EP2821163A1 - Method for molding amorphous alloy, and molded object produced by said molding method - Google Patents
Method for molding amorphous alloy, and molded object produced by said molding method Download PDFInfo
- Publication number
- EP2821163A1 EP2821163A1 EP13755554.6A EP13755554A EP2821163A1 EP 2821163 A1 EP2821163 A1 EP 2821163A1 EP 13755554 A EP13755554 A EP 13755554A EP 2821163 A1 EP2821163 A1 EP 2821163A1
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- European Patent Office
- Prior art keywords
- melt
- casting mold
- molding
- amorphous alloy
- casting
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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.)
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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
- B22D25/00—Special casting characterised by the nature of the product
- B22D25/06—Special casting characterised by the nature of the product by its physical properties
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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
- B22D21/00—Casting non-ferrous metals or metallic compounds so far as their metallurgical properties are of importance for the casting procedure; Selection of compositions therefor
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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
- B22D17/20—Accessories: Details
- B22D17/22—Dies; Die plates; Die supports; Cooling equipment for dies; Accessories for loosening and ejecting castings from dies
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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
- B22D17/20—Accessories: Details
- B22D17/22—Dies; Die plates; Die supports; Cooling equipment for dies; Accessories for loosening and ejecting castings from dies
- B22D17/2218—Cooling or heating equipment for dies
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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
- B22D23/00—Casting processes not provided for in groups B22D1/00 - B22D21/00
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
- B22D27/04—Influencing the temperature of the metal, e.g. by heating or cooling the mould
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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
- B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
- B22D27/09—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting by using pressure
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
- B22D27/09—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting by using pressure
- B22D27/11—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting by using pressure making use of mechanical pressing devices
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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
- B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
- B22D27/09—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting by using pressure
- B22D27/13—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting by using pressure making use of gas pressure
Definitions
- the present invention relates to a method of molding an amorphous alloy that is excellent in quality and has a high degree of shape freedom, and to a molded object produced by the molding method.
- the present invention relates to a molding method capable of processing metallic glass while keeping a supercooled state in a casting mold, and to a molded article, such as a rotor of a uniaxial eccentric screw pump, produced by the molding method.
- metallic glass that is a kind of an amorphous alloy has specific mechanical property that is not inherent in general metals. Specifically, the metallic glass has a low Young' s modulus (flexibility) while keeping the mechanical strength due to its high strength and high hardness. Therefore, the metallic glass has been expected to be utilized for various materials, and the application thereof to a bar-shaped member having a small diameter, such as a rotor of a uniaxial eccentric screw pump described later, has been expected.
- a method of molding an amorphous alloy involves casting a melt into a water-cooled mold.
- Patent Literature 1 JP 2002-224249 A
- an alloy material of an amorphous alloy member is melted by heating with a high-frequency induction heating coil, and the melt is cast into a water-cooled casting mold and quenched in the mold.
- Patent Literature 1 merely involves pouring the melt into the casting mold, thereby causing the following problems. Specifically, surrounding atmospheric gas is liable to be drawn in, the melt is solidified due to quenching before the drawn-in gas and occluded gas that has occluded the surrounding atmospheric gas during melting are released, and those gases are confined in metallic glass to form pores having various sizes.
- the pores refer to void parts such as micropores present in a material for the metallic glass and cause significant decrease in mechanical strength of the material in a cast molded object.
- Patent Literature 2 JP 2006-175508 A discloses a method of molding an amorphous alloy, which involves melting an amorphous alloy, pouring the melt into a casting mold, pressurizing the melt in the casting mold by pressing, and quenching the melt.
- This molding method has the following advantage. Specifically, the melt in the casting mold is pressurized by pressing and quenched, and hence gas in the melt that causes pores is forcibly discharged to reduce inner pores.
- the method of molding an amorphous alloy of Patent Literature 2 has the following drawback. Specifically, the method adopts the steps of pouring the melt into the casting mold, pressurizing the melt to eliminate the pores, and quenching the melt. Thus, the melt is annealed and crystallized while being poured into the casting mold when a small molded article is produced, with the result that an amorphous alloy is not formed in some cases. Accordingly, the shape and size of an article to be molded depend on the material for and the amount of the melt, and a molded article has a small degree of work freedom.
- the present invention has been made so as to solve the above-mentioned problems, and it is an obj ect of the present invention to provide a method of molding an amorphous alloy, which has a high degree of work freedom regardless of components of an amorphous alloy, in particular, metallic glass and of the shape of an article to be molded, and is capable of producing a molded article having less pores, and to provide a molded object produced by the molding method.
- a method of molding an amorphous alloy including: a melting step of melting an alloy; a differential-pressure casting step of injecting a melt of the alloy into a casting mold positioned below the melt and evacuating the casting mold; and a processing step of processing the melt by pressurizing a casting metal in the casting mold under a high-temperature state while keeping the melt in a supercooled state.
- the melt when the amorphous alloy is molded, the melt is filled into a small casting mold rapidly by evacuating the casting mold while the melt is poured into the casting mold, and pores and the like formed in this case are reduced by pressurizing the melt.
- the melt can be filled into the casting mold sufficiently in a temperature region falling within a temperature range (supercooling temperature range) that corresponds to an intermediate temperature lower than a crystallization temperature of the metal and higher than a glass transitiontemperatureofthe metal.
- a molded article required to have a small shape or a larger longitudinal length ratio, or to have high fluidity in the melt in the casting mold can be provided with less pores.
- the "amorphous alloy” as used herein is preferably metallic glass.
- the metallic glass is a kind of an amorphous alloy and is a metal in which glass transition can be observed clearly.
- the metallic glass is processed in a state of a supercooled fluid. That is, the metallic glass is processed in a time region in which the formation of a crystal phase does not occur even when the metal temperature decreases, and thereafter, the metallic glass is strongly pressurized with the temperature being kept in the casting mold while the fluidity of the metallic glass ismonitored. Withthis, a metallic glass molded article having a shape without defects in which pores are crushed can be produced in a bulk shape. Accordingly, the effect of mass productivity of molded articles can be expected by optimizing the conditions of the processing step, and cost can be reduced.
- the casting metal is heated in the processing step by causing a high-frequency current to flow through a coil provided on a periphery of the casting mold.
- the casting metal is heated, for example, by causing the high-frequency current to flow through the coil wound around the periphery of the casting mold to conduct heat from the outside to the inside of the casting mold (high-frequency induction heating) .
- This method is advantageous in that the temperature of the melt can be controlled by regulating a coil current, and the temperature can be controlled easily in accordance with a change in the melt and the external atmosphere.
- the casting metal may be heated by irradiating the casting mold with infrared light or may be heated through use of radiation heat obtained by irradiating the casting mold with infrared light.
- melt is pressurized in the processing step by pressurizing the melt with gas through a hole formed in the casting mold.
- the melt can be pressurized uniformly without preparing a mechanical pressurizing device separately as long as gas inflow means to an inlet hole and an output hole of the casting mold, for pressurizing the melt with gas, and air tightness are ensured.
- melt is pressurized in the processing step by pressurizing the melt with an actuator through a hole formed in the casting mold.
- a molded article produced by the above-mentioned method of molding an amorphous alloy can be produced in a bulk shape even from the metallic glass with high accuracy.
- a minute rotor of a uniaxial eccentric screw pump having a shape with a larger longitudinal length ratio can be produced with high mechanical strength and repetition fatigue strength simply by optimizing heating and processing conditions.
- shaping can be performed while the pores and the like are reduced by pressurizing the melt and the supercooled state is kept in the casting mold, and hence a molded article of an amorphous alloy having various shapes, sizes, and components can be provided easily.
- an amorphous alloy in particular, metallic glass to be molded in a method of molding an amorphous alloy of the present invention is described.
- General metals and alloys have a crystal structure in which atoms are arranged periodically. When melted by heating, the metals and alloys become a liquid to have a structure in which the atoms are packed densely at random. The state not having a periodic structure is called an amorphous state. In general, when the liquid is solidified, the liquid changes to a crystal. However, predetermined alloys form a solid while keeping an amorphous structure when quenched. Such an alloy is called an amorphous alloy. Of the amorphous alloys, an alloy exhibiting glass transition that is one of the features of glass is called metallic glass.
- FIG. 1(a) shows a specific heat curve of an amorphous alloy
- FIG. 1(b) shows a specific heat curve of metallic glass.
- the amorphous alloy reaches a crystallization temperature by heating before reaching a glass transition point T g and the crystallization thereof proceeds. Thus, no glass transition is observed.
- T g glass transition point
- the amorphous alloy in the case of an amorphous alloy having a resistance to crystallization, which is stable in a supercooled liquid state, that is, stable in an amorphous structure, the amorphous alloy reaches the glass transition point T g prior to a crystallization temperature T x due to an increase in temperature, and the crystallization thereof proceeds when the temperature becomes higher than the glass transition point T g .
- the amorphous alloy having the glass transition point T g lower than the crystallization temperature T x is called metallic glass, and the general amorphous alloy (T x ⁇ T g ) and the metallic glass (T x >T g ) are discriminated from each other.
- the dotted line (a) on a left side represents a general amorphous alloy.
- the general metal is solidified at a melting point T m or less, and the crystallization thereof proceeds and the work hardening thereof also increases at the glass transition temperature T g or less unless the metal is further quenched.
- the dotted line (b) on a right side represents metallic glass.
- the supercooled region of the metallic glass is still large even at the melting point T m or less and can be molded to a bulk product having a thickness to some degree even over a long period of time.
- a melt of metallic glass is injected into a casting mold, and the melt is processed by heating and pressurizing the melt in the casting mold while being kept in a supercooled state.
- description is made of an exemplary case where a rotor of a uniaxial eccentric screw pump made of metallic glass is an article to be molded by the molding method. Note that, the uniaxial eccentric screw pump and the use example thereof are described later.
- FIGS. 3 are schematic views illustrating a molding step for a rotor 1 of a uniaxial eccentric screw pump made of metallic glass in time series.
- FIG. 4 is a flowchart thereof (specific device configuration example is described later).
- a columnar standard rod 2 is used as a basic material of a metallic glass material as illustrated in FIG. 3(a) .
- the standard rod 2 is produced by performing selection and blending of an alloy in consideration of mechanical physical properties.
- a Pd-based alloy excellent in castability, a low-cost Ni-based alloy excellent in mass productivity, and the like are considered as candidate materials for the rotor 1.
- the standard rod 2 is split in an axial direction as illustrated in FIG.
- the step is herein referred to as a differential-pressure casting step, in which the melt 7 pressurized with gas is injected into the casting mold 4 through an inlet on a left end of the drawing sheet of FIG. 3(c) (STEP 3), and the casting mold 4 is evacuated with a vacuum pump (described later) through an outlet on a right end of the drawing sheet of FIG. 3(c) (STEP 4).
- a vacuum pump described later
- the melt 7 is injected into the casting mold 4 through the inlet on the left end in a gap between an upper die 4-1 and a lower die 4-2 in FIG.
- the molding method of the present invention additionally includes a viscous flow processing step illustrated in FIG. 3(d) (STEP 5).
- the melt 7 in the casting mold 4 is heated and pressurized. That is, in the viscous flow processing step, high-temperature control (STEP 6) and pressurizing treatment (STEP 7) are performed simultaneously in the casting mold 4.
- high-temperature control (STEP 6) and pressurizing treatment (STEP 7) are performed simultaneously in the casting mold 4.
- the pressurizing treatment the inlet port and the outlet port of the casting mold 4 are pressurized from both sides as indicated by the arrows F, and in the high-temperature control, the casting mold 4 is heated by supplying a high-frequency coil current from an AC power source to a coil 5 wound around the periphery of the casting mold 4.
- the melt 7 in the casting mold 4 is heated from an outer surface of the casting mold 4 by heat conduction, and for example, PID control is adopted as the temperature control.
- the high-frequency heating is preferred as the high-temperature control (STEP 6) because deviation between the coil current and the increase/decrease in temperature is small, it is also considered to use infrared light or radiation heat.
- the pressurizing treatment (STEP 7) is advantageous in that a method of applying a pressure with inert gas can be provided with a simple configuration. Alternatively, a method of directly pressurizing the inlet port and the outlet port of the casting mold 4 through use of an actuator is also considered as the pressurizing treatment.
- the processing process of the melt 7 in the casting mold 4 in the viscous flow processing is described with reference to a specific heat curve of FIG. 5 .
- a metallic glass Pd alloy as a material for the molded article (rotor 1) is described.
- the viscous flow processing encompasses processing in a state of a supercooled fluid and refers to processing at a temperature of from the melting point T m to the glass transition point Tg.
- the metallic glass Pd alloy is processed in a time region in which the formation of a crystal phase does not occur even when the metal temperature of the Pd alloy decreases.
- the metallic glass Pd alloy is then strongly pressurized with the temperature in the casting mold 4 being kept while the fluidity thereof is monitored, pores are crushed and the number thereof is reduced significantly, with the result that a shape without defects can be obtained.
- a Pd alloy having a melting point T m of 400°C is used and pressurized while the viscous fluidity is kept so that the cooling rate has a rate gradient of about 1°C/sec or more in a temperature region of from the crystallization temperature T x of 380°C to the glass transition point T g of 350°C after the casting. Accordingly, an amorphous metallic glass is formed.
- the mass productivity effect of a molded article can be expected and cost can be reduced by setting the optimum conditions of the viscous flow processing.
- the supercooled state is finished by cooling the melt 7, and the melt 7 is solidified (STEP 8).
- the cooling treatment is generally performed by cooling the casting mold 4 that contains the melt 7 to the glass transition point Tg or less with water (detailed example is described later).
- the Pd alloy is quenched to 350°C or less.
- the casting mold 4 is separated (split) into the upper die 4-1 and the lower die 4-2, and the solidified metallic glass 7 is ejected from the casting mold 4 (STEP 9).
- the rotor 1 being a molded article has parting lines formed therein. Therefore, rolling finish is performed as illustrated in FIG. 3 (e) (STEP 10).
- the rolling finish is performed with a rolling die 6 so as to enhance the dimensional accuracy, and herein, description is made of an exemplary case where the rotor 1 is held while an upper rolling die 6a and a lower rolling die 6b each having a shape conforming with the shape of the rotor 1 are axially rotated. Further, the rolling die 6 may perform rolling by causing two rotating round dies to hold the rotor 1. Then, the surface of the rotor 1 subjected to rolling finish as illustrated in FIG. 3(f) is finally polished by electrolytic polishing or the like (STEP 11). In this manner, the rotor 1 is completed.
- FIGS. 6 to 7 illustrate a specific configuration example of a molding device for metallic glass, which actually carries out the molding method of the present invention described above with reference to FIGS. 3 and 4 .
- FIG. 6 is a partial side view schematically illustrating a state of the molding device for carrying out the molding method of the present invention, when viewed from a lateral side.
- FIG. 7 is an enlarged sectional view of the casting mold 4 in the molding device of FIG. 6 , when viewed from a lateral side.
- the configuration of injecting the melt of metallic glass from above is adopted, and the melt is injected into the casting mold 4 through the injection port 5a on the upper surface on the right side of the casting mold 4.
- a lower end of an injection tube 11 for injecting the melt into the casting mold 4 ascends or descends as indicated by the arrow X, and is connected to the injection port 5a during injection and distanced from the injection port 5 a during non-injection.
- the pellet 3 (see FIGS. 3 (a) and 3(b) ), which is obtained by cutting the standard rod 2 into a portion corresponding to one shot for the casting mold 4, is arranged in a pellet storage tube 13, and the pellet 3 is heated with a ceramic heater positioned below the pellet storage tube 13. In this manner, the metallic glass material is melted. Then, the melt of the metallic glass is injected into the casting mold 4 through the melt injection tube 11 while being pressurized with inert gas from the lower end.
- the inert gas to be used for pressurization during the injection of the melt is guided from a gas introduction port 14 formed above the pellet storage tube 13 to the lower end of the injection tube 11.
- the coil 5 is wound around the periphery of the casting tube 4, and the casting mold 4 is subjected to heating treatment when a high-frequency current flows through the coil 5 from the AC power source as described above (see FIG. 3(d) and STEP 6 of FIG. 4 ). Further, the casting mold 4 is supported by a support member 10. The casting mold 4 and the support member 10 are arranged in a vacuum chamber 15 indicated by the dotted line so that the melt (metallic glass) can spread sufficiently inside the mold when the casting mold 4 is evacuated through a gap of the casting mold 4, a left-end opening 4b, and a right-end opening 4c during the injection of the melt into the casting mold 4.
- the melt 7 described above is subjected to the heating treatment and the pressurizing treatment simultaneously in the casting mold 4 (see FIG. 3(d) and STEP 7 of FIG. 4 ), and in the configuration adopted in FIG. 6 , the melt 7 is pressurized by holding the left-end opening 4b and the right-end opening 4c from both sides with pressurizing pistons (arranged in side parts denoted by reference numeral 8).
- pressurizing pistons arranged in side parts denoted by reference numeral 8
- a linear slider 9 that reciprocates in a direction of the arrow Y may be used or a dedicated actuator may be provided instead.
- a method of pressurizing the melt 7 a method of pressurizing the melt 7 with inert gas from the left-end opening 4b and/or the right-end opening 4c may be adopted.
- FIG. 7(a) a detailed example of the casting mold 4 illustrated in FIG. 6 is described with reference to the side sectional view of FIG. 7(a) .
- the coil 5 is omitted.
- a lower end nozzle of the injection tube 11 illustrated only in FIG. 6
- the melt 7 of metallic glass is injected into the casting mold 4.
- the injection port 4a extends from a deepest part of a receiving portion 4d that is an elliptical recessed part to a molding gap 4j in the casting mold 4.
- the receiving portion 4d serves as a guide hole for guiding the lower end nozzle of the injection tube 11 into the injection port 4a. Inordertoinject the melt 7 through the injection port 4a, the melt 7 is pushed into the casting mold 4 while being pressurized with inert gas such as argon gas as described above.
- the molding gap 4j extends in an axial direction in the casting mold 4, and the melt is filled into the casting gap 4j.
- a cooling water path through which cooling water flows in the axial direction is arranged on the periphery of the casting mold 4, and the water having cooled the casting mold 4 is discharged outside through a cooling water pipe on the left end.
- a cooling water path 4g for an upper die which extends in the axial direction, is formed in the upper die 4-1. Then, the cooling water path 4g for an upper die is connected to a cooling water pipe 4e for an upper die on the left end of the casting mold 4, and the cooling water is discharged outside.
- the cooling water path 4g for an upper die extends from a left-end vicinity of the casting mold 4 to the right side in the axial direction and returns to the left side in the axial direction when reaching the right-end vicinity of the casting mold 4 to reach the cooling water pipe 4e for an upper die.
- FIG. 7(c) is a left side view of FIG. 7(a) .
- the cooling water flows into the casting mold 4 through the cooling water pipe 4e for an upper die on the right side of FIG. 7(c) and the cooling water is discharged from the cooling water pipe 4e for an upper die on the left side.
- the same cooling configuration as that of the upper die 4-1 is also arranged in the lower die 4-2.
- the cooling water path 4g for an upper die which extends in the axial direction, is formed in the lower die 4-2.
- the cooling water path 4h for a lower die is connected to a cooling water pipe 4f for an upper die on the left end of the casting mold 4, and the cooling water is discharged outside.
- the cooling water path 4h for a lower die extends from the left-end vicinity of the casting mold 4 to the right side in the axial direction and returns to the left end in the axial direction when reaching the right-end vicinity of the casting mold 4 to reach the cooling water pipe 4f for a lower die in the same way as the above. Note that, both end portions of the casting mold 4 are held by the support member 10 as described with reference to FIG. 6 and the like.
- a molded article molded through use of the method of molding an amorphous alloy such as metallic glass of the present invention is described.
- a rotor of a uniaxial eccentric screw pump is exemplified as a molded article.
- the rotor serving as a metallic glass molded article denoted by reference numeral 130 in FIG. 8
- a uniaxial eccentric screw pump 100 including the rotor as one component are described.
- FIG. 8 illustrates the uniaxial eccentric screw pump 100.
- the uniaxial eccentric screw pump 100 is mounted, for example, at an arm tip end or the like of an industrial robot, and ejects and applies an appropriate amount of liquid or the like to a desired place from a tip end nozzle 112a.
- the uniaxial eccentric screw pump 100 is a so-called rotary displacement pump, and receives a stator 120, the rotor 130, a power transmission mechanism 150, and the like in a casing 112, as illustrated in FIG. 8 .
- the casing 112 is a metallic tubular member, and a needle (first opening) 114a is provided at the nozzle 112a mounted on one end side in a longitudinal direction.
- an outer circumferential portion of the casing 112 has an opening (second opening) 114b.
- the opening 114b communicates to an inner space of the casing 112 in an intermediate portion 112d positioned in an intermediate part in the longitudinal direction of the casing 112.
- the needle 114a and the opening 114b respectively serve as a suction port and an ejection port of the pump 100.
- the uniaxial eccentric screw pump 100 is capable of pumping a fluid so that the needle 114a serves as the ejection port and the opening 114b serves as the suction port when the rotor 130 is rotated in a forward direction.
- the uniaxial eccentric screw pump 100 is capable of pumping a fluid so that the needle 114a serves as the suction port and the opening 114b serves as the ejection port when the rotor 130 is rotated in a backward direction.
- the rotor 130 is operated so that the needle 114a serves as the ejection port and the opening 114b serves as the suction port.
- the stator 120 is a member being formed of an elastic body or a resin typified by a rubber and having a substantially cylindrical external shape.
- the material for the stator 120 is appropriately selected depending on the kind, characteristics, and the like of a fluid to be conveyed through use of the uniaxial eccentric screw pump 100.
- the stator 120 is received in a stator mounting portion 112b positioned adjacent to the needle 114a in the casing 112.
- An outer diameter of the stator 120 is substantially the same as an inner diameter of the stator mounting portion 112b. Therefore, the stator 120 is mounted on the stator mounting portion 112b in a state in which an outer circumferential surface of the stator 120 is substantially held in close contact with an inner circumferential surface of the stator mounting portion 112b. Further, one end side of the stator 120 is held by the nozzle 112a in an end portion of the casing 112.
- an inner circumferential surface 124 of the stator 120 has a double threaded multi-stage female screw shape. More specifically, a through-hole 122 extending in the longitudinal direction of the stator 120 and being twisted at the above-mentioned pitch is formed in the stator 120.
- the through-hole 122 is formed so that a sectional shape thereof (opening shape) has a substantially elliptical shape even in a cross-section at any position in the longitudinal direction of the stator 120.
- An inner diameter D i of the female screw shape portion formed by the inner circumferential surface 124 of the stator 120 is set in a stepwise manner so as to be enlarged at every step proceeding in the longitudinal direction by the length L from the opening 114b side (right side of FIG. 8 ) serving as the suction port to the needle 114a side (left side of FIG. 10) serving as the ejection port.
- An outer diameter of the portion formed into the male screw shape of the rotor 130 is set in a stepwise manner so as to be reduced at every step proceeding in the longitudinal direction by the length L from the suction side (right side of FIG. 8 ) to the ejection port side (needle 114a side (left side of FIG. 8 )).
- an outer circumferential surface 132 of the rotor 130 and the inner circumferential surface 124 of the stator 120 are brought into close contact with each other at the respective tangents, and a fluid conveyance path 140 is formed between the inner circumferential surface 124 of the stator 120 and the outer circumferential surface of the rotor 130.
- the fluid conveyance path 140 serves as a multi-stage (d-stage) flow path with a length that is d times as large as the reference length S of the lead in the axial direction of the stator 120 and the rotor 130, assuming that the reference length S is the length L of the lead of the stator 120 and the rotor 130 described above. Further, the fluid conveyance path 140 extends in a spiral shape in the longitudinal direction of the stator 120 and the rotor 130.
- the fluid conveyance path 140 proceeds in the longitudinal direction of the stator 120 while rotating in the stator 120 when the rotor 130 is rotated in the through-hole 122 of the stator 120. Therefore, when the rotor 130 is rotated, a fluid can be conveyed sucked into the fluid conveyance path 140 from one end side of the stator 120, and the fluid can be conveyed to the other end side of the stator 120 while being confined in the fluid conveyance path 140 to be ejected on the other end side of the stator 120.
- the pump 110 of this embodiment is capable of pumping the fluid sucked through the opening 114b to eject the fluid through the needle 114a, when the rotor 130 is rotated in a forward direction.
- the power transmission mechanism 150 is provided so as to transmit power from a power source (not shown), such as a motor provided outside of the casing 112, to the rotor 130 described above.
- the power transmission mechanism 150 includes a power transmission portion 152 and an eccentric rotation portion 154.
- the power transmission portion 152 is provided on one end side in the longitudinal direction of the casing 112, more specifically, on an opposite side of the nozzle 112a described above (hereinafter also referred to simply as "base end side").
- the power transmission portion 152 includes a drive shaft, and is connected to a driving machine 165 formed of a servo motor and a speed reducer through the drive shaft.
- the drive shaft can be rotated by operating the driving machine 165.
- the eccentric rotation portion 154 is a portion for connecting the drive shaft and the rotor 130 to each other so that power can be transmitted.
- the eccentric rotation portion 154 includes a coupling shaft 162 and two coupling bodies 164, 166.
- the coupling shaft 163 is formed of a coupling rod, a screw rod, or the like, which are publicly known in the related art.
- the coupling body 164 couples the coupling shaft 162 and the rotor 130 to each other, and the coupling body 166 couples the coupling shaft 162 and a drive shaft 156 to each other.
- the coupling bodies 164, 166 are each formed of a universal joint, which is publicly known in the related art and are capable of transmitting a rotation force, which is transmitted through the drive shaft, to the rotor 130 to eccentrically rotate the rotor 130.
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Abstract
Description
- The present invention relates to a method of molding an amorphous alloy that is excellent in quality and has a high degree of shape freedom, and to a molded object produced by the molding method. Specifically, the present invention relates to a molding method capable of processing metallic glass while keeping a supercooled state in a casting mold, and to a molded article, such as a rotor of a uniaxial eccentric screw pump, produced by the molding method.
- In general, metallic glass that is a kind of an amorphous alloy has specific mechanical property that is not inherent in general metals. Specifically, the metallic glass has a low Young' s modulus (flexibility) while keeping the mechanical strength due to its high strength and high hardness. Therefore, the metallic glass has been expected to be utilized for various materials, and the application thereof to a bar-shaped member having a small diameter, such as a rotor of a uniaxial eccentric screw pump described later, has been expected.
- Hitherto, a method of molding an amorphous alloy involves casting a melt into a water-cooled mold. For example, in Patent Literature 1 (
JP 2002-224249 A - However, the casting into the casting mold in
Patent Literature 1 merely involves pouring the melt into the casting mold, thereby causing the following problems. Specifically, surrounding atmospheric gas is liable to be drawn in, the melt is solidified due to quenching before the drawn-in gas and occluded gas that has occluded the surrounding atmospheric gas during melting are released, and those gases are confined in metallic glass to form pores having various sizes. The pores refer to void parts such as micropores present in a material for the metallic glass and cause significant decrease in mechanical strength of the material in a cast molded object. - Further, for example, Patent Literature 2 (
JP 2006-175508 A - However, the method of molding an amorphous alloy of
Patent Literature 2 has the following drawback. Specifically, the method adopts the steps of pouring the melt into the casting mold, pressurizing the melt to eliminate the pores, and quenching the melt. Thus, the melt is annealed and crystallized while being poured into the casting mold when a small molded article is produced, with the result that an amorphous alloy is not formed in some cases. Accordingly, the shape and size of an article to be molded depend on the material for and the amount of the melt, and a molded article has a small degree of work freedom. -
- [PTL 1]
JP 2002-224249 A - [PTL 2]
JP 2006-175508 A - The present invention has been made so as to solve the above-mentioned problems, and it is an obj ect of the present invention to provide a method of molding an amorphous alloy, which has a high degree of work freedom regardless of components of an amorphous alloy, in particular, metallic glass and of the shape of an article to be molded, and is capable of producing a molded article having less pores, and to provide a molded object produced by the molding method.
- According to one embodiment of the present invention, there is provided a method of molding an amorphous alloy, including: a melting step of melting an alloy; a differential-pressure casting step of injecting a melt of the alloy into a casting mold positioned below the melt and evacuating the casting mold; and a processing step of processing the melt by pressurizing a casting metal in the casting mold under a high-temperature state while keeping the melt in a supercooled state.
- According to one embodiment of the present invention, when the amorphous alloy is molded, the melt is filled into a small casting mold rapidly by evacuating the casting mold while the melt is poured into the casting mold, and pores and the like formed in this case are reduced by pressurizing the melt. At this time, the melt can be filled into the casting mold sufficiently in a temperature region falling within a temperature range (supercooling temperature range) that corresponds to an intermediate temperature lower than a crystallization temperature of the metal and higher than a glass transitiontemperatureofthe metal. Thus, a molded article required to have a small shape or a larger longitudinal length ratio, or to have high fluidity in the melt in the casting mold can be provided with less pores.
- In particular, the "amorphous alloy" as used herein is preferably metallic glass.
- The metallic glass is a kind of an amorphous alloy and is a metal in which glass transition can be observed clearly. In the present invention, the metallic glass is processed in a state of a supercooled fluid. That is, the metallic glass is processed in a time region in which the formation of a crystal phase does not occur even when the metal temperature decreases, and thereafter, the metallic glass is strongly pressurized with the temperature being kept in the casting mold while the fluidity of the metallic glass ismonitored. Withthis, a metallic glass molded article having a shape without defects in which pores are crushed can be produced in a bulk shape. Accordingly, the effect of mass productivity of molded articles can be expected by optimizing the conditions of the processing step, and cost can be reduced.
- Further, the casting metal is heated in the processing step by causing a high-frequency current to flow through a coil provided on a periphery of the casting mold.
- The casting metal is heated, for example, by causing the high-frequency current to flow through the coil wound around the periphery of the casting mold to conduct heat from the outside to the inside of the casting mold (high-frequency induction heating) . This method is advantageous in that the temperature of the melt can be controlled by regulating a coil current, and the temperature can be controlled easily in accordance with a change in the melt and the external atmosphere.
- Alternatively, the casting metal may be heated by irradiating the casting mold with infrared light or may be heated through use of radiation heat obtained by irradiating the casting mold with infrared light.
- On the other hand, such a method is conceived that the melt is pressurized in the processing step by pressurizing the melt with gas through a hole formed in the casting mold.
- The melt can be pressurized uniformly without preparing a mechanical pressurizing device separately as long as gas inflow means to an inlet hole and an output hole of the casting mold, for pressurizing the melt with gas, and air tightness are ensured.
- Alternatively, such a method is adopted that the melt is pressurized in the processing step by pressurizing the melt with an actuator through a hole formed in the casting mold.
- It is advantageous to pressurize the melt with the actuator in that there is no response lag caused by the compression and the like of gas as in gas pressurization because the melt is pressurized directly and mechanically.
- A molded article produced by the above-mentioned method of molding an amorphous alloy can be produced in a bulk shape even from the metallic glass with high accuracy. Thus, even a minute rotor of a uniaxial eccentric screw pump having a shape with a larger longitudinal length ratio can be produced with high mechanical strength and repetition fatigue strength simply by optimizing heating and processing conditions.
- According to one embodiment of the present invention, shaping can be performed while the pores and the like are reduced by pressurizing the melt and the supercooled state is kept in the casting mold, and hence a molded article of an amorphous alloy having various shapes, sizes, and components can be provided easily.
-
-
FIG. 1(a) shows a specific heat curve of an amorphous alloy, andFIG. 1(b) shows a specific heat curve of metallic glass. -
FIG. 2 is a transformation diagram of a related-art amorphous alloy and metallic glass. -
FIGS. 3 are schematic views illustrating a molding step for arotor 1 of a uniaxial eccentric screw pump made of metallic glass in time series. -
FIG. 4 is a flowchart of the schematic view ofFIGS. 3 . -
FIG. 5 describes, while referring to, a specific heat curve of a melt of metallic glass in a casting mold in a processing step (viscous flow processing step) in a method of molding an amorphous alloy of the present invention. -
FIG. 6 is a partial side view schematically illustrating a state of a molding device for performing the molding method of the present invention, when viewed from a lateral side. -
FIG. 7 (a) is an enlarged horizontal sectional view of a casting mold in the molding device ofFIG. 6 ,FIG. 7 (b) is an enlarged plan view of an injection port in the vicinity of a right end when viewed from above, andFIG. 7(c) is a side view ofFIG. 7(a) . -
FIG. 8 is a view illustrating a uniaxial eccentric screw pump. - First, an amorphous alloy, in particular, metallic glass to be molded in a method of molding an amorphous alloy of the present invention is described.
- General metals and alloys have a crystal structure in which atoms are arranged periodically. When melted by heating, the metals and alloys become a liquid to have a structure in which the atoms are packed densely at random. The state not having a periodic structure is called an amorphous state. In general, when the liquid is solidified, the liquid changes to a crystal. However, predetermined alloys form a solid while keeping an amorphous structure when quenched. Such an alloy is called an amorphous alloy. Of the amorphous alloys, an alloy exhibiting glass transition that is one of the features of glass is called metallic glass.
-
FIG. 1(a) shows a specific heat curve of an amorphous alloy, andFIG. 1(b) shows a specific heat curve of metallic glass. As seen in the specific heat curve ofFIG. 1(a) , in general, the amorphous alloy reaches a crystallization temperature by heating before reaching a glass transition point Tg and the crystallization thereof proceeds. Thus, no glass transition is observed. On the other hand, as shown inFIG. 1(b) , in the case of an amorphous alloy having a resistance to crystallization, which is stable in a supercooled liquid state, that is, stable in an amorphous structure, the amorphous alloy reaches the glass transition point Tg prior to a crystallization temperature Tx due to an increase in temperature, and the crystallization thereof proceeds when the temperature becomes higher than the glass transition point Tg. The amorphous alloy having the glass transition point Tg lower than the crystallization temperature Tx is called metallic glass, and the general amorphous alloy (Tx<Tg) and the metallic glass (Tx>Tg) are discriminated from each other. - Next, the difference between the amorphous alloy and the metallic glass is described with reference to a transformation diagram therebetween of
FIG. 2 . - The dotted line (a) on a left side represents a general amorphous alloy. The general metal is solidified at a melting point Tm or less, and the crystallization thereof proceeds and the work hardening thereof also increases at the glass transition temperature Tg or less unless the metal is further quenched. On the other hand, the dotted line (b) on a right side represents metallic glass. The supercooled region of the metallic glass is still large even at the melting point Tm or less and can be molded to a bulk product having a thickness to some degree even over a long period of time.
- Next, a basic configuration of the method of molding an amorphous alloy of the present invention is described.
- In the molding method described above, a melt of metallic glass is injected into a casting mold, and the melt is processed by heating and pressurizing the melt in the casting mold while being kept in a supercooled state. Herein, description is made of an exemplary case where a rotor of a uniaxial eccentric screw pump made of metallic glass is an article to be molded by the molding method. Note that, the uniaxial eccentric screw pump and the use example thereof are described later.
-
FIGS. 3 are schematic views illustrating a molding step for arotor 1 of a uniaxial eccentric screw pump made of metallic glass in time series.FIG. 4 is a flowchart thereof (specific device configuration example is described later). As a basic material of a metallic glass material as illustrated inFIG. 3(a) , a columnarstandard rod 2 is used. Thestandard rod 2 is produced by performing selection and blending of an alloy in consideration of mechanical physical properties. Herein, a Pd-based alloy excellent in castability, a low-cost Ni-based alloy excellent in mass productivity, and the like are considered as candidate materials for therotor 1. Thestandard rod 2 is split in an axial direction as illustrated inFIG. 3(b) , andpellets 3 each corresponding to the amount of onerotor 1 are stacked and stored. Then, thepellet 3 is heated to generate a melt of metallic glass (seeSTEP 1 ofFIG. 4 (hereinafter only STEP No. is described)). - Next, the process proceeds to a step of injecting a
melt 7 of metallic glass into a casting mold 4 (STEP 2). The step is herein referred to as a differential-pressure casting step, in which themelt 7 pressurized with gas is injected into the castingmold 4 through an inlet on a left end of the drawing sheet ofFIG. 3(c) (STEP 3), and the castingmold 4 is evacuated with a vacuum pump (described later) through an outlet on a right end of the drawing sheet ofFIG. 3(c) (STEP 4). Although themelt 7 is injected into the castingmold 4 through the inlet on the left end in a gap between an upper die 4-1 and a lower die 4-2 inFIG. 3 (c) , it is also considered to form aninjection port 4a in an upper part of the castingmold 4 as illustrated inFIG. 6 and to inject themelt 7 into the castingmold 4 through theinjection port 4a. There is an advantage in that, when the differential-pressure casting step is performed, themelt 7 is sufficiently filled into the castingmold 4 even in the case where an article to be molded has a thin shape at a larger longitudinal length ratio as in therotor 1. On the other hand, a great number of pores and the like are formed in themelt 7. If themelt 7 is cooled to produce a molded article while a great number of pores are formed, the mechanical strength of the molded article cannot be ensured sufficiently. In order to reduce the pores, the molding method of the present invention additionally includes a viscous flow processing step illustrated inFIG. 3(d) (STEP 5). - As illustrated in
FIG. 3(d) , in the viscous flow processing step (STEP 5), themelt 7 in the castingmold 4 is heated and pressurized. That is, in the viscous flow processing step, high-temperature control (STEP 6) and pressurizing treatment (STEP 7) are performed simultaneously in the castingmold 4. In the pressurizing treatment, the inlet port and the outlet port of the castingmold 4 are pressurized from both sides as indicated by the arrows F, and in the high-temperature control, the castingmold 4 is heated by supplying a high-frequency coil current from an AC power source to acoil 5 wound around the periphery of the castingmold 4. In the case of high-frequency heating, themelt 7 in the castingmold 4 is heated from an outer surface of the castingmold 4 by heat conduction, and for example, PID control is adopted as the temperature control. Although the high-frequency heating is preferred as the high-temperature control (STEP 6) because deviation between the coil current and the increase/decrease in temperature is small, it is also considered to use infrared light or radiation heat. Further, the pressurizing treatment (STEP 7) is advantageous in that a method of applying a pressure with inert gas can be provided with a simple configuration. Alternatively, a method of directly pressurizing the inlet port and the outlet port of the castingmold 4 through use of an actuator is also considered as the pressurizing treatment. - The processing process of the
melt 7 in the castingmold 4 in the viscous flow processing is described with reference to a specific heat curve ofFIG. 5 . Herein, the case of using a metallic glass Pd alloy as a material for the molded article (rotor 1) is described. - The viscous flow processing encompasses processing in a state of a supercooled fluid and refers to processing at a temperature of from the melting point Tm to the glass transition point Tg. The metallic glass Pd alloy is processed in a time region in which the formation of a crystal phase does not occur even when the metal temperature of the Pd alloy decreases. When the metallic glass Pd alloy is then strongly pressurized with the temperature in the casting
mold 4 being kept while the fluidity thereof is monitored, pores are crushed and the number thereof is reduced significantly, with the result that a shape without defects can be obtained. InFIG. 5 , a Pd alloy having a melting point Tm of 400°C is used and pressurized while the viscous fluidity is kept so that the cooling rate has a rate gradient of about 1°C/sec or more in a temperature region of from the crystallization temperature Tx of 380°C to the glass transition point Tg of 350°C after the casting. Accordingly, an amorphous metallic glass is formed. The mass productivity effect of a molded article can be expected and cost can be reduced by setting the optimum conditions of the viscous flow processing. - The description is made with reference to
FIGS. 3 again. After the viscous flow processing is performed inFIG. 3(d) , the supercooled state is finished by cooling themelt 7, and themelt 7 is solidified (STEP 8). Although not shown, the cooling treatment is generally performed by cooling the castingmold 4 that contains themelt 7 to the glass transition point Tg or less with water (detailed example is described later). For example, as described above with reference toFIG. 5 , the Pd alloy is quenched to 350°C or less. After that, the castingmold 4 is separated (split) into the upper die 4-1 and the lower die 4-2, and the solidifiedmetallic glass 7 is ejected from the casting mold 4 (STEP 9). - In the metallic glass ejected from the casting
mold 4, in general, therotor 1 being a molded article has parting lines formed therein. Therefore, rolling finish is performed as illustrated inFIG. 3 (e) (STEP 10). The rolling finish is performed with a rollingdie 6 so as to enhance the dimensional accuracy, and herein, description is made of an exemplary case where therotor 1 is held while an upper rolling die 6a and a lower rolling die 6b each having a shape conforming with the shape of therotor 1 are axially rotated. Further, the rolling die 6 may perform rolling by causing two rotating round dies to hold therotor 1. Then, the surface of therotor 1 subjected to rolling finish as illustrated inFIG. 3(f) is finally polished by electrolytic polishing or the like (STEP 11). In this manner, therotor 1 is completed. - Next,
FIGS. 6 to 7 illustrate a specific configuration example of a molding device for metallic glass, which actually carries out the molding method of the present invention described above with reference toFIGS. 3 and4 .FIG. 6 is a partial side view schematically illustrating a state of the molding device for carrying out the molding method of the present invention, when viewed from a lateral side. Further,FIG. 7 is an enlarged sectional view of the castingmold 4 in the molding device ofFIG. 6 , when viewed from a lateral side. As illustrated inFIG. 6 , the configuration of injecting the melt of metallic glass from above is adopted, and the melt is injected into the castingmold 4 through the injection port 5a on the upper surface on the right side of the castingmold 4. A lower end of an injection tube 11 for injecting the melt into the castingmold 4 ascends or descends as indicated by the arrow X, and is connected to the injection port 5a during injection and distanced from the injection port 5 a during non-injection. Further, the pellet 3 (seeFIGS. 3 (a) and 3(b) ), which is obtained by cutting thestandard rod 2 into a portion corresponding to one shot for the castingmold 4, is arranged in apellet storage tube 13, and thepellet 3 is heated with a ceramic heater positioned below thepellet storage tube 13. In this manner, the metallic glass material is melted. Then, the melt of the metallic glass is injected into the castingmold 4 through the melt injection tube 11 while being pressurized with inert gas from the lower end. Herein, the inert gas to be used for pressurization during the injection of the melt is guided from agas introduction port 14 formed above thepellet storage tube 13 to the lower end of the injection tube 11. - The
coil 5 is wound around the periphery of thecasting tube 4, and the castingmold 4 is subjected to heating treatment when a high-frequency current flows through thecoil 5 from the AC power source as described above (seeFIG. 3(d) andSTEP 6 ofFIG. 4 ). Further, the castingmold 4 is supported by asupport member 10. The castingmold 4 and thesupport member 10 are arranged in avacuum chamber 15 indicated by the dotted line so that the melt (metallic glass) can spread sufficiently inside the mold when the castingmold 4 is evacuated through a gap of the castingmold 4, a left-end opening 4b, and a right-end opening 4c during the injection of the melt into the castingmold 4. Further, themelt 7 described above is subjected to the heating treatment and the pressurizing treatment simultaneously in the casting mold 4 (seeFIG. 3(d) andSTEP 7 ofFIG. 4 ), and in the configuration adopted inFIG. 6 , themelt 7 is pressurized by holding the left-end opening 4b and the right-end opening 4c from both sides with pressurizing pistons (arranged in side parts denoted by reference numeral 8). Although the movement of the pressurizing piston 8 is not shown, alinear slider 9 that reciprocates in a direction of the arrow Y may be used or a dedicated actuator may be provided instead. Further, as the method of pressurizing themelt 7, a method of pressurizing themelt 7 with inert gas from the left-end opening 4b and/or the right-end opening 4c may be adopted. - Next, a detailed example of the casting
mold 4 illustrated inFIG. 6 is described with reference to the side sectional view ofFIG. 7(a) . InFIG. 7(a) , thecoil 5 is omitted. First, when a lower end nozzle of the injection tube 11 (illustrated only inFIG. 6 ) is connected to theinjection port 4a positioned on the right side of the castingmold 4, themelt 7 of metallic glass is injected into the castingmold 4. As illustrated inFIG. 7 (b) , theinjection port 4a extends from a deepest part of a receivingportion 4d that is an elliptical recessed part to amolding gap 4j in the castingmold 4. The receivingportion 4d serves as a guide hole for guiding the lower end nozzle of the injection tube 11 into theinjection port 4a. Inordertoinject themelt 7 through theinjection port 4a, themelt 7 is pushed into the castingmold 4 while being pressurized with inert gas such as argon gas as described above. Themolding gap 4j extends in an axial direction in the castingmold 4, and the melt is filled into thecasting gap 4j. - A cooling water path through which cooling water flows in the axial direction is arranged on the periphery of the casting
mold 4, and the water having cooled the castingmold 4 is discharged outside through a cooling water pipe on the left end. For example, a coolingwater path 4g for an upper die, which extends in the axial direction, is formed in the upper die 4-1. Then, the coolingwater path 4g for an upper die is connected to a cooling water pipe 4e for an upper die on the left end of the castingmold 4, and the cooling water is discharged outside. Herein, the coolingwater path 4g for an upper die extends from a left-end vicinity of the castingmold 4 to the right side in the axial direction and returns to the left side in the axial direction when reaching the right-end vicinity of the castingmold 4 to reach the cooling water pipe 4e for an upper die. This configuration is also apparent fromFIG. 7(c) , which is a left side view ofFIG. 7(a) . For example, the cooling water flows into the castingmold 4 through the cooling water pipe 4e for an upper die on the right side ofFIG. 7(c) and the cooling water is discharged from the cooling water pipe 4e for an upper die on the left side. Note that, in the above-mentioned description, the case where the coolingwater path 4g for an upper die returns once is described, but the case where the coolingwater path 4g for an upper die returns a plurality of times to enhance the cooling performance is also considered. - Further, the same cooling configuration as that of the upper die 4-1 is also arranged in the lower die 4-2. For example, the cooling
water path 4g for an upper die, which extends in the axial direction, is formed in the lower die 4-2. The coolingwater path 4h for a lower die is connected to a coolingwater pipe 4f for an upper die on the left end of the castingmold 4, and the cooling water is discharged outside. The coolingwater path 4h for a lower die extends from the left-end vicinity of the castingmold 4 to the right side in the axial direction and returns to the left end in the axial direction when reaching the right-end vicinity of the castingmold 4 to reach the coolingwater pipe 4f for a lower die in the same way as the above. Note that, both end portions of the castingmold 4 are held by thesupport member 10 as described with reference toFIG. 6 and the like. - Next, a molded article molded through use of the method of molding an amorphous alloy such as metallic glass of the present invention is described. Herein, a rotor of a uniaxial eccentric screw pump is exemplified as a molded article. Now, the rotor serving as a metallic glass molded article (denoted by
reference numeral 130 inFIG. 8 ) and a uniaxialeccentric screw pump 100 including the rotor as one component are described. -
FIG. 8 illustrates the uniaxialeccentric screw pump 100. The uniaxialeccentric screw pump 100 is mounted, for example, at an arm tip end or the like of an industrial robot, and ejects and applies an appropriate amount of liquid or the like to a desired place from atip end nozzle 112a. The uniaxialeccentric screw pump 100 is a so-called rotary displacement pump, and receives astator 120, therotor 130, apower transmission mechanism 150, and the like in acasing 112, as illustrated inFIG. 8 . Thecasing 112 is a metallic tubular member, and a needle (first opening) 114a is provided at thenozzle 112a mounted on one end side in a longitudinal direction. Further, an outer circumferential portion of thecasing 112 has an opening (second opening) 114b. The opening 114b communicates to an inner space of thecasing 112 in anintermediate portion 112d positioned in an intermediate part in the longitudinal direction of thecasing 112. - The
needle 114a and the opening 114b respectively serve as a suction port and an ejection port of thepump 100. More specifically, the uniaxialeccentric screw pump 100 is capable of pumping a fluid so that theneedle 114a serves as the ejection port and the opening 114b serves as the suction port when therotor 130 is rotated in a forward direction. On the contrary, the uniaxialeccentric screw pump 100 is capable of pumping a fluid so that theneedle 114a serves as the suction port and the opening 114b serves as the ejection port when therotor 130 is rotated in a backward direction. In the uniaxialeccentric screw pump 100, therotor 130 is operated so that theneedle 114a serves as the ejection port and the opening 114b serves as the suction port. - The
stator 120 is a member being formed of an elastic body or a resin typified by a rubber and having a substantially cylindrical external shape. The material for thestator 120 is appropriately selected depending on the kind, characteristics, and the like of a fluid to be conveyed through use of the uniaxialeccentric screw pump 100. Thestator 120 is received in astator mounting portion 112b positioned adjacent to theneedle 114a in thecasing 112. An outer diameter of thestator 120 is substantially the same as an inner diameter of thestator mounting portion 112b. Therefore, thestator 120 is mounted on thestator mounting portion 112b in a state in which an outer circumferential surface of thestator 120 is substantially held in close contact with an inner circumferential surface of thestator mounting portion 112b. Further, one end side of thestator 120 is held by thenozzle 112a in an end portion of thecasing 112. - As illustrated in
FIG. 8 , an innercircumferential surface 124 of thestator 120 has a double threaded multi-stage female screw shape. More specifically, a through-hole 122 extending in the longitudinal direction of thestator 120 and being twisted at the above-mentioned pitch is formed in thestator 120. Thestator 120 has a multi-stage (d-stage) female screw shape with a length that is d times (d=natural number) as large as a reference length S, which is a length L (length obtained by multiplying a length of the pitch by the number of threads) of a lead of the female screw shape portion formedinside. Further, the through-hole 122 is formed so that a sectional shape thereof (opening shape) has a substantially elliptical shape even in a cross-section at any position in the longitudinal direction of thestator 120. - An inner diameter Di of the female screw shape portion formed by the inner
circumferential surface 124 of thestator 120 is set in a stepwise manner so as to be enlarged at every step proceeding in the longitudinal direction by the length L from the opening 114b side (right side ofFIG. 8 ) serving as the suction port to theneedle 114a side (left side of FIG. 10) serving as the ejection port. - The
rotor 130 is an axis body made of a metal and had a single-threaded multi-stage eccentric male screw shape. More specifically, the length L of the lead of therotor 130 is the same as that of thestator 120 described above. Further, therotor 130 is formed so as to have a multi-stage (d-stage) male screw shape with a length that is d times (d=natural number) as large as the reference length S corresponding to the length L of the lead. Therotor 130 is formed so that the sectional shape thereof has a substantially true circle shape even in a cross-section at any position in the longitudinal direction. Therotor 130 is inserted into the through-hole 122 formed in thestator 120 described above and eccentrically rotatable freely in the through-hole 122. - An outer diameter of the portion formed into the male screw shape of the
rotor 130 is set in a stepwise manner so as to be reduced at every step proceeding in the longitudinal direction by the length L from the suction side (right side ofFIG. 8 ) to the ejection port side (needle 114a side (left side ofFIG. 8 )). When therotor 130 is inserted into thestator 120, an outercircumferential surface 132 of therotor 130 and the innercircumferential surface 124 of thestator 120 are brought into close contact with each other at the respective tangents, and a fluid conveyance path 140 is formed between the innercircumferential surface 124 of thestator 120 and the outer circumferential surface of therotor 130. The fluid conveyance path 140 serves as a multi-stage (d-stage) flow path with a length that is d times as large as the reference length S of the lead in the axial direction of thestator 120 and therotor 130, assuming that the reference length S is the length L of the lead of thestator 120 and therotor 130 described above. Further, the fluid conveyance path 140 extends in a spiral shape in the longitudinal direction of thestator 120 and therotor 130. - Further, the fluid conveyance path 140 proceeds in the longitudinal direction of the
stator 120 while rotating in thestator 120 when therotor 130 is rotated in the through-hole 122 of thestator 120. Therefore, when therotor 130 is rotated, a fluid can be conveyed sucked into the fluid conveyance path 140 from one end side of thestator 120, and the fluid can be conveyed to the other end side of thestator 120 while being confined in the fluid conveyance path 140 to be ejected on the other end side of thestator 120. The pump 110 of this embodiment is capable of pumping the fluid sucked through the opening 114b to eject the fluid through theneedle 114a, when therotor 130 is rotated in a forward direction. - The
power transmission mechanism 150 is provided so as to transmit power from a power source (not shown), such as a motor provided outside of thecasing 112, to therotor 130 described above. Thepower transmission mechanism 150 includes apower transmission portion 152 and aneccentric rotation portion 154. Thepower transmission portion 152 is provided on one end side in the longitudinal direction of thecasing 112, more specifically, on an opposite side of thenozzle 112a described above (hereinafter also referred to simply as "base end side"). Thepower transmission portion 152 includes a drive shaft, and is connected to a drivingmachine 165 formed of a servo motor and a speed reducer through the drive shaft. The drive shaft can be rotated by operating the drivingmachine 165. Ashaft seal 161 formed of aVariseal 163, another mechanical seal, a ground packing, or the like is provided in the vicinity of thepower transmission portion 152, with the result that the fluid to be conveyed is prevented from leaking to the drivingmachine 165 side. - The
eccentric rotation portion 154 is a portion for connecting the drive shaft and therotor 130 to each other so that power can be transmitted. Theeccentric rotation portion 154 includes acoupling shaft 162 and two couplingbodies coupling shaft 163 is formed of a coupling rod, a screw rod, or the like, which are publicly known in the related art. Thecoupling body 164 couples thecoupling shaft 162 and therotor 130 to each other, and thecoupling body 166 couples thecoupling shaft 162 and a drive shaft 156 to each other. Thecoupling bodies rotor 130 to eccentrically rotate therotor 130. - In the above, the embodiment and concept of the method of molding an amorphous alloy and the molded article produced by the molding method of the present invention are described. However, the present invention is not limited thereto. Those skilled in the art would understand that other alternative examples and modified examples can be obtained without departing from the spirit and teaching described in the claims, the specification, etc.
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- 1
- rotor
- 2
- standard rod
- 3
- pellet
- 4
- casting mold
- 4a
- injection port
- 4b
- left-end opening
- 4c
- right-end opening
- 4d
- receiving portion
- 4e
- cooling water pipe for upper die
- 4f
- cooling water pipe for lower die
- 4g
- cooling water path for upper die
- 4h
- cooling water path for lower die
- 4i
- injection port
- 4j
- molding gap
- 5
- coil
- 6
- rolling die
- 6a
- upper rolling die
- 6b
- lower rolling die
- 7
- melt (metallic glass)
- 8
- pressurizing piston
- 9
- linear slider
- 10
- support member
- 11
- melt injection tube
- 12
- ceramic heater
- 13
- pellet storage tube
- 14
- gas introduction port
- 15
- vacuum chamber
- 16
- actuator
Claims (8)
- A method of molding an amorphous alloy, comprising:a melting step of melting an alloy;a differential-pressure casting step of injecting a melt of the alloy into a casting mold positioned below the melt and evacuating the casting mold; anda processing step of processing the melt by pressurizing a casting metal in the casting mold under a high-temperature state while keeping the melt in a supercooled state.
- A method of molding an amorphous alloy according to claim 1, wherein the alloy comprises metallic glass.
- A method of molding an amorphous alloy according to claim 1 or 2, wherein the casting metal is processed and pressurized in the processing step in a supercooling temperature range corresponding to an intermediate temperature lower than a crystallization temperature of the casting metal and higher than a glass transition temperature of the casting metal.
- A method of molding an amorphous alloy according to claim 1, wherein a temperature in the high-temperature state in the casting mold is controlled by causing a high-frequency current to flow through a coil provided on a periphery of the casting mold.
- A method of molding an amorphous alloy according to claim 1, wherein a temperature in the high-temperature state in the casting mold is controlled by irradiating the casting mold with infrared light.
- A method of molding an amorphous alloy according to any one of claims 1 to 5, wherein the melt is pressurized in the processing step by pressurizing the melt with gas through a hole formed in the casting mold.
- A method of molding an amorphous alloy according to any one of claims 1 to 5, wherein the melt is pressurized in the processing step by pressurizing the melt with an actuator through a hole formed in the casting mold.
- A molded object produced from an amorphous alloy by the method of molding an amorphous alloy according to claims 1 to 7,
the molded article comprising a rotor of a uniaxial eccentric screw pump.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP2012042613A JP6417079B2 (en) | 2012-02-29 | 2012-02-29 | Metal glass forming apparatus and metal glass rod-shaped member forming apparatus |
PCT/JP2013/051998 WO2013129012A1 (en) | 2012-02-29 | 2013-01-30 | Method for molding amorphous alloy, and molded object produced by said molding method |
Publications (2)
Publication Number | Publication Date |
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EP2821163A1 true EP2821163A1 (en) | 2015-01-07 |
EP2821163A4 EP2821163A4 (en) | 2015-12-30 |
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EP13755554.6A Withdrawn EP2821163A4 (en) | 2012-02-29 | 2013-01-30 | Method for molding amorphous alloy, and molded object produced by said molding method |
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US (1) | US20150202684A1 (en) |
EP (1) | EP2821163A4 (en) |
JP (1) | JP6417079B2 (en) |
KR (1) | KR20140131366A (en) |
CN (1) | CN104302424B (en) |
WO (1) | WO2013129012A1 (en) |
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CN105710334B (en) * | 2014-11-30 | 2017-11-21 | 中国科学院金属研究所 | A kind of amorphous alloy component forming method |
CN108339853B (en) * | 2018-01-10 | 2019-12-03 | 上海交通大学 | A kind of glassy metal micron foil and preparation method thereof |
Family Cites Families (17)
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US4601321A (en) * | 1984-05-10 | 1986-07-22 | Toyota Kidosha Kogyo Kabushiki Kaisha | Vertical die casting device |
DE3640370A1 (en) * | 1985-11-26 | 1987-05-27 | Ube Industries | INJECTION METHOD OF AN INJECTION MOLDING MACHINE |
JPH0722813B2 (en) * | 1989-01-30 | 1995-03-15 | 宇部興産株式会社 | Injection device |
JP2930880B2 (en) * | 1994-10-14 | 1999-08-09 | 井上 明久 | Method and apparatus for producing differential pressure cast metallic glass |
US5711363A (en) * | 1996-02-16 | 1998-01-27 | Amorphous Technologies International | Die casting of bulk-solidifying amorphous alloys |
JP3484360B2 (en) * | 1998-03-10 | 2004-01-06 | 明久 井上 | Manufacturing method of amorphous alloy hollow molded article |
JP3852810B2 (en) * | 1998-12-03 | 2006-12-06 | 独立行政法人科学技術振興機構 | Highly ductile nanoparticle-dispersed metallic glass and method for producing the same |
JP4343313B2 (en) * | 1999-03-23 | 2009-10-14 | 明久 井上 | Metal glass manufacturing method and apparatus |
JP2002224249A (en) | 2001-02-07 | 2002-08-13 | Sumitomo Rubber Ind Ltd | Method of manufacturing golf club head |
EP1499461B1 (en) * | 2002-02-01 | 2009-09-02 | Liquidmetal Technologies | Thermoplastic casting of amorphous alloys |
JP4339135B2 (en) * | 2004-01-15 | 2009-10-07 | Ykk株式会社 | Injection casting equipment for forming amorphous alloys |
JP2006175508A (en) | 2004-12-24 | 2006-07-06 | Tohoku Univ | Method for molding amorphous alloy and device therefor |
CN100352581C (en) * | 2005-12-16 | 2007-12-05 | 华中科技大学 | Metal glass melt cast moulding method and its device |
JP2008238214A (en) * | 2007-03-27 | 2008-10-09 | Bmg:Kk | Method and apparatus for forming metallic glass |
CN101829772B (en) * | 2010-05-26 | 2011-11-02 | 浙江大学 | Thermoplasticity shaping and processing method of metal glass micro construction member |
CN102029381A (en) * | 2010-11-10 | 2011-04-27 | 华中科技大学 | Processing and forming method for workpieces made of blocky metal glass or composite material of blocky metal glass |
WO2013070240A1 (en) * | 2011-11-11 | 2013-05-16 | Crucible Intellectual Property, Llc | Dual plunger rod for controlled transport in an injection molding system |
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2012
- 2012-02-29 JP JP2012042613A patent/JP6417079B2/en not_active Expired - Fee Related
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2013
- 2013-01-30 CN CN201380022498.5A patent/CN104302424B/en not_active Expired - Fee Related
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- 2013-01-30 KR KR1020147026751A patent/KR20140131366A/en active Search and Examination
- 2013-01-30 WO PCT/JP2013/051998 patent/WO2013129012A1/en active Application Filing
- 2013-01-30 EP EP13755554.6A patent/EP2821163A4/en not_active Withdrawn
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KR20140131366A (en) | 2014-11-12 |
CN104302424B (en) | 2017-03-08 |
JP6417079B2 (en) | 2018-10-31 |
CN104302424A (en) | 2015-01-21 |
JP2013176791A (en) | 2013-09-09 |
US20150202684A1 (en) | 2015-07-23 |
WO2013129012A1 (en) | 2013-09-06 |
EP2821163A4 (en) | 2015-12-30 |
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