies, or a plurality of rows of arc bodies, or a plurality of ring bodies and a plurality of columnar bodies to form a grid shape; the side wall thickness of the copper inner sleeve is 6-20 mm; the excitation coils are divided into two groups, and each group of the two groups of the excitation coils is connected in series and is respectively connected with a power supply;
the method comprises the following steps:
(1) introducing cooling water into the cooling water tank, and spraying the cooling water from the two cooling water spray holes; guiding the metal melt into a crystallizer to enable the liquid level of the metal melt to reach a preset height; the metal melt is non-ferrous metal or non-ferrous metal alloy;
(2) respectively introducing alternating current or pulse current to the two groups of excitation coils through a power supply to enable each group of excitation coils to respectively generate a group of alternating electromagnetic signals or pulse electromagnetic signals to respectively form a magnetic field; the phase difference of alternating current or pulse current introduced by the two groups of excitation coils is 90 degrees, and a formed phase difference magnetic field acts on the metal melt in the crystallizer;
(3) and starting the electromagnetic semi-continuous casting device for the nonferrous metal and the alloy thereof to cast the metal melt, and cooling the ingot below the crystallizer by the secondary cold water sprayed from the secondary cold water spray holes until the casting is finished.
In the method, the vertical section of the reinforcing rib is rectangular, laterally placed trapezoid or laterally placed semicircle; when the vertical section is rectangular, the outward transverse thickness of the copper inner sleeve is 3-9 mm, and the height is 6-20 mm; when the vertical section is a trapezoid with a side-placed trapezoid shape, the upper side of the trapezoid is 3-10 mm long, the lower side of the trapezoid is 6-20 mm long, and the height of the trapezoid is 3-9 mm; when the vertical section is semicircular, the diameter of the semicircle is 6-20 mm.
In the method, the vertical section of the inner space of the copper inner sleeve is an isosceles trapezoid or an inverted isosceles trapezoid, and the included angle theta between the side edge of the isosceles trapezoid or the side edge of the inverted isosceles trapezoid and the axis is 1-8 degrees.
In the method, the inner side wall of the copper inner sleeve is provided with a plating layer which is a chromium plating layer, a Ni-Fe plating layer, a Ni-Co alloy plating layer, a Ni-Fe-W-Co alloy plating layer or a Ni-P alloy plating layer.
In the method, the crystallizer shell is made of steel, the upper cover plate and the crystallizer water sealing plate are made of paramagnetic stainless steel, and the paramagnetic stainless steel is 304 stainless steel, 321 stainless steel or 347 stainless steel.
In the method, when the reinforcing rib consists of a plurality of ring bodies, the vertical distance between two adjacent ring bodies is 15-50 mm; when the reinforcing rib consists of a plurality of rows of arc-shaped bodies, the vertical distance between two adjacent rows of arc-shaped bodies is 15-50 mm, and the horizontal distance between two adjacent arc-shaped bodies in each row of arc-shaped bodies is 5-25 mm; when the strengthening rib comprises a plurality of tours and a plurality of columnar body latticedly, the perpendicular interval 15~50mm of two adjacent tours, the columnar body divide into long columnar body and short columnar body, the both ends of long columnar body are connected with the tours of the top and the tours of below respectively, the both ends of short columnar body are connected with two adjacent tours respectively.
In the method, the section of the secondary cooling water spray hole is circular, and the aperture is 0.5-3.5 mm.
In the method, in the two groups of excitation coils, the aspect ratio of the two groups of excitation coils is simultaneously set to be 1: N, or the aspect ratio of one group of excitation coils is 1: N, and the aspect ratio of the other group of excitation coils is N:1, wherein N is 1-5.
In the method, the number of turns of the exciting coils is 30-150, and the distance between two adjacent exciting coils is 10-50 mm; the turn ratio of the two groups of excitation coils is 1: N, wherein N is 0.2-5; and each excitation coil monomer in the two groups of excitation coils is arranged from top to bottom, and takes the axis of the crystallizer as an axis.
In the method, each coil in the two groups of excitation coils is arranged in the same direction, namely the flow direction of alternating current introduced into each coil is the same, and the magnetic lines of force of the magnetic field generated by each coil are ensured to be the same.
In the method, when the metal melt is copper or copper alloy, the thickness of the side wall of the copper inner sleeve is 8-20 mm.
In the method, when the diameter of the ingot is smaller than 150mm, the thickness of the side wall of the copper inner sleeve is at least 8mm, when the diameter of the ingot is between 150mm and 300mm, the thickness of the side wall of the copper inner sleeve is at least 10mm, and when the diameter of the ingot is larger than 300mm, the thickness of the side wall of the copper inner sleeve is at least 12 mm.
In the method, when the metal melt is copper or copper alloy, the aperture of the secondary cooling water spray hole is 1-3.5 mm; when the metal melt is aluminum, magnesium, aluminum alloy or magnesium alloy, the aperture of the secondary cooling water spray hole is 0.5-2.5 mm.
In the method, when alternating current or pulse current is respectively introduced into the two groups of excitation coils, the current intensity is 50-200A, and the frequency is 10-30 Hz; when pulse current is introduced, the duty ratio is 10-30%.
The device and the method have strong applicability to round ingots or flat ingots.
The device and the method are also suitable for electromagnetic semi-continuous casting of steel.
The main technical principle of the invention is as follows: aiming at the defect that the action area of a magnetic field generated by a single coil in the traditional electromagnetic continuous casting process is small, the excitation coils are divided into two groups, and through phase difference currents with the phase difference of 90 degrees, the strength and the action area of the magnetic field in the metal melt are obviously improved by adjusting the height of the coils and the axial distance between the coils, and the electromagnetic utilization rate is improved; aiming at the defects that the effect and the magnetic field intensity in a melt are reduced due to the fact that the traditional copper inner sleeve is large in thickness and the loss of a magnetic field in the inner sleeve is large, the thickness of the inner sleeve is reduced, and reinforcing ribs in different forms and distribution are applied to different casting alloys to increase the strength of the inner sleeve; by adopting the mode, the magnetic field intensity and the action area acting on the melt can be obviously increased, and the cast ingot with fine grains, uniformity and good surface quality can be produced.
Through the technical characteristics, the invention can realize the following positive effects:
(1) the copper inner sleeve has smaller thickness than the traditional inner sleeve, obviously improves the magnetic permeability, improves the electromagnetic utilization rate, and can play a positive role in the semi-continuous casting of metals such as copper alloy, aluminum alloy, magnesium alloy, steel and the like;
(2) the casting method has strong applicability to casting alloys with different sizes, specifications and types, and can change the thickness of the inner sleeve according to the different types of the alloys and apply reinforcing ribs with different distributions to strengthen the strength of the inner sleeve;
(3) the exciting coil can adjust the turn ratio and the length-width ratio of the coil according to the characteristics of different casting alloys, the position of the exciting coil is adjusted, and parameters (current intensity I and frequency f) of the differential phase current applied by the coil are adjusted, so that the generated differential phase magnetic field can effectively improve the electromagnetic utilization rate and has high permeability to the melt, and the magnetic field in the metal melt is uniformly distributed with a positive effect;
(4) the electromagnetic force acts on the metal melt, is not directly contacted with the melt, does not introduce other impurities and does not pollute the metal melt;
(5) the device has compact structure, high safety, simple assembly and easy maintenance.
Drawings
FIG. 1 is a schematic cross-sectional view of an electromagnetic semi-continuous casting apparatus for nonferrous metals and alloys thereof according to embodiment 1 of the present invention; in the figure, 1, a crystallizer upper cover plate, 2, a crystallizer shell, 3, a cooling water inlet, 4, a fixing bolt, 5, a coil pressing plate, 6, a coil supporting block, 7, a crystallizer water sealing plate, 8, an excitation coil, 9, a fastening bolt, 10, a sealing ring, 11, a copper inner sleeve, 12, two cold water spray holes, 13, a ring body, 14, an arc body, 15, a long column body, 16 and a short column body;
FIG. 2 is a schematic diagram of a copper inner sleeve structure according to an embodiment of the present invention; in the figure, (a) the reinforcing rib is composed of a plurality of circular ring bodies; (b) the reinforcing rib consists of a plurality of rows of arc-shaped bodies, each row of arc-shaped bodies is provided with a plurality of single arc-shaped bodies, and the arc-shaped bodies of each row are staggered in the vertical direction; (c) the reinforcing rib is in a grid shape formed by a plurality of circular ring bodies and a plurality of columnar bodies, and the columnar bodies are long columnar bodies; (d) the reinforcing rib is in a grid shape formed by a plurality of circular ring bodies and a plurality of columnar bodies, and the columnar bodies are short columnar bodies;
FIG. 3 is a schematic cross-sectional view of a reinforcing bar according to an embodiment of the present invention; in the figure, (a) the vertical section is rectangular; (b) the vertical section is trapezoidal; (c) the vertical section is semicircular;
FIG. 4 is a schematic diagram of an arrangement of the field coils according to an embodiment of the present invention; wherein: (a) two groups of excitation coils are arranged in sequence; (b) two groups of excitation coils are alternately arranged;
FIG. 5 is a cloud of magnetic induction intensity distributions in a metal melt at different aspect ratios of exciting coils in example 1 of the present invention; in the figure, (a) the excitation coil aspect ratio is 4: 1; (b) the length-width ratio of the excitation coil is 2: 1; (c) the length-width ratio of the excitation coil is 1: 1; (d) the length-width ratio of the excitation coil is 1: 2; (e) the length-width ratio of the excitation coil is 1: 4;
fig. 6 is a cloud chart of distribution of lorentz forces in a period after pulse currents with the same phase are introduced into two groups of coils in embodiment 1 of the present invention; in the figure, T is the period; (a)0.2T, (b)0.4T, (c)0.6T, (d)0.8T, (e) 1T;
fig. 7 is a cloud chart of distribution of lorentz forces in a period after pulse currents with a phase difference of 90 ° are introduced into two groups of coils in embodiment 1 of the present invention; in the figure, T is the period; (a)0.2T, (b)0.4T, (c)0.6T, (d)0.8T, (e) 1T;
FIG. 8 is a schematic diagram illustrating a spacing arrangement of two cold water spray holes according to an embodiment of the present invention; in the figure, d is the diameter of two cold water spray holes, and L is the distance between two adjacent cold water spray holes;
FIG. 9 is a macroscopic texture map of a 300mm diameter pure copper ingot prepared in example 3 of the present invention and in a conventional DC casting comparative test; in the drawings, (a) conventional DC casting; (b) example 3 of the invention;
FIG. 10 is a photograph showing the appearance of a 300mm diameter pure copper ingot prepared in example 3 of the present invention and a conventional DC casting comparative test; in the drawings, (a) conventional DC casting; (b) example 3 of the invention;
FIG. 11 is a macroscopic texture map of AZ31 magnesium alloy prepared in example 2 of the present invention and in a conventional DC casting comparative test; in the drawings, (a) conventional DC casting; (b) example 2 of the invention;
FIG. 12 is a graph showing the macrosegregation of the major elements in the radial direction of AZ31 magnesium alloy prepared in example 2 of the present invention and in a conventional DC casting comparative test; in the drawings, (a) conventional DC casting; (b) inventive example 2.
Detailed Description
The copper inner sleeve adopted in the embodiment of the invention consists of an upper flange and a side wall, and the upper flange and the side wall are of an integrated structure.
In the embodiment of the invention, the thickness of the side wall of the copper inner sleeve is 6-20 mm.
In the embodiment of the invention, the vertical section of the reinforcing rib is rectangular, trapezoidal in side arrangement or semicircular in side arrangement; the structure is shown in FIG. 3; when the vertical section is rectangular, the outward transverse thickness of the copper inner sleeve is 3-9 mm, and the height is 6-20 mm; when the vertical section is a trapezoid with a side-placed trapezoid shape, the upper side of the trapezoid is 3-10 mm long, the lower side of the trapezoid is 6-20 mm long, and the height of the trapezoid is 3-9 mm; when the vertical section is semicircular, the diameter of the semicircle is 6-20 mm.
In the embodiment of the invention, the inner side wall of the copper inner sleeve is provided with a plating layer which is a chromium plating layer, a Ni-Fe plating layer, a Ni-Co alloy plating layer, a Ni-Fe-W-Co alloy plating layer or a Ni-P alloy plating layer.
In the embodiment of the invention, the crystallizer shell is made of steel, the upper cover plate and the crystallizer water sealing plate are made of paramagnetic stainless steel, and the paramagnetic stainless steel is 304 stainless steel, 321 stainless steel or 347 stainless steel.
In the embodiment of the invention, when the reinforcing rib is composed of a plurality of annular bodies 13, the vertical distance between two adjacent annular bodies 13 is 15-50 mm; when the reinforcing rib consists of a plurality of rows of arc-shaped bodies 14, the vertical distance between two adjacent rows of arc-shaped bodies 14 is 15-50 mm, and the horizontal distance between two adjacent arc-shaped bodies 14 in each row of arc-shaped bodies 14 is 5-25 mm; when the reinforcing rib is in a grid shape formed by a plurality of circular rings 13 and a plurality of cylindrical bodies, the vertical distance between two adjacent circular rings is 15-50 mm, each cylindrical body is divided into a long cylindrical body 15 and a short cylindrical body 16, two ends of the long cylindrical body 15 are respectively connected with the uppermost circular ring and the lowermost circular ring 13, and two ends of the short cylindrical body 16 are respectively connected with two adjacent circular rings 13; the structure is shown in fig. 2.
In the embodiment of the invention, the vertical section of the inner space of the copper inner sleeve is an isosceles trapezoid or an inverted isosceles trapezoid, and the included angle theta between the side edge of the isosceles trapezoid or the inverted isosceles trapezoid and the axis is 1-8 degrees; when the casting alloy is copper or copper alloy, the vertical section is an inverted isosceles trapezoid; when the casting alloy is aluminum, magnesium, aluminum alloy or magnesium alloy, the vertical section is isosceles trapezoid.
In the two groups of excitation coils in the embodiment of the invention, the length-width ratio of one group of excitation coils is 1: N, and the length-width ratio of the other group of excitation coils is N:1, wherein N is 1-5; the number of turns of the magnet exciting coils is 30-150, the distance between every two adjacent magnet exciting coils is 10-50 mm, the turn ratio of the two groups of magnet exciting coils is 1: N, wherein N is 0.2-5; and each excitation coil monomer in the two groups of excitation coils is arranged from top to bottom, and takes the axis of the crystallizer as an axis.
In the embodiment of the invention, each coil in the two groups of excitation coils is arranged in the same direction, namely the flow direction of alternating current introduced into each coil is the same, so that the magnetic lines of force of the magnetic field generated by each coil are ensured to be the same.
In the embodiment of the present invention, when the number of the excitation coils in each group of the excitation coils exceeds 1, the excitation coils are arranged up and down in each group, as shown in fig. 4 (a); or the individual field coils in each set of field coils are alternately arranged as shown in fig. 4 (b).
In the embodiment of the invention, when the metal melt is copper or copper alloy, the thickness of the upper flange is 10-20 mm; when the metal melt is aluminum, magnesium, aluminum alloy or magnesium alloy, the thickness of the upper flange is 6-15 mm.
In the electromagnetic semi-continuous casting device for nonferrous metals and alloy thereof, when the diameter of the prepared cast ingot is less than 200mm, the copper inner sleeve is not provided with the reinforcing rib.
The electromagnetic wire adopted by the excitation coil in the embodiment of the invention is a flat copper wire covered by a commercially available double-layer polyimide-fluorine 46 composite film.
In the embodiment of the invention, in each excitation coil monomer, the horizontal height of the lowermost excitation coil monomer is higher than the height of the liquid cavity center of the metal melt in the crystallizer.
In the embodiment of the invention, when no metal melt exists in the crystallizer and the excitation coil generates a magnetic field, the magnetic induction intensity in the copper inner sleeve is 20-200 mT.
In the embodiment of the invention, the section of the second cold water spray hole is circular; when the metal melt is copper or copper alloy, the aperture of the secondary cooling water spray hole is 1-3.5 mm; when the metal melt is aluminum, magnesium, aluminum alloy or magnesium alloy, the aperture of the secondary cooling water spray hole is 0.5-2.5 mm; when the metal melt is copper or copper alloy, the distance between two adjacent secondary cooling water spray holes is 3-5 times of the diameter of the secondary cooling water spray holes; when the metal melt is aluminum, magnesium, aluminum alloy or magnesium alloy, the distance between every two adjacent cold water spray holes is 2-4 times of the diameter of each two adjacent cold water spray holes; the structure is shown in fig. 8.
In the embodiment of the invention, when the metal melt is copper or copper alloy, the thickness of the side wall of the copper inner sleeve is 8-20 mm.
In the embodiment of the invention, when the diameter of the ingot is less than 150mm, the thickness of the side wall of the copper inner sleeve is at least 8mm, when the diameter of the ingot is between 150mm and 300mm, the thickness of the side wall of the copper inner sleeve is at least 10mm, and when the diameter of the ingot is more than 300mm, the thickness of the side wall of the copper inner sleeve is at least 12 mm.
In the embodiment of the invention, when the metal melt is copper or copper alloy, the aperture of the secondary cooling water spray hole is 1-3.5 mm; when the metal melt is aluminum, magnesium, aluminum alloy or magnesium alloy, the aperture of the secondary cooling water spray hole is 0.5-2.5 mm.
In the embodiment of the invention, when alternating current is respectively introduced into the two groups of excitation coils, the current intensity is 50-200A, and the frequency is 10-30 Hz.
In the embodiment of the invention, the upper cover plate and the water sealing plate are made of paramagnetic stainless steel, so that a differential phase magnetic field generated by the two groups of excitation coils can smoothly pass through the shell, the magnetic lines of force are not deformed, the shell of the crystallizer is made of common steel, the magnetic field cannot easily pass through the shell of the crystallizer, and the loss of the magnetic field outside is reduced.
In the embodiment of the invention, because the side wall of the copper inner sleeve is thinner, the problem that the copper inner sleeve has large temperature gradient and can generate thermal deformation in the semi-continuous casting process is considered, and the like, reinforcing ribs with different section shapes and different forms are applied to the outer surface of the copper inner sleeve to enhance the strength of the inner sleeve.
In the embodiment of the invention, the used current is a differential phase current, and the differential phase current is respectively introduced into two groups of magnet exciting coils to generate a differential phase magnetic field to act on the metal melt; the current with the initial phase of 0 degree is introduced into one group of excitation coils, and the current with the initial phase of 90 degrees is introduced into the other group of coils; the axial distance between the individual exciter coils is adjusted by the height of the coil support block.
Example 1
The electromagnetic semi-continuous casting device for the nonferrous metal and the alloy thereof comprises a crystallizer and an excitation coil system; the structure is shown in figure 1, the crystallizer consists of an upper cover plate 1, a crystallizer outer shell 2, a copper inner sleeve 11 and a crystallizer water sealing plate 7, the upper part of the crystallizer outer shell 2 is provided with a cooling water inlet 3, and the bottom of the copper inner sleeve 11 is provided with two cold water spray holes 12;
the vertical section of the inner space of the copper inner sleeve 11 is an inverted isosceles trapezoid;
the upper part of the upper cover plate 1 of the crystallizer is fixed with an upper flange of a copper inner sleeve 11 through bolts and is hermetically connected with the upper flange through a sealing ring 10;
the upper part of the crystallizer shell 2 is fixedly connected with the upper cover plate 1 of the crystallizer through a fastening bolt 9; the bottom of the crystallizer shell 2 is fixedly connected with a crystallizer water sealing plate 7 through a fastening bolt 9;
the crystallizer water sealing plate 7 is annular, is fixed with the crystallizer shell 2 through a fastening bolt 9 and is connected with the crystallizer shell in a sealing way through a sealing ring 10;
the excitation coil system is fixed in a cooling water tank between the crystallizer shell 2 and the copper inner sleeve 11 and consists of a fixing bolt 4, a coil pressing plate 5, a coil supporting block 6 and an excitation coil 8;
the fixed bolt 4 is welded and fixed at the bottom of the crystallizer shell 2; a plurality of coil pressing plates 5 are fixed on the fixing bolts 4; each excitation coil 8 and each coil supporting block 6 are alternately arranged up and down, and only one coil supporting block 6 is arranged between every two adjacent coil pressing plates 5; the coil supporting block 6 and the excitation coil 8 are pressed and fixed through the fixing bolt 4, the coil pressing plate 5 and the bottom of the crystallizer shell 2;
the outer side wall of the copper inner sleeve 11 is provided with a reinforcing rib 13, the reinforcing rib 13 and the side wall of the copper inner sleeve 11 are of an integral structure, the reinforcing rib 13 is composed of a plurality of ring bodies, and the structure is shown in fig. 2 (a);
the excitation coils 8 are divided into two groups, and each group of the two groups of the excitation coils is connected in series and is respectively connected with a power supply;
by adopting the device, the magnetic field distribution in the magnesium alloy melt under different coil length-width ratios (4:1, 2:1, 1:1, 1:2, 1:4) is numerically simulated, two groups of excitation coils are fixed in a crystallizer water tank, the number of turns of the coils is 40, each group of the excitation coils is one, the two groups of the coils are positioned at the center of the height of the magnesium alloy melt, the distance between the two groups of the coils is 10mm, the excitation coil at the upper part is introduced with a pulse current with an initial phase of 0 DEG, the coil at the lower part is introduced with a pulse current with an initial phase of 90 DEG, the electromagnetic parameter of the introduced pulse current is set as the current intensity I being 80A, the frequency f being 20Hz, and the duty ratio D being 20%; the results of the numerical simulation are shown in fig. 5; simulation results show that the size and distribution of magnetic induction intensity in the melt can be effectively changed by changing the length-width ratio of the coil; the smaller the length-width ratio of the coil is, the smaller the magnetic induction intensity in the melt is, but the distribution area in the melt is increased and the distribution uniformity is better;
pulse currents with the same phase and pulse currents with the phase difference of 90 degrees are respectively introduced into the two groups of coils; the distribution of the Lorentz force in the metal melt under the two conditions is numerically simulated, and a cloud chart of the distribution of the Lorentz force in one period is shown as fig. 6 and 7; the number of turns of the two groups of coils is 40, each group of coils is provided, the axial distance between the coils is 30mm, when the phase difference is 90 degrees, the excitation coil at the upper part is connected with pulse current with the initial phase of 0 degree, the coil at the lower part is connected with pulse current with the initial phase of 90 degrees, the electromagnetic parameters of the connected pulse current are set as current intensity I being 80A, frequency f being 20Hz, and duty ratio D being 20%; simulation results show that the magnitude of the Lorentz force in the melt is not changed greatly under the condition of introducing unidirectional pulse current and differential phase pulse current, but the maximum value of the Lorentz force can be alternately changed at the central plane positions of two groups of coils in the melt under the action of a differential phase magnetic field, so that a flow field, a temperature field and a solute field in the melt are more uniformly distributed under the action of the unidirectional magnetic field, and the metallurgical quality of a metal ingot is obviously improved; therefore, the stirring effect of the differential phase magnetic field on the metal melt is better than that of the unidirectional magnetic field under the same electromagnetic parameters.
Example 2
The apparatus structure is different from embodiment 1 in that: the axial distance between the two coils is 20-40 mm, the vertical section of the inner space of the copper inner sleeve is an isosceles trapezoid, the diameter of the inner space of the copper inner sleeve is 320mm, the thickness of the inner space of the copper inner sleeve is 8mm, no reinforcing rib is arranged, and the current introduced into the excitation coil is harmonic current;
the device is adopted to carry out crystallizer continuous casting on AZ31 magnesium alloy with the diameter of 320mm, cooling water is firstly introduced into a cooling water tank, and the cooling water is sprayed out from two cooling water spray holes; guiding the metal melt into a crystallizer to enable the liquid level of the metal melt to reach a preset height; the metal melt is non-ferrous metal or non-ferrous metal alloy;
respectively introducing harmonic currents with different initial phases to the two groups of excitation coils through a power supply, so that each group of excitation coils respectively generate a group of electromagnetic signals and respectively form a harmonic magnetic field; the phase difference of alternating currents introduced by the two groups of excitation coils is 90 degrees, and a formed phase difference harmonic magnetic field acts on the metal melt in the crystallizer;
starting an electromagnetic semi-continuous casting device for casting nonferrous metals and alloys thereof, wherein the casting temperature is 720 ℃, the casting speed is 1.12mm/s, and the cooling water amount is 10.5-12.5 m3H, the intensity of the differential phase current is 50-80A, the frequency is 10-30 Hz, and secondary cooling water sprayed out through secondary cooling water spray holes cools an ingot below the crystallizer until casting is finished;
the same magnesium alloy is prepared by adopting the traditional DC casting for a comparison test; the macroscopic structure is shown in fig. 11, and it can be seen from the figure that the cast ingot cast by the traditional DC casting has large columnar crystals, and the cast ingot obtained by the above method has fine and uniform crystal grains; the ratio of the macrosegregation of the main elements in the radial direction of the ingot is shown in FIG. 12, and it can be seen from the figure that the macrosegregation of the ingot elements cast by the method is smaller and more uniformly distributed compared with the macrosegregation of the ingot elements cast by the traditional DC casting method.
Example 3
The apparatus structure is different from embodiment 1 in that:
(1) the reinforcing rib consists of 5 rows of arc-shaped bodies, as shown in figure 2 (b);
(2) each group of the excitation coils consists of two excitation coils, and the arrangement mode is shown in fig. 4 (a); the axial distance between adjacent excitation coils is 30-50 mm,
(3) the vertical section of the inner space of the copper inner sleeve is an inverted isosceles trapezoid, and the thickness of the side wall of the inner space is 10 mm;
the device is adopted to prepare pure copper ingots with the diameter of 300mm, the casting temperature of 1180 ℃, the casting speed of 4m/h and the cooling water pressure of 34-38 m3The method comprises the following steps that (1)/h, two groups of excitation coils are fixed in a crystallizer, the current intensity is 200A, the frequency is 20Hz, and the duty ratio is 20%;
preparing the same pure copper ingot by adopting the traditional DC casting for a comparison test; a macroscopic photograph of the tissue is shown in fig. 9; as can be seen from the figure, the ingot columnar crystal obtained by the method of the embodiment is smaller, and the fine isometric crystal area is obviously increased; the appearance photograph is shown in fig. 10, and it can be seen from the figure that the surface of the ingot obtained by the conventional DC casting has obvious defects such as wrinkles, while the surface of the ingot obtained by the present embodiment is smoother and has better surface quality.
Claims (1)
1. A non-ferrous metal and its alloy electromagnetism semi-continuous casting method, characterized by using the non-ferrous metal and its alloy electromagnetism semi-continuous casting device, the device includes crystallizer and excitation coil system; the crystallizer consists of an upper cover plate, a crystallizer shell, a copper inner sleeve and a crystallizer water sealing plate, wherein the upper part of the crystallizer shell is provided with a cooling water inlet, and the bottom of the copper inner sleeve is provided with two cooling water spray holes; the excitation coil system is fixed in a cooling water tank between the crystallizer shell and the copper inner sleeve and consists of a fixing bolt, a coil pressing plate, a coil supporting block and an excitation coil; the outer side wall of the copper inner sleeve is provided with a reinforcing rib, the reinforcing rib and the copper inner sleeve are of an integral structure, and the reinforcing rib is composed of a plurality of rows of arc-shaped bodies or is in a grid shape formed by a plurality of annular bodies and a plurality of columnar bodies; the side wall thickness of the copper inner sleeve is 6-20 mm; the excitation coils are divided into two groups, and each group of the two groups of the excitation coils is connected in series and is respectively connected with a power supply; the vertical section of the reinforcing rib is rectangular, trapezoidal in side arrangement or semicircular in side arrangement; when the vertical section is rectangular, the outward transverse thickness of the copper inner sleeve is 3-9 mm, and the height is 6-20 mm; when the vertical section is a trapezoid with a side-placed trapezoid shape, the upper side of the trapezoid is 3-10 mm long, the lower side of the trapezoid is 6-20 mm long, and the height of the trapezoid is 3-9 mm; when the vertical section is semicircular, the diameter of the semicircle is 6-20 mm; the vertical section of the inner space of the copper inner sleeve is an isosceles trapezoid or an inverted isosceles trapezoid, and the included angle theta between the side edge of the isosceles trapezoid or the inverted isosceles trapezoid and the axis is = 1-8 degrees; in the two groups of excitation coils, the length-width ratio of the two groups of excitation coils is set to be 1: N simultaneously, or the length-width ratio of one group of excitation coils is 1: N, and the length-width ratio of the other group of excitation coils is N:1, wherein N = 1-5; when the reinforcing rib consists of a plurality of rows of arc-shaped bodies, the vertical distance between two adjacent rows of arc-shaped bodies is 15-50 mm, and the horizontal distance between two adjacent arc-shaped bodies in each row of arc-shaped bodies is 5-25 mm; when the reinforcing rib is in a grid shape formed by a plurality of circular rings and a plurality of cylindrical bodies, the vertical distance between every two adjacent circular rings is 15-50 mm, each cylindrical body is divided into a long cylindrical body and a short cylindrical body, two ends of each long cylindrical body are respectively connected with the uppermost circular ring and the lowermost circular ring, and two ends of each short cylindrical body are respectively connected with the two adjacent circular rings; the number of turns of the excitation coils is 30-150, and the distance between every two adjacent excitation coils is 10-50 mm; the turn ratio of the two groups of excitation coils is 1: N, wherein N = 0.2-5; each excitation coil monomer in the two groups of excitation coils is arranged from top to bottom, and the axis of the crystallizer is taken as a shaft; when the diameter of the cast ingot is smaller than 150mm, the thickness of the side wall of the copper inner sleeve is at least 8mm, when the diameter of the cast ingot is between 150mm and 300mm, the thickness of the side wall of the copper inner sleeve is at least 10mm, and when the diameter of the cast ingot is larger than 300mm, the thickness of the side wall of the copper inner sleeve is at least 12 mm; the inner side wall of the copper inner sleeve is provided with a plating layer which is a chromium plating layer, a Ni-Fe plating layer, a Ni-Co alloy plating layer, a Ni-Fe-W-Co alloy plating layer or a Ni-P alloy plating layer; the crystallizer shell is made of steel, and the upper cover plate and the crystallizer water sealing plate are made of 304 stainless steel, 321 stainless steel or 347 stainless steel;
the method comprises the following steps:
(1) introducing cooling water into the cooling water tank, and spraying the cooling water from the two cooling water spray holes; guiding the metal melt into a crystallizer to enable the liquid level of the metal melt to reach a preset height; the metal melt is non-ferrous metal or non-ferrous metal alloy;
(2) respectively introducing alternating current or pulse current to the two groups of excitation coils through a power supply to enable each group of excitation coils to respectively generate a group of alternating electromagnetic signals or pulse electromagnetic signals to respectively form a magnetic field; the phase difference of alternating current or pulse current introduced by the two groups of excitation coils is 90 degrees, and a formed phase difference magnetic field acts on the metal melt in the crystallizer;
(3) starting the electromagnetic semi-continuous casting device for the nonferrous metal and the alloy thereof to cast the metal melt, and cooling the ingot below the crystallizer by the secondary cold water sprayed from the secondary cold water spray holes until the casting is finished;
when alternating current is respectively introduced into the two groups of excitation coils, the current intensity is 50-200A, and the frequency is 10-30 Hz; when no metal melt exists in the crystallizer, the magnetic induction intensity in the copper inner sleeve is 20-200 mT when the magnetic field is generated by the exciting coil.
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| CN110405171B (en) * | 2019-08-28 | 2020-09-29 | 东北大学 | Electromagnetic semi-continuous casting device and method capable of achieving precise matching adjustment in cooling process |
| CN110548843A (en) * | 2019-09-20 | 2019-12-10 | 江苏科技大学 | Electromagnetic stirring device for continuous casting machine |
| CN110434301B (en) * | 2019-09-20 | 2021-01-15 | 哈尔滨工业大学 | Travelling wave magnetic field semi-continuous casting multi-stage follow-up core equipment for multi-model thin-wall alloy castings with equal outer diameters |
| CN112475252B (en) * | 2020-12-10 | 2021-10-15 | 东北大学 | Electromagnetic semi-continuous casting device and method for high casting stress alloy cast ingot |
| CN115415507A (en) * | 2022-08-12 | 2022-12-02 | 中国兵器装备集团西南技术工程研究所 | Device for intervening solidification process of aluminum alloy melt through magnetic field |
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| JP3124217B2 (en) * | 1995-12-07 | 2001-01-15 | 新日本製鐵株式会社 | Flow controller for molten metal |
| JP2000176609A (en) * | 1998-12-18 | 2000-06-27 | Daido Steel Co Ltd | Mold used in continuous casting |
| CN2865934Y (en) * | 2005-12-30 | 2007-02-07 | 东北大学 | Magnetic field reinforcing aluminium alloy low-frequency electromagnetic casting crystallizer |
| CN202192235U (en) * | 2011-08-17 | 2012-04-18 | 中国科学院金属研究所 | Low-frequency pulsed magnetic field aided semi-continuous casting mold for magnesium alloys |
| JP5431438B2 (en) * | 2011-11-10 | 2014-03-05 | 高橋 謙三 | Molding device for continuous casting with stirring device |
| EP2808103B1 (en) * | 2012-08-29 | 2018-01-03 | Nippon Steel & Sumitomo Metal Corporation | Electromagnetic stirring apparatus, and continuous casting method |
| CN106925736B (en) * | 2017-04-01 | 2018-12-28 | 东北大学 | The Electromagnetic Treatment device and its working method of a kind of semi-continuous casting liquid cave melt |
| CN106944598B (en) * | 2017-04-01 | 2018-10-02 | 东北大学 | A kind of electromagnetism semi-continuous casting device and its casting method |
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