CN202779647U - 一种半固态的有色金属连铸装置 - Google Patents
一种半固态的有色金属连铸装置 Download PDFInfo
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- CN202779647U CN202779647U CN 201220346232 CN201220346232U CN202779647U CN 202779647 U CN202779647 U CN 202779647U CN 201220346232 CN201220346232 CN 201220346232 CN 201220346232 U CN201220346232 U CN 201220346232U CN 202779647 U CN202779647 U CN 202779647U
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- 229910052782 aluminium Inorganic materials 0.000 description 3
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminum Chemical compound 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[Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 3
- RYGMFSIKBFXOCR-UHFFFAOYSA-N copper Chemical compound 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- 229910052786 argon Inorganic materials 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N carbon Chemical compound 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Abstract
一种半固态的有色金属连铸装置，是由一个带可进行半固态的加工的压铸室、有色合金液储存室、感应加热器、有色合金液注入室、放液孔及由有色合金泵通过隧道连通熔铸室和合金液储存室的保温炉装置和另一个由带脉冲搅动器和水冷系统的结晶器装置组成的装置，该装置可使连铸有色合金液进行半固态加工后结晶凝固。该装置工作稳定，可消除大直径铸坯偏析、缩松等缺陷，从而可获得高质量有色合金铸坯，实现高质量有色合金连续铸锭的生产。
Description
—种半固态的有色金属连铸装置
[0001] 技术领域
[0002] 本实用新型属金属材料液态加工成形技术，特别是各类金属材料的高性能半固态加工成形技术。
[0003] 本实用新型还属金属材料连续铸胚技术，特别是有色合金连续铸胚技术。
[0004] 背景技术
[0005] 现代科学技术的发展，对各类高性能异形构件性能提出了越来越高的要求。半固态加工技术可使金属材料的晶粒细化，获得细小、近球形、非枝晶组织，从而大大提高工件 的力学性能，特别是提高各类高性能异形构件的性能、降低加工成本具有重要意义。
[0006] 对有色金属材料如铜、铝、镁、锌等合金的需求日益增大，特别是铜合金，但是由于铜合金的价格昂贵，而镁、铝、锌是较常见的金属，仅次于铁、铝及铜，而锌的许多性能与铜相近，因此越来越多的受到工业界的重视.
[0007] 水平连铸具有工艺流程短，质量好，投资省，上马快等优点。本实用新型对推有色合金材料的应用，特别是对提高锌合金性能具有重要意义。
[0008] 金属材料的半固态加工技术是各类高性能构件精确成形技术中的关键性技术，它直接影响各类高性能异形构件性能的质量，《半固态金属浆料制备新工艺和加工新技术》(江运喜、谢水生、李兴刚着，“锻压技术” 2003年28. 6)中，公开了目前国内外半固态加工技术技术的发展。
[0009] 传统的半固态加工的方法主要有：
[0010] (I)新MIT工艺“新MIT工艺”法是2000年由麻省理工学院（MassachusettsInstitute of Technology,简称 MIT)的 Flemings 等提出，Idraprince 有限公司获得这项技术专利。其原理是合金溶体在液相线温度下，由于搅拌与冷却的共同作用，导致了溶体体积中合金晶粒的过冷形核，再迅速冷却合金溶体，就能获得较理想的半固态浆料，然后再注入型腔中成形。
[0011] (2)冷却斜槽法冷却斜槽法的原理为：将略高于液相线温度的熔融金属倒在冷却斜槽上，由于斜槽的冷却作用，在斜槽壁上有细小的晶粒形核长大，金属流体的冲击和材料的自重作用使晶粒从斜槽壁上脱落并翻转，以达到搅拌效果。通过冷却斜槽的金属浆料落入容器，控制容器温度，即缓慢冷却，冷却到一定的半固态温度后保温，达到要求的固相体积分数，随后可进行流变成形和触变成形。
[0012] (3)双螺旋半固态金属流变注射成形法该方法的工作原理是，熔融金属在坩埚中熔炼，达到比液相线温度高出约50°C的预定温度，将熔融金属保温15分钟，获得均匀的化学成分。当熔融金属为镁合金时，坩埚采用氩气保护。融熔金属以一定的速度进入双螺旋剪切装置，调整其温度，同时受到双螺杆的剪切作用，获得一定固相百分数的理想的半固态浆料。
[0013] (4)剪切-冷却-轧制法该方法的工作原理是：将加热到一定温度的熔融金属经喷嘴注入辊缝上方的导向槽中，轧辊与靴形座之间留有一定的间隙，同时轧辊表面具有一定的粗糙度，轧辊内通水冷却。由于轧辊与靴形座的冷却作用，合金液发生凝固，转动的轧辊对部分凝固的合金产生剪切搅拌作用，使合金液转化为半固态浆料，并通过轧辊施加的摩擦力将半固态浆料从轧辊与靴形座间隙中拖出，通过安装在出料口的剥离器引导半固态浆料流动。可直接进行流变成形，也可制成所需尺寸的半固态坯料，然后进行触变成形。
[0014] (5)NRC工艺NRC方法的生产工艺过程为：①将熔融金属控制在液相线温度以上几度范围内；②将熔融金属倒入隔热容器中，由于容器的冷却作用，在熔融金属内部产生大量的初生相晶粒；③在容器上下用陶瓷覆盖，防止过冷；④利用风冷将金属冷却到设定的半固态温度；⑤通过隔热容器外部的高频感应加热器调整浆料的温度，调整金属浆料的固相体积分数，形成球形浆料，满足成形需要，这个过程需要3到5分钟；©翻转隔热容器，将半固态浆料倒入套筒。同时，上表面的氧化层沉到套 筒底部，可防止氧化层进入产品；⑦将浆料直接倒入模腔中，并成形。
[0015] (6)不同液体混合法不同液体混合法是将两种或三种亚共晶成分的熔融金属混合，或将亚共晶和过共晶成分的熔融金属混合，将要混合的熔融金属均保持在液相线以上，熔融金属内没有晶核或者晶核很少。混合是在绝热容器中进行，或者在一个通过向绝热容器的表面涂镀石墨的静止混合槽中进行，混合槽要预热，保证熔体流过混合槽时，其温度保持在液相线温度以上。熔体在混合槽上以湍流方式流动，使其混合程度良好。两种熔体的混合导致自发的热传导(热释放)，亚共晶吸收过共晶热量，混合后得到的新合金温度在液相线温度上下，含有大量的晶核，进一步热处理可以形成具有细小，球状组织的半固态浆料。
[0016] (7)近液相线铸造法近液相线铸造法主要采用控制铸造的温度、静置时间、铸造速度及冷却强度等因素，将熔融温度在液相线温度以上或接近于液相线温度经保温静置后，并在一定的冷速下浇注，从而获得细小、近球形、非枝晶半固态组织。
[0017] 以上所介绍的新工艺均为半固态流变成形技术，目前的半固态加工工艺可分为半固态流变成形和半固态触变成形二种，它们的共同特点是先在铸型外制成半固态浆料，再实施流变或触变成形工艺。流变成形工艺是将先将制备的半固态浆料直接铸轧成板带坯，触变成形工艺是将制备的半固态浆料铸造成坯锭后，再二次加热，重熔后触变成形的工艺过程。目前半固态流变技术的主要问题是在浇注前需要一个半固态降温和制浆过程，需要严格的温控设奋和一定的制浆设备，因此大大提高了制造成本和工艺的复杂度。
[0018] 水平连铸的优点是工序短、工艺成本低、生产效率高，占地面积小，常用于热加工性能不佳的有色金属合金材料。
[0019] 发明内容
[0020] 本实用新型的目的是设计出一种新的可进行半固态加工的有色金属连铸装置，该装置可使有色合金金属液经半固态加工后结晶凝固，从而消除传统连铸大直径铸坯时易产生的偏析、缩松、晶枝粗大等缺陷，获得高质量的有色合金铸胚。
[0021] 本实用新型总的技术方案是：建立一个由带脉冲搅动器和水冷系统的结晶器装置(A)和另一个由可进行半固态加工的压铸室、有色合金液储存室、感应加热器、有色合金液注入室、放液孔及由有色合金泵通过隧道连通压铸室和合金液储存室的保温炉装置（B)、感应加热装置（C)以及定量浇注装置⑶和抽锭装置（E)组成的“一种半固态的有色金属连铸装置”，以实现高质量有色合金连续铸胚的生产，如图I所示。
[0022] 本实用新型结构包括结晶器装置，保温炉装置，感应加热装置，定量浇注装置，抽锭装置，具体结构包括：储存室下口，排液口，注入室口，储存室，通气孔，恒压隧道，有色合金泵，半固态加工压铸室，控制阀，高压气体容器，结晶器，脉冲搅动器，拉坯机，小车，同步锯。
[0023] 浇注装置通过侵入式交口与注入室连接，注入室与相邻的储存室在下部联通，储存室与半固态加工压铸室也通过下部恒压隧道连接，恒压隧道内部安装有驱动合金溶液流动的有色合金泵，外部安装有控制合金温度的感应加热装置，半固态加工压铸室上部焊接管道与高压气体容器密封连接，管道上安装有控制阀以控制半固态加工压铸室的压力，半固态加工压铸室出口通过焊接与结晶器接通，结晶器外部安装有脉冲搅动器，结晶器出口处安装抽锭装置和拉坯机。
[0024] 本实用新型的实施过程是：由熔炼炉熔炼出的有色合金熔液经定量浇注包向注入室口注入，经储存室下口进入储存室，此时设在储存室上部的可替闭的通气孔打开，当进入储存室的有色合金熔液到达指定液位高度时，设在恒压隧道口的有色合金泵开动，有色合金熔液注入半固态加工压铸室和结晶器，此时设在半固态加工压铸室上的控制阀处于排气 状态，当进入半固态加工压铸室的有色合金熔液到达指定液位高度时，设在结晶器上的脉冲搅动器开启，同时设在半固态加工压铸室上的控制阀打开，容器中的高压气体经控制阀进入半固态加工压铸室上部并对半固态加工压铸室的有色合金熔液半固态加工，当半固态加工压铸室的压力达到设定值时，结晶器前部的有色合金熔液已经凝固，拉坯机做直线拉坯运动，有色合金铸锭在拉坯机的拉力和高压气体压力的共同作用下缓慢拉出，半固态有色合金铸胚拉出后，由安装在小车上的同步锯按设定尺寸进行锯断。与此同时有色合金泵继续向半固态加工压铸室输入有色合金液，而定量浇注包按设定流量连续向注入室口注入有色合金熔液。如此往复实现半固态有色合金铸胚的连续生产。当连铸中止时，室内剩余有色合金金属液由排液口排出。
[0025] 特别是设在恒压隧道口的有色合金泵可将有色合金熔液由处于常压的有色合金液储存室连续注入可保持一定压力的半固态压铸室和结晶器，从而实现结晶器中的有色合金熔液经半固态加工后结晶凝固。其特征是设在结晶器上的脉冲搅动器在连续生产过程中始终保持搅动状态。
[0026] 由熔炼炉熔炼出的合格有色合金熔液经定量浇注包向注入室口注入，经储存室下口进入储存室，并经有色合金泵经恒压隧道进入半固态加工压铸室和结晶器，在结晶器上的脉冲搅动器的搅动下，半固态有色合金凝固成优质铸锭被垃坯机拉出并切断，如此连续往复制造出优质有色合金铸锭产品。
[0027] 本实用新型可以达到如下效果：
[0028] I、本实用新型是在压铸室和结晶器上对有色合金液进行半固态加工，从而可以省去传统的给液态金属在型外进行温度控制和半固态制浆的工艺过程及相应的半固态制浆和温控装备。
[0029] 2、本实用新型是在压铸室和结晶器上对有色合金液进行半固态加工，从而可以省去传统的在结晶器上安装的用于电磁搅拌铁芯及线圈，外围有线圈，从而可以消除因存在外围漏磁、不便于与外壳固定、成本较高等缺点。
[0030] 3、本实用新型是有色合金熔液连续在半固态加工的压铸室和结晶器上的脉冲搅动器的搅动下结晶，因此所生产的铸锭组织致密，产品质量优良。
[0031] 4、本实用新型釆用了有芯工频感应加热保温炉，热效率高，它克服了熔沟熔断而使工作失效的缺点。
[0032] 5、本实用新型的结晶器处于恒温恒压下，拉坯阻力小，工作平稳。
[0033] 6、本实用新型采用了有色合金泵送有色合金液因此在连铸工作结朿时，浇铸压力室和储存室的金属液可降之最少，而且可方便的从放液孔倒出。
[0034] 7、结构简单，易实现精确定量和自动控制。
[0035] 8、适用范围广，可广泛用于各类有色金属及合金。
[0036] 9、节能，经济效益显著。
[0037] 附图说明
[0038] 图I为本实用新型的结构示意图；·
[0039] 图中：A-结晶器装置，B-保温炉装置，C-感应加热装置，D-定量浇注装置，E-抽锭装置；
[0040] I-储存室下口、2-排液口、3-注入室入口，4-储存室、5-通气孔、6-恒压隧道、7-有色合金泵、8-固态加工压铸室、9-控制阀、10-高压气体容器、11-结晶器、12-脉冲搅动器、13-拉坯机、14-小车、15-同步锯。
[0041] 具体实施方式
[0042] 本实用新型包括结晶器装置，保温炉装置，感应加热装置，定量浇注装置，抽锭装置，具体结构包括：储存室下口，排液口，注入室口，储存室，通气孔，恒压隧道，有色合金泵，半固态加工压铸室，控制阀，高压气体容器，结晶器，脉冲搅动器，拉坯机，小车，同步锯。
[0043] 浇注装置通过侵入式交口与注入室连接，注入室与相邻的储存室在下部联通，储存室与半固态加工压铸室也通过下部恒压隧道连接，恒压隧道内部安装有驱动合金溶液流动的有色合金泵，外部安装有控制合金温度的感应加热装置，半固态加工压铸室上部焊接管道与高压气体容器密封连接，管道上安装有控制阀以控制半固态加工压铸室的压力，半固态加工压铸室出口通过焊接与结晶器接通，结晶器外部安装有脉冲搅动器，结晶器出口处安装抽锭装置和拉坯机。
[0044] 本实用新型的实施过程是：由熔炼炉熔炼出的有色合金熔液经定量浇注包向注入室口注入，经储存室下口进入储存室，此时设在储存室上部的可替闭的通气孔打开，当进入储存室的有色合金熔液到达指定液位高度时，设在恒压隧道口的有色合金泵开动，有色合金熔液注入半固态加工压铸室和结晶器，此时设在半固态加工压铸室上的控制阀处于排气状态，当进入半固态加工压铸室的有色合金熔液到达指定液位高度时，设在结晶器上的脉冲搅动器开启，同时设在半固态加工压铸室上的控制阀打开，容器中的高压气体经控制阀进入半固态加工压铸室上部并对半固态加工压铸室的有色合金熔液半固态加工，当半固态加工压铸室的压力达到设定值时，结晶器前部的有色合金熔液已经凝固，拉坯机做直线拉坯运动，有色合金铸锭在拉坯机的拉力和高压气体压力的共同作用下缓慢拉出，半固态有色合金铸胚拉出后，由安装在小车上的同步锯按设定尺寸进行锯断。与此同时有色合金泵继续向半固态加工压铸室输入有色合金液，而定量浇注包按设定流量连续向注入室口注入有色合金熔液。如此往复实现半固态有色合金铸胚的连续生产。当连铸中止时，室内剩余有色合金金属液由排液口排出。
[0045] 特别是设在恒压隧道口的有色合金泵可将有色合金熔液由处于常压的有色合金液储存室连续注入可保持一定压力的半固态压铸室和结晶器，从而实现结晶器中的有色合金熔液经半固态加工后结晶凝固。其特征是设在结晶器上的脉冲搅动器在连续生产过程中始终保持搅动状态。
[0046] 由熔炼炉熔炼出的合格有色合金熔液经定量浇注包向注入室口注入，经储存室下口进入储存室，并经有色合金泵经恒压隧道进入半固态加工压铸室和结晶器，在结晶器上的脉冲搅动器的搅 动下，半固态有色合金凝固成优质铸锭被垃坯机拉出并切断，如此连续往复制造出优质有色合金铸锭产品。
Claims (1)
1. 一种半固态的有色金属连铸装置，其特征在于：所述装置包括结晶器装置，保温炉装置，感应加热装置，定量浇注装置，抽锭装置，具体结构包括：储存室下口，排液口，注入室口，储存室，通气孔，恒压隧道，有色合金泵，半固态加工压铸室，控制阀，高压气体容器，结晶器，脉冲搅动器，拉坯机，小车，同步锯； 浇注装置通过侵入式交口与注入室连接，注入室与相邻的储存室在下部联通，储存室与半固态加工压铸室也通过下部恒压隧道连接，恒压隧道内部安装有驱动合金溶液流动的有色合金泵，外部安装有控制合金温度的感应加热装置，半固态加工压铸室上部焊接管道与高压气体容器密封连接，管道上安装有控制阀以控制半固态加工压铸室的压力，半固态加工压铸室出口通过焊接与结晶器接通，结晶器外部安装有脉冲搅动器，结晶器出口处安装抽锭装置和拉坯机。
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| CN103231041A (zh) * | 2013-04-27 | 2013-08-07 | 淄博在天工贸有限责任公司 | 纳米保温结晶装置及有色金属节能气化炉 |
| CN103495717A (zh) * | 2013-10-14 | 2014-01-08 | 南昌大学 | 一种半固态加工自动生产线 |
| CN104493125A (zh) * | 2014-12-02 | 2015-04-08 | 中国科学院力学研究所 | 一种应用于金属构件移动微压铸成型方法的双仓式精炼炉 |
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| CN103231041A (zh) * | 2013-04-27 | 2013-08-07 | 淄博在天工贸有限责任公司 | 纳米保温结晶装置及有色金属节能气化炉 |
| CN103231041B (zh) * | 2013-04-27 | 2015-11-25 | 许在天 | 纳米保温结晶装置及有色金属节能气化炉 |
| CN103495717A (zh) * | 2013-10-14 | 2014-01-08 | 南昌大学 | 一种半固态加工自动生产线 |
| CN103495717B (zh) * | 2013-10-14 | 2016-01-20 | 南昌大学 | 一种半固态加工自动生产线 |
| CN104493125A (zh) * | 2014-12-02 | 2015-04-08 | 中国科学院力学研究所 | 一种应用于金属构件移动微压铸成型方法的双仓式精炼炉 |
| CN104493125B (zh) * | 2014-12-02 | 2017-02-08 | 中国科学院力学研究所 | 一种应用于金属构件移动微压铸成型方法的双仓式精炼炉 |
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