EP2145704A1 - Procédé et appareil pour l'extrusion en continu de thixo-magnésium en produits d'extrusion en forme de plaques ou de barres - Google Patents

Procédé et appareil pour l'extrusion en continu de thixo-magnésium en produits d'extrusion en forme de plaques ou de barres Download PDF

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Publication number
EP2145704A1
EP2145704A1 EP08159939A EP08159939A EP2145704A1 EP 2145704 A1 EP2145704 A1 EP 2145704A1 EP 08159939 A EP08159939 A EP 08159939A EP 08159939 A EP08159939 A EP 08159939A EP 2145704 A1 EP2145704 A1 EP 2145704A1
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EP
European Patent Office
Prior art keywords
feedstock
thixotropic
extrusion
magnesium
slurry
Prior art date
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.)
Withdrawn
Application number
EP08159939A
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German (de)
English (en)
Inventor
Raymond Gerardus Theodorus Marie Mannens
Wilhelmus Hubertina Sillekens
Daniel Cornelis Wilhelmus van der Linden
Robert Jan Werkhoven
Johannes Bosco Jacobus Maria van Lieshout
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Nederlandse Organisatie voor Toegepast Natuurwetenschappelijk Onderzoek TNO
Original Assignee
Nederlandse Organisatie voor Toegepast Natuurwetenschappelijk Onderzoek TNO
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Publication date
Application filed by Nederlandse Organisatie voor Toegepast Natuurwetenschappelijk Onderzoek TNO filed Critical Nederlandse Organisatie voor Toegepast Natuurwetenschappelijk Onderzoek TNO
Priority to EP08159939A priority Critical patent/EP2145704A1/fr
Priority to PCT/NL2009/050413 priority patent/WO2010005306A1/fr
Publication of EP2145704A1 publication Critical patent/EP2145704A1/fr
Withdrawn legal-status Critical Current

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    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C23/00—Alloys based on magnesium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C23/00—Extruding metal; Impact extrusion
    • B21C23/002—Extruding materials of special alloys so far as the composition of the alloy requires or permits special extruding methods of sequences

Definitions

  • the invention relates to a method and apparatus for extrusion of thixotropic metal structures, in particular using magnesium, or magnesium alloys.
  • thixotropic magnesium alloy in which a billet is used for pressurizing and feeding a thixotropic slurry from a buffer space through a forming die and with cooling at or near the forming die is known.
  • Such an extrusion process can only be used for thixomolding of discrete products of finite length. It is also known to use screw extruders in feeding injection moulds with charges of thixotropic magnesium to obtain discrete products.
  • the use of thixotropic material by the known processes and apparatus, is thereby limited to relatively small products. Such processes are discontinuous. Larger products such as continuous plate or sheet extrusions and profiled bars cannot be obtained by the known thixomolding processes. For continuous extrusion it is important that the creation of fresh thixotropic material and the increase of pressure takes place simultaneously and continuously.
  • the present invention envisions continuous extrusion of thixotropic magnesium, or magnesium alloy to enable manufacture of larger products, such as sheet and profiled bars. It is thus an object of the present invention to overcome or ameliorate at least one of the disadvantages of the prior art. It is also an object of the present invention to provide alternative apparatus and process solutions which are less cumbersome in operation and which moreover can be practiced relatively inexpensively. Alternatively it is an object of the invention to at least provide the public with a useful choice.
  • the invention provides a method for extrusion of magnesium based alloys for obtaining net shapes, or near net shapes, having a thixotropic structure, the method including: providing magnesium based alloy feed stock; converting at least a portion of the feedstock into a thixotropic slurry; exerting a driving force on the feedstock, upstream of the thixotropic slurry, to advance the feedstock in a downstream direction; subjecting a downstream end of the thixotropic slurry to controlled rapid cooling to retain a thixotropic structure; and allowing a downstream end of the converted feedstock to escape through a shaping die, to obtain bar stock having a predefined cross-sectional shape.
  • the invention provides for continuous extrusion of thixotropic magnesium, or magnesium alloys, in which the primary formation of the non-dendritic, thixotropic structure is incorporated within the extrusion process itself.
  • the step of conversion includes inductively heating and electromagnetically stirring the slurry in a partly solid and a partly liquid state.
  • the electromagnetic stirring is enhanced by an impeller structure immersed in the thixotropic slurry.
  • the impeller structure may be set into motion by the electromagnetic action of the inductive heating.
  • the invention thereby includes at least one practical solution for mechanical and/or electromagnetic stirring compatible with the configuration of an extruder accepting billets or bar as feedstock.
  • the invention also provides for an extrusion device from which a thixotropic metal composition emanates continuously.
  • an extruder device including: a supply arrangement for feeding feedstock; a conversion chamber; agitation means; cooling means; and a shaping die, wherein the agitation means includes an inductive heater that electromagnetically agitates any liquid or semi-liquid metal in the conversion chamber.
  • One aspect of the extrusion device according to the invention is an agitation zone in a conversion chamber and the use of a pressure differential between the at least partially molten metal and an outlet opening of the conversion chamber to create a continuous flow of metal in a thixotropic state.
  • the conversion chamber may have one or more conduits for connecting to one or more of a source of inert gas and a supply of at least one reaction component or additive.
  • the invention also enables using the process and extrusion device for obtaining porous thixo-magnesium extrusions.
  • the invention thus includes a process and device for obtaining lightweight porous metal structures and the lightweight metal composites obtained thereby.
  • Magnesium and magnesium-alloy foams are characterized by a high impact energy absorption capacity, low thermal conductivity, good electrical conductivity and high absorptive acoustic properties. Such materials are useful as load-bearing materials and as thermal insulators.
  • Porous thixo-magnesium is also particularly usefull for biomedical applications, including biocompatible and biomedical devices, such as implants or scaffolds.
  • porous biomedical implants may also be useful in drug delivery from the pores of the porous structure.
  • the adding, in a controlled manner, of other materials and/or additives during thixomolding production is also envisioned by the invention.
  • the process features the steps of heating a composite of a metal matrix and finely divided solid stabilizer particles above the liquidus temperature of the metal to form a molten metal composite and mixing the molten metal composite and drawing in a gas, or by adding gas forming compounds, into the melt to obtain metal foam.
  • the resulting expanded, viscous molten composite material contains evenly distributed pores. This viscous molten composite material is directly formed into a solidified shaped extrusion product without destroying the integrity of the foam pores.
  • the invention thus also relates to a continuous production of gas foamed thixo-magnesium extrusion product.
  • FIG. 1 is schematically illustrated a first proposed solution for continuously extruding thixotropic magnesium or thixotropic magnesium alloy.
  • a bar of magnesium feedstock 3 is advanced into a heating zone 5.
  • the magnesium material obtains a semi-solid state
  • a stirring arrangement 7 changes the semi-solid material into a thixotropic slurry.
  • the thixotropic slurry is advanced from heating zone 5 into a cooling zone 9 by means of a force F exerted on the feedstock 3.
  • the thixotropic slurry takes the form of magnesium with a thixotropic structure of a temperature still sufficiently elevated to enable extrusion through a die 11.
  • Leaving die 11 is a shaped profile 13 of magnesium alloy, with a thixotropic structure and stable shape.
  • the stirring arrangement 7 is schematically shown as an impeller or mixer, but this may also be stirring by an electromagnetic field. Conventionally stirring may also be accomplished by a single or double extruder screw. It is usually important that cooling in the cooling zone 9 after the formation of the thixotropic slurry in heating zone 5 is accomplished rapidly. After sufficient cooling, the thixotropic structure becomes stable.
  • FIG. 2 shows schematically a variation of the continuous extrusion shown in Figure 1 .
  • a schematically illustrated extruder 101 is again fed with a bar of magnesium alloy feedstock 103.
  • the magnesium material is converted to a semi-solid state in which it is stirred by a stirring arrangement 107 to obtain a thixotropic slurry.
  • the thixotropic slurry is advanced directly to the die 111, which is cooled so that a separate cooling zone can be eliminated.
  • the magnesium material While being shaped by the die 111 into a particular cross-sectional shape, the magnesium material is also cooled down sufficiently to ensure that the profile 113 leaving the die 111 has a thixotropic structure and stable shape.
  • the magnesium material is advanced through the successive stages of the process according to Figure 2 by a force F exerted on an upstream end of the feedstock bar 103.
  • FIG. 3 shows an example of a nozzle head 115 suitable for use with the cooled die 111 of the arrangement according to Figure 2 .
  • This nozzle head 115 can have several cooling zones which will determine its length.
  • Such a nozzle head provided with successively staged cooling zones may effectively achieve controlled cooling at or near the forming die.
  • Eliminating the joints between successive shots of bar feedstock has the additional advantage that the extruded profiles are homogenous in structure throughout their length. This eliminates the practice of detecting and removing defective portions by sawing and scrapping the detective portions. Moreover eliminating defective joints also has the benefit that the obtained extruded profiles or bars are not limited in length.
  • Figure 4 is a top plan view of an extruder for thixotropic magnesium according to the invention and Figure 5 is a longitudinal cross-section according to the line V-V in Figure 4 .
  • the extruder 201 of Figures 4 and 5 is fed by a magnesium alloy bar 203.
  • This bar 203 is fed into the extruder 201 by a pair of driven rollers 221, 223 by which it is advanced into a heating chamber 205.
  • the heating chamber 205 in its interior is additionally supplied with an inert gas atmosphere through a first conduit 225.
  • An optional second conduit 227 is provided to enable circulation of the inert gas to provide additional temperature control .It is also envisioned to mix the inert gas with a reaction component such as a foaming agent and then the gas atmosphere can be recirculated from the second conduit 227. The gas withdrawn from the second conduit 227 can then be suppleted with the reaction component and be returned to the first conduit 225.
  • Foam-forming gas may be selected from the group consisting of carbon dioxide, inert gases, such as argon (Ar), or the like. It is important for the foaming gas, not to react with the molten magnesium. Also a blowing agent that reacts with the Magnesium melt may be employed. Such blowing agents may include magnesium carbonate (MgCO 3 ) or magnesium hydride (MgH 2 ). Similarly zirconium hydride (ZrH2) may be added as a gas forming compound to obtain metal foam. The cell size of the foam may be controlled by adjusting the gas flow rate and/or the agitation parameters. The flow direction of the inert gas or the mixture of inert gas and the reaction component can also be reversed from the second conduit 227 to the first conduit 225, if so desired.
  • inert gases such as argon (Ar), or the like. It is important for the foaming gas, not to react with the molten magnesium.
  • alloying elements that can be commercially used to modify the properties of magnesium include: aluminium (Al), silver (Ag), beryllium (Be), cadmium (Ca), lithium (Li), manganese (Mn), rare earth elements (REE), silicon (Si), zinc (Zn), and zirconium (Zr).
  • Certain alloying elements that can be used to increase corrosion resistance include manganese (Mn) and rare earth elements (REE).
  • Medical agents can notably include hydroxy apatite (HA) Ca10(PO4)6(OH)2, which in orthopedic applications (implants) stimulates bone growth.
  • the inert gas atmosphere may be supplied via the first conduit 225.
  • the inert gas is supplied to the first conduit at a controlled over pressure so that losses of gas escaping from the heating chamber 205, by gaps around the perimeter of feedstock bar 203 are suppleted through the same first conduit 225.
  • the second conduit 227 will then be available for additives that may have a desired reaction with the thixotropic slurry before it is being cooled.
  • Administering additives through the second conduit 227 may include feeding of further components, for example alloying components when manufacturing alloys, reinforcing components when manufacturing magnesium compound materials or other additional materials for modifying the magnesium materials.
  • an induction coil 229 Surrounding the heating chamber 205 is an induction coil 229, which includes a helically wound conductor wire 231, for heating and stirring, which is partially represented by its centre line 233. Alternatively a travelling magnetic field may be employed as will be explained herein below.
  • the cooling section 237 is provided with a coolant passage 241, which is helically wound about a central passage 243 of the cooling section 237.
  • the helically extending coolant passage 241 in Figure 5 is partially represented by its centre line 245.
  • the coolant passage 241 has a first entrance or exit 247 and a second entrance or exit 249.
  • the flow of coolant through passage 241 may be either from the first entrance or exit 247 to the second entrance or exit 249 or vice versa.
  • the proper selection of the coolant flow direction depends on whether the largest absorption of heat is desired at an upstream or a downstream end of the cooling section 237.
  • the flow of coolant may be adjustable for flow rage and flow direction to best meet the rapid cooling required to freeze the thixotropic structure obtained in the heating chamber 205.
  • an extrusion product 251 emits in its final cross-sectional shape.
  • FIG. 6 shows an alternative embodiment 201A of the device of Figure 5 .
  • the device 201A is similar in having contoured driving wheels 221A, 223A feeding a feedstock bar 203A into a heating chamber 205A.
  • the heating chamber 205A has again a first conduit 225A for supplying an inert gas atmosphere and a second conduit 227A for recirculating the inert gas or for supplying an additive reaction component to the thixotropic slurry that is formed in the heating chamber 205A.
  • the heating chamber 205A is surrounded by a helically wound induction coil 229A for heating and stirring the feedstock bar 203A in its semi-solid state.
  • a die block 235A is positioned at a distance downstream of the heating chamber 205A, so that the thixotropic slurry formed in heating chamber 205A is air cooled to a solid thixotropic structure, which is still at a sufficiently elevated temperature to be malleable by the die block 235A to obtain the extrusion product 251A.
  • FIGs 7 and 8 show yet another embodiment of extruder 301 according to the invention.
  • this extruder 301 of which Figure 8 shows a cross-section according to line VIII-VIII of Figure 7 , is similar to the extruders of Figures 4-6 except for the section where the extrusion is formed.
  • a magnesium alloy bar 303 is again fed by a pair of driven rollers 321, 323 into an upstream end of a heating chamber 305.
  • the first and second rollers 321, 323 are formed as wheels with a circumference contoured in accordance with the outer circumferential contour of the feedstock bar 303 for maximum frictional engagement with the circumference of the bar 303.
  • the heating chamber 305 is surrounded by a helically wound induction coil 329 for heating and stirring the feed stock 303 in its semi-solid/semi-liquid state.
  • the electromagnetic stirring action imposed by the induction coil 329 may be enhanced by a mechanical stirring device (not shown, but conventional) within the heating chamber 305.
  • This additional mechanical stirring device such as an impeller or mixer, may be engaged for rotation by the electromagnetic field of the induction coil 329, or may employ a conventional separate driving means.
  • a usefull alternative to heating and stirring may be provided by a travelling magnetic field, as will be further explained herein below.
  • the heating chamber 305 is also provided with a first conduit 325 for supplying an inert gas and a second conduit 327 for supplying a reaction agent or for recirculating the inert gas atmosphere.
  • the induction coil conductor wire 331 is again in part represented by its centre line 333. Downstream of the heating chamber 305 there can be a cooling section 337 contained within a housing 339 and having a helical coolant passage 341.
  • the coolant passage extends from a first entrance or exit 347 to, or from, a second entrance or ext 349.
  • the extrusion device 301 does not have a die block associated with the cooling section 337. Similar to the embodiment 201A of Figure 6 , the cooling section 337 is also optional in the embodiment of Figures 7 and 8 and may be deleted in favour of air cooling. A separate description of such an alternative execution of the embodiment of Figures 7 and 8 is deemed redundant. Whatever the means of cooling employed, the feed stock bar 303 downstream of the heating chamber 305 emerges as a converted bar 353 of frozen thixotropic structure towards a grooved rotatable wheel 355 of a stationary shoe 357 extrusion device.
  • the grooved wheel 355 is rotatable about shaft 359 and has a counter roller 361, rotatable about shaft 363 to bring the bar 353 of converted thixotropic magnesium alloy in frictional engagement with the groove 365 of wheel 355.
  • the stationary shoe 357 is provided with an abutment 367 extending into the groove 365 of wheel 355.
  • An extrusion die 369 with an exit opening 371 that extends radially away from the wheel 355 is formed in the vicinity of the abutment 367.
  • the converted bar 353 engaged in groove 365 is advanced by friction of the wheel 355. Extrusion pressure is then generated by the abutment 367 as the shoe 357 covers the groove 365 in a stationary manner.
  • the invention thus provides for a method for the extrusion of magnesium based alloys for obtaining net shapes, or near net shapes in the form of plate or bar shaped extrusion products.
  • the extrusion product of the method has a thixotropic structure and stable shape.
  • the method of the invention includes providing magnesium based alloy feed stock and converting at least a portion of the feedstock into thixotropic slurry.
  • the method further exerts a driving force on the feedstock, upstream of the thixotropic slurry, to advance the feedstock in a downstream direction and subjecting a downstream end of the thixotropic slurry to controlled rapid cooling to obtain a thixotropic structure.
  • the method of the invention further allows a downstream end of the converted feedstock to escape through a shaping die, so as to obtain bar stock having a predefined cross-sectional shape.
  • An extrusion device for carrying out the method is also provided by the invention as described above.
  • the extrusion devices as described herein above each include a supply arrangement for feeding feedstock, a conversion chamber, agitation means, cooling means and a shaping die.
  • the agitation means advantageously includes an inductive heater that electromagnetically agitates any liquid or semi-liquid metal in the conversion chamber.
  • FIG. 9 several successive induction coils 429A, 429B and 429C may be arranged about heating chamber 405.
  • a linear travelling field can be obtained by feeding the coils with an alternating current and shifting phases between the current flowing through the individual coils 429A, 429B, 429C.
  • Figure 9 in which reference numerals differ a full "200" with those used in Figures 4 and 5 , thus shows continuous thixo-extrusion with three induction coils to obtain a travelling magnetic field for stirring heating and propulsion of magnesium slurry.
  • first and second drive roller 421, 423 are optional in regard of the transport of the feedstock bar 403 during extrusion, but can be a useful addition to assist in the initial supply of magnesium feedstock when starting the extrusion process.
  • the number of windings and the number of coils indicated in Figure 9 is merely a schematic indication and can be varied in accordance with the skilled person's knowledge.
  • Figure 10 is a transverse cross section of yet another form of extruder showing an alternative radial arrangement of coils for obtaining a rotating travelling field.
  • an extrusion device 501 uses a combination of an induction coil, or other form of heating element 529, and radially arranged coils 571, 572, 573 for excitating a rotating travelling field.
  • Induction coil 529 ensures the heating of the magnesium slurry, while stirring is accomplished by the rotating travelling field of the radial coils 571-573.
  • Optional active or passive cooling can be accomplished after the aforementioned steps.
  • the stirring action of a rotating travelling magnetic field can be further enhanced by adding one or mere further sets of radially disposed coils, which excitate rotation in opposite directions.
  • the heating chamber 5, 105, 205, 205A, 305, 405 or, bij way of example, 505 can also be provided with a stationary stirring arrangement, in the form of a stator 507, as shown in Figure 12 .
  • the magnesium based alloy extrusion products with a thixotropic structure, obtained by the invention are particularly suitable for load bearing and shock absorbing applications such as found in the automotive industry.
  • Advantageous features of the structures obtainable by the invention additionally include its biodegradable character, which makes it particularly suitable for medical and biomedical structures, such as implants for various purposes.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Extrusion Of Metal (AREA)
EP08159939A 2008-07-08 2008-07-08 Procédé et appareil pour l'extrusion en continu de thixo-magnésium en produits d'extrusion en forme de plaques ou de barres Withdrawn EP2145704A1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
EP08159939A EP2145704A1 (fr) 2008-07-08 2008-07-08 Procédé et appareil pour l'extrusion en continu de thixo-magnésium en produits d'extrusion en forme de plaques ou de barres
PCT/NL2009/050413 WO2010005306A1 (fr) 2008-07-08 2009-07-08 Procédé et appareil d’extrusion continue de thixo-magnésium en produits extrudés en forme de plaques ou de barres

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EP08159939A EP2145704A1 (fr) 2008-07-08 2008-07-08 Procédé et appareil pour l'extrusion en continu de thixo-magnésium en produits d'extrusion en forme de plaques ou de barres

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
RU2444412C1 (ru) * 2010-09-13 2012-03-10 Государственное Образовательное Учреждение Высшего Профессионального Образования "Московский Государственный Технический Университет Имени Н.Э. Баумана" Способ тиксопрессования цилиндрической тиксозаготовки в режиме сверхпластичности ее твердой фазы
CN102489958A (zh) * 2011-12-08 2012-06-13 李跃华 一种成卷生产宽幅镁合金板的工艺及设备

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CN101892445B (zh) * 2010-07-07 2011-11-09 中南大学 一种强力变形制备超高强镁合金棒材的方法
WO2012061474A2 (fr) 2010-11-04 2012-05-10 3M Innovative Properties Company Procédé de formation d'éléments de filtre
US9555468B2 (en) * 2012-09-12 2017-01-31 Lucio Megolago Albani Process and plant for producing components made of an aluminium alloy for vehicles and white goods, and components obtained thereby
DE102015101767A1 (de) 2015-02-06 2016-08-11 Technische Universität Dresden Blaue Fluoreszenzemitter
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DE102016110970A1 (de) 2016-06-15 2017-12-21 Technische Universität Dresden Effiziente lichtemittierende Emittermoleküle für optoelektronische Anwendungen durch gezielte Verstärkung der Emission aus ladungsseparierten CT-Zuständen auf Basis dual fluoreszierender Benzol-(Poly)carboxylat-Akzeptoren
JP7078839B2 (ja) * 2017-12-12 2022-06-01 富士通株式会社 マグネシウム合金、及びその製造方法、並びに電子機器
US11691201B2 (en) * 2021-03-04 2023-07-04 Kumar Kandasamy Processes and/or machines for producing continuous plastic deformation, and/or compositions and/or manufactures produced thereby

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Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
RU2444412C1 (ru) * 2010-09-13 2012-03-10 Государственное Образовательное Учреждение Высшего Профессионального Образования "Московский Государственный Технический Университет Имени Н.Э. Баумана" Способ тиксопрессования цилиндрической тиксозаготовки в режиме сверхпластичности ее твердой фазы
WO2012036583A1 (fr) * 2010-09-13 2012-03-22 Государственное Образовательное Учреждение Высшего Профессионального Образования "Московский Государственный Технический Университет Имени Н.Э.Баумана" (Мгту Им. Н.Э.Баумана) Procédé de thixo-pressage d'une thixo-ébauche cylindrique en mode de phase solide superplastique
CN102489958A (zh) * 2011-12-08 2012-06-13 李跃华 一种成卷生产宽幅镁合金板的工艺及设备
CN102489958B (zh) * 2011-12-08 2014-10-08 李跃华 一种成卷生产宽幅镁合金板的工艺及设备

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