EP0439981A1 - Process and device for manufacturing metallic thixotropic products by continuous casting and electromagnetic stirring - Google Patents

Process and device for manufacturing metallic thixotropic products by continuous casting and electromagnetic stirring Download PDF

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Publication number
EP0439981A1
EP0439981A1 EP90420578A EP90420578A EP0439981A1 EP 0439981 A1 EP0439981 A1 EP 0439981A1 EP 90420578 A EP90420578 A EP 90420578A EP 90420578 A EP90420578 A EP 90420578A EP 0439981 A1 EP0439981 A1 EP 0439981A1
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Prior art keywords
mold
axis
discs
zone
wall
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German (de)
French (fr)
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EP0439981B1 (en
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Jean-Luc Meyer
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Rio Tinto France SAS
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Aluminium Pechiney SA
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
    • B22D11/10—Supplying or treating molten metal
    • B22D11/11—Treating the molten metal
    • B22D11/114—Treating the molten metal by using agitating or vibrating means
    • B22D11/115—Treating the molten metal by using agitating or vibrating means by using magnetic fields
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/12—Making non-ferrous alloys by processing in a semi-solid state, e.g. holding the alloy in the solid-liquid phase
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S164/00—Metal founding
    • Y10S164/90—Rheo-casting

Definitions

  • the invention relates to a process for manufacturing thixotropic metal products by continuous casting of plates or billets of circular, elliptical or polygonal section.
  • a thixotropic metal product is a metal product having a non-dendritic primary phase consisting in particular of dendrites degenerated into roughly spherical nodules.
  • thixotropic products provide advantages during shaping compared to conventional products: the shaping energy is lower, the cooling time shorter, the shrinkage reduced, the wear of the molds and die reduced.
  • US Patent 3,948,650 (equivalent to French Patent 2,141,979) describes a casting process which consists in raising the temperature of a composition to the liquid state, in cooling to cause partial solidification and in vigorous stirring of the liquid-solid mixture to breaking the dendrites and transforming them into degenerate substantially spherical nodules representing up to about 65% by weight of the initial composition.
  • US patent 4434837 describes an electromagnetic stirring device applied to the continuous casting of thixotropic metal in which a two-pole stator creates a magnetic field rotating in a plane perpendicular to the axis of the mold and directed towards this axis. The interaction of this field with the current induced in the metal parallel to this axis generates electromagnetic forces located in a horizontal and tangential plane at the ingot mold resulting in a shear rate of at least 500 sec -1 .
  • the patent US 4482012 describes an improvement consisting in using an ingot mold formed by two chambers connected to each other by a non-conductive seal, the first of which plays the role of heat exchanger and in the patent US 4565241, conditions of agitation such that the ratio of the shear rate to the solidification rate is between 2.103 and 8.103.
  • the present invention consists in obtaining the transformation of dendrites into nodules by causing a reflow of the surface of these dendrites by a continuous transfer from the cold zone where they form towards a warmer zone. According to the invention, it is therefore an essentially thermal effect.
  • the liquid metal is poured into a mold with a vertical or horizontal axis with a movable bottom consisting of: of a so-called hot upstream part whose wall or at least its internal face is made of a heat insulating material of a so-called cold downstream part, the wall of which, at least partially, made of a heat conducting material is in external contact with a cooling fluid.
  • a solidification front is shown, as in known manner in continuous casting, represented in FIG. 1 by the reference 7.
  • a liquid-solid zone made up of primary crystals suspended in still liquid metal.
  • the invention consists in imparting to this liquid metal in the course of solidification a movement represented by the arrow of FIG. 1, ensuring a transfer of the primary crystals from the cold zone to the hot zone in a time less than or equal to 1 second to cause a reflow on the surface of the dendritic crystals and transform them into degenerate nodules.
  • This transfer movement is provided by one or more polyphase inductors, the arrangement of which is explained below.
  • the continuous casting apparatus intended for implementing the invention is shown in vertical half-section in FIG. 1. This is an example illustrating a particular embodiment of the invention, that of a vertical casting; similar devices, having the same functions are found in another embodiment of the invention that of a horizontal casting.
  • the device intended for casting, solidification and extraction of the metal will be described successively, then the electromagnetic device intended for ensuring the circulation of the metal.
  • the electromagnetic stirring device whose combination with the pouring device constitutes the invention consists of one or more inductors supplied with polyphase current surrounding the entire casting device, hot zone and cold zone.
  • inductors supplied with polyphase current surrounding the entire casting device, hot zone and cold zone.
  • three-phase current this is what is illustrated on figure 1.
  • six successive windings A, B, C, D, E, F have been represented from top to bottom of the figure. These windings are placed in planes perpendicular to the casting axis.
  • the chamber consists of an inner wall, cylindrical or prismatic, depending on the shape of the cast product, in preferably insulating material or poorly conductive of electricity, but in any case non-magnetic 16 and an outer wall, with internal surface also cylindrical or prismatic, which may consist of a magnetic yoke 12.
  • the water chamber is closed at its upper and lower parts by two pieces 18 and 19 joined together by a threaded tie rod 20 whose role is also to ensure the tightening of the discs forming the winding by means of two nuts 21 and 22. Its central part, in contact with the copper discs is insulated.
  • a water inlet 23 and an outlet 24 are disposed respectively at the bottom and at the top of the chamber.
  • the stacks of copper discs 13 and of insulator 15 are arranged inside the chamber.
  • the copper and insulating discs are pierced with holes, judiciously distributed to constitute the cooling conduits 25 and allow the passage of the tie rods.
  • the casting speed was 150 mm / minute.
  • the casting temperature was 640 ° C.
  • the upstream part of the mold consisted of a ring of refractory material with an internal diameter of 145 mm and a height of 100 mm.
  • the downstream part had the conventional form of an ingot mold for the casting of this type of alloy in this diameter.
  • a linear cylindrical motor with a total winding height of 180mm surrounded these two parts. It consisted of 9 windings, each made using 15 copper discs 1 mm thick, 200 mm internal diameter and 300 mm external diameter.
  • the assembly was supplied with three-phase star mounting and the voltage applied between phases was 15 volts.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Continuous Casting (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)
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Abstract

The invention relates to a continuous casting method for producing thixotropic metallic alloys containing degenerated dendrites. It consists of casting the liquid metal in a movable occluded mould consisting of a hot upstream zone produced from insulating material and a cooled downstream zone in which the metal solidifies, while carrying out by means of a sliding magnetic field, obtained by a series of polyphase inductors, an electromagnetic agitation which causes the dendrites formed in the cold zone to pass into the hot zone where they change to nodules by superficial refusion. This invention is particularly applicable to the production of aluminum plates or bars having thixotropic properties.

Description

DESCRIPTION DE L'ART ANTERIEURDESCRIPTION OF THE PRIOR ART

L'invention est relative à un procédé de fabrication de produits métalliques thixotropes par coulée continue de plaques ou de billettes de section circulaire, elliptique ou polygonale.The invention relates to a process for manufacturing thixotropic metal products by continuous casting of plates or billets of circular, elliptical or polygonal section.

Un produit métallique thixotrope est un produit métallique présentant une phase primaire non dendritique constituée en particulier de dendrites dégénérées en nodules à peu près sphériques.A thixotropic metal product is a metal product having a non-dendritic primary phase consisting in particular of dendrites degenerated into roughly spherical nodules.

Ces produits thixotropes procurent lors de leur mise en forme des avantages par rapport aux produits classiques:
l'énergie de mise en forme est plus faible, la durée de refroidissement plus courte, la retassure réduite, l'usure des moules et filières atténuée.These thixotropic products provide advantages during shaping compared to conventional products:
the shaping energy is lower, the cooling time shorter, the shrinkage reduced, the wear of the molds and die reduced.

Plusieurs brevets enseignent des moyens d'obtention de produits métalliques thixotropes:
Le brevet US 3948650 (équivalent au brevet français 2141979) décrit un procédé de coulée consistant à élever la température d'une composition jusqu'à l'état liquide, à refroidir pour provoquer une solidification partielle et à agiter énergiquement le mélange liquide-solide pour briser les dendrites et les transformer en nodules dégénérés sensiblement sphériques représentant jusque environ 65% en poids de la composition initiale.Several patents teach means of obtaining thixotropic metallic products:
US Patent 3,948,650 (equivalent to French Patent 2,141,979) describes a casting process which consists in raising the temperature of a composition to the liquid state, in cooling to cause partial solidification and in vigorous stirring of the liquid-solid mixture to breaking the dendrites and transforming them into degenerate substantially spherical nodules representing up to about 65% by weight of the initial composition.

Le brevet US 4434837 décrit un dispositif d'agitation électromagnétique appliqué à la coulée continue de métal thixotrope dans lequel un stator à deux pôles crée un champ magnétique tournant dans un plan perpendiculaire à l'axe de la lingotière et dirigé vers cet axe. L'interaction de ce champ avec le courant induit dans le métal parallèlement à cet axe génère des forces électromagnétiques situées dans un plan horizontal et tangentielles à la lingotière entraînant un taux de cisaillement d'au moins 500 sec-¹.US patent 4434837 describes an electromagnetic stirring device applied to the continuous casting of thixotropic metal in which a two-pole stator creates a magnetic field rotating in a plane perpendicular to the axis of the mold and directed towards this axis. The interaction of this field with the current induced in the metal parallel to this axis generates electromagnetic forces located in a horizontal and tangential plane at the ingot mold resulting in a shear rate of at least 500 sec -¹ .

Le brevet US 4457355 décrit une lingotière formée de deux parties de conductibilité thermique différente et le brevet européen EP 71822 une lingotière formée d'une succession de tôles isolantes et conductrices.US Pat. No. 4,457,355 describes an ingot mold formed from two parts of different thermal conductivity and European patent EP 71822 an ingot mold formed from a succession of insulating and conductive sheets.

Le brevet US 4482012 décrit une amélioration consistant à utiliser une lingotière formée de deux chambres reliées entre elles par un joint non conducteur, dont la première joue le rôle d'échangeur de chaleur et dans le brevet US 4565241, on a préconisé des conditions d'agitation telles que le rapport du taux de cisaillement au taux de solidification soit compris entre 2.10³ et 8.10³.The patent US 4482012 describes an improvement consisting in using an ingot mold formed by two chambers connected to each other by a non-conductive seal, the first of which plays the role of heat exchanger and in the patent US 4565241, conditions of agitation such that the ratio of the shear rate to the solidification rate is between 2.10³ and 8.10³.

EXPOSE DE L'INVENTIONSTATEMENT OF THE INVENTION

L'art antérieur rappelé ci-dessus et en particulier les conditions fixées au taux de cisaillement montrent que le problème essentiel rencontré par les inventeurs est que les forces électromagnétiques appliquées au métal en cours de solidification soient suffisantes pour briser les dendrites déjà formées et les transformer en nodules. La dégénérescence des dendrites en nodules est obtenue par effet mécanique uniquement, et non pas par effet thermique. En effet, les forces appliquées aux dendrites sont, dans le cas de billettes rondes, tangentielles à des cercles concentriques centrés sur l'axe de la lingotière. Or, ces cercles sont, en raison de la symétrie de révolution de la lingotière et du produit coulé, des isothermes.The prior art recalled above and in particular the conditions fixed at the shear rate show that the essential problem encountered by the inventors is that the electromagnetic forces applied to the metal being solidified are sufficient to break the dendrites already formed and transform them in nodules. The degeneration of dendrites into nodules is obtained by mechanical effect only, and not by thermal effect. Indeed, the forces applied to the dendrites are, in the case of round billets, tangential to concentric circles centered on the axis of the ingot mold. However, these circles are, due to the symmetry of revolution of the ingot mold and of the cast product, isotherms.

La présente invention consiste à obtenir la transformation des dendrites en nodules en provoquant une refusion de la surface de ces dendrites par un transfert en continu de la zône froide où elles se forment vers une zône plus chaude. Il s'agit donc selon l'invention d'un effet essentiellement thermique.The present invention consists in obtaining the transformation of dendrites into nodules by causing a reflow of the surface of these dendrites by a continuous transfer from the cold zone where they form towards a warmer zone. According to the invention, it is therefore an essentially thermal effect.

Dans le procédé de l'invention, on verse le métal liquide dans un moule d'axe vertical ou horizontal à fond mobile constitué:
d'une partie amont dite chaude dont la paroi ou tout au moins sa face interne est réalisée en un matériau isolant de la chaleur
d'une partie aval dite froide dont la paroi réalisée, au moins partiellement, en un matériau conducteur de la chaleur est en contact extérieur avec un fluide de refroidissement.In the process of the invention, the liquid metal is poured into a mold with a vertical or horizontal axis with a movable bottom consisting of:
of a so-called hot upstream part whose wall or at least its internal face is made of a heat insulating material
of a so-called cold downstream part, the wall of which, at least partially, made of a heat conducting material is in external contact with a cooling fluid.

Dans la partie amont, isolée thermiquement, le métal versé reste liquide; dans la partie aval refroidie, il se forme, comme de façon connue en coulée continue, un front de solidification représentée sur la figure 1 par le repère 7. Immédiatement en amont de ce front, se trouve une zône liquide-solide constituée de cristaux primaires en suspension dans du métal encore liquide.In the upstream part, thermally insulated, the metal poured remains liquid; in the downstream cooled part, a solidification front is shown, as in known manner in continuous casting, represented in FIG. 1 by the reference 7. Immediately upstream of this front, is a liquid-solid zone made up of primary crystals suspended in still liquid metal.

L'invention consiste à imprimer à ce métal liquide en cours de solidification un mouvement représenté par la flèche de la figure 1, assurant un transfert des cristaux primaires de la zône froide vers la zône chaude en un temps inférieur ou égal à 1 seconde pour provoquer une refusion en surface des cristaux dendritiques et les transformer en nodules dégénérés.
Ce mouvement de transfert est assuré par un ou plusieurs inducteurs polyphasés dont la disposition est expliquée ci-après.The invention consists in imparting to this liquid metal in the course of solidification a movement represented by the arrow of FIG. 1, ensuring a transfer of the primary crystals from the cold zone to the hot zone in a time less than or equal to 1 second to cause a reflow on the surface of the dendritic crystals and transform them into degenerate nodules.
This transfer movement is provided by one or more polyphase inductors, the arrangement of which is explained below.

L'appareil de coulée continue destiné à la mise en oeuvre de l'invention est représentée en demi-coupe verticale sur la figure 1. Il s'agit d'un exemple illustrant un cas particulier de réalisation de l'invention celui d'une coulée verticale; des dispositifs analogues, ayant les mêmes fonctions se retrouvent dans un autre mode de réalisation de l'invention celui d'une coulée horizontale.The continuous casting apparatus intended for implementing the invention is shown in vertical half-section in FIG. 1. This is an example illustrating a particular embodiment of the invention, that of a vertical casting; similar devices, having the same functions are found in another embodiment of the invention that of a horizontal casting.

On décrira successivement le dispositif destiné à la coulée, à la solidification et à l'extraction du métal puis le dispositif électromagnétique destiné à assurer la circulation du métal.The device intended for casting, solidification and extraction of the metal will be described successively, then the electromagnetic device intended for ensuring the circulation of the metal.

Le dispositif de coulée, solidification et extraction est proche de celui utilisé pour la coulée continue en charge (ou avec rehausse) des métaux et en particulier de l'aluminium. Il comprend:

  • a) une partie chaude réalisée en matériau isolant thermique 1 qui contient le métal liquide 2. Le matériau isolant est du type utilisé couramment en fonderie pour la confection de goulottes et de busettes.
  • b) une partie froide reliée à la partie chaude de manière étanche au métal liquide. Cette partie froide comprend comme élément essentiel une lingotière 3 en métal conducteur de la chaleur refroidie extérieurement. Ce refroidissement peut être assuré par un film de fluide de refroidissement, généralement de l'eau, 5 provenant d'une boîte à eau 6, tel que représenté sur la figure 1. Il peut aussi être assuré directement par une chambre d'eau accolée de manière connue à la lingotière. Dans ce dernier cas, on formera de préférence des jets ou une lame d'eau au bas de l'ensemble chambre d'eau-lingotière qui viendront assurer par ruissellement le refroidissement direct du produit en cours de coulée. Cette lingotière peut être munie, à sa partie supérieure d'un anneau de graphite 4 jouant un rôle de lubrifiant vis-à-vis du métal coulé, en complément d'un agent de lubrification dont il s'avère parfois nécessaire de revêtir la paroi interne de la partie aval pour faciliter la coulée de certains métaux. Suivant une technique de l'art antérieur, il est aussi possible d'amener en continu par la lingotière un agent de lubrification qui traverse l'anneau de graphite et assure ainsi une lubrification en continu. Toujours dans la perspective de lubrifier en continu, on peut, au lieu d'utiliser un anneau de graphite, insérer dans la lingotière des crayons de graphite qui débouchent sur la face interne de la lingotière et sont connectés à leur autre extrémité à une chambre où le lubrifiant est mis sous pression.
  • c)le système d'extraction constitué d'un fond obturant la partie inférieure de la lingotière au démarrage, porté dans le cas d'une coulée verticale, par un plateau animé d'un mouvement régulier vertical et vers le bas, réglable selon les alliages et le format des produits coulés. Dans le cas de la coulée horizontale, ce système est porté soit par un tapis motorisé, soit par une table à rouleaux dont l'un est motorisé, un rouleau presseur venant garantir l'entraînement.
The casting, solidification and extraction device is close to that used for continuous casting under load (or with enhancement) of metals and in particular of aluminum. He understands:
  • a) a hot part made of thermal insulating material 1 which contains liquid metal 2. The insulating material is of the type commonly used in foundries for making trunking and nozzles.
  • b) a cold part connected to the hot part in a sealed manner to the liquid metal. This cold part comprises as an essential element an ingot mold 3 made of heat-conductive metal externally cooled. This cooling can be ensured by a film of cooling fluid, generally water, 5 coming from a water box 6, as shown in FIG. 1. It can also be provided directly by an adjoining water chamber in a known manner in the mold. In the latter case, jets or a layer of water will preferably be formed at the bottom of the water chamber-ingot mold assembly which will ensure direct cooling of the product during casting by trickling. This ingot mold can be provided, at its upper part with a graphite ring 4 playing a role of lubricant with respect to the cast metal, in addition to a lubricating agent with which the wall sometimes turns out to be necessary. internal of the downstream part to facilitate the casting of certain metals. According to a technique of the prior art, it is also possible to supply continuously by the ingot mold a lubricating agent which passes through the graphite ring and thus ensures continuous lubrication. Still with a view to continuous lubrication, it is possible, instead of using a graphite ring, to insert graphite pencils into the ingot mold which open onto the internal face of the ingot mold and are connected at their other end to a chamber where the lubricant is pressurized.
  • c) the extraction system consisting of a bottom closing the lower part of the ingot mold at start-up, carried in the case of vertical casting, by a plate animated with a regular vertical and downward movement, adjustable according to the alloys and the format of the cast products. In the case of horizontal casting, this system is carried either by a motorized mat or by a roller table, one of which is motorized, a pressure roller coming to guarantee the drive.

Après le démarrage, le produit déjà solidifié sert de moule pour la solidification du métal alimenté en continu et l'on arrive à un état d'équilibre représenté sur la figure 1.After start-up, the already solidified product serves as a mold for the solidification of the continuously supplied metal and we arrive at a state balance shown in Figure 1.

A partir de la lingotière se développe une enveloppe extérieure solidifiée tandis qu'à l'intérieur du produit coulé s'établit un front de solidification 7 ayant la forme approximative représentée sur la figure. Au-dessous de ce front, le métal est complètement solide; au-dessus, dans ce que l'on appelle le "marais", il y a un mélange de liquide et de particules solides, généralement dendritiques, particules qui s'intègrent progressivement au front de solidification en permettant à la partie solide 8 de se développer et à la coulée de progresser.From the ingot mold develops a solidified outer envelope while inside the cast product is established a solidification front 7 having the approximate shape shown in the figure. Below this front, the metal is completely solid; above, in what is called the "swamp", there is a mixture of liquid and solid particles, generally dendritic, particles which integrate progressively at the solidification front by allowing the solid part 8 to to develop and to progress.

Le dispositif électromagnétique de brassage dont la combinaison avec le dispositif de coulée constitue l'invention se compose de un ou plusieurs inducteurs alimentés en courant polyphasé entourant l'ensemble du dispositif de coulée, zône chaude et zône froide. En principe, on peut utiliser n'importe quel type de courant à n phases, en pratique on utilisera évidemment le courant triphasé: c'est ce qui est illustré sur la figure 1.
Sur cette figure, six bobinages successifs: A,B, C, D, E, F ont été représentés de haut en bas de la figure. Ces bobinages sont placés dans des plans perpendiculaires à l'axe de coulée. Ils sont alimentés d'une façon analogue à celle de l'alimentation des moteurs linéaires à induction respectivement par les phases 1, -2, 3, -1, 2, -3 de manière à créer un champ glissant vertical ascendant, descendant ou périodiquement ascendant puis descendant, suivant l'ordre dans lequel sont alimentées les trois phases. De manière classique, on utilise généralement une longueur de bobinage qui soit un multiple du pas polaire, le pas polaire étant la longueur des trois bobinages de la séquence élémentaire 1, -2, 3. Cela signifie en pratique qu'on utilisera 6, 9, 12, 15..... bobinages mais rien n'interdit en théorie de couper une séquence au milieu. De plus des moyens sont connus de l'homme de l'art en électrotechnique consistant à utiliser des bobinages particuliers aux extrémités en vue d'éliminer les effets de bord dans les moteurs linéaires. L'interaction de ce champ glissant avec les courants induits dans le métal engendre des forces qui induisent des mouvements dans des plans passant par l'axe de la lingotière et donc du produit coulé. Ces mouvements sont représentés schématiquement sur la figure 1 par la flèche 10.The electromagnetic stirring device whose combination with the pouring device constitutes the invention consists of one or more inductors supplied with polyphase current surrounding the entire casting device, hot zone and cold zone. In principle, one can use any type of current with n phases, in practice one will obviously use the three-phase current: this is what is illustrated on figure 1.
In this figure, six successive windings: A, B, C, D, E, F have been represented from top to bottom of the figure. These windings are placed in planes perpendicular to the casting axis. They are supplied in a manner analogous to that of the supply of linear induction motors respectively by phases 1, -2, 3, -1, 2, -3 so as to create an ascending, descending or periodically vertical sliding field ascending then descending, in the order in which the three phases are supplied. Conventionally, a winding length is generally used which is a multiple of the pole pitch, the pole pitch being the length of the three windings of the elementary sequence 1, -2, 3. This means in practice that we will use 6, 9 , 12, 15 ..... windings but nothing theoretically prohibits cutting a sequence in the middle. In addition, means are known to those skilled in the art of electrical engineering consisting in using special windings at the ends in order to eliminate edge effects in linear motors. The interaction of this sliding field with the currents induced in the metal generates forces which induce movements in planes passing through the axis of the ingot mold and therefore of the cast product. These movements are represented diagrammatically in FIG. 1 by the arrow 10.

Il est clair que ces mouvements permettent l'entraînement des dendrites formées au voisinage du front de solidification et noyées dans le métal encore liquide vers la partie supérieure plus chaude du marais où elles subissent une fusion superficielle les transformant en nodules, puis de nouveau vers la zône froide dans le sens de la flèche 11.It is clear that these movements allow the entrainment of the dendrites formed in the vicinity of the solidification front and embedded in the still liquid metal towards the warmer upper part of the marsh where they undergo a surface fusion transforming them into nodules, then again towards the cold zone in the direction of the arrow 11.

Les inducteurs triphasés A à F décrits ci-dessus peuvent être réalisés de deux façons:

  • 1°) de façon classique avec des bobinages sous forme de galettes en fil de cuivre non refroidi ou en tube de cuivre refroidi, les différentes galettes étant superposées et de préférence placées dans les encoches d'une culasse magnétique feuilletée 12 destinée à canaliser les lignes de force du champ magnétique. (figure 2). Les feuilles métalliques, isolées électriquement les unes des autres, sont situées dans des plans passant par l'axe du moule. Dans le cas où une chambre d'eau est accolée à la lingotière pour assurer le refroidissement de celle-ci, on peut placer les bobinages à l'intérieur de cette chambre. Ils sont ainsi efficacement refroidis.
  • 2°) selon l'invention telle que représentée sur la figure 3:
    Le bobinage est constitué de disques minces d'épaisseur de l'ordre du mm en métal bon conducteur, du cuivre par exemple. Chaque disque 13 en forme d'anneau et muni d'une fente 14 constitue une spire du bobinage (figure 3a). Pour constituer le bobinage, on empile les disques en décalant deux disques successifs d'un angle donné. Une feuille d'isolant 15 est interposée entre deux disques de cuivre successifs sauf dans la zône entre les fentes de ces deux disques successifs. Il y a donc dans cette zône une plage de contact assurant la liaison électrique entre deux disques successifs et la continuité du bobinage. (figure 3b).
The three-phase inductors A to F described above can be produced in two ways:
  • 1) in a conventional manner with coils in the form of pancakes made of uncooled copper wire or of cooled copper tube, the various pancakes being superimposed and preferably placed in the notches of a laminated magnetic yoke 12 intended to channel the lines strength of the magnetic field. (figure 2). The metal sheets, electrically isolated from each other, are located in planes passing through the axis of the mold. In the case where a water chamber is attached to the ingot mold to ensure the cooling thereof, the windings can be placed inside this chamber. They are thus effectively cooled.
  • 2) according to the invention as shown in FIG. 3:
    The winding consists of thin discs with a thickness of the order of mm in good conductive metal, copper for example. Each disc 13 in the form of a ring and provided with a slot 14 constitutes a turn of the winding (FIG. 3a). To constitute the winding, the discs are stacked by shifting two successive discs by a given angle. An insulating sheet 15 is interposed between two successive copper discs except in the area between the slots of these two successive discs. There is therefore in this zone a contact area ensuring the electrical connection between two successive discs and the continuity of the winding. (Figure 3b).

Pour assurer le refroidisement des disques de cuivre, on a imaginé deux solutions selon le mode de refroidissement de la lingotière. Dans le cas de refroidissement par film d'eau de la lingotière, on place les bobinages selon l'invention décrite ci-dessus dans une chambre d'eau annulaire entourant les parties amont et aval et laissant le passage pour le film d'eau au niveau de la lingotière. Une demi-coupe de cette chambre est représentée sur la figure 4.To ensure the cooling of the copper disks, two solutions have been devised according to the method of cooling the ingot mold. In the case of water film cooling of the mold, the windings according to the invention described above are placed in a annular water chamber surrounding the upstream and downstream parts and leaving the passage for the water film at the level of the mold. A half-section of this chamber is shown in Figure 4.

La chambre est constituée d'une paroi intérieure, cylindrique ou prismatique, selon la forme du produit coulé, en matière de préférence isolante ou faiblement conductrice de l'électricité, mais en tout cas amagnétique 16 et d'une paroi extérieure, à surface interne également cylindrique ou prismatique, qui peut être constituée d'une culasse magnétique 12.
La chambre d'eau est fermée à ses parties supérieure et inférieure par deux pièces 18 et 19 réunies entre elles par un tirant fileté 20 dont le rôle est d'assurer également le serrage des disques formant le bobinage grâce à deux écrous 21 et 22. Sa partie centrale, au contact avec les disques de cuivre est isolée.The chamber consists of an inner wall, cylindrical or prismatic, depending on the shape of the cast product, in preferably insulating material or poorly conductive of electricity, but in any case non-magnetic 16 and an outer wall, with internal surface also cylindrical or prismatic, which may consist of a magnetic yoke 12.
The water chamber is closed at its upper and lower parts by two pieces 18 and 19 joined together by a threaded tie rod 20 whose role is also to ensure the tightening of the discs forming the winding by means of two nuts 21 and 22. Its central part, in contact with the copper discs is insulated.

Une arrivée d'eau 23 et une sortie 24 sont disposées respectivement en bas et en haut de la chambre. Les empilages de disques de cuivre 13 et d'isolant 15 sont disposés à l'intérieur de la chambre. Les disques de cuivre et d'isolant sont percés de trous, judicieusement répartis pour constituer les conduits de refroidissement 25 et permettre le passage des tirants.A water inlet 23 and an outlet 24 are disposed respectively at the bottom and at the top of the chamber. The stacks of copper discs 13 and of insulator 15 are arranged inside the chamber. The copper and insulating discs are pierced with holes, judiciously distributed to constitute the cooling conduits 25 and allow the passage of the tie rods.

Dans le cas où le refroidissement de la lingotière est assuré par une chambre d'eau, on peut tirer profit de cette solution en plaçant les bobinages directement dans cette chambre. (Figure 5).
La paroi interne de la chambre est dans ce cas la lingotière elle-même 26 qui est revêtue en amont (Partie chaude) d'un matériau isolant thermiquement 27 et en aval (Partie froide) d'un anneau en graphite 28. On retrouve la partie solide 29 du produit en cours de coulée délimitée par le front 30. L'eau qui arrive en 31 sert non seulement à refroidir les bobinages 32 par l'intermédiaire des perçages 33, et la lingotière par passage dans l'interstice 34, mais aussi à former la lame d'eau 35 qui ruisselle 36 sur le produit. Une vanne 37 située sur le circuit de sortie 38 du refroidissement du bobinage permet de contrôler les quantités respectives circulant dans chacun des passages. Le reste de la technologie est similaire à ce qui a été décrit pour la figure 4.If the ingot mold is cooled by a water chamber, this solution can be taken advantage of by placing the coils directly in this chamber. (Figure 5).
The internal wall of the chamber is in this case the ingot mold itself 26 which is coated upstream (hot part) with a thermally insulating material 27 and downstream (cold part) with a graphite ring 28. We find the solid part 29 of the product during casting delimited by the front 30. The water which arrives at 31 serves not only to cool the windings 32 by means of the holes 33, and the ingot mold by passing through the gap 34, but also to form the blade of water 35 which flows 36 over the product. A valve 37 located on the output circuit 38 of the winding cooling makes it possible to control the respective quantities circulating in each of the passages. The rest of the technology is similar to what has been described for figure 4.

EXEMPLE.EXAMPLE.

Une billette de diamètre 150 mm en alliage d'aluminium du type AS₇G₀,₃ (Al-7% Si-O,3% Mg ), modifié au strontium, a été coulée selon le procédé décrit ci-dessus.A 150 mm diameter billet of aluminum alloy of the AS₇G₀ , ₃ type (Al-7% Si-O, 3% Mg), modified with strontium, was poured according to the method described above.

La vitesse de coulée était de 150 mm/minute. La température de coulée était de 640°C. La partie amont du moule était constituée d'un anneau de matériau réfractaire de diamètre interne 145 mm et de hauteur 100 mm. La partie aval avait la forme classique d'une lingotière pour la coulée de ce type d'alliage dans ce diamètre. Un moteur linéaire cylindrique de hauteur totale de bobinage 180mm entourait ces deux parties. Il était constitué de 9 bobinages, chacun réalisé à l'aide de 15 disques de cuivre d'épaisseur 1 mm, de diamètre interne 200 mm et de diamètre externe 300 mm. L'ensemble était alimenté en triphasé en montage étoile et la tension appliquée entre phases était de 15 volts.The casting speed was 150 mm / minute. The casting temperature was 640 ° C. The upstream part of the mold consisted of a ring of refractory material with an internal diameter of 145 mm and a height of 100 mm. The downstream part had the conventional form of an ingot mold for the casting of this type of alloy in this diameter. A linear cylindrical motor with a total winding height of 180mm surrounded these two parts. It consisted of 9 windings, each made using 15 copper discs 1 mm thick, 200 mm internal diameter and 300 mm external diameter. The assembly was supplied with three-phase star mounting and the voltage applied between phases was 15 volts.

Un examen micrographique au coeur de la billette a montré que l'on a obtenu effectivement une structure dendritique dégénérée avec une taille typique des globules voisine de 60 µm.A micrographic examination at the heart of the billet showed that a degenerate dendritic structure was indeed obtained with a typical size of the globules close to 60 μm.

Claims (19)

Procédé de fabrication par coulée continue de produits métalliques thixotropes et, en particulier, de produits en alliage d'aluminium, dont une partie au moins de la phase primaire est sous forme de nodules provenant de dendrites dégénérées, dans lequel on verse le métal liquide dans un moule obturé à sa partie aval par un fond mobile et constitué de deux parties de même axe: a) une partie amont, dite zône chaude (1) dont la paroi est réalisée en matériau isolant thermique au moins sur sa face interne b) une partie aval, dite zône froide (3) dont la paroi, réalisée en matériau conducteur thermique est refroidie par un fluide de refroidissement (5) de façon à provoquer dans le métal liquide l'apparition de cristaux primaires, la formation au contact de la paroi refroidie d'une croûte solide et d'un front de solidification (7) permettant l'extraction progressive du produit à l'aide du fond mobile, caractérisé en ce que l'on dispose autour des zônes chaude et froide du moule une série d'inducteurs constitués de bobinages annulaires ayant pour axe l'axe du moule et alimentés en courant polyphasé avec un ordre des phases tel que s'établisse à l'intérieur du moule un champ glissant parallèle à l'axe du moule se déplaçant dans un sens ou dans l'autre ou alternativement dans un sens puis dans l'autre, engendrant des forces électromagnétiques entraînant le métal dans des mouvements dans des plans passant par l'axe du moule et assurant le transfert des cristaux dendritiques de la zône froide vers la zône chaude (10) et vice-versa (11) pour provoquer une refusion superficielle de ces cristaux et leur dégénérescence en nodules.Process for the production by continuous casting of thixotropic metal products and, in particular, of aluminum alloy products, at least part of the primary phase of which is in the form of nodules originating from degenerate dendrites, in which the liquid metal is poured into a mold closed at its downstream part by a movable bottom and consisting of two parts of the same axis: a) an upstream part, called a hot zone (1), the wall of which is made of thermal insulating material at least on its internal face b) a downstream part, known as the cold zone (3), the wall of which, made of thermal conductive material, is cooled by a cooling fluid (5) so as to cause in the liquid metal the appearance of primary crystals, the formation on contact the cooled wall of a solid crust and a solidification front (7) allowing the gradual extraction of the product using the movable bottom, characterized in that around the hot and cold zones of the mold are arranged a series of inductors consisting of annular coils having the axis of the mold axis and supplied with polyphase current with a phase order such as established at inside the mold a sliding field parallel to the axis of the mold moving in one direction or the other or alternately in one direction then in the other, generating electromagnetic forces driving the metal in movements in planes passing through the axis of the mold and ensuring the transfer of the dendritic crystals from the cold zone to the hot zone (10) and vice versa (11) to cause a superficial reflow of these crystals and their degeneration into nodules. Procédé selon la revendication 1 caractérisé en ce que la coulée continue se fait verticalement.Method according to claim 1 characterized in that the continuous casting takes place vertically. Procédé selon la revendication 1 caractérisé en ce que la coulée continue se fait horizontalement.Process according to Claim 1, characterized in that the continuous casting takes place horizontally. Dispositif pour la coulée continue de produits métalliques thixotropes comportant un moule obturé à sa partie aval par un fond mobile et constitué de deux parties de même axe:
une partie amont, dite zône chaude (1) dont la paroi est réalisée en matériau isolant thermique au moins sur sa face interne
une partie aval, dite zône froide (3) dont la paroi, réalisée en matériau conducteur thermique est refroidie par un fluide de refroidissement (5), un système de déplacement du fond mobile permettant l'extraction progressive du produit, caractérisé en ce que sont disposés autour des zônes chaude et froide du moule une série d'inducteurs constitués de bobinages annulaires ayant pour axe l'axe du moule et alimentés en courant polyphasé avec un ordre des phases tel que s'établisse à l'intérieur du moule un champ glissant parallèle à l'axe du moule se déplaçant dans un sens ou dans l'autre ou alternativement dans un sens puis dans l'autre, engendrant des forces électromagnétiques situées dans des plans passant par l'axe du moule.Device for the continuous casting of thixotropic metal products comprising a mold closed at its downstream part by a movable bottom and consisting of two parts of the same axis:
an upstream part, called hot zone (1) whose wall is made of thermal insulating material at least on its internal face
a downstream part, known as the cold zone (3), the wall of which, made of thermal conductive material, is cooled by a cooling fluid (5), a system for moving the movable bottom allowing the gradual extraction of the product, characterized in that are arranged around the hot and cold zones of the mold a series of inductors consisting of annular coils having for axis the axis of the mold and supplied with polyphase current with a phase order such that a sliding field is established inside the mold parallel to the axis of the mold moving in one direction or the other or alternately in one direction then in the other, generating electromagnetic forces located in planes passing through the axis of the mold. Dispositif selon la revendication 4 caractérisé en ce que l'axe du moule est vertical.Device according to claim 4 characterized in that the axis of the mold is vertical. Dispositif selon la revendication 4 caractérisé en ce que l'axe du moule est horizontal.Device according to claim 4 characterized in that the axis of the mold is horizontal. Dispositif selon l'une des revendications 4 à 6 caractérisé en ce que la paroi interne de la lingotière située dans la zône froide est munie sur toute sa périphérie et à sa partie la plus en amont d'une bague en graphite de même axe que celui de la lingotière.Device according to one of Claims 4 to 6, characterized in that the internal wall of the mold located in the cold zone is provided over its entire periphery and at its most upstream part with a graphite ring of the same axis as that of the mold. Dispositif selon l'une des revendications 4 à 6 caractérisé en ce que la paroi interne de la lingotière située dans la zône froide est traversée sur toute sa périphérie et à sa partie la plus en amont par des crayons en graphite qui amènent le lubrifiant à la paroi interne de la lingotière.Device according to one of Claims 4 to 6, characterized in that the internal wall of the ingot mold located in the cold zone is traversed over its entire periphery and at its most upstream part by graphite pencils which bring the lubricant to the internal wall of the mold. Dispositif selon l'une des revendications 4 à 8 caractérisé en ce que les bobinages sont alimentés en courant triphasé.Device according to one of claims 4 to 8 characterized in that the windings are supplied with three-phase current. Dispositif selon l'une des revendications 4 à 9 caractérisé en ce que la longueur totale des bobinages est un multiple du pas polaire.Device according to one of Claims 4 to 9, characterized in that the total length of the windings is a multiple of the pole pitch. Dispositif selon l'une quelconque des revendications 4 à 10 caractérisé en ce que le système de refroidissement de la partie aval est constitué d'un film provenant d'une boîte à eau.Device according to any one of Claims 4 to 10, characterized in that the cooling system of the downstream part consists of a film coming from a water box. Dispositif selon l'une quelconque des revendications 4 à 10 caractérisé en ce que le système de refroidissement de la partie aval est constitué par une chambre d'eau accolée à la lingotière et formant à sa base des jets ou une lame d'eau venant ruisseler sur le produit coulé.Device according to any one of Claims 4 to 10, characterized in that the cooling system of the downstream part consists of a water chamber attached to the ingot mold and forming at its base jets or a layer of water coming to run off on the cast product. Dispositif selon l'une quelconque des revendications 4 à 12 caractérisé en ce que les bobinages sont réalisés sous forme de galettes superposées en fil de cuivre ou en tube de cuivre refroidi.Device according to any one of Claims 4 to 12, characterized in that the coils are produced in the form of superposed wafers made of copper wire or of cooled copper tube. Dispositif selon la revendication 13 caractérisé en ce que les galettes sont placées dans les encoches d'une culasse magnétique feuilletée.Device according to claim 13 characterized in that the wafers are placed in the notches of a laminated magnetic yoke. Dispositif selon l'une des revendications 4 à 12 caractérisé en ce que les bobinages sont constitués de disques métalliques annulaires minces, de préférence en cuivre, chacun d'eux étant muni d'une fente radiale, ces disques étant empilés avec à chaque disque successif un décalage d'un angle donné de la fente et avec interposition entre deux disques voisins d'une feuille d'isolant sauf dans la zône entre les fentes de deux disques voisins de façon à créer une plage de contact entre ces deux disques et assurer ainsi la continuité du bobinage.Device according to one of Claims 4 to 12, characterized in that the windings consist of thin annular metal discs, preferably made of copper, each of them being provided with a radial slot, these discs being stacked with each successive disc. an offset of a given angle of the slot and with interposition between two neighboring discs of an insulating sheet except in the area between the slots of two neighboring discs so as to create a contact area between these two discs and thus ensure the continuity of the winding. Dispositif selon la revendication 15 caractérisé en ce que les bobinages ainsi constitués sont placés à l'intérieur d'une chambre parcourue par une circulation d'eau, de forme annulaire entourant le moule de coulée, munie de moyens de serrage de l'empilement de disque de cuivre et de feuilles d'isolant et en ce que ces disques de cuivre et d'isolant sont percés de trous alignés permettant la circulation de l'eau de refroidissement.Device according to Claim 15, characterized in that the coils thus formed are placed inside a chamber traversed by a circulation of water, of annular shape surrounding the casting mold, provided with means for clamping the stack of disk of copper and insulation sheets and in that these copper and insulation discs are drilled with aligned holes allowing the circulation of cooling water. Dispositif selon la revendication 16 caractérisé en ce que la paroi externe de la chambre est constituée d'une culasse magnétique.Device according to claim 16 characterized in that the external wall of the chamber consists of a magnetic yoke. Dispositif selon l'une des revendications 12 à 14 caractérisé en ce que, pour assurer leur refroidissement, les bobinages sont placés à l'intérieur de la chambre d'eau accolée à la lingotière.Device according to one of claims 12 to 14 characterized in that, to ensure their cooling, the coils are placed inside the water chamber attached to the mold. Dispositif selon les revendications 15 et 16 caractérisé en ce que la chambre destinée au refroidissement des empilements de disques de cuivre et d'isolant est constituée par la chambre d'eau destinée au refroidissement du produit coulé, dont la paroi interne est la lingotière elle-même revêtue en amont d'un matériau isolant thermique.Device according to claims 15 and 16 characterized in that the chamber intended for cooling the stacks of copper discs and of insulation is constituted by the water chamber intended for cooling the cast product, the internal wall of which is the mold itself. even coated upstream with a thermal insulating material.
EP90420578A 1990-01-04 1990-12-28 Process and device for manufacturing metallic thixotropic products by continuous casting and electromagnetic stirring Expired - Lifetime EP0439981B1 (en)

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FR9000516 1990-01-04

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Publication number Publication date
CA2033233A1 (en) 1991-07-05
NO910019L (en) 1991-07-05
EP0439981B1 (en) 1994-08-31
US5219018A (en) 1993-06-15
FR2656552A1 (en) 1991-07-05
NO910019D0 (en) 1991-01-03
NZ236594A (en) 1992-12-23
NO177560B (en) 1995-07-03
DE69012090D1 (en) 1994-10-06
DK0439981T3 (en) 1994-10-03
AU6860491A (en) 1991-07-11
JPH084877B2 (en) 1996-01-24
ATE110603T1 (en) 1994-09-15
ES2060118T3 (en) 1994-11-16
JPH0768345A (en) 1995-03-14
NO177560C (en) 1995-10-11
CA2033233C (en) 1995-10-31
AU634845B2 (en) 1993-03-04
FR2656552B1 (en) 1995-01-13
DE69012090T2 (en) 1995-01-26

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