CN1994622A - Slurrying-forming separated aluminium alloy rheological forming method - Google Patents
Slurrying-forming separated aluminium alloy rheological forming method Download PDFInfo
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Abstract
The invention relates to a pulping-shaping detachable aluminum alloy rheologic shaping method, wherein it also provides a quick prepare system of semi-solid alloy pulp. Said method comprises that: preparing heated liquid alloy; preheating mixing pot to 350-400Deg. C; filling heated flux into said semi-solid alloy pulp mixing pot; putting pot into electromagnetic mixer prepare room; starting the mixer to electromagnetically mix; when the mixing is end, taking out the pot, pouring the alloy pulp into the injection cylinder of casting machine; injecting and shaping at 220Deg. C of mould. In said invention, the mixer and shaping device are separated. And it has high efficiency.
Description
Technical field
The quick preparation system that the present invention relates to a kind of semi-solid alloy slurry separates the aluminium alloy rheological manufacturing process with the component shaping system, belongs to semi-solid alloy manufacturing process technical field.
Background technology
The semi-solid alloy forming technique is divided into rheological molding and thixotropic forming two big classes usually.Because the semi-solid die casting technology is in application process, expose that technological process length, base cost height (the blank cost accounts for cost of parts about 40%), remelting energy consumption height, blank surface oxidation are serious, the heating process blank runs off serious (running off up to 10%), production waste can't be in problems such as production scene recovery, since the nineties in 20th century, the rheological molding technology becomes the direction of giving priority to of domestic and international semi-solid state forming technique gradually, and has obtained certain progress.
In existing rheological molding technology, it is numerous that the research both at home and abroad of casting technology is penetrated in the mechanical agitation type rheology, but problem such as exist slurry easily to pollute, stirring intensity is low, still be in laboratory stage (Wang K K, Peng H, Wang N, et al.Method and apparatus for injection molding of semi-solid metals.US Patent 5501266,1996; Peng Xuan. the method and apparatus of semi-solid alloy ejection formation. Chinese patent 97120579.5,1997; JiS, Fan Z, Bevis M J.Semi-solid processing of engineering alloys by a twin-screw rheomoulding process.Materials Science and Engineering, 2001,299A:210-217; Luo Jirong, Wu Shusen, Song Xiangjun, etc. the preparation facilities of semi-solid alloy slurry. Chinese patent 01212744.2,2001; Kang Yonglin, peace woods, Sun Jianlin. preparation of drum-type semi-solid alloy slurry and former. Chinese patent 01109074.X, 2001).Though the chamber of penetrating prepares the quality that slurry formula rheocasting technology can guarantee semi solid slurry, but exist the efficient of electromagnetic agitation lower, it is complicated that die casting machine presses house to transform, huge deficiency (the Shibata R that waits of expense, Kaneuchi T, Soda T, et al.Formation of sphericalsolid phase in die casting shot sleeve without any agitation.In:Dardano C, FranciscoM, Proud J, eds.Processings of the Fifth International Conference on Semi-SolidProcessing of Alloys and Composites.Sheffield:University of Sheffeild, 1998.465-470).Liquidus curve casting (die forging) is by low overheat cast and entire pressurisation effect, make whole alloy liquid enter supercooled state simultaneously, realized simultaneously forming core and grown up simultaneously, but can only be used for the shaping of simple knot member, and production efficiency lower (Cui Jianzhong. the semi solid slurry method is produced in magnesium alloy ultralow temperature casting. Chinese patent 03133389.3,2003; Luo Shoujing. method for preparing semi-solid blank material by using liquides line die stamping process. Chinese patent 01116406.9,2001).These three class methods belong to slurrying-forming integrated technology, though avoided the transfer process of slurry from the preparation system to the formation system dexterously, have significant limitation separately, so application prospect is not quite optimistic.
UBE New Rheocasting (UNRC) technology, Semi-Solid Rheocasting (SSR
TM) technology and Continuous Rheoconversion Proces (CRP) technology, realized that successfully the pulp preparation system separates with the component shaping system, need not carry out big transformation to builder, and realize trial production respectively.These two kinds of rheological molding technology have higher knowledge innovation and practical value, but owing to reasons such as knowledge protections, not not open (the Haga T of concrete ins and outs separately, Kapranos P.Simple rheocasting processes.Journal of Materials Processing Technology, 2002,130-131:594-598:Masashi Uchida.Feature of UBE squeeze process and UNRC process (semi solid casting). see: Li Rongde, compile. the 3rd the international die casting proceeding of China. Shenyang: publishing house of Northeastern University, 2002.207-219; Flemings M C, Martinez R A, de Figueredo A M.Metal alloycompositions and process.US Patent 20020096231,2002; Findon M, Apelian D.Continuous rheoconversion processs for semi-solid slurry production.Transactions of the American Foundrymen ' s Society, 2004,112:305-322).
The early-stage Study of inventor seminar shows, be no more than 5 ℃ if guarantee semi solid slurry temperature decline in transfer process, then can not produce too much influence to the mechanical property of its rheological property, microscopic structure and workpiece, therefore, on the basis of traditional die-casting technique, the rheological molding system that development slurrying-shaping separates is fully feasible.
Summary of the invention
The purpose of this invention is to provide a kind of slurrying-forming separated aluminium alloy rheological forming method, it is better that the present invention adopts " melt treatment+bi-directional electromagnetic stirs " complex technique to prepare rheological property fast, semi-solid alloy slurry with subsphaeroidal grain morphology, and adopt suitable transfer device that it is delivered to component shaping equipment reposefully from preparation system, method by compression casting or liquid forging obtains even tissue at last, the workpiece of good mechanical properties, be traditional former to be transformed under the less situation, realized the novel aluminum alloy rheological molding method that slurrying-shaping separates.
A kind of slurrying-forming separated aluminium alloy rheological forming method, this method may further comprise the steps:
1, preparation superheated liquid alloy
1.1 the employing prior art such as resistance melting furnace and PID temperature control technique, prepares the superheated liquid alloy with the alloy blank melting;
The temperature of liquid alloy satisfies follow-up melt treatment requirement, and chemical composition is even, constant, and segregation is as far as possible little; The volume of melting furnace guarantees can provide enough liquid alloys at any time;
1.2 described overheated liquid alloy is carried out melt treatment: change the liquid alloy in the melting furnace over to electric resistance holding furnace with casting ladle, select intermediate alloy to join in the overheated liquid alloy as powdered form fining agent and deformation states alterant according to alloy blank;
The temperature of the overheated liquid alloy of control is noted insulation in the melt treatment process;
2, stir
2.1 stirring crucible is preheated to 350～400 ℃;
Send into 5s turn on agitator before the agitator 2.2 in step 1.2, carry out after the melt treatment liquid alloy of gained;
2.3 the superheated melt after step 1.2 melt treatment is changed in the semi-solid alloy slurry stirring crucible, and detect melt temperature immediately, the melt temperature of transferring in the stirring crucible should be higher than 30～35 ℃ of liquidus curves; Stirring crucible is inserted in the preparation room of electromagnetic mixing apparatus;
2.4 carry out electromagnetic agitation according to setting the alr mode turn on agitator, main technologic parameters has:
Above 5～15 ℃ of beginning whipping temp liquidus curve,
Unidirectional mixing time 3s,
Just change-reverse reversing mode and adopt intermittently commutation of nothing,
Stirring frequency 30Hz,
Stir voltage and set maximum allowable voltage under the stirring frequency;
In whipping process, temperature is gathered in real time, when solid rate reaches 5% in the whipping process, promptly stop to stir;
3, die cast
3.1 steadily shifting fast of alloy pulp: after treating that the preparation of step (2.4) alloy pulp finishes, the preparation room of stirring crucible from electromagnetic mixing apparatus taken out, in 3s, be transferred to the die casting machine injection tube, directly pour alloy pulp into the die casting machine injection tube;
3.2 the rheological molding of workpiece:
3.2.1 former is selected cold house or hot chamber machine for use; The running channel flow process of mould is short, and running channel, cast gate all adopt Open architecture; Monolateral gap between drift and the pressure chamber is 0.08mm; Mould is reserved the position of heating system; Mold temperature is 220 ℃;
3.2.2 boost pressure is 180MPa, adopts the secondary fast shot to be shaped, and finishes aluminium alloy rheological and is shaped.
The principle of the invention:
When the overheated liquid alloy of preparation: adopt resistance melting furnace and PID temperature control technique, guarantee that the temperature of liquid alloy satisfies follow-up melt treatment requirement fully, and chemical composition is even, constant, segregation is as far as possible little.The volume of melting furnace guarantees can provide enough liquid alloys at any time.When the liquid towards alloy carries out refining, refinement, melt treatment such as rotten: change the liquid alloy in the melting furnace over to electric resistance holding furnace with casting ladle, carry out melt treatment.At this moment: (a) temperature of control liquid alloy in the melt treatment process; (b) selecting fine powder final states fining agent and deformation states alterant, is example with the A356 alloy, can select for use micron order Al-5Ti-B alloy powder as fining agent, and deflection is that about 50% extruding attitude Al-10Sr bianry alloy is as alterant; (c) melt treatment makes in the electromagnetic agitation stage and obtains primary crystal nucleus as much as possible and best eutectic modification effect.Bi-directional electromagnetic stirs when preparing semi-solid alloy slurry fast: will send in the two-way multistage fast electromagnetic mixing apparatus through the liquid alloy of melt treatment and carry out stirring pulping.At this moment: (a) the bi-directional electromagnetic rabbling mechanism started before alloy liquid is sent into, can promote alloy liquid forming core first, thereby shorten the slurrying time, improve slurrying efficient, second can guarantee that the central authorities of barrel and the alloy at inwall place are stirred fully, make that the interior hot-fluid transmission of barrel is abundant, guarantee that the each several part slurry tissues is even in the barrel, suppress the material tube inner wall place and dendrite occurs because of Quench; (b) the bi-directional electromagnetic rabbling mechanism is regulated stirring intensity by frequency modulation, adopts the moment break-in, makes alloy pulp be subjected to strong inertia impact effect, obtains maximum nucleus disperse distribution effect and nucleus spin behavior; (c) this device need not dispose special heat tracing measure, guarantees that cooling velocity is very fast, takes lower pouring temperature, to shorten the preparation time of semi solid slurry as far as possible; (d) adopt stirring end temp control mixing time, the stirring end temp is lower than alloy liquid phase line (i.e. 5% solid rate) slightly can be finished to stir.During steadily fast the shifting of alloy pulp: utilize the semi-solid alloy slurry stirring crucible directly alloy pulp to be poured into the die casting machine injection tube from preparation equipment.At this moment: (a) for guarantee alloy pulp when pouring the injection tube into not with sidewall of crucible generation viscous, can adopt " alumina silicate fibre powder+waterglass (in right amount)+water " coating; (b) for coating is combined with crucible firmly, coating does not produce and peels off in semi-solid alloy slurry preparation process and course of conveying, can process the through hole of φ 3mm～φ 5mm at sidewall of crucible (comprising sidewall and ground) interval 10mm; When (c) applying coating in crucible, thickness is as far as possible little and thin and thick is even, is subjected to maximum electromagnetic stirring force to guarantee slurry, and crucible internal diameter unanimity; When (d) crucible took out from electromagnetic stirring equipment, operation was wanted steadily; (e) can outside the injection tube of die casting machine, slag blocking ring be set, to pull out the alloy pulp oxide on surface, to be mingled with or other booty.During the rheological molding of workpiece.At this moment: (a) former can be selected cold house or hot chamber machine for use; (b) rheological molding mould: the first, the most of die cavity of die joint is on dynamic model; The second, the running channel flow process is shorter than the mould of liquid die casting, and running channel, cast gate can adopt Open architecture; The 3rd, overflow launder and air discharge duct are littler than the mould of liquid die casting; The 4th, select suitable fit clearance between drift and the pressure chamber; The 5th, in the rheo-diecasting, material cake thickness is a bit larger tham liquid die casting; The 6th, mould is reserved the position of heating system; The 7th, the mold cavity material is selected 4Cr5MoSiV1 (H13) steel, and other functional features (backing plate, briquetting, push rod etc.) is selected T10A or 45 steel, and carries out modifier treatment, and is relatively good to making workpiece like this; (c) boost pressure and fast shot speed all are a bit larger tham liquid die casting, and the injection time is suitable with liquid die casting, and mold temperature is at 200 ℃～220 ℃.Apparatus of the present invention are successfully separated with former, and device structure and technology controlling and process are simple, and are connected easy with traditional die casting equipment and hydraulic test, and the slurry transfer process is simple and quick simultaneously; Adopt the alloy pulp of " micron powder attitude intermediate alloy melt treatment+bi-directional electromagnetic stirs " combination process preparation, not only organize excellent (grain morphology rounding, size is less), and preparation efficiency is very high, can realize that pulping equipment and former " one to one " are supporting, change the production design of many corresponding formers of pulping equipment in the past; Adopt the stainless steel crucible of Wang Kongshi and " alumina silicate fibre powder+waterglass (in right amount)+water " coating during actual experiment of the present invention, has good result of use, can guarantee that slurry is transferred to the former from preparation facilities in 3s, and sticking phenomenon does not take place in slurry and crucible.
Advantage of the present invention:
(1) device of the present invention separates pulping device with former, need not traditional die casting machine is carried out structure of modification, can make the spherocrystal product of good quality, solved device structure complexity in slurrying-forming integrated rheological molding technology, the difficult problem that state is difficult to keep in the slurry transfer process in the difficult problem that improvement expenses is higher and the traditional rheological molding technology; The technology applicability is stronger, also can attempt carrying out on hydraulic press die-forging forming.
(2) electromagnetic agitating technology that pulp preparation efficient is more traditional greatly improves, and can realize that pulping equipment and former " one to one " are supporting.In simple electromagnetic agitation technology, though electromagnetic agitation makes melt produce strong convection current, whole melt is under same temperature or the minimum temperature fluctuation, guarantee that whole melt realizes whole forming core, but because forming core carries out below liquidus curve, if mixing time is shorter, stir end temp higher (degree of supercooling is not enough), just be at the later just forming core of electromagnetic agitation end and according to the crystallization of flourishing dendrite mode with some crystal grain, final non-dendrite of formation and dendrite and the microstructure of semisolid of depositing, so mixing time is longer.And in " melt treatment+electromagnetic agitation " technology, melt treatment makes alloy form a large amount of effective forming core cores before crystallization, and disperse is distributed in the whole melt under function composite by electromagnetic stirring subsequently, therefore under less degree of supercooling, just can finish the whole forming core of melt, in the growth course afterwards, be subjected to the influence of adjacent nucleus growth resistance, can not (or few) form flourishing dendrite, thereby obtain non-dendritic structure completely.
(3) adopt the semi-solid alloy slurry stirring crucible directly to carry, this method has three advantages.The first, close between crucible and the slurry in the preparation process of alloy pulp by heat exchange temperature, solved the problem that the excessive slurry solid rate that may bring of temperature difference increases between means of delivery and the slurry, rheological characteristic weakens.The second, if adopt new means of delivery, slurry will contact with the low thermo-paint of new coating, and part coatings will be fallen into slurry inevitably, and it is polluted.Adopt the slurrying crucible to reduce the number of times that slurry contacts with low thermo-paint, promptly reduced the chance that slurry is polluted.The 3rd, reduce the replacing instrument, applied the operation of coating.
Description of drawings
Fig. 1 is a process flow diagram of the present invention.
Fig. 2 is a kind of two-way multistage fast electromagnetic mixing apparatus schematic diagram.
Fig. 3 is a kind of stirring crucible schematic diagram of the present invention.
Fig. 4 is a rheo-diecasting workpiece different wall place microscopic structure schematic diagram; Wherein scheme (a): wall thickness 6mm; Figure (b): wall thickness 5mm; Figure (c): wall thickness 4mm.
The specific embodiment
Specify the present invention below in conjunction with accompanying drawing.
Fig. 1 is a process flow diagram of the present invention.The present invention mainly comprises:
1, the preparation of superheated liquid alloy
(1.1) preparation of superheated melt.Equipment is not had specific (special) requirements, can adopt various heating means of the prior art, but need to guarantee that melt temperature is even, melt is pure, do not have dirtyization.
(1.2) melt treatment process.In traditional air electric resistance holding furnace, carry out.The first, require to select for use suitable intermediate alloy.With the A356 alloy is example, should select for use micron order Al-5Ti-B alloy powder as fining agent, and deflection is that about 50% extruding attitude Al-10Sr bianry alloy is as alterant.The second, to compare with the conventional blocks intermediate alloy, the addition of intermediate alloy powder is many slightly, and time of repose is shorter.The 3rd, intermediate alloy powder granularity difference then adds the temperature difference, and powder particle is thin more, and the adding temperature is low more.With the Al-5Ti-B attritive powder A356 alloy being carried out melt treatment is example, when powder mean particle sizes be respectively＜when 100 μ m, 100～200 μ m, 200～250 μ m, 250～500 μ m, add temperature and be followed successively by 665 ℃, 680 ℃, 700～720 ℃, 720 ℃.
2, stir
Fig. 2 is a kind of two-way multistage fast electromagnetic mixing apparatus photo.
The first, can apply one deck " alumina silicate fibre powder+waterglass (in right amount)+water " coating equably at the stirring crucible inwall earlier; The second, stirring crucible is preheated to 350～400 ℃ so that higher, and after guaranteeing that melt enters stirring crucible, the temperature of sidewall of crucible place melt is higher than stirring beginning temperature; The 3rd, in the electromagnetic mixing apparatus preparation room, place heat-preservation cotton, to guarantee not occur too fast being as the criterion of sidewall of crucible part melt cooling in the electromagnetic agitation process; The 4th, 5s turn on agitator before melt is sent into agitator; The 5th, the superheated melt after the melt treatment is changed in the stirring crucible, and detect melt temperature immediately, the melt temperature of transferring in the stirring crucible should be higher than 30～35 ℃ of liquidus curves; The 6th, carry out electromagnetic agitation according to setting alr mode, main technologic parameters has: begin whipping temp (above 5～15 ℃ of liquidus curve), unidirectional item mixing time (3s), just change-reverse reversing mode (adopt and do not have the commutation at intermittence), stirring frequency (30Hz), stirring voltage (setting maximum allowable voltage under the stirring frequency).In whipping process temperature is gathered in real time, mixing time is set with final whipping temp, promptly when solid rate reaches 5% in the whipping process, can stop to stir.Fig. 3 is a kind of stirring crucible photo of the present invention.
3, die cast
(1) alloy pulp steadily shifts fast.After treating that the alloy pulp preparation finishes, the preparation room of stirring crucible from two-way multistage fast electromagnetic mixing apparatus taken out, in 3s, be transferred to the die casting machine injection tube, directly pour alloy pulp into the die casting machine injection tube.
(2) rheological molding of workpiece.The first, former is selected cold house or hot chamber machine for use; The second, the running channel flow process of mould is short, and running channel, cast gate all adopt Open architecture; The 3rd, the monolateral gap between drift and the pressure chamber is 0.08mm; The 4th, mould is reserved the position of heating system; The 4th, technological parameter is chosen as: adopt the secondary fast shot to be shaped, boost pressure is 180MPa, and mold temperature is 220 ℃.
Introduce specific embodiments of the invention below.
With resistance furnace melting A356 alloy.In electric resistance holding furnace, be incubated then, adopt Al-5Ti-B attritive powder and Al-10Sr pressure ram to carry out melt treatment after body temperature degree fusion reaches 700～720 ℃.Melt treatment is: (1) Al-5Ti-B powder size requires≤500 μ m; (2) the powder addition is 0.15%Ti; (3) adding temperature is: meal adopts high temperature, fine powder adopts low temperature, that is: powder mean particle sizes be respectively＜when 100 μ m, 100～200 μ m, 200～250 μ m, 250～500 μ m, add temperature and be followed successively by 665 ℃, 680 ℃, 700～720 ℃, 720 ℃; (4) Al-5Ti-B and Al-10Sr alloy 10min adding at interval when Al-5Ti-B powder adding temperature is lower than 720 ℃, is adopted " adding Ti after adding Sr earlier " technology, otherwise adopts " adding Sr after adding Ti earlier " technology; Al-5Ti-B and Al-10Sr all add back time of repose 20min reaction;
When carrying out melt treatment, apply " alumina silicate fibre powder+waterglass (in right amount)+water " coating at the stirring crucible inner surface, and be preheated to 400 ℃.Aluminium liquid through melt treatment is poured into stirring crucible, open electromagnetic mixing apparatus simultaneously, when treating that temperature of aluminum liquid is reduced to 615～625 ℃ in the stirring crucible, stirring crucible is put into the electromagnetic mixing apparatus preparation room immediately, the beginning electromagnetic agitation.The electromagnetic agitation technological parameter is as follows: alr mode is not for just-instead having intermittently two-way stirring, and unidirectional rotational time is 3s, and supply frequency is 30Hz, and pouring temperature is 615 ℃～620 ℃, and whipping process adopts the refractory material insulation.Whipping process is gathered in real time to slurry temperature, when temperature is reduced to 607 ℃～605 ℃, promptly stops to stir.The whole stirring roughly needs about 25s～30s.
The slurry of preparing utilizes stirring crucible directly to be delivered to the injection tube of die casting machine, and transfer process is steady, and the time can guarantee in 3s, and when pouring the injection tube into, the slag blocking ring that utilizes injection tube opening part is descaling and other booties.
The rheo-diecasting process choice is: boost pressure 180MPa, 200～220 ℃ of mold temperatures.Fig. 4 rheo-diecasting workpiece different wall place microscopic structure; Wherein scheme (a): wall thickness 6mm; Figure (b): wall thickness 5mm; Figure (c): wall thickness 4mm.Under this technology, workpiece tensile strength and percentage elongation reach 280～310MPa, 12～15% respectively, improve 11.6%～18.2%, 42.5%～50% than liquid die casting respectively.
Claims (3)
1, a kind of slurrying-forming separated aluminium alloy rheological forming method is characterized in that, this method may further comprise the steps:
(1) preparation superheated liquid alloy
(1.1) adopt resistance melting furnace and PID temperature control technique, the alloy blank melting is prepared the superheated liquid alloy;
(1.2) change the liquid alloy in the melting furnace over to electric resistance holding furnace with casting ladle, select intermediate alloy to join in the overheated liquid alloy according to alloy blank described overheated liquid alloy is carried out melt treatment as powdered form fining agent and deformation states alterant;
The temperature that in the melt treatment process, keeps overheated liquid alloy;
(2) stir
(2.1) stirring crucible is preheated to 350～400 ℃;
(2.2) in step 1.2, carry out after the melt treatment liquid alloy of gained and send into 5 seconds turn on agitator before the agitator;
(2.3) superheated melt after step 1.2 melt treatment is changed in the semi-solid alloy slurry stirring crucible, and detect melt temperature immediately, the melt temperature of transferring in the stirring crucible should be higher than 30～35 ℃ of liquidus curves; Stirring crucible is inserted in the preparation room of electromagnetic mixing apparatus;
(2.4) carry out electromagnetic agitation according to setting the alr mode turn on agitator, main technologic parameters has:
Above 5～15 ℃ of beginning whipping temp liquidus curve,
Unidirectional item mixing time 3 seconds,
Just change-reverse reversing mode and adopt intermittently commutation of nothing,
Stirring frequency 30Hz,
Stir voltage and set maximum allowable voltage under the stirring frequency;
In whipping process, temperature is gathered in real time, when solid rate reaches 5% in the whipping process, stop to stir;
(3) die cast
(3.1) treat that step (2.4) electromagnetic agitation finishes after, the preparation room of stirring crucible from electromagnetic mixing apparatus taken out, in 3s, be transferred to the die casting machine injection tube, directly pour alloy pulp into the die casting machine injection tube;
(3.2) rheological molding of workpiece:
(3.2.1) former is selected cold house or hot chamber machine for use; The running channel flow process of mould is short, and running channel, cast gate all adopt Open architecture; Monolateral gap between drift and the pressure chamber is 0.08mm; Mould is reserved the position of heating system; Mold temperature is 220 ℃;
(3.2.2) boost pressure is 180MPa, adopts the secondary fast shot to be shaped, and finishes aluminium alloy rheological and is shaped.
2, a kind of slurrying-forming separated aluminium alloy rheological forming method according to claim 1 is characterized in that, applies one deck " alumina silicate fibre powder+waterglass+water " coating equably at the stirring crucible inwall earlier before stirring the stirring crucible preheating.
3, a kind of slurrying-forming separated aluminium alloy rheological forming method according to claim 1 is characterized in that, places heat-preservation cotton in the preceding preparation room at electromagnetic mixing apparatus in stirring the preparation room of stirring crucible being inserted electromagnetic mixing apparatus.
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