CN118002755A - Ultrasonic reinforcement for direct cooling of cast materials - Google Patents
Ultrasonic reinforcement for direct cooling of cast materials Download PDFInfo
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- CN118002755A CN118002755A CN202410092930.8A CN202410092930A CN118002755A CN 118002755 A CN118002755 A CN 118002755A CN 202410092930 A CN202410092930 A CN 202410092930A CN 118002755 A CN118002755 A CN 118002755A
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- 229910000838 Al alloy Inorganic materials 0.000 claims abstract description 11
- 239000007789 gas Substances 0.000 claims description 58
- 238000010926 purge Methods 0.000 claims description 54
- 238000005266 casting Methods 0.000 claims description 40
- 239000007787 solid Substances 0.000 claims description 35
- 229910052751 metal Inorganic materials 0.000 claims description 31
- 239000002184 metal Substances 0.000 claims description 31
- 239000012530 fluid Substances 0.000 claims description 30
- 239000000523 sample Substances 0.000 claims description 24
- 239000002826 coolant Substances 0.000 claims description 13
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- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 8
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- 229910052757 nitrogen Inorganic materials 0.000 claims description 2
- 238000004519 manufacturing process Methods 0.000 abstract description 3
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Classifications
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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
- B22D11/049—Continuous casting of metals, i.e. casting in indefinite lengths into open-ended moulds for direct chill casting, e.g. electromagnetic casting
-
- 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
- B22D11/041—Continuous casting of metals, i.e. casting in indefinite lengths into open-ended moulds for vertical casting
-
- 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
-
- 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
-
- 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
- B22D11/116—Refining the metal
- B22D11/117—Refining the metal by treating with gases
-
- 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
- B22D11/1246—Nozzles; Spray heads
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Continuous Casting (AREA)
- Manufacture And Refinement Of Metals (AREA)
Abstract
A method and apparatus for direct chill casting of metals and metal alloys is provided that includes applying vibrational energy to molten material in an open-ended mold and at an outlet of the mold. In one aspect, the method involves the production of a cast aluminum alloy.
Description
The application is a divisional application of a patent application with the name of 'ultrasonic enhancement of direct cooling casting materials' (International application date 2019-7-25, international application No. PCT/US 2019/043445) entering China and having the application number 201980058785.9 of 3 months and 9 days of the stage of 2021.
Technical Field
The present invention relates to direct cooling (DIRECT CHILL, DC) casting of metals and metal alloys, particularly aluminum and aluminum alloys, wherein a homogeneous product suitable for forming metal products, such as sheet-like and plate-like articles, is directly obtained.
Background
Metals and metal alloys, particularly aluminum and aluminum alloys, are cast from the molten phase to produce ingots or billets which are then further processed, such as by rolling or hot working, to produce sheet-like or plate-like articles which can be converted into final products. Throughout the following description, the term "billet" will be used to describe the product of the DC casting process. The billet represents an elongated metal cast product, generally cylindrical, and having a smaller diameter than its length. However, the principles and operations applied herein may also be applied to the production of ingots (inget). Typically, DC casting to produce billets or ingots is performed in a shallow, open-ended, axially vertical mold that is initially closed at its lower end by a downwardly movable platform (commonly referred to as a bottom block). The mold is surrounded by a cooling jacket (cooling jacket) through which a cooling fluid, such as water, is continuously circulated to provide external cooling of the mold walls. Molten aluminum (or other metal) is introduced to the upper end of the cooled mold and the platform moves downward as the molten metal solidifies in the region adjacent the inner periphery of the mold. By an effectively continuous movement of the platform and a correspondingly continuous supply of molten aluminium to the mould, a billet of the desired length can be produced.
Fig. 1 (prior art) shows a schematic cross section of an example of a conventional vertical DC casting machine 10. Molten metal 12 is introduced into a vertically oriented water-cooled open-ended mold 14 through a mold inlet 15 and emerges from a mold outlet 17 as a billet 16. The upper part of the billet 16 has a molten metal core 24, which molten metal core 24 forms an inwardly tapering depression 19 in a solid shell 26. As the billet cools, the solid shell 26 thickens with increasing distance from the billet outlet 17 until a fully solidified cast billet is formed a distance below the die outlet 17. The mold 14 has liquid cooled mold walls (casting surfaces) that cool the molten metal as a result of liquid coolant flowing through the surrounding cooling jacket, the mold 14 peripherally confining and cooling the molten metal to initiate the formation of the solid shell 26, and the cooled metal is removed from the mold and exits the mold through the mold outlet 17 in the direction of advance indicated by arrow a. As the blank emerges from the die, a jet (jets) 18 of cooling fluid is directed from the cooling jacket onto the outer surface of the blank 16 to provide direct cooling that thickens the shell 26 to enhance the cooling process. The cooling fluid is typically water, but other suitable fluids may be used for the particular alloy. A fixed annular wiper 20 of the same shape as the billet may be provided, the wiper 20 contacting the outer surface of the billet spaced a distance X below the outlet 17 of the mould and this has the effect of removing coolant liquid (indicated by flow 22) from the surface of the billet so that as the billet advances further, the surface of the part of the billet below the wiper is free of coolant liquid.
The outside of the billet from the lower (output) end of the mould in vertical DC casting is solid but still in the molten state in its central core. In other words, a pool (pool) of molten metal within the mold extends downwardly into the central portion of the downwardly moving ingot and extends a distance below the mold as a depression (sump) of molten metal. The depressions have a progressively decreasing cross-section in the downward direction as the ingot solidifies inwardly from the outer surface until the core portion thereof becomes fully solid.
The direct chill cast bloom produced in this manner will typically be subjected to hot and cold rolling steps, or other hot working procedures, to produce an article having the desired shape. However, homogenization treatments have conventionally been necessary to convert the metal into a more usable form. During solidification of the DC cast alloy, a number of events occur in the microstructure. First, the metal phase nucleates in grains, which may be cellular, dendritic, or a combination thereof, and chemical grain refinement chemicals are conventionally added to aid the process. Such chemicals add cost and create problems in operation and may even adversely affect the properties of the final product. In addition, in the presence of non-equilibrium solidification conditions (non-equilibrium solidification conditions), the alloy constituents may be expelled from the forming grains and collect in small pockets (pockets) in the microstructure, thus also adversely affecting the properties of the product. These events not only result in compositional changes in the regions across the grains, but also in regions adjacent to the intermetallic phase (INTERMETALLIC PHASES), where structurally relatively soft and hard regions coexist, and if not altered or deformed, will produce unacceptable differences in properties for the final product.
Homogenization (homogenization) typically involves a heat treatment to correct the above-described microscopic defects in the cast microstructure. Homogenization involves heating the cast ingot to a high temperature (typically a temperature above the transformation temperature (transition temperature), e.g., a temperature near the liquidus temperature (liquidus temperature) of aluminum or aluminum alloys, for several hours up to 24 hours, or even longer, as a result of the homogenization process, the distribution of the grains becomes more uniform, further, low melting point component particles that may form during casting are dissolved back into the grains, further, any large intermetallic particles (INTERMETALLIC PARTICLES) that may form during casting may be fragmented, finally, as the ingot cools, the potentially formed precipitates (PRECIPITATES) of chemical additives for the strengthening material are dissolved and then evenly redistributed.
It is an object of the present invention to provide a DC casting method and apparatus that directly provides cast metal billets having a homogeneous microstructure without or with minimal homogenization heat treatment.
It is another object of the present invention to provide a DC casting method and apparatus that directly provides cast metal billets having a homogeneous microstructure without the inclusion of grain refining chemicals (GRAIN REFINING CHEMICAL) or with minimal inclusion of grain refining chemicals.
Disclosure of Invention
These and other objects are provided by the present invention, a first embodiment of which provides a direct chill casting process for metals or metal alloys, comprising:
supplying a fluid melt comprising molten metal or molten metal alloy to a Direct Cooling (DC) mold, the direct cooling mold having an inlet and an outlet;
cooling a fluid melt located in a mold to obtain a billet having a molten core forming an inwardly tapered depression and a solid shell that thickens with increasing distance from the mold outlet;
applying vibrational energy to the fluid melt in the molten core depression of the billet exiting the mold by means of a device located within the mold;
Injecting a purge gas (purge gas) stream into the fluid melt in the molten core depression of the billet;
applying vibrational energy to the solid shell of the blank beyond the outlet of the die in the region of the conical depression;
Removing the blank from the die outlet; and
The billet outside the die outlet is further cooled to obtain a solid billet.
In one aspect of the first embodiment, applying vibrational energy to the solid shell of the blank in the region of the pyramidal depressions comprises: vibration energy is applied from a plurality of vibration energy sources located at a plurality of locations around the circumference of the billet.
In another aspect of the first embodiment, applying ultrasonic vibration energy to the solid shell of the blank in the region of the tapered depression includes: the vibratory energy is applied through a coolant layer sprayed on the outer surface of the blank beyond the die outlet.
In another aspect of the first embodiment, the direct cooling die is a vertical DC die.
In another aspect of the first embodiment, the direct cooling die is a horizontal DC die.
In a second embodiment, the present invention provides a Direct Cooling (DC) casting mold comprising:
A vertically oriented open-ended mold having an inlet positioned at an upper portion and an outlet positioned at a lower portion;
a feed tank for supplying a fluid melt to an upper inlet of the mold;
a liquid cooling system providing a fluid cooling jacket at the outlet of the die;
a source of vibrational energy positioned vertically above the mold inlet and extending into the mold;
a purge gas supply unit vertically above the mold inlet and extending into the mold; and
A plurality of vibration energy sources circumferentially arranged below the outlet of the die;
wherein the vertical position of the plurality of vibration energy sources arranged circumferentially is disposed immediately adjacent the die outlet such that vibration energy is applied to the billet exiting the die in the region of the inwardly tapered melt depression within the billet.
In an aspect of the second embodiment, the vertically positioned source of vibratory energy comprises at least one ultrasonic transducer, at least one mechanically driven vibrator, or a combination thereof.
In another aspect of the second embodiment, the vertically positioned vibrational energy source and the purge gas supply unit are combined into an ultrasonic degasser (degasser) unit, wherein the ultrasonic degasser comprises: an elongate probe comprising a first end attached to an ultrasonic transducer and a second end comprising a tip at an outlet of the mould, and a purge gas delivery section comprising a purge gas inlet and a purge gas outlet provided at the tip of the elongate probe for introducing purge gas into an area at the outlet of the mould.
In another aspect of the second embodiment, each of the plurality of vibration energy sources circumferentially arranged below the outlet of the die comprises at least one ultrasonic transducer, at least one mechanically driven vibrator, or a combination thereof.
In another aspect of the second embodiment, each of the plurality of vibration energy sources circumferentially arranged below the outlet of the die is positioned in direct contact with a solid surface of a billet exiting the die.
In another aspect of the second embodiment, each of the plurality of vibration energy sources circumferentially arranged below the outlet of the die is positioned in contact with a cooling fluid jacket on the solid surface of the blank exiting the die.
In a third embodiment, the present invention provides a Direct Cooling (DC) casting mold comprising:
an open-ended horizontally oriented die having an inlet and an outlet;
A feed tank for supplying a fluid melt to an inlet of a mold;
a liquid cooling system providing a fluid cooling jacket at the outlet of the die;
A source of vibrational energy positioned at the mold inlet and extending into the mold;
a purge gas supply unit located at the inlet of the mold and extending into the mold; and
A plurality of vibration energy sources circumferentially arranged beyond the outlet of the die;
wherein the plurality of circumferentially arranged sources of vibrational energy are positioned proximate the die outlet such that vibrational energy is applied to the billet exiting the die in the region of the inwardly tapered melt depression within the billet.
In an aspect of the third embodiment, the vibration energy source positioned at the die inlet comprises at least one ultrasonic transducer, at least one mechanically driven vibrator, or a combination thereof.
In another aspect of the third embodiment, the source of vibratory energy positioned at the die inlet and the purge gas supply unit are combined into an ultrasonic degasser unit, wherein the ultrasonic degasser comprises: an elongate probe comprising a first end attached to an ultrasonic transducer and a second end comprising a tip at an outlet of the mould, and a purge gas delivery section comprising a purge gas inlet and a purge gas outlet, the purge gas outlet being provided at the tip of the elongate probe for introducing purge gas into a region at the outlet of the mould.
In another aspect of the third embodiment, each of the plurality of vibration energy sources disposed circumferentially beyond the outlet of the die comprises at least one ultrasonic transducer, at least one mechanically driven vibrator, or a combination thereof.
In another aspect of the second embodiment, each of the plurality of vibration energy sources disposed circumferentially beyond the exit of the die is positioned in direct contact with the solid surface of the billet exiting the die.
In another aspect of the third embodiment, each of the plurality of vibration energy sources disposed circumferentially beyond the exit of the die is positioned in contact with a cooling fluid jacket on the solid surface of the billet exiting the die.
In a fourth embodiment, the present invention provides a metal or metal alloy billet obtained by the method of the first embodiment, wherein the billet does not contain a grain refining chemical (GRAIN REFINING CHEMICAL) and is not subjected to a thermal homogenization treatment (thermal homogenation treatment).
In a particular aspect of the fourth embodiment, the blank is an aluminum or aluminum alloy blank.
The preceding paragraphs are provided by way of general introduction and are not intended to limit the scope of the claims. The described embodiments and other advantages will be better understood by reference to the following detailed description in conjunction with the accompanying drawings.
Drawings
Fig. 1 shows a schematic diagram of a conventional Direct Cooling (DC) die casting unit, and is labeled "prior art".
Fig. 2 shows the visual concept of a standard DC casting system and is labeled "prior art".
Fig. 3 shows an open interior view of the standard DC casting system of fig. 2 and is labeled "prior art".
Fig. 4 illustrates the visual concept of a DC casting system according to one embodiment of the invention.
Fig. 5 shows an open interior view of the DC casting system shown in fig. 4.
Detailed Description
In the following description, the words "a" and "an" and similar expressions have the meaning of "one or more". The phrase "selected from the group consisting of the following items", "selected from" and similar expressions include mixtures of the indicated materials. Unless otherwise indicated, "comprising" and similar expressions are open-ended terms that mean "including at least". All references, patents, applications, tests, standards, documents, publications, brochures, texts, articles, etc. mentioned herein are incorporated by reference. Where numerical limits or ranges are indicated, the endpoints are included. Also, all values and subranges within a numerical limitation or range are explicitly included as if explicitly written out.
In the remainder of this specification, aluminum alloys will be discussed. However, it should be understood that the gist of the described embodiments may not be limited to aluminum alloys and may be equally applied to any metal or metal alloy cast in a DC casting operation. Furthermore, although a billet is described in the embodiments, the method may also be considered suitable for casting ingot bodies. Thus, according to the present method embodiment, a method of applying vibrational or ultrasonic energy in a two-stage system to a DC casting process is provided. In the first stage, a combination of ultrasonic energy and/or purge gas is inserted directly into the melt pocket of the billet formed in the open mold of the DC casting system at a point where the billet is located outside the mold outlet. This combination of vibrational energy and purge gas serves to uniformly distribute the alloying elements in the melt pool area and remove entrained gases from the melt. In addition, it is believed that grain refinement is also caused by the application of vibration energy directly into the melt pocket area. Since this melt pool area is adjacent to the solidification boundary of the billet being cooled, the uniform distribution of alloying elements may be retained in the solidified billet. Furthermore, in the second stage, by applying vibrational energy, particularly ultrasonic energy, across the billet wall in the region of the melt depression, the crystals solidified at the solidification front are broken away from the front into smaller crystal units and become more uniformly distributed in the solidified alloy.
Thus, as a result of the two-stage treatment, a billet having an even distribution of alloying elements and fine grains is obtained. This is the result that is sought in the thermal homogenization process as previously described, and therefore energy and operating costs for the homogenization operation can be avoided. In addition, as described above, since fine crystal grains are generated by applying ultrasonic energy at the solidification front, a fine grain structure is obtained without containing a grain refining chemical such as titanium boride (TIBOR) or titanium carbon mixture (TiCar).
In this way, high quality DC aluminum alloy casting billets can be obtained without the use of refining chemicals and with significantly reduced production time and energy costs. This improvement in quality and cost in billet DC casting is highly unexpected and has significant advantages over conventional DC casting systems currently in operation.
Thus, in a first embodiment, the present invention provides a Direct Cooling (DC) casting method of a metal or metal alloy, the method comprising:
Supplying a fluid melt comprising molten metal or molten metal alloy to a direct cooling die, the direct cooling die having an inlet and an outlet;
cooling a fluid melt located in a mold to obtain a billet having a molten core forming an inwardly tapered depression and a solid shell that thickens with increasing distance from the mold outlet;
applying vibrational energy to the fluid melt in the molten core depression of the billet exiting the mold by means of a device located within the mold;
Optionally, injecting a purge gas (purge gas) stream into the fluid melt in the molten core depression of the billet;
Applying vibrational energy to the solid shell of the blank beyond the outlet of the die in the region of the conical depression; and
Removing the blank from the die outlet;
The billet outside the die outlet is further cooled to obtain a solid billet.
The DC casting mold may be oriented vertically or horizontally.
The preparation and supply of a fluid melt of molten metal or metal alloy is conventionally known and any known system may be used in the present invention. Furthermore, the handling of the cured blanks is also conventionally known, and any such system may be suitably combined with the present invention.
Applying ultrasonic vibration energy to the solid shell of the blank in the region of the pyramidal depression comprises: vibration energy is applied from a plurality of vibration energy sources located at a plurality of locations around the circumference of the billet. Theoretically, the greater the amount of vibrational energy input applied, the greater the efficiency of producing fine grains from the solidification front. In practice, however, the maximum number may be limited by the spatial configuration of the DC-shaping unit. Generally, at least two sources of vibration energy may be used, preferably 2 to 8 sources of vibration energy may be used, more preferably 3 to 6 and most preferably 4 devices of vibration energy may be used.
The purge gas may be any gas suitable for use with molten metal or molten metal alloy. In general, inert gases such as nitrogen or argon are preferred. In certain applications, however, other gases, including combinations of gases, may be used as purge gases.
In one aspect of the invention employing purge gas, a vibrational energy source positioned in the mold and the purge gas supply unit are combined into an ultrasonic degasser (degasser) unit, wherein the ultrasonic degasser comprises: an elongate probe comprising a first end attached to an ultrasonic transducer and a second end comprising a tip at an outlet of the mould, and a purge gas delivery section comprising a purge gas inlet and a purge gas outlet provided at the tip of the elongate probe for introducing purge gas into an area at the outlet of the mould.
As previously described, the blank below or beyond the die outlet is covered with a coolant jacket, preferably a water jacket. Thus, there are two configurations for applying vibrational energy to the blank housing. In one configuration, a source of vibrational energy may be inserted through the coolant jacket and directly contact the billet surface. In a second configuration, the vibrational energy source contacts the water jacket and ultrasonic energy is transferred to the billet surface by the coolant.
In either configuration, the location of the vibration energy device relative to the tapered depression may be located near the die exit where the thickness of the solid wall is minimal, taking into account that the vibration energy is attenuated by the structure of the solid blank. In some arrangements, the positioning of the plurality of vibration energy devices may be arranged at different locations of the depression such that ultrasonic energy is applied across a maximum area of the curing front.
The vibration energy device may be any such device suitable for use in a DC casting mould as described above. Power and ultrasonic frequencies over a wide range may be used with the DC casting methods described herein and may be adjusted to achieve optimal performance depending on the particular alloy being cast and the depth, shape and size of the mold. In one aspect, the ultrasonic vibration source may provide 1.5kW of power at an acoustic frequency of 20 kHz.
Typically, the power range of a probe (vibration energy device) may be between 50 and 5000W, depending on the size of the probe (probe). These powers are typically applied to the probe to ensure that the power density at the probe tip is above 100W/cm 2, which can be considered the threshold for grain splitting at the solidification front. The power range of this region may be from 50 to 5000W,100 to 3000W,500 to 2000W,1000 to 1500W or any intermediate or overlapping range. It is possible that larger probes use higher power and smaller probes use lower power. In various embodiments of the present invention, the applied vibrational energy power density may be in the following range: 10W/cm 2 to 500W/cm 2, or 20W/cm 2 to 400W/cm 2, or 30W/cm 2 to 300W/cm 2, or 50W/cm 2 to 200W/cm 2, or 70W/cm 2 to 150W/cm 2, or any intermediate or overlapping ranges therein.
Typically, frequencies of 5 to 400kHz (or any intermediate range) may be used. Or 10 and 30kHz (or any intermediate range) may be used. Or 15 and 25kHz (or any intermediate range) may be used. The frequency of application may range from 5 to 400KHz, 10 to 30KHz, 15 to 25KHz, 10 to 200KHz, or 50 to 100KHz, or any intermediate or overlapping range therein.
The vibration energy device may be any such device known in the art, and may be an ultrasonic probe (or sonotrode), a piezoelectric transducer (piezoelectric transducer), an ultrasonic radiator, or a magnetostrictive (magnetostrictive) element. Ultrasound transducers may be preferred in the case of vibration energy transmitted through a cooling medium. In one embodiment of the invention, ultrasonic energy is provided from a transducer capable of converting electrical current into mechanical energy, thereby producing a vibration frequency above 20kHz (e.g., up to 400 kHz), wherein ultrasonic energy is provided from one or both of a piezoelectric element or a magnetostrictive element.
In embodiments where the ultrasonic probe contacts the liquid cooling medium, the separation distance from the tip of the ultrasonic probe to the solid billet wall may be variable. The separation distance may be, for example, less than 1mm, less than 2mm, less than 5mm, less than 1cm, less than 2cm, less than 5cm, less than 10cm, less than 20, or less than 50cm.
In one aspect of the invention, the vibration energy device may be a piezoelectric transducer formed of a ceramic material sandwiched between electrodes that provide attachment points for electrical contact. Once a voltage is applied across the ceramic through the electrodes, the ceramic expands and contracts at the ultrasonic frequency.
As is known in the art, ultrasonic boosters (boost) can be used to amplify or enhance the vibrational energy generated by a piezoelectric transducer. The booster does not increase or decrease the vibration frequency; it increases the amplitude of the vibration. In one embodiment of the invention, the booster is connected between the piezoelectric transducer and the probe.
Magnetostrictive transducers typically comprise a large number of plates of material that expand and contract upon application of an electromagnetic field. More specifically, in one embodiment, a magnetostrictive transducer suitable for use in the present invention may comprise a plurality of parallel arranged nickel (or other magnetostrictive material) plates or laminations, with one edge of each lamination attached to the bottom or other surface to be vibrated of the process vessel. A coil is placed around the magnetostrictive material to provide a magnetic field. For example, when a current flows through a coil, a magnetic field is generated. The magnetic field causes the magnetostrictive material to contract or elongate, thereby introducing acoustic waves into the fluid in contact with the magnetostrictive material that is expanding and contracting. A typical ultrasonic frequency range for magnetostrictive transducers suitable for use in the present invention is 20 to 200kHz. Depending on the natural frequency of the magnetostrictive element, higher or lower frequencies may be used.
Nickel is one of the most commonly used materials for magnetostrictive transducers. When a voltage is applied to the transducer, the nickel material expands and contracts at the ultrasonic frequency. In one embodiment of the invention, the nickel plate is silver brazed (silver brazed) directly to the stainless steel plate. The stainless steel plate of the magnetostrictive transducer is a surface that vibrates at ultrasonic frequencies and is a surface (or probe) that is directly coupled to a cooling medium. Then, cavities (cavitations) created in the cooling medium by the plate vibrating at ultrasonic frequencies impinge on the solid surface of the blank.
Mechanical vibrators useful for the present invention may operate at 8,000 to 15,000 vibrations per minute, although higher and lower frequencies may also be used. In one embodiment of the invention, the vibration mechanism is configured to vibrate between 565 and 5,000 vibrations per second. Thus, the range of mechanical vibrations suitable for use in the present invention includes: ranges from 0 to 10KHz, 10Hz to 4000Hz, 20Hz to 2000Hz, 40Hz to 1000Hz, 100Hz to 500Hz, and intermediate and combined ranges of the foregoing ranges, including preferred ranges from 565 to 5,000 Hz.
Although described above with respect to embodiments that are ultrasonically and mechanically driven, the invention is not limited to one or the other of these ranges, but is applicable to a wide range of vibrational energy spectra up to 400KHz, including single and multiple frequency sources. In addition, a combination of sources (sources driven ultrasonically and mechanically, or different ultrasonic sources, or sources driven differently mechanically, or sound sources to be described below) may also be used.
In a second embodiment, the present invention provides a Direct Cooling (DC) casting mold comprising:
a vertically oriented open mold having an upper positioned inlet and a lower positioned outlet;
A vertically oriented open-ended mold having an inlet positioned at an upper portion and an outlet positioned at a lower portion;
a feed tank for supplying a fluid melt to an upper inlet of the mold;
a liquid cooling system providing a fluid cooling jacket at the outlet of the die;
a source of vibrational energy positioned vertically above the mold inlet and extending into the mold;
Optionally, a purge gas supply unit positioned vertically above the mold inlet and extending into the mold; and
A plurality of vibration energy sources circumferentially arranged below the outlet of the die;
wherein the vertical position of the plurality of vibration energy sources arranged circumferentially is disposed immediately adjacent the die outlet such that vibration energy is applied to the billet exiting the die in the region of the inwardly tapered melt depression within the billet.
The mold may be constructed of any material that is compatible with the molten metal composition to be cast. Typically, the mold may be composed of copper or graphite.
In one aspect, the vertically positioned source of vibratory energy comprises at least one ultrasonic transducer, at least one mechanically driven vibrator, or a combination thereof.
In another aspect, the vertically positioned vibrational energy source and the purge gas supply unit are combined into an ultrasonic degasser (degasser) unit, wherein the ultrasonic degasser comprises: an elongate probe comprising a first end attached to an ultrasonic transducer and a second end comprising a tip at an outlet of the mould, and a purge gas delivery section comprising a purge gas inlet and a purge gas outlet provided at the tip of the elongate probe for introducing purge gas into an area at the outlet of the mould.
Fig. 4 shows a schematic visual concept of a DC casting mold system, wherein an ultrasonic degasser unit is positioned vertically above the mold and protrudes to a point below the mold outlet (fig. 5). Four ultrasonic devices are positioned symmetrically around the periphery of the billet, directly below the die outlet and adjacent to the region of the billet containing the inwardly tapered melt depression.
As previously described, each of the plurality of vibration energy sources circumferentially arranged below the outlet of the die comprises at least one ultrasonic transducer, at least one mechanically driven vibrator, or a combination thereof. Furthermore, each of the plurality of vibration energy sources arranged circumferentially below the outlet of the die may be positioned in direct contact with the solid surface of the billet exiting the die. In another aspect, as shown in fig. 4 and 5, each of the plurality of vibration energy sources circumferentially arranged below the outlet of the die is positioned in contact with a cooling fluid jacket on the solid surface of the blank exiting the die. Preferably, the cooling jacket is a water jacket.
In a third embodiment, the present invention provides a Direct Cooling (DC) casting mold comprising:
an open-ended horizontally oriented die having an inlet and an outlet;
A feed tank for supplying a fluid melt to an inlet of a mold;
a liquid cooling system providing a fluid cooling jacket at the outlet of the die;
a source of vibrational energy located at the inlet of the mold and extending into the mold;
optionally, a purge gas supply unit located at the mold inlet and extending into the mold; and
A plurality of vibration energy sources circumferentially arranged beyond the outlet of the die;
wherein the plurality of circumferentially arranged sources of vibrational energy are positioned proximate the die outlet such that vibrational energy is applied to the billet exiting the die in the region of the inwardly tapered melt depression within the billet.
The mold may be constructed of any material that is compatible with the molten metal composition to be cast. Typically, the mold may be composed of copper or graphite.
In one aspect, the source of vibratory energy positioned within the mold comprises at least one ultrasonic transducer, at least one mechanically driven vibrator, or a combination thereof.
In another aspect, when purge gas is used, the source of vibratory energy positioned in the mold and the purge gas supply unit are combined into an ultrasonic degasser unit, wherein the ultrasonic degasser comprises: an elongate probe comprising a first end attached to an ultrasonic transducer and a second end comprising a tip at an outlet of the mould, and a purge gas delivery section comprising a purge gas inlet and a purge gas outlet, the purge gas outlet being provided at the tip of the elongate probe for introducing purge gas into a region at the outlet of the mould.
In a fourth embodiment, the present invention relates to a cast alloy billet obtained by the method of the present invention. The ingot does not contain grain refining chemicals, or is in a significantly reduced amount, and the ingot is not subjected to thermal homogenization treatment. In a preferred aspect, the blank is an aluminum or aluminum alloy blank.
The previous description is provided to enable any person skilled in the art to make or use the present invention, and is provided in the context of a particular application and its requirements. Various modifications to the preferred embodiment will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments and applications without departing from the spirit and scope of the invention. Thus, the present invention is not intended to be limited to the embodiments shown, but is to be accorded the widest scope consistent with the principles and features disclosed herein. In this regard, certain embodiments within the present invention may not exhibit all of the benefits of the present invention in a broad sense.
Claims (20)
1. A method of direct cooling casting of a metal or metal alloy comprising:
Supplying a fluid melt comprising molten metal or molten metal alloy to a direct cooling die, the direct cooling die having an inlet and an outlet;
cooling a fluid melt located in a mold to obtain a billet having a molten core forming an inwardly tapered depression and a solid shell that thickens with increasing distance from the mold outlet;
Applying vibrational energy to the fluid melt in the molten core depression of the billet exiting the mold by means of a vibrational energy source located within the mold;
Applying vibratory energy across a billet wall to a solid shell of a billet beyond an outlet of a die in a region of the conical depression adjacent a solidification boundary of the billet being cooled, a plurality of vibratory energy sources being circumferentially arranged beyond the outlet of the die and positioned immediately adjacent the outlet of the die;
Removing the blank from the die outlet; and
Further cooling the billet outside the die outlet to obtain a solid billet,
Wherein the plurality of vibration energy sources disposed circumferentially beyond the outlet of the die are positioned in contact with a cooling fluid jacket on the solid outer shell of the blank.
2. The method of claim 1, wherein the vibrational energy applied to the fluid melt in the molten core depression of the billet exiting the die and the vibrational energy applied to the solid shell of the billet below the outlet of the die in the region of the tapered depression are provided by at least one ultrasonic transducer, at least one mechanically driven vibrator, or a combination thereof.
3. The method of claim 1, wherein applying ultrasonic vibration energy to the solid shell of the blank in the region of the pyramidal depressions comprises: vibration energy is applied from a plurality of vibration energy sources located at a plurality of locations around the perimeter of the blank.
4. The method of claim 1, wherein applying ultrasonic vibration energy to the solid shell of the blank in the region of the pyramidal depressions comprises: the vibration energy is applied by a coolant layer sprayed on the outer surface of the blank at the exit of the die.
5. The method of claim 1, further comprising injecting a purge gas stream into the fluid melt in the melt core depression of the billet by a vibrational energy source used to apply ultrasonic vibrational energy to the fluid melt in the melt core depression of the billet exiting the mold.
6. The method of claim 5, wherein the purge gas comprises nitrogen or argon.
7. The method of claim 1, wherein the frequency of vibration energy applied to the fluid melt in the core depression of the billet is 5 to 400kHz.
8. The method of claim 1, wherein the frequency of the vibrational energy applied to the solid outer shell of the billet is from 5 to 400kHz.
9. The method of claim 4, wherein the frequency of the vibrational energy applied to the coolant layer on the solid outer shell of the blank is from 5 to 400kHz.
10. The method of claim 1, wherein the metal alloy is DC cast and the metal alloy is an aluminum alloy.
11. A Direct Cooling (DC) casting mold comprising:
A vertically oriented open-ended mold having an inlet positioned at an upper portion and an outlet positioned at a lower portion;
a feed tank for supplying a fluid melt to an upper inlet of the mold;
a liquid cooling system providing a fluid cooling jacket at the outlet of the die;
a source of vibrational energy positioned vertically above the mold inlet and extending into the mold; and
A plurality of vibration energy sources circumferentially arranged below the outlet of the die;
Wherein the vertical position of the plurality of vibration energy sources arranged circumferentially is disposed proximate the die outlet such that vibration energy is applied across the billet wall to the billet exiting the die in a region of the inward tapered melt depression within the billet adjacent the solidification boundary of the billet being cooled,
Wherein the plurality of vibration energy sources disposed circumferentially beyond the outlet of the die are positioned in contact with a cooling fluid jacket on a solid outer shell of the blank.
12. The direct cooled casting mold of claim 11 wherein the vertically positioned source of vibratory energy comprises at least one ultrasonic transducer, at least one mechanically driven vibrator, or a combination thereof.
13. The direct cooled casting mold of claim 11 wherein the vertically positioned vibrational energy source comprises a purge gas supply comprising a purge gas inlet and a purge gas outlet for introducing a purge gas into the region at the outlet of the mold.
14. The direct cooled casting mold of claim 11 wherein each of the plurality of sources of vibratory energy disposed circumferentially below an outlet of the mold comprises at least one ultrasonic transducer, at least one mechanically driven vibrator, or a combination thereof.
15. A Direct Cooling (DC) casting mold comprising:
an open-ended horizontally oriented die having an inlet and an outlet;
A feed tank for supplying a fluid melt to an inlet of a mold;
a liquid cooling system providing a fluid cooling jacket at the outlet of the die;
a source of vibrational energy positioned in the mold; and
A plurality of vibration energy sources circumferentially arranged beyond the outlet of the die;
Wherein the plurality of circumferentially arranged sources of vibrational energy are positioned proximate the die outlet such that vibrational energy is applied across the billet wall to the billet exiting the die in an inwardly tapered region of the melt depression within the billet adjacent the solidification boundary of the billet being cooled,
Wherein the plurality of vibration energy sources disposed circumferentially beyond the outlet of the die are positioned in contact with a cooling fluid jacket on a solid outer shell of the blank.
16. The direct cooled casting mold of claim 15 wherein the source of vibratory energy positioned in the mold comprises at least one ultrasonic transducer, at least one mechanically driven vibrator, or a combination thereof.
17. The direct cooled casting mold of claim 15, further comprising a purge gas supply, and the source of vibratory energy positioned in the mold and the purge gas supply unit are combined into an ultrasonic degasser unit, wherein the ultrasonic degasser comprises: an elongate probe comprising a first end attached to an ultrasonic transducer and a second end comprising a tip at an outlet of the mould, and a purge gas delivery section comprising a purge gas inlet and a purge gas outlet, the purge gas outlet being provided at the tip of the elongate probe for introducing purge gas into a region at the outlet of the mould.
18. The direct cooled casting mold of claim 15 wherein each of the plurality of sources of vibratory energy disposed circumferentially beyond the outlet of the mold comprises at least one ultrasonic transducer, at least one mechanically driven vibrator, or a combination thereof.
19. A metal or metal alloy ingot obtained by the method of claim 1, wherein the ingot does not contain grain refining chemicals and the ingot is not subjected to a thermal homogenization treatment.
20. The metal or metal alloy blank of claim 19, wherein the blank is an aluminum or aluminum alloy blank.
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| US201862703035P | 2018-07-25 | 2018-07-25 | |
| US62/703,035 | 2018-07-25 | ||
| CN201980058785.9A CN112703073B (en) | 2018-07-25 | 2019-07-25 | Ultrasonic reinforcement for direct cooling of cast materials |
| PCT/US2019/043445 WO2020023751A1 (en) | 2018-07-25 | 2019-07-25 | Ultrasonic enhancement of direct chill cast materials background of the invention |
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| US5360329A (en) * | 1957-10-22 | 1994-11-01 | Lemelson Jerome H | Molding/extrusion apparatus with temperature and flow control |
| US3153820A (en) * | 1961-10-09 | 1964-10-27 | Charles B Criner | Apparatus for improving metal structure |
| JPS5155726A (en) * | 1974-11-12 | 1976-05-17 | Nippon Steel Corp | Bisaisoshiki ojusuru kinzokuno renzokuchuzoho |
| JPS56114560A (en) * | 1980-02-14 | 1981-09-09 | Kawasaki Steel Corp | Ultrasonic treatment for unsolidified ingot in horizontal conditinous casting |
| CH646623A5 (en) * | 1980-03-20 | 1984-12-14 | Concast Ag | METHOD AND DEVICE FOR SUPPORTING A STEEL STRAND PRODUCED IN THE CONTINUOUS METHOD WHOSE LIQUID CORE IS STIRRED ELECTROMAGNETICALLY. |
| FR2648063B1 (en) * | 1989-06-12 | 1994-03-18 | Irsid | METHOD AND DEVICE FOR VIBRATION OF A CONTINUOUS CASTING LINGOTIERE OF METALS |
| FR2656552B1 (en) * | 1990-01-04 | 1995-01-13 | Pechiney Aluminium | PROCESS FOR THE MANUFACTURE OF THIXOTROPIC METAL PRODUCTS BY CONTINUOUS CASTING WITH ELECTROMAGNETIC BREWING IN POLYPHASE CURRENT. |
| US5246060A (en) * | 1991-11-13 | 1993-09-21 | Aluminum Company Of America | Process for ingot casting employing a magnetic field for reducing macrosegregation and associated apparatus and ingot |
| JPH11254106A (en) * | 1998-03-10 | 1999-09-21 | Kawasaki Steel Corp | Method for continuously casting blank for pc steel bar and continuous casting apparatus |
| JP4163817B2 (en) * | 1999-06-21 | 2008-10-08 | 新日本製鐵株式会社 | Method for continuous casting of molten steel, electromagnetic vibration applying device and continuous cast slab |
| JP3835185B2 (en) * | 2001-03-19 | 2006-10-18 | 住友金属工業株式会社 | Steel continuous casting method |
| JP4061404B2 (en) * | 2003-04-09 | 2008-03-19 | 独立行政法人産業技術総合研究所 | Continuous casting method and apparatus for refinement of structure by electromagnetic vibration |
| CN100534669C (en) * | 2007-03-19 | 2009-09-02 | 东北大学 | Vertical semi-continuous light alloy ingot casting process and apparatus with cooperation of power ultrasound wave and low frequency electromagnetic wave |
| KR101149294B1 (en) * | 2009-01-28 | 2012-05-25 | 현대제철 주식회사 | Method and device for reducing centerline segregation of continuously cast slab segments |
| US8652397B2 (en) | 2010-04-09 | 2014-02-18 | Southwire Company | Ultrasonic device with integrated gas delivery system |
| CN102161081A (en) * | 2011-04-01 | 2011-08-24 | 天津福来明思铝业有限公司 | Continuous casting method for producing aluminium alloy semisolid casting ingot |
| JP5565734B2 (en) * | 2011-04-05 | 2014-08-06 | 昭和電工株式会社 | Aluminum alloy continuous casting rod, continuous casting rod casting method, continuous casting equipment |
| US8813827B2 (en) * | 2012-03-23 | 2014-08-26 | Novelis Inc. | In-situ homogenization of DC cast metals with additional quench |
| JP5551297B1 (en) * | 2013-08-08 | 2014-07-16 | 高橋 謙三 | Molding device for continuous casting with stirring device |
| JP6340893B2 (en) * | 2014-04-23 | 2018-06-13 | 日本軽金属株式会社 | Method for producing aluminum alloy billet |
| CN114871418A (en) | 2015-09-10 | 2022-08-09 | 南线有限责任公司 | Ultrasonic grain refinement and degassing procedure and system for metal casting |
| CN205324670U (en) * | 2016-02-02 | 2016-06-22 | 吉林大学 | Magnesium alloy rod power supersound semi -continuous casting and device of detecting a flaw |
| KR20170100221A (en) * | 2016-02-25 | 2017-09-04 | 조선대학교산학협력단 | Direct chill casting for grain refiment of microstructure |
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| CN112703073B (en) | 2024-02-06 |
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