CN212857680U - Melt processing device for preparing ultra-large aluminum alloy ingots - Google Patents
Melt processing device for preparing ultra-large aluminum alloy ingots Download PDFInfo
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- CN212857680U CN212857680U CN202020974208.4U CN202020974208U CN212857680U CN 212857680 U CN212857680 U CN 212857680U CN 202020974208 U CN202020974208 U CN 202020974208U CN 212857680 U CN212857680 U CN 212857680U
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Abstract
The utility model discloses a preparation super big specification is fuse-element processing apparatus for aluminum alloy ingot casting. The device mainly comprises an annular electromagnetic melt processor, a hot top, a crystallizer water tank, a graphite ring, a dummy ingot and a lifting mechanism; the annular electromagnetic melt processor is arranged in the crystallizer, is concentric with the crystallizer, is provided with a line port and a connecting mechanism at the top, is connected with the lifting structure, can move up and down in the height direction of the crystallizer through the lifting mechanism, and is positioned at the corresponding position in the crystallizer. The device is adopted to carry out melt processing, and an annular electromagnetic melt processor is applied to the alloy melt in the semi-continuous casting process, so that the temperature field and the component field of the alloy melt with the ultra-large volume are effectively and uniformly controlled, the melt flow is effectively controlled, and the high-quality and ultra-large-specification aluminum alloy cast ingot with uniform and fine structure and uniform components is prepared. The utility model discloses simple structure, effect are showing, production efficiency is high, easily combine together with large industrial automation production.
Description
Technical Field
The utility model belongs to metal material processing field, in particular to preparation super big specification is fuse-element processing apparatus for aluminum alloy ingot casting.
Background
The ultra-large aluminum alloy cast ingot plays a vital role in the important fields of aerospace, rail transit, national defense military industry and the like, and has a very wide application prospect. The large-size aluminum alloy ingot is cast by adopting common semi-continuous casting, has the problems of large and uneven structure, composition segregation, looseness, cracking and the like, has low yield and difficult quality guarantee, and can not meet the performance requirements of subsequent processing procedures on aluminum alloy ingots, particularly ultra-large-size high-quality high-strength aluminum alloy ingots. The non-uniform temperature field, composition field and stress field during solidification of the aluminum alloy melt are one of the major factors contributing to such problems. Along with the oversize of the ingot casting size, the temperature difference between the central part and the edge part of a melt in the casting process is increased, liquid cavities are deeper, the flow is complex, alloy elements cannot be uniformly distributed on the metallurgical size under the non-equilibrium solidification condition, the temperature distribution of the front edge of a solid-liquid interface is inconsistent with the temperature gradient, the grain growth speed is inconsistent, the growth lap joint of dendritic crystals in a pasty zone and the flow of an intercrystalline liquid phase are influenced by various factors, and finally the problems of coarse and uneven ingot casting structure, segregation, looseness, cracking and the like are caused.
Many methods are proposed to solve the above problems, and among them, the electromagnetic field has the characteristics of high cleanness, high energy density, high reliability, high controllability, high automation level, etc., and gradually becomes an important technical means for improving the quality of a casting blank, stabilizing the operation, and expanding the range and specification of production varieties in the high-efficiency continuous casting production process, and is an important research direction and approach in the field of external field control metal material molding. However, due to the skin effect of electromagnetism, the density of induced current generated by alternating electromagnetic induction decays exponentially from the surface to the center of the ingot, so the improvement of the structure and the performance of the ingot by the stirring action is mainly concentrated in the surface layer range, the uniformity of components is difficult to control, and therefore, a lot of beneficial exploration is conducted at home and abroad.
Chinese patent CN 106925730B discloses a device and a method for preparing large-size fine-grain homogeneous aluminum alloy cast ingots, which are characterized in that an electromagnetic processor is arranged outside a crystallizer, a central cooler is arranged inside a melt, and the electromagnetic processor and the central cooler are coupled to form an annular space to stir the aluminum alloy melt, so that the uniformity of a temperature field and a component field of the large-size melt is greatly improved, and the fine-grain homogeneous aluminum alloy cast ingots with the diameter of phi 500mm can be prepared. However, as the size of the ingot increases, the electromagnetic field applied outside the crystallizer is severely attenuated, and the uniformity improvement of the temperature field and the component field in the melt stirring process is greatly limited. Chinese patent CN 106623832B discloses a method for treating an alloy melt by directly immersing an electromagnetic processor in the alloy melt and applying an electromagnetic field from the inside of the melt, wherein the magnetic field attenuation is reduced and the internal and external temperature uniformity of the large-volume melt can be remarkably improved due to stirring treatment from the inside to the outside of the melt, and the method can realize the preparation of an aluminum alloy cast ingot with the specification of phi 800 mm. However, with the further increase of the ingot specification, the size of the electromagnetic processor placed in the melt is correspondingly increased, the melt in the core range cannot be stirred by the electromagnetic field, and the electromagnetic processing effect is greatly reduced.
SUMMERY OF THE UTILITY MODEL
In order to overcome not enough that preparation super large specification aluminum alloy ingot casting exists at present, the utility model aims to provide a preparation melt processing apparatus for super large specification aluminum alloy ingot casting adopts the device to carry out the melt processing in the casting process, can obtain the aluminum alloy ingot casting of the super large specification that the tissue is tiny, the composition is even.
In order to achieve the above purpose, the utility model adopts the following technical scheme:
a melt processing device for preparing an oversized aluminum alloy ingot mainly comprises an annular electromagnetic melt processor, a hot top, a crystallizer water tank, a graphite ring, a dummy ingot and a lifting mechanism; the annular electromagnetic melt processor is arranged in the crystallizer, is concentric with the crystallizer, is provided with a line port and a connecting mechanism at the top, is connected with the lifting structure, can move up and down in the height direction of the crystallizer through the lifting mechanism and is positioned at a corresponding position in the crystallizer; the lower end of the hot top is hermetically connected with the crystallizer through a graphite ring; the crystallizer water tank is arranged on the periphery of the crystallizer.
The annular electromagnetic melt processor has the main functions of simultaneously applying electromagnetic fields and cooling temperature control effects on alloy melts outside and inside the annular processor, is in an annular cylindrical hollow structure in the whole shape, and mainly comprises an upper cavity, a lower cavity, an inner electromagnetic coil, an outer electromagnetic coil, a temperature control unit, a cooling end and a cooling medium; the upper cavity and the lower cavity are divided into independent spaces through partition plates; the inner electromagnetic coil and the outer electromagnetic coil are placed in the upper cavity, the inner electromagnetic coil is placed on the inner side of the upper cavity, and the outer electromagnetic coil is placed on the outer side of the upper cavity; the temperature control unit is coated on the periphery of the upper cavity; the cooling end is arranged at the lower part of the lower cavity; the upper cavity, the lower cavity and the temperature control unit are respectively filled with cooling media, and realize circulating cooling with the outside.
The annular electromagnetic melt processor divides a large-volume melt into an external melt processing area and an internal melt processing area, and the annular electromagnetic melt processor is 500-1000 mm in outer diameter, 200-600 mm in inner diameter and 100-500 mm high.
The inner electromagnetic coil and the outer electromagnetic coil can be respectively a rotary electromagnetic generator, a traveling wave electromagnetic generator or a spiral electromagnetic generator, the two groups of electromagnetic coils act independently and are composed of two groups of polygonal silicon steel magnet yokes and two groups of coil groups wound by enamelled copper wires, and the two groups of electromagnetic coils respectively play roles in stirring, shearing and controlling flow of melts in melt processing areas inside and outside the annular electromagnetic melt processor. The melts in the inner and outer melt processing areas of the annular electromagnetic melt processor are subjected to electromagnetic stirring and cooling by the cooling unit to achieve the aim of homogenizing the temperature field component field, and the bottom cooling end is washed, so that nucleation is promoted, crystal grains are refined, and the casting of high-quality and ultra-large-specification aluminum alloy ingots is realized.
The ampere turns of an outer electromagnetic coil of the annular electromagnetic melt processor are 5000-40000 At, the ampere turns of an inner electromagnetic coil of the annular electromagnetic melt processor are 2000-30000 At, the frequency of the inner electromagnetic coil is 0.5-50 Hz, and the shearing rate of the inner electromagnetic coil and the outer electromagnetic coil is 10-1000 mm/s.
The temperature control unit comprises a temperature control layer, a heat insulation layer and a thermocouple, wherein the temperature control layer has the main function of keeping the temperature of the melt in the inner melt processing area consistent with that of the melt in the outer melt processing area through different cooling media and flow, the temperature control layer is composed of two layers of high-temperature-resistant heat conduction materials, a spiral pipe is arranged in the temperature control layer, and the cooling media are introduced into the spiral pipe. The heat insulating layer has the main functions of preventing the direct contact between the melt and the casing and protecting the inner and outer electromagnetic coils from being damaged by the high-temperature melt, is made of high-temperature-resistant heat-insulating ceramic and is arranged between the temperature control layer and the upper casing forming the upper cavity, and the thickness of the heat insulating layer is controlled by the specific specification of the temperature control layer. The thermocouple is arranged in the temperature control layer and used for detecting and controlling the temperature.
The temperature control unit is in an annular cylinder shape and is in smooth transition with the cooling end of the lower cavity, and the thickness of the temperature control unit is 5-15 mm. The spiral number of the spiral pipe of the temperature control unit is 3-30, and the spiral distance is 1-8 mm. And cooling medium is introduced in the working process of the spiral pipe, reaches the bottom of the temperature control unit from the connecting circuit ports at different positions, exchanges heat through the spiral pipe and is discharged through the outlet end.
The cooling end is semicircular, the outer diameter of the cooling end is 300-1000 mm, a cooling pipe and a thermocouple are arranged in the cooling end, and the cooling pipe is communicated with the outside through an upper cavity body and a lower cavity body through a connecting mechanism; the thermocouple is arranged in the lower cavity, is close to the position of the cooling end, and is communicated with the outside through the upper cavity and the lower cavity through a connecting mechanism. The cooling end is made of high temperature resistant heat conducting material, such as graphite, steel, copper, molybdenum, titanium and composite materials thereof.
The cooling medium is air, nitrogen or argonVarious fluids such as gas, water, oil and the like, the flow rate of a cooling medium is 0-1000L/min, and the cooling intensity is 100-4000W/(m)2·k)。
The main principle of the utility model is that: the annular electromagnetic melt processor is applied to large-volume alloy melt in the semi-continuous casting process from the inside, the melt is divided into an external melt processing area and an internal melt processing area by the structure of the annular electromagnetic melt processor, the position of the annular electromagnetic melt processor is adjusted by applying different electromagnetic fields, namely a spiral magnetic field, a rotating magnetic field and a traveling wave magnetic field, melt in two parts of the solidification process is driven to flow, and the accurate control of the uniformity of a temperature field and a component field of the alloy melt with super-large volume in the continuous casting process is realized by a mode of uniformly cooling the inner wall and the outer wall. Under the action of the inner and outer groups of electromagnetic coils of the annular electromagnetic melt processor, melts in the inner and outer melt processing areas are effectively processed respectively, multi-dimensional strong shearing movement is generated, and the problems caused by uneven stirring due to the fact that the size of the melts is too large and the skin effect is not uniform and caused by the uneven stirring are solved. In addition, because the solid-liquid phases are subjected to different electromagnetic forces, a speed difference is generated between the solid-liquid phases, so that a concentration boundary layer for solute secondary distribution is extremely thin, the dendrite is broken, the nucleation core is increased, the temperature gradient and the composition supercooling at the crystal nucleus interface are homogenized, the crystal grains are in a relatively uniform environment, the growth of the dendrite is inhibited, and the generation of isometric crystals is facilitated; meanwhile, the inner electromagnetic coil and the outer electromagnetic coil can accelerate the melt in the inner melt processing area to move downwards, the cooling strength in the ingot casting solidification process is increased by scouring the cooling end at the bottom of the melt processor, the melt is restrained from flowing to the center of the ingot casting along the wall of the crystallizer and the solidification front edge, the depth of liquid cavities is reduced, the heat transfer and the uniformity of the melt are promoted, and the nucleation is promoted, so that the high-quality and ultra-large-specification aluminum alloy ingot casting is prepared.
Based on the device, the utility model discloses utilize the device to prepare melt processing method of super large specification aluminum alloy ingot casting includes following step:
(1) in the semi-continuous casting process, firstly, a hot top and a dummy ingot are preheated to a set temperature, a refined alloy melt reaches a crystallizer through a runner, the melt level rises, continuous casting is started, the dummy ingot slowly descends, the cooling water flow is slowly increased, and the casting process enters a stable state;
(2) after the casting process enters a stable state, introducing a cooling medium into the annular electromagnetic field melt processor, immersing the annular electromagnetic field melt processor into an appointed position above a graphite ring in a crystallizer through a lifting mechanism, dividing the melt into an outer melt processing area and an inner melt processing area by the structure of the annular melt processor, and enabling a cooling end to reach the appointed position, so that a temperature control unit and the cooling end exchange heat with the melt to realize forced cooling of the alloy melt;
(3) opening an inner electromagnetic coil and an outer electromagnetic coil, adjusting parameters of the inner electromagnetic coil and the outer electromagnetic coil, and carrying out strong shearing stirring treatment on the alloy melt in the inner melt treatment zone and the outer melt treatment zone to homogenize the melt components and the temperature; adjusting the flow rates of cooling media of the temperature control unit and the cooling end to enable the cooling intensity of the temperature control unit and the cooling end to reach set parameters and enable the alloy melt temperature of the inner melt processing area and the outer melt processing area to reach the specified temperature;
(4) before casting, closing the inner electromagnetic coil and the outer electromagnetic coil, lifting the lifting mechanism, lifting the annular electromagnetic melt processor above the water tank of the crystallizer, closing a cooling medium, and cleaning and maintaining the annular electromagnetic melt processor;
(5) and finishing casting to obtain the ultra-large aluminum alloy ingot.
The annular electromagnetic melt processor is placed in the core of the oversized melt through a lifting structure, and the bottom of the cooling end is located 2-200 mm above the graphite ring.
The cooling strength of the electromagnetic melt processor is 500-5000W/(m)2K) the cooling intensity of the temperature control layer unit is 200-2000W/(m)2K) keeping the temperature of the internal and external melts stable.
The utility model discloses a preparation melt processing apparatus for super large specification aluminum alloy ingot casting sets up annular electromagnetism melt treater on semicontinuous casting platform, makes the ingot casting receive even cooling and electromagnetism shearing processing at semicontinuous casting in-process, adjusts the melt flow state, improves the homogeneity in solidification process temperature field and composition field. The utility model discloses can be used to prepare the diameter in the semicontinuous casting equipment and be greater than 900 mm's aluminum alloy round ingot, diameter 1400 mm's super large specification aluminum alloy ingot casting for example.
The beneficial effects of the utility model are mainly embodied in that:
1. compare traditional semicontinuous casting method, the utility model discloses place annular electromagnetic melt treater inside the crystallizer, the electromagnetic field of production can realize producing stirring shearing action simultaneously or selectively inside and outside fuse-element in the annular structure, there is corresponding change fuse-element mobile state, can produce the strong shearing of multidimension degree in the fuse-element and flow, the inside fuse-element of drive erodees the cooling end many times and promotes the nucleation, the realization is to the effective control that super large volume fuse-element flows, the core fuse-element has the shearing dead zone to lead to the inhomogeneous problem of temperature field and component field when effectively having avoided ordinary electromagnetic stirring to handle super large volume fuse-element.
2. The utility model discloses place annular melt treater inside the crystallizer in the semicontinuous casting in-process, combine even cooling and electromagnetic treatment are ingenious in the crystallizer, position through control melt treater, the temperature control unit on the interior outer wall, the interact of cooling end and inside and outside solenoid, improve super large volume melt temperature field, component field homogeneity and flow situation, increase the cooling strength in the solidification process, reduce core and limit portion temperature difference, reduce the liquid cave degree of depth, promote core fuse-element nucleation, it is tiny even to have realized solidifying the tissue, the component segregation is showing and is reducing, hot crack tendency diminishes.
3. Compare traditional semicontinuous casting method, the utility model discloses the feasibility is high, and the flexibility is good, and the suitability is good, conveniently carries out controllable processing to super large specification fuse-element, implements effectually, easily with realize industrial production, and production facility cost especially super large-scale ingot casting equipment cost obviously reduces, and the super large specification ingot casting surface quality of preparation is good, and the tissue is tiny even, reduces follow-up homogenization and processing cost by a wide margin, and casting speed is fast, is showing and has improved production efficiency and lumber recovery.
Drawings
FIG. 1 is a schematic structural view of the main part of the melt processing apparatus of the present invention.
Fig. 2 is a cross-sectional view of the annular electromagnetic melt processor of the present invention.
Fig. 3 is a schematic structural view of the melt and the annular electromagnetic melt processor when the melt apparatus of the present invention is viewed from the top down, wherein the annular electromagnetic melt processor shows only a partial structure.
FIG. 4 is a liquid phase fraction diagram of 2219 aluminum alloy cast ingot with the diameter of 1400mm prepared by the utility model and the common semi-continuous casting.
FIG. 5a is a microstructure of a 2219 aluminum alloy ingot of phi 1400mm prepared by conventional semi-continuous casting; FIG. 5b shows a 2219 aluminum alloy ingot microstructure of 1400mm phi prepared by the present invention.
FIG. 6 shows the distribution of the components in the radial direction of a 2219 aluminum alloy ingot with the diameter of 1400mm prepared by the utility model and the common semi-continuous casting.
Reference numerals
1 lifting mechanism 2 hot top 3 crystallizer 4 melt 5 crystallizer water tank 6 annular electromagnetic melt processor
7 graphite ring 8 ingot 9 dummy ingot 10 connecting mechanism and line port 11 temperature control layer 12 spiral tube
13-1 thermocouple 13-2 thermocouple 14 heat insulation layer 15-1 upper shell 15-2 lower shell
16 outer solenoid 17 inner solenoid 18 cooling end 19 outer melt treatment zone
20 internal melt processing zone 21 external solenoid yoke 22 internal solenoid yoke 23 cooling medium
Detailed Description
The present invention may be practiced, but is not limited to, in the following examples which are intended to be illustrative of the practice of the invention, and are not intended to limit the scope of the invention in any way, and in the following examples, various procedures and methods not described in detail are conventional and well known in the art.
As shown in fig. 1, the melt processing device for preparing high-quality ultra-large aluminum alloy ingots mainly comprises an annular electromagnetic melt processor 6, a hot top 2, a crystallizer 3, a crystallizer water tank 5, a graphite ring 7, a dummy ingot 9 and a lifting mechanism 1; in the casting process, the annular electromagnetic melt processor 6 is arranged in the crystallizer 3 and is concentric with the crystallizer 3, a line port and a connecting mechanism are arranged at the top of the annular electromagnetic melt processor 6 and are connected with the lifting structure 1, and the annular electromagnetic melt processor can move up and down in the height direction of the crystallizer 3 through the lifting mechanism 2 and is positioned at a corresponding position in the crystallizer 3. The hot top 2 is arranged above the crystallizer 3, the lower end of the hot top 2 is hermetically connected with the crystallizer 3 through a graphite ring 7, a dummy ingot 9 is positioned below the crystallizer 3, the annular electromagnetic melt processor 6 is positioned above the semi-continuous casting platform, the crystallizer 3 is arranged in the casting process, the electromagnetic melt processor 6 is clamped by the lifting mechanism 1, and the crystallizer water tank 5 is arranged at the periphery of the crystallizer 3.
The number of the annular electromagnetic melt processors 6 is one, as shown in fig. 2 and 3, the whole shape of the annular electromagnetic melt processors is an annular cylindrical hollow structure, the structure of the annular cylindrical hollow structure is divided into an upper cavity body and a lower cavity body which are independent closed spaces by partition plates, and the upper cavity body and the lower cavity body are arranged at proper positions in the central height direction of the crystallizer 3; the upper cavity is enclosed by the upper shell 15-1, and the lower cavity is enclosed by the lower shell 15-2. The inner electromagnetic coil 17 and the outer electromagnetic coil 16 are placed in the upper cavity, the inner electromagnetic coil 17 is placed inside the upper cavity, the outer electromagnetic coil 16 is placed outside the upper cavity, and corresponding lines are led out through the line port 10 of the top cover of the upper cavity to be connected with external equipment. The inner and outer electromagnetic coils 16, 17 are two groups of independent rotating electromagnetic stirrers, and the stirring mode can be rotating electromagnetic stirring or spiral stirring. The two groups of electromagnetic coils act independently and consist of two groups of polygonal silicon steel magnetic yokes 21 and 22 and two groups of coil groups wound by waterproof copper wires, and the two groups of electromagnetic coils respectively shear and stir the internal and external melts 19 and 20, change the flow condition of the large-volume melts, realize the intervention and adjustment of the melt flow field, further play a role in improving the uniformity of tissue components, refine grains, reduce segregation and reduce the tendency of heat intensity. And a cooling medium 23 is introduced into the upper cavity from the upper pipe of the top cover and flows out from the upper pipe of the top cover after circulation, and the inner electromagnetic coil 16 and the outer electromagnetic coil 17 are cooled in a circulating way.
The inner wall and the outer wall of the annular electromagnetic melt processor 6 are respectively coated with a set of temperature control unit, the temperature control unit is coated on the periphery of the upper cavity and consists of a temperature control layer 11, a spiral pipe 12, a heat insulation layer 14 and a thermocouple 13-1; the temperature control unit of the annular electromagnetic melt processor 6 close to the melt is cylindrical, consists of an outer temperature control layer 11 and an inner heat insulation layer 14, and is in smooth transition with a lower cavity cooling end 18; the inner diameter of the annular electromagnetic melt processor 6 is 200-600 mm, the outer diameter is 500-1000 mm, the inner wall and the outer wall are respectively flush with the cooling end 18, the thickness of the inner wall and the thickness of the outer wall are respectively 5-20 mm, the temperature control layer is made of high-temperature-resistant heat conduction materials, and the heat insulation layer is made of high-temperature-resistant heat insulation materials.
The temperature control layer 11 is provided with a spiral pipe 12 in a multi-spiral mode, all the spiral pipes are arranged from the radial position to the bottom of the temperature control layer in a multi-spiral layout by a line port, reversely discharged after heat exchange, and made of materials with good heat conductivity, such as copper, steel, titanium and alloys and composite materials thereof; the inner diameter of the spiral pipe 12 is 2-10 mm, the thickness is 0.5-3 mm, the number of the spiral pipes 12 is 3-30, and the spiral distance is 1-8 mm. Inlets of the spiral pipes 12 are arranged at different positions at the bottom of the cooling end, a cooling medium 23 is introduced in the working process, the cooling medium 23 reaches the bottom of the temperature control layer 11 from the connecting line ports 10 at different positions, and is discharged through the outlet end after spiral heat exchange, so that the temperature distribution of the whole melt is uniform. The insulation 14 is made of a high temperature resistant insulation material, such as ceramic fiber, to prevent heat transfer to the upper chamber body from damaging the solenoid coil. And a plurality of groups of replaceable thermocouples 13-1 are arranged on the temperature control unit for measuring the temperature of the monitoring equipment and the melt.
The annular electromagnetic melt processor 6 of the utility model is composed of an upper cavity and a lower cavity, and the lower part of the lower cavity is provided with a cooling end 18. The cooling end 18 is of a semicircular hollow structure, has the outer diameter of 500-1000 mm, the inner diameter of 200-600 mm, the diameter of the cross section of 300mm and the thickness of the same as that of the lower shell 15-2, and is made of high-temperature-resistant heat-conducting materials such as graphite, copper, molybdenum, titanium and composite materials thereof; the cooling end 18 is positioned at the bottom of the annular electromagnetic melt processor 6, a plurality of groups of pipelines penetrate through the upper cavity and are uniformly distributed to realize the alternating-current heat exchange of a cooling medium, and the thermocouple 13-2 is arranged in the lower cavity, is close to the bottom of the cooling end and is communicated with the outside through the upper cavity and the lower cavity through the connecting mechanism 10. The cooling medium 23 enters from the upper line port 10 of the annular electromagnetic melt processor 6, passes through the upper cavity, flows in the cooling end 18 through different positions, exchanges heat with the cooling end 18 to cool the melt 4, then passes through the upper cavity and flows out, and continuous dynamic uniform cooling of the melt 4 at the cooling end 18 can be realized. The melt 4 continuously washes the bottom of the cooling end 18 for cooling and nucleation, the flow condition of a liquid cavity mushy zone is improved, the component segregation degree and the floating crystal flow condition are reduced, and the continuous dynamic uniform cooling and feeding of the melt 4 are realized.
Adopt the utility model discloses a device preparation super large specification aluminum alloy ingot casting's fuse-element processing method does: an annular electromagnetic melt processor 6 is arranged above the semi-continuous casting platform, is immersed into a proper position in the middle of the crystallizer 3 from the upper part of the hot top 2 in the casting process, and applies uniform cooling and electromagnetic stirring to the melt 4 from the inside of the melt. In the semi-continuous casting process, firstly, a hot top 2 and a dummy ingot 9 are preheated, the refined alloy melt 4 enters the hot top 2 and a crystallizer 3, the melt level rises, continuous casting is started, the dummy ingot slowly descends, the cooling water flow is slowly increased, the casting process enters a stable state, a cooling medium is introduced to immerse an annular electromagnetic melt processor 6 into the crystallizer 3 through a lifting mechanism 1, a cooling end 18 is controlled to be positioned at the corresponding position of the crystallizer 3, a heat conduction shell at the bottom of the cooling end 18 exchanges heat with the melt, and forced cooling treatment of the alloy melt is realized; the temperature control layer 11 is filled with a cooling medium 23, the thermocouple 13-1 detects the temperature of the melt, real-time monitoring of the temperature of the external melt and the internal melt is realized, current is applied to the electromagnetic coils 16 and 17, the electromagnetic stirring is generated by singly or completely starting the electromagnetic coils, the melt is divided into an external melt processing area 19 and an internal melt processing area 20 by using an annular structure of an electromagnetic stirrer, and uniform stirring of the large-volume melt is realized.
Example 1
A certain aluminum processing enterprise prepares 2219 aluminum alloy ingot with the specification of phi 1400mm, strict requirements are provided for the uniformity of internal structure components of the ingot, the average grain size of the cross section is superior to grade 3, the grain size deviation requirement is controlled within 8 percent, and the segregation rate of alloy elements is controlled within 5 percent.
Adopt the utility model discloses production diameter is 1400 mm's 2219 aluminum alloy round ingot, and device structure schematic diagram is shown in fig. 1-3. Annular electromagnetic melt treater 6 sets up on the casting platform, and 6 external diameters of annular electromagnetic melt treater are 750mm, and the internal diameter is 360mm, and high 300mm, annular electromagnetic melt treater 6, hot top 2 and crystallizer 3 are concentric, and 6 bottom of annular electromagnetic melt treater and the bottom parallel and level of crystallizer 3. The crystallizer water tank 5 is arranged on the periphery of the crystallizer 3, two groups of independent electromagnetic coils 16 and 17 are adopted in an electromagnetic stirring mode, and electric wires are connected with an external power supply through a connecting mechanism line port 10.
The temperature control layer 11 of the temperature control unit on the outer wall of the annular electromagnetic melt processor 6 is made of high-temperature-resistant heat conduction material titanium, the outer diameter is 750mm, the thickness is 20mm, the spiral pipe 12 arranged inside the annular electromagnetic melt processor is made of pure copper, the inner diameter of the spiral pipe is 5mm, the thickness is 1mm, the number of spirals is 3, and the spiral distance is 5 mm; the outer wall temperature control unit heat insulation layer 11 is made of high temperature resistant heat insulation ceramics, the outer diameter is 730mm, and the thickness is 10 mm. The temperature control unit temperature control layer 11 on the inner wall of the electromagnetic melt processor 6 is made of high-temperature-resistant heat conduction material titanium, the outer diameter is 340mm, the thickness is 10mm, the heat conduction pipe arranged in the electromagnetic melt processor is made of pure copper, the inner diameter of the spiral pipe is 5mm, the thickness is 1mm, the number of spirals is 3, and the spiral distance is 5 mm; the heat insulating layer 13 of the inner wall temperature control unit is made of high temperature resistant heat insulating ceramics, the outer diameter is 320mm, and the thickness is 10 mm. The lower cooling end 18 is 750mm in outer diameter, 320mm in inner diameter and 280mm in cross section and is made of titanium alloy.
In the continuous casting process, when the melt 4 enters the crystallizer 3, the continuous casting equipment is started, the annular electromagnetic melt processor 6 is started after the casting enters a stable state, the cooling medium is air, and the cooling water flow is 40m3The water pressure is stabilized at 3 kPa.
The specific process comprises the following steps: firstly, fully preheating a hot top 2, a crystallizer 3 and a dummy ingot 9 to 250 ℃, using high-purity aluminum for bottom paving, injecting high-temperature melt 4(750 ℃) subjected to online degassing and multistage filtration into the crystallizer 3 through the hot top 2, starting continuous casting equipment when the liquid level of the melt 4 is 230mm away from the top of the hot top 2, slowly increasing the casting speed to 20mm/min, and gradually increasing the flow of cooling water to 40m3H, when casting is in a stable state, the pouring temperature is about 710 ℃, cooling treatment is carried out on the melt by controlling the introduction of a cooling medium 23 such as air, the melt processor with the dried surface is immersed below the liquid level of the melt, the bottom of the cooling end is 50mm above the graphite ring, and the cooling strength is kept to be 1500W/(m)2K) thenThen, an outer electromagnetic coil and an inner electromagnetic coil are respectively started, the external electromagnetic parameters are 20Hz, the current intensity is 50A, and the ampere turns are 10000 At; the internal electromagnetic parameters are 5Hz, the current intensity is 40A, the ampere turns are 6000At, the external electromagnetic coil and the internal electromagnetic coil respectively stir the external melt 19 and the internal melt 20, and the shearing rate is ensured to be 190mm s-1And on the left and right, slowing the center of the liquid cavity upwards, changing the flow condition of the melt in the liquid cavity, slowing the liquid cavity until the casting process is finished, stabilizing the temperature of the cooling end 18 at 645 ℃ in the production process, and controlling the temperature of the inner melt and the outer melt to be kept at 665 ℃ by the temperature control unit.
Through contrast the utility model discloses with the 2219 aluminum alloy phi 1400mm round ingot of ordinary semicontinuous casting preparation, simulation result figure 4 shows and adopts the utility model discloses an ingot casting liquid cave becomes shallow, and the liquid cave is obvious mild, and the condition of flowing is controllable, has obvious improvement effect to improving crystalline grain homogeneity and composition segregation. The quality detection result is shown in fig. 5-a, 5-b and 6, wherein a in fig. 5 shows 2219 aluminum alloy ingot casting tissue prepared by common semi-continuous casting, b shows 2219 aluminum alloy ingot casting tissue prepared by the utility model, the ingot casting section tissue prepared by the utility model is fine and uniform, the average grain size is 478 mu m, and the integral grain size is superior to 3 grades; fig. 6 shows with ordinary semicontinuous casting contrastive analysis, the utility model discloses the homogeneity of the ingot casting alloying element Cu of preparation all has obvious improvement, and the segregation rate of Cu element is 4.8%, consequently adopts the utility model discloses the ingot casting composition homogeneity of preparation improves greatly, satisfies technical requirement.
The thick inequality of tissue, composition segregation, defects such as fracture that traditional semicontinuous casting preparation super large specification aluminum alloy ingot casting exists, the utility model discloses an annular electromagnetic melt treater is applyed to the alloy melt at semicontinuous casting in-process, realizes effectively even to super large volume alloy melt temperature field and composition field, realizes the effective control that flows to the fuse-element, prepares out the even tiny, the even high quality super large specification aluminum alloy ingot casting of composition of tissue. The utility model discloses simple structure, suitability are high, and the effect is showing, need not special preparation crystallizer equipment, and production efficiency is high, easily combines together with large industrial automation production, has wide industrial application prospect in heavy structure spare manufacturing fields such as aerospace, rail transit, boats and ships.
Claims (9)
1. The utility model provides a preparation melt processing apparatus for extra large specification aluminum alloy ingot casting which characterized in that: the device mainly comprises an annular electromagnetic melt processor, a hot top, a crystallizer water tank, a graphite ring, a dummy ingot and a lifting mechanism; the annular electromagnetic melt processor is arranged in the crystallizer, is concentric with the crystallizer, is provided with a line port and a connecting mechanism at the top, is connected with the lifting structure, can move up and down in the height direction of the crystallizer through the lifting mechanism and is positioned at a corresponding position in the crystallizer; the lower end of the hot top is hermetically connected with the crystallizer through a graphite ring; the crystallizer water tank is arranged on the periphery of the crystallizer.
2. The melt processing device for preparing the ultra-large-specification aluminum alloy ingot according to claim 1, characterized in that: the annular electromagnetic melt processor is of an annular cylindrical hollow structure and mainly comprises an upper cavity, a lower cavity, an inner electromagnetic coil, an outer electromagnetic coil, a temperature control unit, a cooling end and a cooling medium; the upper cavity and the lower cavity are divided into independent spaces through partition plates; the inner electromagnetic coil and the outer electromagnetic coil are placed in the upper cavity, the inner electromagnetic coil is placed on the inner side of the upper cavity, and the outer electromagnetic coil is placed on the outer side of the upper cavity; the temperature control unit is coated on the periphery of the upper cavity; the cooling end is arranged at the lower part of the lower cavity; the upper cavity, the lower cavity and the temperature control unit are respectively filled with cooling media, and realize circulating cooling with the outside.
3. The melt processing device for preparing the ultra-large-specification aluminum alloy ingot according to claim 2, characterized in that: the inner electromagnetic coil and the outer electromagnetic coil are respectively a rotating electromagnetic generator, a traveling wave electromagnetic generator or a spiral electromagnetic generator; the two groups of electromagnetic coils act independently and are composed of two groups of polygonal silicon steel magnet yokes and two groups of coil groups wound by enamelled copper wires, and the two groups of polygonal silicon steel magnet yokes and the coil groups respectively play roles in stirring, shearing and controlling flow of melts in inner and outer melt processing areas of the annular electromagnetic melt processor.
4. The melt processing device for preparing the ultra-large-specification aluminum alloy ingot according to claim 2, characterized in that: the temperature control unit consists of a temperature control layer, a heat insulation layer and a thermocouple, wherein the temperature control layer consists of two layers of high-temperature-resistant heat conduction materials, a spiral pipe is arranged in the temperature control layer, and a cooling medium is introduced into the spiral pipe; the heat insulation layer is made of high-temperature-resistant heat insulation ceramic and is arranged between the temperature control layer and the upper shell forming the upper cavity, and the thermocouple is arranged in the temperature control layer and is used for detecting and controlling the temperature.
5. The melt processing device for preparing the ultra-large-specification aluminum alloy ingot according to claim 4, characterized in that: the temperature control unit is in an annular cylinder shape and is in smooth transition with the cooling end of the lower cavity, and the thickness of the temperature control unit is 5-15 mm; the spiral number of the spiral pipe of the temperature control unit is 3-30, the spiral distance is 1-8 mm, a cooling medium is introduced into the spiral pipe in the working process, and the cooling medium reaches the bottom of the temperature control unit from connecting circuit ports at different positions and is discharged through an outlet end after heat exchange of the spiral pipe.
6. The melt processing device for preparing the ultra-large-specification aluminum alloy ingot according to claim 4, characterized in that: the cooling end is semicircular, the outer diameter of the cooling end is 300-1000 mm, a cooling pipe and a thermocouple are arranged in the cooling end, and the cooling pipe is communicated with the outside through an upper cavity body and a lower cavity body through a connecting mechanism; the thermocouple is arranged in the lower cavity, is close to the position of the cooling end, and is communicated with the outside through the upper cavity and the lower cavity through a connecting mechanism; the cooling end is made of high-temperature-resistant heat conduction materials.
7. The melt processing device for preparing the ultra-large-specification aluminum alloy ingot according to claim 2, characterized in that: the cooling medium is air, nitrogen, argon, water or oil, the flow rate of the cooling medium is 0-1000L/min, and the cooling intensity is 100-4000W/(m)2·k)。
8. The melt processing device for preparing the ultra-large-specification aluminum alloy ingot according to claim 2, characterized in that: the annular electromagnetic melt processor divides a large-volume melt into an external melt processing area and an internal melt processing area, and the annular electromagnetic melt processor is 500-1000 mm in outer diameter, 200-600 mm in inner diameter and 100-500 mm high.
9. The melt processing device for preparing the ultra-large-specification aluminum alloy ingot according to claim 2, characterized in that: the ampere turns of the outer electromagnetic coil of the annular electromagnetic melt processor are 5000-40000 At, the ampere turns of the inner electromagnetic coil are 2000-30000 At, the frequency is 0.5-50 Hz, and the shearing rate of the inner electromagnetic coil and the outer electromagnetic coil is 10-1000 mm/s.
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| CN202020974208.4U CN212857680U (en) | 2020-06-01 | 2020-06-01 | Melt processing device for preparing ultra-large aluminum alloy ingots |
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| CN202020974208.4U CN212857680U (en) | 2020-06-01 | 2020-06-01 | Melt processing device for preparing ultra-large aluminum alloy ingots |
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