BACKGROUND OF THE INVENTION
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This application claims the priority of Korean Patent Application No.
2004-7227, filed on February 4, 2004, in the Korean Intellectual Property Office, the
disclosure of which is incorporated herein in its entirety by reference.
1. Field of the Invention
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The present invention relates to a rheoforming apparatus, and more
particularly, to a rheoforming apparatus for manufacturing predetermined products
from semi-solid metal slurries with a fine, uniform, spherical particle structure.
2. Description of the Related Art
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Metal slurries in a combined solid and liquid phase, i.e., semi-molten or
semi-solid metal slurries, generally refer to intermediates manufactured by
composite processing of rheoforming and thixoforming. Semi-solid metal slurries
consist of solid particles suspended in a liquid phase in an appropriate ratio at
temperature ranges of a semi-solid state, and thus, they can be transformed even by
a little force due to their thixotropic properties and can be easily cast like a liquid due
to their high fluidity.
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Rheoforming refers to a process of manufacturing billets or final products from
semi-solid metal slurries having a predetermined viscosity through forming or forging.
Such rheoforming is closely related to thixoforming and thus is also expressed as
rheoforming/thixoforming. Thixoforming refers to a process involving reheating
billets manufactured through rheoforming back into semi-molten slurries and forming
or forging the slurries to manufacture final products.
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Such rheoforming/thixoforming has many advantages, compared to general
forming processes using molten metals, such as casting or squeeze-forming.
Because metal slurries used in rheoforming/thixoforming are fluid at a temperature
lower than molten metals, it is possible to maintain dies contacting with the slurries at
a lower temperature than the molten metals, thereby extending the lifespan of the
dies.
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In addition, when slurries are extruded through a cylinder, turbulence is less
likely to occur, and thus less air is incorporated during forming. Therefore, the
formation of air pockets in final products is prevented. Besides, the use of
semi-solid metal slurries leads to reduced shrinkage during solidification, improved
working efficiency, mechanical properties, and anti-corrosion property, and
lightweight products. Therefore, such semi-solid metal slurries can be used as new
materials in the fields of automobiles, airplanes, and electrical, electronic information
communications equipment.
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As described above, semi-solid metal slurries are used both in rheoforming
and thixoforming. In detail, semi-solid slurries solidified from molten metals by a
predetermined method are used in rheoforming, and semi-molten slurries obtained
by reheating solid billets are used in thixoforming. Throughout the specification of
the present invention, the term "semi-solid metal slurries" means metal materials in a
combined solid and liquid state at a temperature range between the liquidus
temperature and the solidus temperature of metals, i.e., at a semi-solid temperature
range at which the crystalline particles of metals are partially molten and are partially
solid, or semi-solid slurries which are obtained by cooling molten metals during
rheoforming.
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Meanwhile, conventional rheoforming is largely classified into a nuclei
formation method using crystalline nuclei grown in molten metals and a stirring
method of destroying dendrites grown in molten metals, according to a slurry
manufacturing method.
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In a conventional nuclei formation method, nuclei formation and growth are
slowly performed since the pouring temperature of molten metals is maintained at a
very low level and a cooling rate is very slow. Therefore, the process duration is
excessivelyretarded, which renders mass production difficult.
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In a conventional stirring method, molten metals are generally stirred at a
temperature lower than the liquidus temperature during cooling, to destroy dendrites
into spherical particles suitable for rheoforming, for example, by mechanical stirring,
electromagnetic stirring, gas bubbling, low-frequency, high-frequency, or
electromagnetic wave vibration, electrical shock agitation, etc.
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For example, U.S. Patent No. 3,948,650 discloses a method and an
apparatus for manufacturing a liquid-solid mixture. In this method, a molten metal is
vigorously stirred while being cooled for solidification. A semi-solid metal slurry
manufacturing apparatus disclosed in this patent uses a stirrer to induce flow of the
solid-liquid mixture having a predetermined viscosity to destroy dendritic structures
or disperse destroyed dendritic structures in the liquid-solid mixture. In this method,
dendritic structures formed during cooling are destroyed and used as crystalline
nuclei for spherical particles. However, because of generation of latent heat due to
formation of solidification layers at an early stage of cooling, the method causes
problems of low cooling rate, long process duration, uneven temperature distribution
in a mixing vessel, and non-uniform crystalline structure. Mechanical stirring
applied in the semi-solid metal slurry manufacturing apparatus inherently leads to
uneven temperature distribution in the mixing vessel. In addition, because the
mixing vessel is located at a chamber, it is difficult to continuously perform a
subsequent process.
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U.S. Patent No. 4,465,118 discloses a method and an apparatus for
manufacturing a semi-solid alloy slurry. A cooling manifold and a die are
sequentially arranged in a coiled electromagnetic field application unit. A molten
metal at an upper position of the die is continuously poured into the die, and cooling
water flows through the cooling manifold to cool the die. According to the method
disclosed in this patent, a molten metal is poured into the die and cooled in the
cooling manifold, thereby resulting in a solidification zone. When a magnetic field is
applied by the electromagnetic field application unit, dendritic structures are
destroyed during cooling. Finally, an ingot is formed and then drawn through a
lower portion of the apparatus. However, since the basic technical idea of this
method and apparatus is to destroy dendrites by vibration after solidification, the
above-described many problems in terms of a manufacturing process and a slurry
structure are involved. In the manufacturing apparatus, since a molten metal is
continuously supplied to form an ingot, it is difficult to control the state of the molten
metal and the overall process. Moreover, prior to applying an electromagnetic field,
the die is cooled using water, whereby a great temperature difference exists between
the peripheral and core regions of the die.
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Other types of rheoforming/thixoforming known in the art are described later.
However, all of the methods are based on the technical idea of destroying dendrites
after their formation to form crystalline nuclei of spherical particles. Therefore,
problems as described above arise.
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Japanese Patent Application Laid-open Publication No. Hei. 11-33692
discloses a method of manufacturing a metal slurry for rheoforming. According to
the method disclosed, a molten metal is poured into a vessel at a temperature near
its liquidus temperature or 50°C above the liquidus temperature. Next, when at
least a portion of the molten metal reaches a temperature lower than the liquidus
temperature, i.e., at least a portion of the molten metal starts to pass through the
liquidus temperature, the molten metal is subjected to a force, for example,
ultrasonic vibration, and slowly cooled into the metal slurry containing spherical
particles. This method also uses a physical force, such as ultrasonic vibration, to
destroy the dendrites formed at an early stage of cooling. Also, if the pouring
temperature is higher than the liquidus temperature, it is difficult to form spherical
particle structures and to rapidly cool the molten metal. Furthermore, this method
leads to non-uniform surface and core structures.
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Japanese Patent Application Laid-open Publication No. Hei. 10-128516
discloses a method for casting a thixotropic metal. This method involves pouring a
molten metal into a vessel and vibrating the molten metal using a vibrating bar
dipped in the molten metal to directly transfer a vibrating force to the molten metal.
After forming a semi-solid and semi-liquid molten alloy which contains crystalline
nuclei at a temperature range lower than the liquidus temperature, the molten alloy is
cooled to a temperature at which it has a predetermined liquid fraction, and then left
stand from 30 seconds to 60 minutes to allow for the growth of the nuclei, thereby
resulting in the thixotropic metal. However, this method provides relatively large
crystalline nuclei of about 100 µm, requires a considerably long process duration, and
cannot be performed in a vessel larger than a predetermined size.
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U.S. Patent No. 6,432,160 discloses a method for making a thixotropic metal
slurry. This method involves simultaneously controlling the cooling and the stirring
of a molten metal to form the thixotropic metal slurry. In detail, after pouring a
molten metal into a mixing vessel, a stator assembly positioned around the mixing
vessel is operated to generate a magnetomotive force sufficient to rapidly stir the
molten metal in the vessel. Next, the molten metal is rapidly cooled by means of a
thermal jacket, equipped around the mixing vessel, for precise temperature control of
the mixing vessel and the molten metal. During cooling, the molten metal is
continuously stirred in such a manner that when the solid fraction of the molten metal
is low, high-speed stirring is provided, and when the solid fraction of the molten
metal increases, a greater magnetomotive force is applied.
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Most of the aforementioned conventional rheoforming/thixoforming methods
and apparatuses use a shear force to destroy dendrites into metal particle structures
during cooling. Since a force such as vibration is applied after at least a portion of
the molten metal is cooled below its liquidus temperature, latent heat is generated
due to formation of solidification layers at an early stage of the cooling. As a result,
there arise many disadvantages such as reduced cooling rate and increased process
duration. In addition, due to uneven temperature distribution between the inner wall
and the center of a vessel, it is difficult to form fine, uniform spherical metal particles.
Therefore, this structural non-uniformity of metal particles will worsen if the pouring
temperature of the molten metal into the vessel is not controlled.
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Meanwhile, in the above-described rheoforming apparatuses, billets are
manufactured by a continuous forming method, which makes it difficult to directly
manufacture products from prepared slurries by a forming process.
SUMMARY OF THE INVENTION
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The present invention provides a rheoforming apparatus that ensures the
manufacturing of products with fine, uniform, spherical particles, with improvements
in energy efficiency and mechanical properties, manufacturing cost reduction,
convenience of forming, and shorter process duration.
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The present invention also provides a rheoforming apparatus for
manufacturing products within a short time, with improvement in durability reduction
of constitutional elements of the apparatus due to pressing and an energy loss.
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In accordance with an aspect of the present invention, there is provided a
rheoforming apparatus comprising: a first sleeve, an end of which is formed with a
slurry outlet port for releasing a slurry; a second sleeve for retaining a molten metal,
an end of which communicates with the first sleeve; a sealing member for opening or
closing the end of the second sleeve; a stirring unit for applying an electromagnetic
field to the second sleeve; and a first plunger, which is slidably inserted into the other
end of the second sleeve to press the slurry manufactured in the second sleeve.
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The sealing member may be a stopper that is removably installed at the end
of the second sleeve communicating with the first sleeve.
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The rheoforming apparatus may further comprise a forming unit, which is
installed outside the slurry outlet port of the first sleeve to form a predetermined
product from the slurry released from the slurry outlet port.
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In this case, the forming unit may comprise: a transfer roller for transferring
the slurry released from the slurry outlet port; and a cooler for cooling the slurry
transferred by the transfer roller.
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The forming unit may be a press-forming unit comprising a press die that
forms a predetermined product by pressing the slurry released from the slurry outlet
port.
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The forming unit may be a forming die comprising a moving die and a fixing
die that define a predetermined forming cavity so that the slurry released from the
slurry outlet port is inserted into the forming cavity.
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The rheoforming apparatus may further comprise a first temperature control
unit, which is installed around the first sleeve to adjust the temperature of the slurry
pressed toward the slurry outlet port.
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The rheoforming apparatus may further comprise a second temperature
control unit, which is installed around the second sleeve to adjust the temperature of
the molten metal retained in the second sleeve.
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The second sleeve may be made of a non-magnetic material.
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The first sleeve may have a cylindrical shape parallel to the ground, and the
second sleeve may be coupled with the first sleeve by moving at a predetermined
angle with respect to the first sleeve.
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The stirring unit may move together with the second sleeve.
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The second sleeve may be branched from the first sleeve, and the
rheoforming apparatus may further comprise a second plunger slidably inserted into
the other end of the first sleeve to press the slurry in the first sleeve toward the slurry
outlet port.
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The second sleeve may be formed in a shape flared from the end intended for
the insertion of the first plunger to the end communicating with the first sleeve.
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The rheoforming apparatus may further comprise an electromagnetic field
control unit, which is electrically connected to the stirring unit and controls the stirring
unit in such a manner that an electromagnetic field is applied to the second sleeve
from prior to pouring the molten metal in the second sleeve and is stopped when
crystalline nuclei are formed in the molten metal.
BRIEF DESCRIPTION OF THE DRAWINGS
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The above and other features and advantages of the present invention will
become more apparent by describing in detail exemplary embodiments thereof with
reference to the attached drawings in which:
- FIG. 1 schematically illustrates a structure of a rheoforming apparatus
according to a first embodiment of the present invention;
- FIG. 2 is a sectional view of an example of a second sleeve used in the
rheoforming apparatus of FIG. 1;
- FIGS. 3 through 6 illustrate a sequential process for manufacturing an
extrudate using the rheoforming apparatus according to the first embodiment of the
present invention;
- FIG. 7 is a graph of a temperature profile applied to a rheoforming apparatus
according to the present invention;
- FIG. 8 schematically illustrates a structure of a rheoforming apparatus
according to a second embodiment of the present invention;
- FIGS. 9 through 14 schematically illustrate operational states of a rheoforming
apparatus according to a third embodiment of the present invention;
- FIGS. 15 through 17 schematically illustrate operational states of a
rheoforming apparatus according to a fourth embodiment of the present invention;
- FIGS. 18 and 19 schematically illustrate operational states of a rheoforming
apparatus according to a fifth embodiment of the present invention;
- FIGS. 20 and 21 schematically illustrate operational states of a rheoforming
apparatus according to a sixth embodiment of the present invention;
- FIG. 22 schematically illustrates a structure of a rheoforming apparatus
according to a seventh embodiment of the present invention;
- FIG. 23 schematically illustrates a structure of a rheoforming apparatus
according to an eighth embodiment of the present invention; and
- FIG. 24 schematically illustrates a structure of a rheoforming apparatus
according to a ninth embodiment of the present invention.
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DETAILED DESCRIPTION OF THE INVENTION
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The present invention will be described more fully in the following exemplary
embodiments of the invention with reference to the accompanying drawings.
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A rheoforming apparatus according to the present invention is used to
manufacture products with a predetermined shape using semi-solid slurries.
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A first embodiment of the present invention will first be described with
reference to FIGS. 1 through 7.
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In a rheoforming process performed using the apparatus of the first
embodiment of the present invention shown in FIGS. 1 through 7, a molten metal M
is poured into a second sleeve 22 to form a semi-solid metal slurry S and then the
slurry is extruded at a low pressure. In this case, the molten metal M is stirred by
applying an electromagnetic field before the molten metal is completely poured into
the second sleeve 22. That is, electromagnetic stirring is performed before the
molten metal is completely poured into the second sleeve 22 to prevent the
formation of solidification layers and dendrites at an early stage. The stirring
process may be performed using ultrasonic waves instead of the electromagnetic
field.
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In detail, after application of an electromagnetic field to a predetermined
portion of the second sleeve 22 surrounded by a stirring unit 1 is begun, the molten
metal is poured into the second sleeve. At this time, the electromagnetic field has a
sufficient intensity so that solidification layers or dendrites are not formed in the
molten metal at an early stage.
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As shown in FIG. 7, the molten metal is poured into the second sleeve 22 at a
pouring temperature Tp. As described above, an electromagnetic field may be
applied to the second sleeve 22 prior to pouring the molten metal into the second
sleeve 22. However, the present invention is not limited to this, and
electromagnetic stirring may be performed simultaneously with or in the middle of
pouring the molten metal into the second sleeve.
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Due to the electromagnetic stirring performed before the molten metal is
completely poured into the second sleeve 22, solidification layers are not formed in
the molten metal near the inner wall of the cold second sleeve 22 at an early stage,
which renders formation of dendrites difficult. That is, because the molten metal is
poured into the second sleeve 22 during applying an electromagnetic field to the
second sleeve 22, temperature differences between the inner wall and the center of
the second sleeve 22 and between the upper portion and the lower portion of the
second sleeve 22 are hardly caused. Therefore, unlike conventional techniques,
solidification near the inner wall of a vessel at an early stage does not occur. Also,
numerous micronuclei are concurrently generated because the entire molten metal in
the second sleeve 22 is uniformly and rapidly cooled to a temperature lower than its
liquidus temperature.
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By applying an electromagnetic field prior to or simultaneously with pouring
the molten metal into the second sleeve 22, the molten metal is actively stirred in the
center and inner wall regions of the second sleeve 22 and heat is rapidly transferred
throughout the second sleeve 22. Therefore, at an early stage of cooling, the
formation of solidification layers near the inner wall of the second sleeve 22 is
prevented.
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In addition, such active stirring of the molten metal induces a convection heat
transfer between the hot molten metal and the inner wall of the cold second sleeve
22, thereby rapidly cooling the molten metal. Due to the electromagnetic stirring,
particles contained in the molten metal scatter simultaneously with pouring the
molten metal into the second sleeve 22 and are uniformly dispersed in the form of
crystalline nuclei throughout the second sleeve 22. Therefore, a temperature
difference throughout the second sleeve 22 is not caused during cooling. However,
in conventional techniques, when the molten metal contacts with a low temperature
inner vessel wall, solidification layers are formed at the inner wall of the vessel and
then grow into dendrites.
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The principles of the present invention will become more apparent when
described in connection with solidification latent heat. That is, the molten metal is
not solidified at the inner wall of the second sleeve 22 at an early stage of cooling,
and thus, no solidification latent heat is generated. Accordingly, discharge of the
amount of heat corresponding to only the specific heat of the molten metal, which
corresponds to about 1/400 of the solidification latent heat, is required to cool the
molten metal.
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Therefore, solidification layers and dendrites which are frequently generated
at the inner wall of a sleeve at an early stage of cooling like in conventional methods
are not formed. The entire molten metal in the second sleeve 22 can be uniformly
and rapidly cooled within merely about 1 to 10 seconds from the pouring of the
molten metal. As a result, numerous crystalline nuclei are uniformly dispersed
throughout the molten metal in the second sleeve 22. The increased nuclei density
reduces the distance between the nuclei, which enables formation of spherical
particles, instead of dendrites.
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The same effects can be achieved even when an electromagnetic field is
applied in the middle of pouring the molten metal into the second sleeve 22. In
other words, application of an electromagnetic field before the pouring of the molten
metal into the second sleeve 22 is completed renders formation of solidification
layers at the inner wall of the second sleeve 22 difficult.
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It is preferable to limit the pouring temperature, Tp, of the molten metal to a
range from its liquidus temperature to 100°C above the liquidus temperature (melt
superheat = 0 to 100°C). Since the entire molten metal contained in the second
sleeve 22 is uniformly cooled, as described above, there is no need to cool the
molten metal to near its liquidus temperature prior to pouring the molten metal into
the second sleeve 22 and the molten metal may have a high temperature of 100°C
above the liquidus temperature.
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On the other hand, in a conventional method, after the pouring of a molten
metal into a vessel is completed, an electromagnetic field is applied to the vessel
when a portion of the molten metal reaches a temperature below its liquidus
temperature. Accordingly, at an early stage of cooling, latent heat is generated due
to the formation of solidification layers near the inner wall of the vessel. Because
the solidification latent heat is about 400 times greater than the specific heat of the
molten metal, a significant time is required to drop the temperature of the entire
molten metal below the liquidus temperature. Therefore, in such a conventional
method, to shorten a process duration, the molten metal is generally poured into a
vessel after being cooled to a temperature near the liquidus temperature or a
temperature of 50°C above the liquidus temperature.
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According to the present invention, the electromagnetic stirring may be
stopped at any point after at least a portion of the molten metal in the second sleeve
22 reaches a temperature lower than the liquidus temperature TI , i.e., after crystalline
nuclei of a predetermined amount is formed so that a solid fraction is about 0.001, as
shown in FIG. 7. That is, the electromagnetic stirring may be stopped when the
molten metal in the second sleeve 22 reaches a temperature near its liquidus
temperature or when crystalline nuclei are uniformly formed in the molten metal in
the second sleeve 22.
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With respect to nuclei density in manufacturing the semi-solid metal slurry
from the molten metal, the nucleation in the molten metal is stopped when the solid
fraction of the molten metal exceeds 0.0001 (10-4) irrespective of the type of a metal
or alloy material for the molten metal. Meanwhile, it is difficult to measure the solid
fraction of the molten metal to a level of 0.0001. Therefore, to manufacture a
semi-solid metal slurry commercially available, there is no need to carry out the
nucleation of the molten metal until the solid fraction of the molten metal is 0.0001.
The solid fraction of 0.001 or more is sufficient. Even with respect to productivity,
the solid fraction of 0.001 or more is preferred.
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Meanwhile, nuclei density in the molten metal can be sufficiently increased by
applying an electromagnetic field only during formation of crystalline nuclei in the
molten metal. Even though the electromagnetic field is applied to the molten metal
for a longer time, the semi-solid metal slurry can be manufactured. However,
applying the electromagnetic field even when the solid fraction of the molten metal
exceeds 0.1 is not preferable in view of energy efficiency. Also, the structure of the
semi-solid metal slurry may become coarse and a process duration may become
long.
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The electromagnetic field can be continuously applied to the molten metal M
in the second sleeve 22 until the cooling process of the molten metal, just before
performing a subsequent pressing process, for example, a forming process. This is
because once crystalline nuclei are uniformly distributed throughout a slurry
manufacturing area of the second sleeve 22, the electromagnetic stirring at the time
of growth of crystalline particles from the nuclei does not affect properties of the
semi-solid metal slurry.
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Therefore, the electromagnetic stirring may be carried out at least until the
solid fraction of the metal in the second sleeve 22 is 0.001 to 0.7. That is, the
electromagnetic stirring may be stopped when the solid fraction of the metal is 0.001
to 0.7. However, in view of energy efficiency, it is preferable to carry out the
electromagnetic stirring until the solid fraction of the metal in the second sleeve is in
a range of 0.001 to 0.4, and more preferably 0.001 to 0.1.
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When uniform crystalline nuclei are formed by the electromagnetic stirring
carried out before the molten metal is completely poured into the second sleeve 22,
the second sleeve 22 is cooled to promote the growth of the nuclei. In this regard,
the cooling process may be performed simultaneously with the pouring of the molten
metal into the second sleeve 22. Also, the electromagnetic field may be
continuously applied during the cooling process. That is, the cooling process may
be carried out during the application of the electromagnetic field to the second sleeve
22. Therefore, the semi-solid metal slurry manufactured in the second sleeve 22
can be directly used in a subsequent process, i.e., a forming process. Such a
cooling process may be carried out by a separate second temperature control unit 44
or may be spontaneously carried out by air.
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Such a cooling process may be carried out until just prior to a subsequent
process such as pressing and forming, and preferably, until the solid fraction of the
metal is 0.1 to 0.7, i.e., up to time t2 of FIG. 7. In detail, when a product made from
the semi-solid metal slurry S has a thin thickness and a complicated shape, the
cooling is carried out until the solid fraction of the molten metal is 0.1 (by experiment)
so that the molten metal is approximately in a liquid phase. Also, there is need to
increase a time required for solidification of the semi-solid metal slurry S in a die so
that an insertion rate of the slurry into the die is promoted. On the other hand, when
a product made from the semi-solid metal slurry S has a thick thickness and a simple
shape, the cooling is carried out until the solid fraction of the metal is 0.7 so that the
molten metal is approximately in a solid phase. Also, there is need to decrease a
time required for solidification of the slurry S in a die so that an insertion rate of the
slurry into the die is retarded.
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When the solid fraction of the metal used in manufacturing the slurry is 0.1 to
0.7, irrespective of the type of a metal or alloy material for the metal, it is possible to
manufacture products of any shape from the slurry made from the molten metal.
The manufacture of the slurry with the solid fraction of 0.1 to 0.7 merely occurs within
30 to 60 seconds from the pouring of the molten metal into the second sleeve 22.
Therefore, in order to manufacture the slurry from the molten metal within 60
seconds, it is preferable to perform the cooling process until the solid fraction of the
metal is 0.1 to 0.7.
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The molten metal may be cooled at a rate of 0.2 to 5.0°C/sec. The cooling
rate may be any value between 0.2 and 2.0°C/sec depending on a desired
distribution of crystalline nuclei and a desired size of particles.
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If the cooling rate of the molten metal is less than 0.2°C/sec, crystalline nuclei
may excessively grow in the molten metal, thereby increasing a time required for
slurry manufacturing. Therefore, productivity and mechanical properties may be
lowered. In this regard, it is necessary to set the cooling rate of the molten metal to
0.2°C/sec or more. Generally, it is preferable to increase the cooling rate of the
molten metal because a time required for slurry manufacturing is shortened and
energy efficiency is enhanced. However, if the cooling rate of the molten metal
exceeds 0.5°C/sec, dendrites may be formed in the molten metal and solidified
during cooling.
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Meanwhile, when distances between crystalline nuclei formed in the molten
metal are large, the nuclei can grow into a large size in the molten metal by cooling
the molten metal at a relatively slow rate of 0.2°C/sec. On the other hand, when
distances between the nuclei formed in the molten metal are small, it is preferable to
perform the cooling at a relatively fast rate of 0.5°C/sec because there is no need to
largely increase the size of the nuclei in the molten metal.
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When the section area of the second sleeve 2 containing the molten metal is
large, it is preferable to perform the cooling at a relatively slow rate of 0.2°C/sec.
On the other hand, when the section area of the second sleeve 2 containing the
molten metal is small, even relatively fast cooling rate of 0.5°C/sec enables sufficient
growth of crystalline nuclei in the molten metal.
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Here, formation of crystalline nuclei in the molten metal poured in the second
sleeve 22 depends on the temperature of the molten metal when the molten metal is
poured in the second sleeve 22, i.e., the pouring temperature. The pouring
temperature can be represented by the degree of heating of the molten metal from
the liquidus temperature, like a temperature of 100°C above the liquidus temperature.
The degree of heating significantly affects steps ranging from pouring the molten
metal in the second sleeve 22 to nucleation.
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On the other hand, crystal growth carried out until solidification of the
semi-solid metal slurry in a die after nucleation in the molten metal is affected by the
thickness of a product made from the molten metal. Therefore, the rate of the
cooling for nuclei growth after completion of nucleation by electromagnetic field
application depends on the degree of heating of the molten metal for nucleation prior
to pouring the molten metal in the second sleeve 22 and the thickness of a product
made from the slurry. That is, when the degree of heating of the molten metal is
constant and the thickness of a product is given, the cooling rate of the slurry to be
inserted in a die is spontaneously determined.
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When the degree of heating of the molten metal is high, the number of
crystalline nuclei formed in the molten metal decreases. In this regard, it is
necessary to retard the cooling rate of the molten metal poured in the second sleeve.
On the other hand, when the degree of heating of the molten metal is low, the
number of crystalline nuclei formed in the molten metal increases. In this regard, it
is necessary to promote the cooling rate of the molten metal, thereby decreasing the
particle size of the slurry.
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Therefore, when the cooling rate of the molten metal is 0.2 to 5.0°C/sec and
the molten metal at the time of being poured in the second sleeve has a temperature
ranging from its liquidus temperature to 100°C above the liquidus temperature, the
semi-solid metal slurry that can be used in the casting industry or has a
predetermined solid fraction can be manufactured. The manufactured semi-solid
metal slurry can be directly subjected to press-forming, to form a predetermined
product.
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According to the aforementioned process, the semi-solid metal slurry can be
manufactured within a short time. That is, a time (t2) required for manufacturing the
slurry with the solid fraction of 0.1 to 0.7 after the pouring of the molten metal into the
second sleeve 22 is only 30 to 60 seconds. The slurry thus manufactured can be
used in forming a product having a uniform, dense, spherical, crystalline structure.
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A rheoforming apparatus using the aforementioned semi-solid slurry
manufacture process will now be described with reference to FIGS. 1 through 6.
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A rheoforming apparatus as shown in FIGS. 1 through 6 is a vertical type and
includes the stirring unit 1 for applying an electromagnetic field and an elongated
cylindrical sleeve. The sleeve is divided into the first sleeve 21 for injection and the
second sleeve 22 for electromagnetic stirring.
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The second sleeve 22 is in a long, slender cylindrical form with both ends
open. Since the second sleeve 22 has a vertical axis direction, it is installed to be
moved from the vertical axis direction to a horizontal axis direction. With respect to
the vertical axis direction of the second sleeve 22, an upper end of the second
sleeve 22 is formed with an injection port 25 and a lower end of the second sleeve
22 opposite to the injection port 25 is formed with a slurry outlet port 26. The
second sleeve 22 retains the molten metal M coming from the injection port 25.
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The second sleeve 22 is formed so that the semi-solid metal slurry made from
the molten metal in the second sleeve 22 is released from the slurry outlet port 26.
Also, the second sleeve 22 may be formed in a shape gradually flared from the
injection port 25 to the slurry outlet port 26. That is, the inner diameter of the
second sleeve 22 may be gradually increased toward the releasing direction of the
semi-solid metal slurry.
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The stirring unit 1 for applying an electromagnetic field to the molten metal
contained in the second sleeve 22 is installed around the second sleeve 22. The
stirring unit 1 is fixed to the second sleeve 22 to be moved together with the second
sleeve 22.
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A flat stopper 31 as a sealing member 3 is installed at the slurry outlet port 26
of the second sleeve 22. The stopper 31 is connected to a driving device (not
shown) and may be made of the same material as that for the second sleeve 22.
As shown in FIG. 1, the stopper 31 seals the slurry outlet port 26 of the second
sleeve 22 in a state wherein the injection port 25 of the second sleeve 22 faces
upward. In this state, the stopper 31 forms a bottom portion 4 of a slurry
manufacturing area T of the second sleeve 22 in which the molten metal is present,
thereby allowing the second sleeve 22 to act as a vessel that retains the molten
metal.
-
When the stopper 31 is removed in a state wherein the second sleeve 22 is
horizontally positioned, the slurry outlet port 26 of the second sleeve 22 is opened to
release the semi-solid metal slurry formed in the second sleeve 22 from the slurry
outlet port 26. The stopper 31 may have a door shape, an end of which is
hinge-connected to an edge of the slurry outlet port 26 of the second sleeve 22 to be
moved. Alternatively, when the stopper 31 is comprised of two parts, the two parts
may be separated from each other to render the slurry outlet port 26 open. There
are no limitations on the shape of the stopper 31 provided that the slurry outlet port
26 of the second sleeve 22 is allowed to be open or closed.
-
The second temperature control unit 44 may be further installed around the
second sleeve 22, as shown in FIG. 2. The second temperature control unit 44
cools the molten metal contained in the second sleeve 22 or the semi-solid metal
slurry manufactured in the second sleeve 22. The second temperature control unit
44 includes a water jacket 46 containing a cooling water pipe 45.
-
The water jacket 46 is concentrically installed around the second sleeve 22 to
surround the outside of the second sleeve 22. The cooling water pipe 45 may be
buried in the second sleeve 22. Any coolers capable of cooling the molten metal
contained in the second sleeve 22 may be used.
-
The second temperature control unit 44 includes an electric heating coil 47 as
a heater. The electric heating coil 47 may be spirally installed to surround the
outside of the water jacket 46. Any heaters except the electric heating coil 47 may
be used.
-
There are no particular limitations on the structure of the second temperature
control unit 44, provided that the second temperature control unit 44 can adjust the
temperature of the molten metal or the semi-solid metal slurry in the second sleeve
22. The molten metal contained in the second sleeve 22 is cooled at an appropriate
rate using the second temperature control unit 44. The second temperature control
unit 44 may be installed around the entire second sleeve 22 or around the slurry
manufacturing area T in which the molten metal is present. The molten metal
contained in the second sleeve 22 may be spontaneously cooled without the aid of
the second temperature control unit 44 to manufacture the semi-solid metal slurry
with a desired solid fraction.
-
In detail, the second temperature control unit 44 may cool the molten metal
contained in the second sleeve 22 until the solid fraction of the molten metal is 0.1 to
0.7. The cooling may be carried out at a rate of 0.2 to 5.0°C/sec, preferably 0.2 to
2.0°C/sec.
-
The cooling by the second temperature control unit 44 may be carried out
after the electromagnetic stirring by the stirring unit 1 is completed or irrespective of
the electromagnetic stirring, i.e., during the electromagnetic stirring. In addition, the
cooling may be carried out simultaneously with the pouring of the molten metal.
-
Meanwhile, an electromagnetic field application coil 11 is disposed in the
stirring unit 1 so as to surround a space 12 defined by the stirring unit 1. The space
12 and the electromagnetic field application coil 11 may be fixed by means of a
separate frame (not shown). The electromagnetic field application coil 11 is used to
apply an electromagnetic field of a predetermined intensity to the second sleeve 22,
which is accommodated in the space 12. Therefore, the molten metal contained in
the second sleeve 22 is electromagnetically stirred. There are no particular
limitations on the electromagnetic field application coil 11, provided that the
electromagnetic field application coil 11 can be used in a conventional
electromagnetic stirring process. An ultrasonic stirrer may also be used.
-
The electromagnetic field application coil 11 may be installed around the
second sleeve 22 to be contacted to the outside of the second sleeve 22. By using
the electromagnetic field application coil 11, the molten metal can be thoroughly
stirred while being poured into the second sleeve 22. When the second sleeve 22
moves, the stirring unit 1 may move together with the second sleeve 22, as shown in
FIG. 3. Although not shown in the drawings, it is understood that only the second
sleeve 22 can move in a state wherein the electromagnetic field application coil 11 is
fixed.
-
The electromagnetic field application coil 11 is electrically connected to an
electromagnetic field control unit 13 for controlling the electromagnetic field
application by the stirring unit 1, as shown in FIGS. 1 and 3 through 6. The
electromagnetic field control unit 13 may include a control element. The control
element includes a switch (not shown) for determining the application of electric
powder or electromagnetic field controller (not shown) for controlling an
electromagnetic field by adjusting voltage, frequency, and electromagnetic force.
That is, the electromagnetic field control unit 13 controls the intensity or duration of
an electromagnetic field.
-
The electromagnetic field control unit 13 operates the electromagnetic field
application coil 11 in such a manner that from prior to pouring the molten metal into
the second sleeve 22, the second sleeve 22 is exposed to an electromagnetic field of
the intensity so that solidification layers and/or dendrites are not formed in the molten
metal at an early stage. Also, the electromagnetic field control unit 13 controls the
electromagnetic field application coil 11 in such a manner that the electromagnetic
field application to the second sleeve 22 is stopped when the molten metal reaches
near its liquidus temperature, i.e., when crystalline nuclei are formed in the molten
metal.
-
In this way, the electromagnetic field application of the electromagnetic field
application coil 11 is controlled by the electromagnetic field control unit 13. As
described above, the application of an electromagnetic field may be sustained until
the prepared semi-solid metal slurry is pressed. However, in view of energy
efficiency, an electromagnetic field may be applied until the slurry is manufactured,
i.e., until the solid fraction of the slurry is 0.001 to 0.7. Preferably, the application of
an electromagnetic field may be carried out until the solid fraction of the slurry is
0.001 to 0.4, and more preferably 0.001 to 0.1. The time required for accomplishing
these solid fraction levels can be determined experimentally by comparing the
measured temperature of the molten metal and the temperature in the phase
diagram of a corresponding metal material.
-
Turning to FIG. 1, the first sleeve 21 and the second sleeve 22 have opposed
ends that are hinge-connected. The second sleeve 22 can move within a
predetermined angle, preferably, less than 90 degrees, with respect to the first
sleeve 21. The second sleeve 22 may be installed in the space 12 defined by the
stirring unit 1 in such a way to be concentric with the electromagnetic field
application coil 11.
-
The first and second sleeves 21 and 22 may be made of a metal material or
an insulating material such as ceramic. Preferably, the first and second sleeves 21
and 22 may be made of a material having a melting point higher than the molten
metal M. The first and second sleeves 21 and 22 may also be made of a
non-magnetic material.
-
In particular, the second sleeve 22 may be made of a non-magnetic metal or
an insulating material. Therefore, when an electromagnetic field is applied to the
second sleeve 22, the second sleeve 22 does not cause induction heating and heat
generation, which is helpful in cooling the molten metal contained in the second
sleeve 22. Also, the cooling of the molten metal may be initiated simultaneously
with pouring the molten metal into the second sleeve 22. When the second sleeve
22 is made of a non-magnetic metal material, it is preferable to use a material having
a melting point higher than the temperature of the molten metal.
-
When the temperature of the second sleeve 22 is raised to that of the molten
metal, there is a risk that the second sleeve 22 may be molten. For this reason, the
temperature of the second sleeve 22 cannot be raised to that of the molten metal.
In this regard, when an electromagnetic field is applied to the second sleeve
immediately after pouring the molten metal, dendrites may be instantly formed at
inner wall portions of the second sleeve 22 contacting with the molten metal due to a
high temperature difference between the second sleeve 22 and the molten metal.
-
Meanwhile, the first sleeve 21 is in a cylindrical form parallel to the ground
and the second sleeve 22 can move at a predetermined angle with respect to an end
of the first sleeve 21 connected to the second sleeve 22. In such a structure, as will
be described later, the second sleeve 22 corresponds to the slurry manufacturing
area T for retaining the molten metal and manufacturing the slurry by
electromagnetic stirring, and the first sleeve 21 corresponds to an area for
press-forming the manufactured slurry.
-
That is, the second sleeve 22 acts as a slurry manufacturing vessel for
manufacturing the semi-solid slurry using the molten metal and the first sleeve 21
acts as a forming die for press-forming the manufactured slurry. Here, both ends of
each of the first and second sleeves 21 and 22 are not necessarily open. There are
no particular limitations on the structures of the first and second sleeves 21 and 22
provided that the first and second sleeves are connected to each other, and the
semi-solid metal slurry S manufactured in the second sleeve 22 moves into the first
sleeve 21 and then released from the first sleeve 21.
-
In detail, the first sleeve 21 is in a long, slender cylindrical form with both ends
open and is fixedly installed in a horizontal axis direction. The first sleeve 21 has
the same diameter as that of the second sleeve 22. A blocking member 20 is
installed at an end of the first sleeve 21. A slurry outlet port 23 of a predetermined
shape is defined by the blocking member 20. The semi-solid slurry S is released
from the first sleeve 21 via the slurry outlet port 23. The slurry outlet port 23 is
present at the end opposite to the end of the first sleeve 21 coupled with the second
sleeve 22.
-
An extrusion device with an extrusion unit 6 is installed downstream of the
slurry outlet port 23. The extrusion unit 6 is used as a forming unit to form an
extrudate E, which is a product of a predetermined shape, using the slurry released
from the slurry outlet port 23. The extrusion unit 6 is installed outside the slurry
outlet port 23 of the first sleeve 21.
-
The extrusion unit 6 includes a transfer roller 61 for transferring the extruded
slurry. A plurality of spray-type coolers 62 for cooling the slurry released from the
slurry outlet port 23 of the first sleeve 21 are installed above a transfer surface 60 of
the transfer roller 61. A cutter 63 is installed outside and above the slurry outlet port
23 of the first sleeve 21 to be moved in an upward and a downward direction to cut
the semi-solid slurry S released from the slurry outlet port 23. The cutter 63 is
installed so that the edge of the cutter 63 faces downward. When the slurry is
released to a desired length from the slurry outlet port 23, the cutter cuts the
released slurry by moving in a downward direction.
-
In the extrusion unit 6, the semi-solid metal slurry is transferred by the transfer
roller 61, cooled by the coolers 62, and cut to a predetermined length by the cutter
63, to form the extrudate E in the form of a wire or a sheet.
-
Since the slurry released from the slurry outlet port 23 is transferred to the
extrusion unit 6, the slurry outlet port 23 of the first sleeve 21 determines the shape
of the slurry S to be released from the slurry outlet port 23. The shape of the slurry
outlet port 23 may be determined by the shape of the extrudate E to be formed in the
extrusion unit 6 installed downstream of the slurry outlet port 23. That is, as will be
described later, since the slurry S is released from the slurry outlet port 23 and
transferred to the extrusion unit 6, the shape of the slurry released is first determined
by the slurry outlet port 23. In this regard, the shape of the slurry outlet port 23
varies depending on the shape of the extrudate to be formed in the extrusion unit 6.
If the extrudate extruded from the slurry outlet port 23 is of a wire form, a circular
outlet port may be used, while if the extrudate is of a sheet form, a rectangular outlet
port may be used.
-
Meanwhile, a slurry inlet port 24 is present at the other end of the first sleeve
21 opposite to the slurry outlet port 23. The slurry outlet port 23 and the slurry inlet
port 24 communicate concentrically with each other. The slurry inlet port 24 is
formed to have a shape conforming to that of the slurry outlet port 26 of the second
sleeve 22 so as to communicate concentrically with the slurry outlet port 26.
Therefore, the slurry S manufactured in the second sleeve 22 is released from the
slurry outlet port 23 via the slurry inlet port 24.
-
The first sleeve 21 may be formed in a shape gradually flared from the slurry
inlet port 24 to the slurry outlet port 23. That is, the inner diameter of the first sleeve
21 may be gradually increased toward the releasing direction of the slurry, i.e., from
the slurry inlet port 24 to the slurry outlet port 23. Therefore, the inner diameter of
the first sleeve 21 may be equal to or larger than that of the second sleeve 22.
-
A first temperature control unit 41 may be further installed around the first
sleeve 21, as shown in FIGS. 1 and 3 through 6. The first temperature control unit
41 adjusts the temperature of the semi-solid slurry S in the first sleeve 21 by
adjusting the temperature of a predetermined area of the first sleeve 21. That is,
the first temperature control unit 41 serves to prevent the semi-solid slurry S pressed
in the first sleeve 21 from rapidly cooling. In this regard, the first temperature
control unit 41 has a predetermined heat insulating function.
-
In detail, the first temperature control unit 41 includes a common water jacket
43 containing a spiral pipe 42. The water jacket 43 is concentrically installed
around the first sleeve 21 to surround the outside of the first sleeve 21. By
appropriately adjusting the temperature of a medium which flows in the pipe 42, the
temperature of the slurry in the first sleeve 21 can be adjusted.
-
The pipe 42 may also be buried in the first sleeve 21. Any temperature
control units capable of adjusting the temperature of the slurry contained in the first
sleeve 22 may be used. An electric heater (not shown) may also be used as the
first temperature control unit 41.
-
Meanwhile, a first plunger 52 as a first pressing device is slidably inserted in
the injection port 25 of the second sleeve 22. The first plunger 52 can move
reciprocally like a piston in the first and second sleeves 21 and 22 while being
connected to a separate cylinder unit (not shown), which is in turn connected to a
controller (not shown). Here, a press face 54 which is a front end of the first
plunger 52 may be a flat surface perpendicular to the moving direction of the first
plunger 52.
-
When the slurry is manufactured in the second sleeve 22, the first plunger 52
is inserted into the injection port 25 of the second sleeve 22 to block the injection
port 25 of the second sleeve 22. The first plunger 52 moves together with the
second sleeve 22 in a state of being inserted into the injection port 25 of the second
sleeve 22, thereby preventing the spill out of the slurry from the injection port 25 of
the second sleeve 22. When the slurry outlet port 26 of the second sleeve 22
communicates with the slurry inlet port 24 of the first sleeve 21 by removal of the
stopper 31, the first plunger 52 pushes the slurry in the second sleeve 22 toward the
slurry outlet port 23 of the first sleeve 21. Therefore, the slurry is transferred to the
transfer surface 60 of the transfer roller 61 of the extrusion unit 6 from the slurry
outlet port 23.
-
In other words, the first plunger 52 is away from the injection port 25 of the
second sleeve 22 while the second sleeve 22 is exposed to an electromagnetic field
and the molten metal in the second sleeve 22 is cooled, i.e., while the semi-solid
slurry is manufactured from the molten metal in the second sleeve 22, as shown in
FIG. 1. After the slurry is manufactured in the second sleeve 22, the first plunger 52
is inserted into the injection port 25 and pushes the slurry in the second slurry 22.
The first plunger 52 moves together with the second sleeve 22, and pushes the
slurry toward the first sleeve 21.
-
A thermocouple (not shown) may be installed in each of the first sleeve 21
and the second sleeve 22 and connected to a controller for providing the
temperature information of the molten metal and the slurry to the controller.
-
Meanwhile, a pouring unit 51 is used to pour the molten metal into the second
sleeve 22. The pouring unit 51 may be a common ladle electrically connected to a
controller (not shown). In addition, any pouring units such as a furnace, which
melts a metal material, directly connected to the second sleeve 22, may be used
provided that the molten metal can be poured into the second sleeve 22.
-
Hereinafter, operation of the rheoforming apparatus having the
aforementioned structure according to the first embodiment of the present invention
will be described.
-
Turning to FIG. 1, first, the second sleeve 22 moves at a predetermined angle,
preferably 90 degrees with respect to the first sleeve 21 so that the injection port 25
of the second sleeve 22 faces upward. At the same time, the slurry outlet port 24 of
the second sleeve 22 is sealed by the stopper 31 to allow the second sleeve 22 to
act as a vessel for receiving the molten metal.
-
Next, the electromagnetic field control unit 13 operates the electromagnetic
field application coil 11 of the stirring unit 1 in such a manner that the empty second
sleeve 22 is exposed to an electromagnetic field of the intensity so that solidification
layers or dendrites are not formed in the molten metal to be poured at an early stage.
-
At this time, the electromagnetic field application coil 11 may apply an
electromagnetic field with an intensity of 500 Gauss at 250 V and 60 Hz, but is not
limited thereto. It is understood that the intensity of an electromagnetic field may be
appropriately adjusted according to process conditions.
-
In this state, the molten metal M that has molten in a separate furnace is
poured via the pouring unit 51 such as a ladle into the second sleeve 22 under an
electromagnetic field. Here, to promote formation of the molten metal poured in the
second sleeve 22 into the semi-solid slurry S and to prevent spill out of the molten
metal through a gap between the slurry outlet port 26 and the stopper 31 of the
second sleeve 22, the solid fraction of the semi-solid slurry is relatively increased.
-
The furnace and the second sleeve 22 may also be directly connected to each
other for directly pouring the molten metal into the second sleeve 22. As described
above, the molten metal may have a temperature of 100°C above its liquidus
temperature. The second sleeve 22 may be connected to a separate gas supply
tube (not shown) for supplying an inert gas such as N2 and Ar, thereby preventing
the oxidation of the molten metal.
-
In this way, when the molten metal is poured into the second sleeve 22 under
the electromagnetic stirring, fine crystalline particles are distributed throughout the
second sleeve 22, without formation of solidification layers at an early stage. The
crystalline particles rapidly grow, thereby preventing the formation of dendritic
structures.
-
Application of an electromagnetic field by the electromagnetic field application
coil 11 may be carried out simultaneously with the pouring of the molten metal into
the second sleeve 22.
-
The application of an electromagnetic field may be sustained until the
semi-solid slurry S is pressed by the first plunger 52, i.e., the solid fraction of the
slurry is in a range of 0.001 to 0.7, preferably 0.001 to 0.4, and more preferably
0.001 to 0.1. The time required for accomplishing these solid fraction levels can be
determined by previous experiments. The application of an electromagnetic field is
carried out during so determined time.
-
After completion or in the middle of application of an electromagnetic field, the
molten metal in the second sleeve 22 is cooled at a predetermined rate until the solid
fraction of the molten metal is in a range of 0.1 to 0.7 to manufacture the semi-solid
slurry.
-
In this case, a cooling rate may be adjusted to 0.2 to 5.0°C/sec, preferably 0.2
to 2.0°C/sec, by the second temperature control unit 44 installed around the second
sleeve 22, as described above. Of course, the cooling may be spontaneously
carried out. The time (t2) required for reaching the solid fraction of 0.1 to 0.7 can be
determined by previous experiments.
-
The semi-solid metal slurry made from the molten metal in the second sleeve
22 has the solid fraction to an extent so that the semi-solid metal slurry is not spilled
out from the slurry outlet port 26 of the second sleeve 22 and the slurry inlet port 24
of the first sleeve 21 while the slurry outlet port 26 is coupled with the slurry inlet port
24.
-
After the semi-solid metal slurry is manufactured in the second sleeve 22, the
first plunger 52 is inserted into the injection port 25 of the second sleeve 22. In this
state, when the second sleeve 22 moves at an angle of 90 degrees, the slurry outlet
port 26 of the second sleeve 22 is coupled with the slurry inlet port 24 of the first
sleeve 21 via the stopper 31, as shown in FIG. 3. At this time, the first plunger 52
moves together with the second sleeve 22.
-
Then, the stopper 31, which is a sealing member, is removed so that the
slurry outlet port 26 communicates with the slurry inlet port 24.
-
In this state, the first plunger 52 pushes the slurry S in the second sleeve 22
toward the slurry outlet port 23 of the first sleeve 21 to force the slurry S into the
extrusion unit 6 from the slurry outlet port 23, as shown in FIG. 4.
-
During the pressing in the first sleeve 21, the temperature of the slurry can be
preserved to a predetermined level by the first temperature control unit 41.
-
As shown in FIG. 5, the slurry released from the slurry outlet port 23 is
transferred by the transfer roller 61 while being rapidly cooled by the coolers 62 of
the extrusion unit 6 and cut by the cutter 63, which is positioned above the slurry
outlet port 23, to form the extrudate E of a predetermined shape.
-
The extrudate E is transferred to a collection unit (not shown) by the transfer
roller 61. On the other hand, a biscuit B left in the first sleeve 21 is removed by a
separate ejection unit (not shown) after returning the first plunger 52 to an original
position and moving back the second sleeve 22 at an angle of 90 degrees to open
the slurry inlet port 24 of the first sleeve 21, as shown in FIG. 6.
-
After the biscuit B is removed, the aforementioned process is repeated by
pouring a molten metal into the second sleeve 22, as shown in FIG. 1. Therefore,
the fine and uniform extrudate E can be obtained.
-
As described above, according to the first embodiment of the present
invention, spherical particles can be obtained by remarkably increasing the density of
nuclei at the inner wall of the second sleeve with stirring at a temperature above the
liquidus temperature of the molten metal within a short time. Therefore, the
semi-solid slurry of fine, uniform, spherical particles can be manufactured in the
second sleeve 22. As a result, the operation duration can be reduced, thereby
minimizing energy loss. Even though the second sleeve 22 has an unsymmetrical
shape instead of a cylindrical shape, the semi-solid slurry of fine, uniform, spherical
particles can be manufactured.
-
Also, since the semi-solid metal slurry in the second sleeve 22 is transferred
to the extrusion unit 6 via the first sleeve 21, the high quality extrudate E can be
obtained at a low pressure. Therefore, power loss can be prevented and the
operation duration can be reduced. At the same time, the reduction of durability of
constitutional elements due to pressing of the slurry can be prevented and energy
loss can be reduced. Therefore, the high quality extrudate E with fine and uniform
structures can be continuously manufactured within a short time.
-
Also, due to improved energy efficiency, a manufacture cost can be reduced
and the mechanical properties of the extrudate can be enhanced. In addition, since
the extrudate E can be simply manufactured within a short time, the entire
manufacturing process can be simplified and productivity can be enhanced.
-
Meanwhile, a portion of the slurry exposed to air may be oxidized. According
to the present invention, since the second sleeve 22 for manufacturing the slurry is
vertically positioned, an upper portion of the slurry is oxidized. The oxidized portion
of the slurry is left on the biscuit B without being transferred to the extrusion unit 6,
as shown in FIGS. 5 and 6. Since the biscuit B is removed, the oxidized portion is
also removed together with the biscuit B. Therefore, the high quality extrudate E
can be obtained.
-
In the first embodiment, the molten metal is injected through the injection port
25 which is an end of the second sleeve 22, and the semi-solid slurry S in the
second sleeve 22 is pressed by the first plunger 52 inserted into the injection port 25.
However, according to a second embodiment of the present invention as shown in
FIG. 8, a separate pouring hole 28 is branched from the second sleeve 22 and the
molten metal is poured into the second sleeve 22 from the pouring hole 28. In this
structure, the first plunger 52 may be permanently inserted in the injection port 25 of
the second sleeve 22. Such a structure of the second sleeve 22 and the first
plunger 52 may be applied in all embodiments as will be described later.
-
According to a third embodiment of the present invention as shown in FIGS. 9
through 14, the aforementioned rheoforming apparatus may be used as a
press-forming apparatus provided with a press-forming unit 7 which is installed
outside the slurry outlet port 23 of the first sleeve 21, instead of the extrusion unit 6
that forms the extrudate E from the slurry released from the slurry outlet port 23.
The press-forming unit 7 includes press dies 71 and 72 and forms a product with a
shape conforming to the shape defined by the press dies 71 and 72 using the slurry
released from the slurry outlet port 23 of the first sleeve 21.
-
In the rheoforming apparatus according to the third embodiment of the
present invention, first, the slurry is manufactured from the molten metal M poured
into the second sleeve 22, as shown in FIG. 9. The slurry outlet port 26 of the
second sleeve 22 is then coupled with the slurry inlet port 24 of the first sleeve 21 by
moving the second sleeve 22, as shown in FIG. 10. Then, the slurry outlet port 26
of the second sleeve 22 is opened by removal of the sealing member 3 so that the
slurry outlet port 26 communicates with the slurry inlet port 24 of the first sleeve 21.
-
In this state, the first plunger 52 pushes the slurry in the second sleeve 22
toward the slurry outlet port 23 of the first sleeve 21. At this time, the temperature
of the slurry can be preserved by the first temperature control unit 41 installed
around the first sleeve 21. As shown in FIGS. 12 and 13, the slurry released from
the slurry outlet port 23 of the first sleeve 21 is formed into a product P with a
predetermined shape by pressing using the press dies 71 and 72 and cut by the
cutter 63, which is positioned above the slurry outlet port 23.
-
The biscuit B left in the first sleeve 21 is removed by a separate ejection unit
after returning the first plunger 52 to an original position and moving back the second
sleeve 22 at a predetermined angle to open the slurry inlet port 24 of the first sleeve
21, as shown in FIG. 14. After the biscuit B is removed, the aforementioned
process is repeated by pouring a molten metal into the second sleeve 22, as shown
in FIG. 9. Therefore, the product P with a fine and uniform particle structure can be
obtained.
-
Like in the first embodiment, according to this embodiment of the present
invention, because the molten metal is subjected to press-forming in the form of a
slurry, the high quality product P can be manufactured at a low pressure. As a
result, the loss of an electric energy and the operation duration can be reduced.
-
Even though an upper portion of the manufactured slurry may be oxidized, the
oxidized portion is removed together with the biscuit B without being formed.
Therefore, a high quality product can be obtained.
-
According to a fourth embodiment of the present invention as shown in FIGS.
15 and 17, a rheoforming apparatus of the present invention may be used as a
die-casting apparatus having a forming die 8. That is, the rheoforming apparatus
according to the fourth embodiment of the present invention includes the forming die
8, which is installed outside the slurry outlet port 23. The forming die 8 includes a
moving die 81 and a fixing die 82. When the moving die 81 and the fixing die 82
meet with each other, a forming cavity 83 of a predetermined shape is defined by the
moving die 81 and the fixing die 82. The fixing die 82 is formed with a funnel 84 for
directing the slurry into the forming cavity 83. The funnel 84 communicates with the
slurry outlet port 23 of the first sleeve 21. The semi-solid metal slurry S released
from the slurry outlet port 23 is directed into the forming cavity 83.
-
The moving die 81 and the fixing die 82 are respectively supported by support
plates 85a and 85b which are attached to the entire equipment (not shown). When
the forming is completed, the moving die 81 is separated from the fixing die 82 and a
die cast formed in the forming cavity 83 is removed.
-
In the rheoforming apparatus according to the fourth embodiment of the
present invention, first, the slurry is manufactured from the molten metal M poured
into the second sleeve 22, as shown in FIG. 15. Then, the second sleeve 22 is
coupled with the first sleeve 21, as shown in FIG. 16, and the slurry outlet port 26 of
the second sleeve 22 is opened by removal of the sealing member 3, as shown in
FIG. 17.
-
In this state, the first plunger 52 pushes the slurry in the second sleeve 22
toward the slurry outlet port 23 of the first sleeve 21. Then, the slurry released from
the slurry outlet port 23 of the first sleeve 21 is directed into the forming die 8. At
this time, the slurry S is inserted into the forming cavity 83 via the funnel 84 of the
forming die 8 and rapidly cooled, to form the die cast corresponding to the shape of
the forming cavity 83, as shown in FIG. 17. When the forming is completed, the
moving die 81 is separated from the fixing die 82. Therefore, the die cast can be
removed from the forming cavity 83.
-
Like in the first embodiment, according to this embodiment of the present
invention, because the molten metal is subjected to die-casting in the form of a slurry,
the high quality die cast can be manufactured at a low pressure. As a result, the
loss of an electric energy and the operation duration can be reduced. Also, since
the slurry with a low temperature is inserted in the forming die 8 under a low
pressure, the reduction of the lifespan of the forming die 8 is prevented. In addition,
since an upper portion of the manufactured slurry may be oxidized but is not inserted
into the forming die 83, a high quality product can be obtained.
-
Meanwhile, the aforementioned rheoforming apparatus may be modified
according to a fifth embodiment of the present invention as shown in FIGS. 18 and
19. According to the fifth embodiment, the first sleeve 21 is installed in a vertical
direction. The second sleeve 22 is installed on the first sleeve 21 so that the slurry
inlet port 24 of the first sleeve 21 communicates concentrically with the slurry outlet
port 26 of the second sleeve 22. Therefore, the first sleeve 21 is connected to the
lower end of the second sleeve 22. The second sleeve 22 is fixedly installed on
support frames 14 and 15.
-
Here, the inner peripheral surface of each of the second sleeve 22 and the
first sleeve 21 may be formed in a shape flared in a downward direction so that the
semi-solid metal slurry S manufactured in the second sleeve 22 can be dropped by
its own gravity. Also, a forming unit such as the forming die 8 is installed outside
the slurry outlet port 23 of the first sleeve 21. FIG. 18 shows only the forming die 8,
but is not limited thereto. The above-described extrusion unit or press-forming unit
may also be provided.
-
In the rheoforming apparatus according to the fifth embodiment of the present
invention, the first sleeve 21 and the second sleeve 22 are fixedly coupled with each
other. The sealing member 3 as described above is interposed between the first
sleeve 21 and the second sleeve 22. The first sleeve 21 and the second sleeve 22
may also be integrally formed. In this case, the sealing member 3 may be installed
in an inner side of an integrally formed sleeve.
-
First, the slurry is manufactured using the molten metal M poured into the
second sleeve 22 from the injection port 25, as shown in FIG. 18. Then, the slurry
outlet port 26 of the second sleeve 22 is opened by removal of the sealing member 3
so that the semi-solid metal slurry S in the second sleeve 22 can be dropped in the
first sleeve 21 by its own gravity. At this time, the slurry S manufactured in the
second sleeve 22 has a solid fraction to an extent so that the slurry S can be
dropped by its own gravity. Then, the first plunger 52 is inserted into the injection
port 25 of the second sleeve 22 and forces the slurry in the first sleeve 21 toward the
forming die 8.
-
The slurry S is inserted into the forming cavity 83 via the funnel 84 of the
forming die 8 and rapidly cooled, to form the die cast corresponding to the shape of
the forming cavity 83. At this time, a separate cooler (not shown) may rapidly cool
the slurry inserted in the forming cavity 83. When the forming is completed, the
moving die 81 is separated from the fixing die 82. Therefore, the die cast can be
removed from the forming cavity 83.
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Like in the fourth embodiment, according to this embodiment of the present
invention, because the molten metal is subjected to die-casting in the form of a slurry,
the high quality die cast can be manufactured at a low pressure. As a result, the
loss of an electric energy and the operation duration can be reduced. Also, since
the slurry with low temperature is inserted in the forming die 8 under a low pressure,
the reduction of the lifespan of the forming die 8 is prevented. In addition, since the
slurry S manufactured in the second slurry 22 can be dropped in the first sleeve 21
by its own gravity, the moving of the slurry from the second sleeve 22 to the first
sleeve 21 can be easily performed.
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In the above structure, the second sleeve 22 may have a shape flared in a
downward direction, as described above. The first sleeve 21 may also be formed in
a shape flared in a downward direction. That is, the first and second sleeves 21
and 22 may be formed in a flared shape so that when the slurry manufactured is
dropped in the direction of the forming die 8 by its own gravity or pressed by the first
plunger 52, the cross-sections of the first sleeve 21 and the second sleeve 22 are
increased in the direction of the forming die 8 to promote the moving of the slurry.
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According to a sixth embodiment of the present invention as shown in FIGS.
20 and 21, an end of the second sleeve 22 may be connected to the body of the first
sleeve 21. That is, the second sleeve 22 may be branched from the first sleeve 21.
In this embodiment, the first sleeve 21 is installed so that its axis direction is parallel
to the ground. The second sleeve 22 is connected to the body of the first sleeve 21
to be positioned above the first sleeve 21. A second plunger 53 for pressing is
slidably inserted in an opening 30 of the first sleeve 21. Here, a press face 55
which is a front face of the second plunger 53 is a flat surface perpendicular to the
moving direction of the second plunger 53.
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A forming unit such as the forming die 8 is installed outside the slurry outlet
port 23 of the first sleeve 21. FIG. 20 shows only the forming die 8, but is not
limited thereto. The above-described extrusion unit or press-forming unit may also
be provided.
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The second sleeve 22 is inclined at an angle of about 45 degrees with respect
to the first sleeve 21 so that the injection port 25 of the second sleeve 22 is
positioned away from the first sleeve 21. The slurry outlet port 26 of the second
sleeve 22 is connected to about intermediate portion of the body of the first sleeve
21. The stopper 31 as the sealing member 3 is removably installed near the slurry
outlet port 26 of the second sleeve 22 to open or close the slurry outlet port 26. The
stirring unit 1 is installed around the second sleeve 22, as described above.
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The second sleeve 22 may be formed with the separate pouring hole 28 for
pouring the molten metal. The pouring hole 28 is positioned at a higher position
than the stirring unit 1 and is protruded in an upward direction from the body of the
second sleeve 22. The pouring hole 28 communicates with the second sleeve 22.
The molten metal M is poured in the slurry manufacturing area T from the pouring
hole 28 under an electromagnetic field applied by the stirring unit 1.
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Meanwhile, the second sleeve 22 may be formed in a shape flared in the
direction of the first sleeve 21. By doing so, the slurry manufactured in the second
sleeve 22 can be easily dropped in the first sleeve 21 by its own gravity or by the first
plunger 52.
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As shown in FIG. 20, the molten metal M is poured in the second sleeve 22
from the pouring hole 28 in a state wherein the stopper 31 is closed, and is formed
into the slurry by an electromagnetic field applied by the stirring unit. Then, the
slurry outlet port 26 of the second sleeve 22 is opened by upward removal of the
stopper 31 so that the slurry advances toward the first sleeve 21. At this time, when
the first plunger 52 pushes the slurry toward the first sleeve 21, the moving of the
slurry toward the first sleeve 21 can be promoted.
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When the slurry is inserted in the first sleeve 21, the second plunger 53 forces
the slurry toward the slurry outlet port 23 so that the slurry is inserted into the forming
die 8, as shown in FIG. 21. The slurry is inserted into the forming cavity 83 via the
funnel 84 and rapidly cooled to form the die cast having a shape corresponding to
that of the forming cavity 83. At this time, a separate cooler (not shown) may
rapidly cool the slurry inserted in the forming cavity 83. When the forming is
completed, the moving die 81 is separated from the fixing die 82. Therefore, the die
cast can be removed from the forming cavity 83.
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Like in the fourth embodiment, according to this embodiment of the present
invention, because the molten metal is subjected to die-casting in the form of a slurry,
the high quality die cast can be manufactured at a low pressure. As a result, the
loss of an electric energy and the operation duration can be reduced. Also, since
the slurry with low temperature is inserted in the forming die 8 under a low pressure,
the reduction of the lifespan of the forming die 8 is prevented.
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According to a seventh embodiment of the present invention as shown in FIG.
22, the first sleeve 21 may be installed vertically with respect to the ground and the
second sleeve 22 may be branched from the first sleeve 21. Therefore, the slurry
manufactured can easily move in the direction of the forming die 8 by its own gravity,
thereby promoting a manufacture process. For this, both the second sleeve 22 and
the first sleeve 21 may be formed in a shape gradually flared from their own inlet
port.
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As described above, in the sixth and seventh embodiments, since an upper
portion of the slurry may be oxidized but is not inserted in the forming die 8, a high
quality product can be obtained.
-
Meanwhile, in the sixth and seventh embodiments, the press face 54 which is
the front face of the first plunger 52 may be inclined at an angle of about 45 degrees
with respect to the moving direction of the first plunger 52 so that when the first
plunger 52 advances toward the first sleeve 21, the press face 54 matches with the
inner peripheral surface of the first sleeve 21.
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In this case, the press face 54 of the first plunger 52 is formed in the same
surface as the inner peripheral surface of the first sleeve 21 so that when the first
plunger 52 pushes the slurry in the second sleeve 22, the entire slurry can be
inserted into the first sleeve 21. That is, the press face 54 of the first plunger 52 is
formed so that the slurry inlet port 24 of the first sleeve 21 is closed along the inner
peripheral surface of the first sleeve 21 by the first plunger 52. Therefore, the slope
of the press face 54 of the first plunger 52 is the same as the inclined angle of the
second sleeve 22 with respect to the first sleeve 21.
-
The press face 54 which is the front face of the first plunger 52 may also be a
flat surface perpendicular to the moving direction of the first plunger 52, according to
an eight embodiment of the present invention as shown in FIG. 23.
-
The same acting effects as in the seventh embodiment can be achieved even
when the forming die 8 is positioned at the upper end of the first sleeve 21 installed
perpendicularly to the ground and the second plunger 53 is slidably inserted into the
lower end of the first sleeve 21, according to a ninth embodiment of the present
invention as shown in FIG. 24.
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As described above, a rheoforming apparatus according to the present
invention can be widely used for rheoforming various kinds of metals or alloys, for
example, aluminum, magnesium, zinc, copper, iron, or an alloy thereof.
-
That is, in view of solidification theory, the temperature of a molten metal to be
inserted in a sleeve can be discussed with respect to the specific heat of a metal or
alloy material that make the molten metal.
-
The specific heat of aluminum is about 0.25 kcal/g. The specific heat of
other metals except aluminum, for example, magnesium (about 0.18 kcal/g), zinc
(about 0.1 kcal/g), copper (about 0.1 kcal/g), and iron (about 0.1 kcal/g) is smaller
than that of aluminum. In this regard, other metals except aluminum require a
smaller thermal energy than aluminum. Therefore, even when molten metals made
from these metals are inserted in a sleeve at a temperature of 100°C above their
liquidus temperature, latent heat is not generated. As a result, crystalline nuclei
may grow in these molten metals by discharge of only the specific heat of the molten
metals. Therefore, the above-described advantages can also be obtained from
molten metals made from other metals or alloys except aluminum.
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Theoretically, when the difference between a temperature (TI) at which liquid
phase is changed to solid phase and a temperature (Ts) at which solid phase is
changed to liquid phase, i.e., TI-Ts = ΔT, is zero (0), crystalline nuclei can be formed
in molten metals made from any metals or alloys by setting the temperature of the
molten metals within a temperature of TI to Ts.
-
Meanwhile, pure aluminum commonly used in the foundry industry contains
about 1 % of impurity. Also, pure magnesium, pure zinc, pure copper, and pure iron
commonly used in the foundry industry also contain about 1% of impurity.
-
Therefore, when a magnetic field by electromagnetic field application is
created in molten metals made from magnesium, zinc, copper, iron, and an alloy
thereof in which ΔT is not "0" and the specific heat is smaller than aluminum, these
metals and alloys can also provide the same results as in aluminum and an alloy
thereof.
-
As apparent from the above descriptions, a rheoforming apparatus according
to the present invention provides the following advantages.
-
First, products having a uniform, fine, and spherical particle structure can be
manufactured.
-
Second, more nuclei can be formed at an inner wall of a sleeve within a short
time through electromagnetic stirring at a temperature above the liquidus
temperature of molten metals to thereby obtain spherical particles.
-
Third, manufactured products have improved mechanical properties.
-
Fourth, the duration of electromagnetic stirring is greatly shortened, thereby
conserving a stirring energy.
-
Fifth, the simplified overall process and the reduced forming duration improve
productivity.
-
Sixth, because products are formed from slurries, lower pressure forming is
possible.
-
Seventh, because products are formed under a low pressure, durability of
constitutional elements of the apparatus can be improved, and energy loss and
manufacturing duration can be reduced.
-
Eighth, upper portions of slurries manufactured may be oxidized but the
oxidized portions are removed together with biscuits without being formed.
Therefore, high quality products can be obtained.
-
While the present invention has been particularly shown and described with
reference to exemplary embodiments thereof, it will be understood by those of
ordinary skill in the art that various changes in form and details may be made therein
without departing from the spirit and scope of the present invention as defined by the
following claims.