EP1981668B1 - Procede de preparation de structure metallique appropriee pour un traitement de metal semi-solide - Google Patents

Procede de preparation de structure metallique appropriee pour un traitement de metal semi-solide Download PDF

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Publication number
EP1981668B1
EP1981668B1 EP07763446A EP07763446A EP1981668B1 EP 1981668 B1 EP1981668 B1 EP 1981668B1 EP 07763446 A EP07763446 A EP 07763446A EP 07763446 A EP07763446 A EP 07763446A EP 1981668 B1 EP1981668 B1 EP 1981668B1
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EP
European Patent Office
Prior art keywords
alloy
solid
metal
gas bubbles
semi
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Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Not-in-force
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EP07763446A
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German (de)
English (en)
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EP1981668A4 (fr
EP1981668A2 (fr
Inventor
Jessada c/o Prince of Songkla Univ. WANNASIN
Raul A. c/o Selmet Inc. MARTINEZ
Merton C. c/o Massachusetts Institute Of Technology FLEMMINGS
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National Science and Technology Development Agency
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National Science and Technology Development Agency
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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
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/007—Semi-solid pressure die casting
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21C—PROCESSING OF PIG-IRON, e.g. REFINING, MANUFACTURE OF WROUGHT-IRON OR STEEL; TREATMENT IN MOLTEN STATE OF FERROUS ALLOYS
    • C21C7/00—Treating molten ferrous alloys, e.g. steel, not covered by groups C21C1/00 - C21C5/00
    • C21C7/04—Removing impurities by adding a treating agent
    • C21C7/072—Treatment with gases
    • 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

Definitions

  • This invention relates to a method to prepare non-dendritic, semi-solid metal slurries for semi-solid casting and forming.
  • the invention flows gas bubbles through at least one solid medium inserted into or accommodates therein the liquid metal or alloy thereby cooling the liquid metal or alloy to a temperature below the melting temperature thereof while agitating the liquid metal or alloy with the gas bobbles and forming solid fractions therein.
  • Thixocasting is a process in which a non-dendritic structure is obtained by reheating a fully solidified billet back into the solid-liquid temperature range then forming it into a part.
  • Rheocasting is a process in which a slurry with non-dendritic structure is created from liquid alloy, and then formed into a part.
  • Electromagnetically stirred billet is produced by continuous casters as described by C. Vives in an article entitled “Elaboration of Semisolid Alloys by Means of New Electromagnetic Rheocasting”(Processes, Metallurgical Transactions B, (23b), April, 1992, pgs 189-206 ).
  • thixocaster would buy these billets, reheat them into the solid-liquid temperature range, and form them into parts. Even though high quality aluminum parts are obtained, issues such as operating cost and process control have prevented wide-spread adoption of thixocasting. In 2000, thixocasting process was estimated to represent only about 1% of the 2.5 million tons of aluminum castings in North America, Europe, and Japan (or about 25,000 tons) in an article by P. Kapranos et al. entitled "Near net shaping by semi-solid metal processing" (Materials and Design, (21), 2000, pgs 387-394 ).
  • US 6,645,322 refers to a method which efficiently rheocasts alloy with spheroidal particles by immersing a cool rotating rod into a melt held above the liquidus temperature.
  • the immersion of the rotating rod simultaneously creates a region of high local cooling, provides vigorous convection, and drops the bulk melt temperature below the liquidus.
  • the process can create slurry from liquid metal with large variability in superheat, making it a robust and efficient method to produce aluminum alloy slurries.
  • the method requires a moving solid medium, some issues may be anticipated. First of all, it may not be simple to apply a water cooling system to the rod continuously while the rod is rotating. Sensors such as temperature sensors may not be simple to be attached inside the rod to measure temperatures. In addition, while the rod is rotating, there is a possibility that a vortex is formed. Formation of a vortex may result in increased metal oxidation.
  • a molten metal vessel includes a first chamber for containing molten metal such as molten aluminum therein, a filtration chamber in which impurities contained in the molten metal are removed, and a second chamber for reserving clean molten metal to be supplied to a casting die.
  • the molten metal flows from the first chamber to the second chamber through the filtration chamber.
  • a pair of filters preferably a pair of cylindrical filters, are disposed in the filtration chamber, so that the impurities contained in the molten metal can be filtered twice.
  • the filters are attached to the bottom of the filtration chamber where molten metal oxides hardly develop, so that the filters are easily replaced with new ones for the maintenance purpose.
  • a rod-shaped heater may be disposed in the cylindrical filters to keep the molten metal temperature in a strictly controlled range.; Thus, the impurities are effectively removed from the molten metal through the filters which are easily replaceable.
  • a method for filtering molten aluminum containing suspended particles using an improved filtration media comprising the steps of providing a source of molten aluminum and providing media having a coating thereon, the coating having a softening point at molten aluminum temperatures to provide adhesive properties and bonding of suspended particles in the molten aluminum thereto.
  • the filtration media is contacted with molten aluminum and suspended particles are adhesively bonded thereto to provide molten aluminum having suspended particles removed therefrom.
  • US 5,846,481 A refers to an improved molten aluminum refining apparatus in which the refining gas passageway is defined by a helical groove in the rotor shaft and sleeve for heating gas by contact with the sleeve as it flows toward the rotor to generally the temperature of the melt; which comprises a stator surrounding the sleeve and occupying a portion of the surface of the molten aluminum, and wherein the vessel comprises side walls that diverge upwardly at an angle of from about 5 degrees to about 16 degrees for permitting the gas bubbles to expand without substantial coalescence as the bubbles move upwardly in the melt reducing the metallostatic pressure on the respective bubbles.
  • US 4,154,689 A teaches an improvement in the filtration of molten metal especially aluminum using a removable vertically disposed filter plate and at least one fluxing gas inlet positioned in such a manner so as to introduce fluxing gas into the filter plate.
  • the filter plate is provided with a bevelled peripheral surface mating with a like bevelled surface in a filter chamber so that the filter plate can be conveniently inserted in the chamber and removed therefrom.
  • Fluxing gas is provided to the melt through the inlet and flows through the filter plate so as to assure extensive contact with the melt. Dissolved gases and non-metallic inclusions are thereby abstracted and removed from the melt.
  • a monolithic, fired ceramic gas diffuser for injecting gas into a molten metal bath, including a first portion, a second portion integrated with the first portion, and a bore passing through the first portion and communicating with the second portion for supplying gas to the second portion, wherein at least the second portion has a network of interconnected pores that provides preferential gas flow from the bore through the second portion to inject gas into the molten metal bath.
  • EP 1561529 A1 provides a rheoforming apparatus that ensures the manufacture of products with fine, uniform, spherical particles, with improvements in energy efficiency and mechanical properties of the products, cost reduction, convenience of forming, and shorter process duration.
  • the apparatus includes 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 plunger, which is slidably inserted into the other end of the second sleeve to press the slurry manufactured in the second sleeve.
  • a metal composition is characterized by greater than about 65 weight percent degenerate denritic or nodular primary discrete solid particles suspended in a secondary phase having a lower melting point than the primary particles and which secondary phase can be solid or liquid.
  • the method involves raising the temperature of a metal alloy to a value at which the alloy is largely or completely in the molten state. The melt is then subjected to vigorous agitation in an apparatus having an inner surface contacting the liquid-primary solid composition that is not wet by the composition and the heat is extracted to increase the portion of the mixture is in solid degenerate dendrite or nodular form greater than about sixty-five percent while continuing the agitation
  • This invention utilizes the principle presented by Martinez and Flemings that if a combination of localized chill with vigorous convection is applied to a melt held just above its liquidus temperature, a non-dendritic structure can form in a matter of seconds after solidification begins.
  • this invention it has been found that by flowing gas bubbles through a solid object into a molten metal alloy held at a temperature above the liquidus temperature, non-dendritic, semi-solid metal slurry is obtained.
  • gas bubbles provide vigorous convection while also provide some localized chill. Localized chill is also achieved through the use of a solid object.
  • this invention uses gas bubbles as the medium to provide agitation, not solid objects such as impellers or cylindrical rods as in the prior art.
  • this invention describes a method to prepare non-dendritic, semi-solid metal slurries by introducing gas bubbles through a solid object into a molten metal alloy held at a temperature above the liquidus temperature.
  • the solid object since the solid object is not rotating, several advantages can be anticipated. With no rotating parts, a cooling system and sensory systems can be applied with simple designs. Since a vortex is not formed in the molten metal alloy, increased metal oxidation due to the vortex is avoided. If a porous solid object is used to provide gas bubbles, wetting and reaction between the molten metal alloy and the immersed medium are avoided since the flow of gas bubbles out of the pores on the solid medium acts as a protective layer between the molten metal alloy and the medium surfaces. In addition, the flow of gas bubbles inside the molten metal alloy help remove slag, dissolved gases, and any impurities from the molten metal alloy, these widely used processes are known as degassing or de-slagging processes.
  • FIG. 1 shows the first embodiment of an apparatus for preparing non-dendritic, semi-solid metal slurries according to the invention.
  • FIG. 2 shows the second embodiment of an apparatus for preparing non-dendritic, semi-solid metal slurries according to the invention.
  • FIG. 3 shows the third embodiment of an apparatus for preparing non-dendritic, semi-solid metal slurries according to the invention.
  • FIG. 4 shows the fourth embodiment of an apparatus for preparing non-dendritic, semi-solid metal slurries according to the invention.
  • FIG. 5 shows a representative micrograph of a dendritic microstructure provided without applying the invention.
  • FIG. 6 shows a representative micrograph of the non-dendritic, semi-solid structure provided according to the invention.
  • FIG. 7 shows a representative micrograph of another microstructure provided according to the invention.
  • FIG. 1 Shown in FIG. 1 is an apparatus for preparing non-dendritic, semi-solid metal slurries in accordance with an embodiment of this invention.
  • the apparatus includes a holding vessel for receiving and hold a molten metal alloy, a lance (a hollow cylindrical tube) for providing inert gas bubbles, and a solid object to provide more localized chill.
  • the lance is immersed in the molten metal alloy which is held at a temperature above the liquidus temperature.
  • inert gas is flowed through the lance creating gas bubbles while a solid object is lowered into the molten metal alloy.
  • the gas is selected of the group consisting of nitrogen, argon, carbon dioxide, and a mixture of these gases.
  • the metal alloy is selected from the group consisting of aluminum alloys, magnesium alloys, copper alloys, ferrous alloys, zinc alloys, nickel alloys, and titanium alloys.
  • FIG. 2 shows another embodiment.
  • inert gas is flowed through a nozzle of a solid object.
  • FIG. 3 inert gas is flowed through a porous solid object.
  • fine and uniform bubbles are obtained.
  • FIG. 4 shows another embodiment.
  • inert gas is flowed through a porous solid located at the wall. Fine gas bubbles can be introduced on all the wall surfaces and the bottom surfaces or only parts of the surfaces.
  • the solid object may be made of graphite, ceramics, metals, or composites of these materials.
  • the molten metal or alloy is cooled by the flow of gas bubbles thereinto and by the contact with the solid object. Since more than one discussed-above solid object can be deployed simultaneously, the melted metal or alloy can be cooled by the contact with multiple solid objects. In addition, the solid object is cooled by flowing air, water, or any cooling fluids through itself.
  • the gas bubbles also protect the solid object from reacting with the metal or alloy, and remove slag, dissolved gases, or impurities from the metal or alloy.
  • the melt was slowly cooled down to 625 °C, with the cooling rate of about 1 °C/minute, and the diffuser was quickly immersed introducing fine argon gas bubbles with the volumetric flow rate of about 2 liter/min.
  • the bubbling process was carried out until solid phase of about 10% in the melt was achieved before the diffuser was quickly removed and the melt allowed to cool slowly.
  • the metal temperature reached 580 °C (about 45% solid fraction)
  • a slice of the metal in the crucible was removed and quenched in water.
  • FIG. 5 is given to show a representative micrograph of the un-processed dendritic microstructure.
  • the micrograph shows coarse grain structure with more than 400 ⁇ m in size.
  • FIG. 6 shows a representative micrograph of the non-dendritic, semi-solid structure processed by this method. In this method, the grain structure is significantly finer with less than 200 ⁇ m in size.
  • the melt was slowly cooled down to 625 °C, with the cooling rate of about 1 °C/minute, and the solid copper chill coated with graphite was quickly immersed with fine argon gas bubbles being introduced through the lance at the same time, see FIG. 1 .
  • the volumetric flow rate was about 1.5 liter/min.
  • the bubbling process was carried out until solid phase of about 5% in the melt was achieved before the solid copper chill was quickly removed and the gas flow was stopped.
  • the melt was then allowed to cool slowly. When the metal temperature reached 580 °C (about 45% solid fraction), a slice of the metal in the crucible was removed and quenched in water. The samples were then polished and examined under an optical microscope.
  • FIG. 7 shows a representative micrograph of the microstructure.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Manufacture And Refinement Of Metals (AREA)
  • Manufacture Of Metal Powder And Suspensions Thereof (AREA)
  • Waste-Gas Treatment And Other Accessory Devices For Furnaces (AREA)
  • Physical Or Chemical Processes And Apparatus (AREA)

Claims (6)

  1. Procédé de formation de métal semi-solide ou alliage ayant des structures de grains non dendritiques utilisant les bulles de gaz, comprenant:
    - une première étape de réchauffer le métal ou l'alliage au-dessus d'une température de fusion de ceux-ci pour obtenir le métal ou l'alliage liquide;
    - une seconde étape d'écouler les bulles de gaz parmi au moins un milieu solide inséré dans ou fait accommoder là dedans ledit métal liquide ou alliage de cette manière en refroidissant ledit métal liquide ou alliage à une température au-dessous de ladite température de fusion de ceux-ci pendant qu'en agitant ledit métal liquide ou alliage avec les bulles de gaz et formant les fractions solides là ddans; et
    - une troisième étape d'arrêter l'écoulement à travers desdites bulles de gaz quand ladite fraction liquide dudit métal liquide ou alliage atteint une rangée de 0,01-0,5 en poids, préférablement une rangée de 0,01-0,2 en poids, ainsi en obtenant le métal semisolide ou alliage ayant des structures de grains non dendritiques.
  2. Procédé selon la revendication 1, où le refroidissement est de plus réalisé par le contact dudit métal liquide ou alliage avec ledit milieu solide.
  3. Procédé selon la revendication 1, où ladite étape d'écoulement de bulles de gaz pourvoit une vitesse d'écoulement d'au moins 1 degré Celsius par minute.
  4. Procédé selon la revendication 3, où le refroidissement est de plus réalisé par le contact dudit métal liquide ou alliage avec au moins un autre milieu solide qui est différent dudit milieu solide.
  5. Procédé selon la revendication 3, où ledit milieu solide est refroidi par moyen de l'air s'écoulant ou d'un fluide de refroidissement.
  6. Procédé selon la revendication 1, où le milieu solide est prévenu d'agitation ou rotation.
EP07763446A 2006-02-02 2007-01-31 Procede de preparation de structure metallique appropriee pour un traitement de metal semi-solide Not-in-force EP1981668B1 (fr)

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US76434806P 2006-02-02 2006-02-02
PCT/US2007/002503 WO2007092203A2 (fr) 2006-02-02 2007-01-31 Procede de preparation de structure metallique appropriee pour un traitement de metal semi-solide

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EP1981668A2 EP1981668A2 (fr) 2008-10-22
EP1981668A4 EP1981668A4 (fr) 2010-03-10
EP1981668B1 true EP1981668B1 (fr) 2013-01-16

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WO (1) WO2007092203A2 (fr)

Cited By (2)

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CN104043792A (zh) * 2014-07-04 2014-09-17 机械科学研究总院（将乐）半固态技术研究所有限公司 轻合金或轻金属半固态浆料的制备装置及制备方法
CN104232953A (zh) * 2014-09-18 2014-12-24 珠海市润星泰电器有限公司 一种轻金属合金半固态浆料制备方法

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CN106413940B (zh) * 2014-05-16 2020-08-25 吉斯科有限公司 制造用于在低至零度的过热温度下铸造的熔融金属的方法
CN106955980B (zh) * 2017-04-20 2022-10-18 昆山伟拓压铸机械有限公司 有色金属半固态汤料成型装置及制备方法
CN106925728B (zh) * 2017-04-21 2019-12-13 苏州金澄精密铸造有限公司 半固态制浆用制浆头
CN106903276B (zh) * 2017-04-21 2019-12-13 苏州金澄精密铸造有限公司 一种半固态浆料制浆机
CN106944599B (zh) * 2017-04-21 2022-06-14 苏州金澄精密铸造有限公司 半固态制浆用制浆机及半固态制浆方法
CN109759555B (zh) * 2019-01-28 2021-03-30 深圳市银宝山新压铸科技有限公司 一种复合场制备半固态浆料的方法
JP7247917B2 (ja) * 2020-02-19 2023-03-29 トヨタ自動車株式会社 半凝固溶湯の製造方法

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CN104232953A (zh) * 2014-09-18 2014-12-24 珠海市润星泰电器有限公司 一种轻金属合金半固态浆料制备方法
CN104232953B (zh) * 2014-09-18 2016-10-26 珠海市润星泰电器有限公司 一种轻金属合金半固态浆料制备方法

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Publication number Publication date
ES2403369T3 (es) 2013-05-17
JP5242416B2 (ja) 2013-07-24
WO2007092203B1 (fr) 2008-04-24
EP1981668A4 (fr) 2010-03-10
JP2009525192A (ja) 2009-07-09
DK1981668T3 (da) 2013-04-15
WO2007092203A3 (fr) 2008-03-06
WO2007092203A2 (fr) 2007-08-16
EP1981668A2 (fr) 2008-10-22

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