EP3586568B1 - Fusion en lévitation - Google Patents

Fusion en lévitation Download PDF

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Publication number
EP3586568B1
EP3586568B1 EP19721225.1A EP19721225A EP3586568B1 EP 3586568 B1 EP3586568 B1 EP 3586568B1 EP 19721225 A EP19721225 A EP 19721225A EP 3586568 B1 EP3586568 B1 EP 3586568B1
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EP
European Patent Office
Prior art keywords
batch
starting material
batches
section
conductive material
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.)
Active
Application number
EP19721225.1A
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German (de)
English (en)
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EP3586568A1 (fr
Inventor
Sergejs SPITANS
Henrik Franz
Björn SEHRING
Markus Holz
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.)
ALD Vacuum Technologies GmbH
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ALD Vacuum Technologies GmbH
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Publication date
Application filed by ALD Vacuum Technologies GmbH filed Critical ALD Vacuum Technologies GmbH
Priority to PL19721225T priority Critical patent/PL3586568T3/pl
Priority to SI201930022T priority patent/SI3586568T1/sl
Publication of EP3586568A1 publication Critical patent/EP3586568A1/fr
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Publication of EP3586568B1 publication Critical patent/EP3586568B1/fr
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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
    • B22D27/02—Use of electric or magnetic effects
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D39/00—Equipment for supplying molten metal in rations
    • B22D39/003—Equipment for supplying molten metal in rations using electromagnetic field
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F27—FURNACES; KILNS; OVENS; RETORTS
    • F27B—FURNACES, KILNS, OVENS, OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
    • F27B14/00—Crucible or pot furnaces
    • F27B14/06—Crucible or pot furnaces heated electrically, e.g. induction crucible furnaces with or without any other source of heat
    • F27B14/061—Induction furnaces
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F27—FURNACES; KILNS; OVENS; RETORTS
    • F27B—FURNACES, KILNS, OVENS, OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
    • F27B14/00—Crucible or pot furnaces
    • F27B14/08—Details peculiar to crucible or pot furnaces
    • F27B14/0806—Charging or discharging devices
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B6/00—Heating by electric, magnetic or electromagnetic fields
    • H05B6/02—Induction heating
    • H05B6/10—Induction heating apparatus, other than furnaces, for specific applications
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B6/00—Heating by electric, magnetic or electromagnetic fields
    • H05B6/02—Induction heating
    • H05B6/22—Furnaces without an endless core
    • H05B6/32—Arrangements for simultaneous levitation and heating

Definitions

  • This invention relates to a levitation melting process for making castings from a single batch material.
  • a starting material is used which has a plurality of individual batches divided by regions with a reduced cross section.
  • more efficient melting of the batches can also be achieved.
  • the melt does not come into contact with the material of a crucible, so that contamination from the crucible material or from reaction of the melt with the crucible material is avoided.
  • metals and alloys with high melting points are, for example, titanium, zirconium, vanadium, tantalum, tungsten, hafnium, niobium, rhenium and molybdenum. But this is also important for other metals and alloys such as nickel, iron and aluminum.
  • U.S. 2,686,864 A also describes a method in which a conductive melt z. B. is suspended in a vacuum under the influence of one or more coils without the use of a crucible.
  • two coaxial coils are used to stabilize the suspended material. After it has melted, the material is dropped or poured into a mold. With the method described there, a 60 g portion of aluminum could be kept in suspension. The molten metal is removed by reducing the field strength, so that the melt escapes downwards through the conical coil. If the field strength is reduced very quickly, the metal falls out of the device in a molten state. It has already been recognized that the "weak spot" of such coil arrangements lies in the center of the coils, so that the amount of material that can be melted in this way is limited.
  • U.S. 4,578,552 A discloses an apparatus and method for levitation melting.
  • the same coil is used both for heating and for holding the melt; the frequency of the alternating current applied is varied to regulate the heating power, while the current strength is kept constant.
  • the particular advantages of levitation melting are that contamination of the melt by a crucible material or other materials that are in contact with the melt in other processes is avoided.
  • the floating melt is only in contact with the surrounding atmosphere, which is z. B. can be a vacuum or inert gas. Since a chemical reaction with a crucible material is not to be feared, the melt can be heated to very high temperatures. In addition, the waste of contaminated material is reduced, especially in comparison to the melt in the cold crucible.
  • levitation melting has not caught on in practice. The reason for this is that with the levitation melting process only a relatively small amount of molten material can be kept in suspension (cf. DE 696 17 103 T2 , Page 2, paragraph 1).
  • the batches of raw material are introduced into the induction coil area in the form of individual ingots. This is usually done by means of a gripper that picks up the ingots at a feed position, moves them into the induction coil area and then releases them after the magnetic field has been switched on. Problems often arise here with the stability of the ingots in the magnetic field and splashing during melting. The production of these relatively small ingots is comparatively complex and expensive.
  • the method should enable a high throughput through an improved effectiveness of the melting process and allow the use of inexpensive ingots for the batches.
  • the volume of the molten charge is preferably sufficient to fill the casting mold to an extent sufficient for the production of a cast body (“filling volume”).
  • filling volume After the casting mold has been filled, it is allowed to cool down or cooled with coolant so that the material solidifies in the mold.
  • the cast body can then be removed from the mold.
  • the casting can consist of dropping the charge, in particular by switching off the electromagnetic alternating field; or the casting can be slowed down by an alternating electromagnetic field, e.g. B. by using a coil.
  • a “conductive material” is understood to mean a material which has a suitable conductivity in order to inductively heat the material and to keep it in suspension.
  • a “state of suspension” is understood to mean a state of complete suspension, so that the batch being treated has no contact whatsoever with a crucible or a platform or the like.
  • a "cylindrical" ingot is to be understood as an ingot in the form of the mathematical definition of a general cylinder, in particular a general straight cylinder, the definition explicitly including the special shapes of the prism, in particular the straight prism, and the cuboid. It is preferably a straight circular cylinder or a straight prism with six- to twenty-four-cornered bases.
  • the “lowest” charge is to be understood as meaning the charge of a starting material according to the invention which is arranged at the end of the starting material which is distal to the end with which the starting material is held and moved.
  • the charge is introduced so far into the electromagnetic alternating field that the induced eddy current is maximal. In this way, the batch can be optimally heated, which speeds up the entire casting process.
  • the starting material for several batches consists of a cylindrical rod which has areas along its longitudinal axis that have a reduced cross-section, the individual areas with the non-reduced cross-section each corresponding to the amount of material of a batch.
  • the inventive effect of stabilization and improved utilization of the generated magnetic field is achieved with any arbitrary shape of the batches.
  • Rods in the form of a circular cylinder or a prism with an approximately circular base area can, however, be manufactured particularly easily and inexpensively, for example by continuous casting. The areas that separate the batches then only have to be introduced into the raw bar by turning, sawing or abrasive cutting.
  • the areas with a reduced cross-section, which divide the individual batches, ensure, on the one hand, lower heat conduction and, on the other hand, a restriction of the induced eddy currents to the batch to be melted in the magnetic field.
  • the cross-section between the batches is therefore preferably so reduced and / or the areas with the reduced cross-section are so long that the eddy current induced in an electromagnetic alternating field in a batch is so largely limited that the adjacent batch is not melted with.
  • this must be taken into account accordingly in order to achieve an optimal ratio of space-saving arrangement and the risk of the adjacent batch melting off.
  • the heat conduction of the areas with the reduced cross section is preferably so low that when one batch is melted, the adjacent batch is not melted at the same time.
  • the areas with the reduced cross-section are at least dimensioned so that they have a mechanical load-bearing force that is sufficient for the weight of the starting material to be carried. Since the starting materials are used in a hanging arrangement, it is advantageous if the areas connecting the batches, which because of the reduced cross-section have the lowest mechanical strength, are each able to support the entire area below them. In this way, it can be avoided that a feed mechanism has to be used that ensures stabilization of the starting material. If the minimum possible cross-sections are used, they decrease from top to bottom. It is not necessary to design all cross-sections in the same way, i.e. to be based on the connection of the top batch.
  • the electrically conductive material used according to the invention has at least one high-melting metal from the following group: titanium, zirconium, vanadium, tantalum, tungsten, hafnium, niobium, rhenium, molybdenum.
  • a metal with a lower melting point such as nickel, iron or aluminum can be used.
  • a mixture or alloy with one or more of the aforementioned metals can also be used as the conductive material.
  • the metal preferably has a proportion of at least 50% by weight, in particular at least 60% by weight or at least 70% by weight, of the conductive material. It has been shown that these metals particularly benefit from the advantages of the present invention.
  • the conductive material is titanium or a titanium alloy, in particular TiAl or TiAlV.
  • These metals or alloys can be processed particularly advantageously, since they have a pronounced dependence of the viscosity on the temperature and, moreover, are particularly reactive, in particular with regard to the materials of the casting mold. Since the method according to the invention combines contactless melting in suspension with extremely fast filling of the casting mold, a particular advantage can be realized for such metals in particular. With the method according to the invention, cast bodies can be produced which have a particularly thin or even no oxide layer from the reaction of the melt with the material of the casting mold. And with refractory metals in particular, the improved utilization of the induced eddy current and the associated faster heating in the cycle times are clearly noticeable.
  • An advantageous embodiment of the method uses the electrically conductive material in powder form. If the batches are to be designed in a spherical shape, for example, a lot of material would have to be removed from a solid metal rod when turning. A structure from individual balls that are screwed to rods would cause considerable extra work in manufacture and assembly. However, if you switch to powder, the shape can be produced more easily. This is most preferably done by pressing with a binder and / or sintering. Conceivable binders are, for example, paraffins, waxes or polymers, each of which allows a low working temperature.
  • the conductive material is superheated during melting to a temperature which is at least 10 ° C., at least 20 ° C. or at least 30 ° C. above the melting point of the material. Overheating prevents the material from solidifying instantly when it comes into contact with the casting mold, the temperature of which is below the melting temperature. The result is that the charge can be distributed in the mold before the viscosity of the material becomes too high. It is an advantage of levitation melting that there is no need to use a crucible that is in contact with the melt. This avoids the high loss of material in the cold crucible process as well as contamination of the melt with crucible components.
  • melt can be heated to a relatively high level, since operation in a vacuum or under protective gas is possible and there is no contact with reactive materials. However, most materials cannot be overheated at will, since otherwise a violent reaction with the mold is to be feared.
  • the overheating is therefore preferably limited to at most 300 ° C., in particular at most 200 ° C. and particularly preferably at most 100 ° C. above the melting point of the conductive material.
  • At least one ferromagnetic element is arranged horizontally around the area in which the charge is melted.
  • the ferromagnetic element can be arranged in a ring around the melting area, with "ring-shaped” not only being understood to mean circular elements, but also angular, in particular square or polygonal ring elements.
  • the element can have several rod sections, which in particular protrude horizontally in the direction of the melting area.
  • the ferromagnetic element consists of a ferromagnetic material, preferably with an amplitude permeability ⁇ a > 10, more preferably ⁇ a > 50 and particularly preferably ⁇ a > 100.
  • the amplitude permeability relates in particular to the permeability in a temperature range between 25 ° C and 100 ° C and at a magnetic flux density between 0 and 400 mT.
  • the amplitude permeability is in particular at least one hundredth, in particular at least 10 hundredth or 25 hundredths of the amplitude permeability of soft magnetic ferrite (e.g. 3C92). Suitable materials are known to those skilled in the art.
  • an electrically conductive material as a starting material for a levitation melting process, in which the starting material has several pre-separated batches separated by areas of reduced cross-section, the pre-separated batches not being separated until they are melted in an alternating electromagnetic field.
  • Figure 1 shows a side view of three embodiments of a starting material according to the invention made of electrically conductive material. All three are vertical circular cylindrical shapes. At the upper end there is an area which is suitable for fastening in a feed device. Depending on the type of fastening, this area can be designed to be smooth, as shown in the figure, or it can be provided with holes or a three-dimensional surface structure, in particular a terminal peripheral widening which enables it to be grasped with a hook or gripper.
  • the starting material on the left has six, the middle five and the right eight batches (1).
  • the individual batches (1) are separated by notches in a triangular shape. These notches can be produced using a punch, for example, without any loss of material.
  • the middle starting material the individual batches (1) are separated by wider areas with a reduced cross-section.
  • Such an embodiment can be produced in a simple and inexpensive way by turning from a cylindrical rod.
  • the starting material on the right has narrow circumferential incisions towards the division of the individual batches (1).
  • the structure is the same as for the middle starting material, the distances are only reduced and the cross-section of the areas with reduced cross-section is reduced even further. Due to the further reduced Cross-section, a better restriction of the induced eddy currents and lower heat conduction can be achieved in order to compensate for the shorter distance.
  • FIG 2 shows the section of the lowest three batches (1) of the middle starting material Figure 1 .
  • the lowest charge (1) is in the area of influence of electromagnetic alternating fields (melting range), which are generated with the help of the coils (2).
  • Below the batch (1) there is an empty casting mold which is held in the filling area by a holder (not shown).
  • a ferromagnetic element (3) is arranged around the area of influence of the coils (2).
  • the charge (1) is melted and suspended in the process according to the invention. After batch (1) has melted, the remaining starting material is pulled upwards and the melt is overheated. The melt is then poured into the casting mold and the solidified casting is finally removed from the casting mold.

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Continuous Casting (AREA)
  • Crucibles And Fluidized-Bed Furnaces (AREA)
  • Manufacture And Refinement Of Metals (AREA)
  • General Induction Heating (AREA)

Claims (13)

  1. Procédé de fabrication de corps moulés à partir d'un matériau électriquement conducteur dans le procédé de fusion en lévitation, comprenant les étapes consistant à :
    - introduire la charge la plus inférieure (1) d'un matériau de base pour plusieurs charges (1) dans la zone d'influence d'au moins un champ alternatif électromagnétique, dans lequel le matériau de base, en un matériau électriquement conducteur, présente plusieurs charges (1) pré-séparées, distinguées via des zones à section transversale réduite, et les zones sont conçues de sorte qu'une séparation des charges pré-séparées (1) ne survient que par fusion dans un champ alternatif électromagnétique,
    - faire fondre la charge (1),
    - soulever le matériau de base non fondu restant à partir de la charge fondue (1) se trouvant dans un état en suspension,
    - surchauffer la charge en suspension (1),
    - positionner un moule dans une zone de remplissage en dessous de la charge en suspension (1),
    - couler l'ensemble de la charge (1) dans le moule,
    - retirer le corps coulé solidifié à partir du moule.
  2. Procédé selon la revendication 1, caractérisé en ce que la charge (1) est introduite tellement loin dans le champ alternatif électromagnétique que le courant de Foucault induit est au maximum.
  3. Procédé selon la revendication 1 ou 2, caractérisé en ce que le matériau de base pour plusieurs charges (1) est constitué d'une tige cylindrique, qui comporte le long de son axe longitudinal des zones qui présentent une section transversale réduite, dans lequel les zones individuelles à section transversale non réduite correspondent chacune à la quantité de matériau d'une charge (1).
  4. Procédé selon l'une quelconque des revendications précédentes, caractérisé en ce que concernant le matériau de base pour plusieurs charges (1), la section transversale entre les charges (1) est réduite à un tel point et/ou les zones à section transversale réduite sont si longues qu'un courant de Foucault induit dans un champ alternatif électromagnétique dans une charge (1) est limité, de sorte que la charge voisine (1) ne soit pas fondue en même temps.
  5. Procédé selon l'une quelconque des revendications précédentes, caractérisé en ce que concernant le matériau de base pour plusieurs charges (1), les zones à section transversale réduite sont au moins dimensionnées pour qu'elles présentent une capacité de charge mécanique suffisante pour le poids du matériau de base respectif à transporter.
  6. Procédé selon l'une quelconque des revendications précédentes, caractérisé en ce que concernant le matériau de base pour plusieurs charges (1), la conduction thermique des zones à section transversale réduite est si faible que lorsqu'une charge (1) est fondue, la charge adjacente (1) n'est pas fondue avec celle-ci.
  7. Procédé selon l'une quelconque des revendications précédentes, caractérisé en ce que le matériau électriquement conducteur contient au moins un métal du groupe suivant : titane, zirconium, vanadium, tantale, tungstène, hafnium, niobium, rhénium, molybdène, nickel, fer, aluminium.
  8. Procédé selon la revendication 7, caractérisé en ce que la proportion du métal est d'au moins 50 % en poids, en particulier d'au moins 60 % en poids ou d'au moins 70 % en poids, du matériau conducteur.
  9. Procédé selon l'une quelconque des revendications précédentes, caractérisé en ce que le matériau électriquement conducteur est du titane ou un alliage de titane, en particulier TiAI ou TiAIV.
  10. Procédé selon l'une quelconque des revendications précédentes, caractérisé en ce que le matériau électriquement conducteur est utilisé sous forme de poudre.
  11. Procédé selon la revendication 10, caractérisé en ce que le matériau de base pour plusieurs charges (1) est réalisé à partir du matériau électriquement conducteur par pressage avec un liant et/ou frittage.
  12. Procédé selon l'une quelconque des revendications précédentes, caractérisé en ce que le matériau conducteur est surchauffé lors de la fusion à une température qui est au moins 10°C, au moins 20°C ou au moins 30°C au-dessus du point de fusion du matériau.
  13. Utilisation d'un matériau électriquement conducteur comme matériau de base pour un procédé de fusion en lévitation, caractérisée en ce que le matériau de base comporte plusieurs charges pré-séparées (1), distinguées par des zones à section réduite, dans laquelle séparation des charges pré-séparées (1) ne survient que par fusion dans un champ alternatif électromagnétique.
EP19721225.1A 2018-04-20 2019-04-18 Fusion en lévitation Active EP3586568B1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
PL19721225T PL3586568T3 (pl) 2018-04-20 2019-04-18 Sposób topienia lewitacyjnego
SI201930022T SI3586568T1 (sl) 2018-04-20 2019-04-18 Postopek lebdilnega taljenja

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102018109592.9A DE102018109592A1 (de) 2018-04-20 2018-04-20 Schwebeschmelzverfahren
PCT/EP2019/060168 WO2019202111A1 (fr) 2018-04-20 2019-04-18 Procédé de fusion en lévitation

Publications (2)

Publication Number Publication Date
EP3586568A1 EP3586568A1 (fr) 2020-01-01
EP3586568B1 true EP3586568B1 (fr) 2020-12-16

Family

ID=66379883

Family Applications (1)

Application Number Title Priority Date Filing Date
EP19721225.1A Active EP3586568B1 (fr) 2018-04-20 2019-04-18 Fusion en lévitation

Country Status (13)

Country Link
US (1) US11370020B2 (fr)
EP (1) EP3586568B1 (fr)
JP (1) JP6883152B1 (fr)
KR (1) KR102226483B1 (fr)
CN (1) CN111742615B (fr)
DE (1) DE102018109592A1 (fr)
ES (1) ES2845253T3 (fr)
PL (1) PL3586568T3 (fr)
PT (1) PT3586568T (fr)
RU (1) RU2736273C1 (fr)
SI (1) SI3586568T1 (fr)
TW (1) TWI727304B (fr)
WO (1) WO2019202111A1 (fr)

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102021125159A1 (de) 2021-09-28 2023-03-30 Ald Vacuum Technologies Gmbh Vorrichtung und ein Verfahren zum Herstellen eines Feingussbauteils

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GB1013851A (en) * 1963-01-31 1965-12-22 Ass Elect Ind Improvements in and relating to the production of metal castings
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US8532158B2 (en) * 2007-11-17 2013-09-10 Inductotherm Corp. Melting and mixing of materials in a crucible by electric induction heel process
DE102010024883A1 (de) * 2010-06-24 2011-12-29 Zenergy Power Gmbh Vorrichtung zum Einschmelzen von Metallstücken
DE102013114811B3 (de) * 2013-12-23 2014-12-31 Ald Vacuum Technologies Gmbh Vorrichtung und Verfahren zum Behandeln von metallischem Material
CN103862046B (zh) * 2014-03-14 2016-01-20 曹炜喜 一种电磁调制熔融发射装置
DE102015107258B3 (de) * 2015-05-08 2016-08-04 Ald Vacuum Technologies Gmbh Vorrichtung und Verfahren zur Herstellung von Ingots
DE102017100836B4 (de) 2017-01-17 2020-06-18 Ald Vacuum Technologies Gmbh Gießverfahren
CN107012290B (zh) * 2017-03-09 2019-02-19 昆明理工大学 一种高氮奥氏体不锈钢的制备方法

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Also Published As

Publication number Publication date
ES2845253T3 (es) 2021-07-26
JP6883152B1 (ja) 2021-06-09
JP2021515374A (ja) 2021-06-17
PT3586568T (pt) 2021-01-21
EP3586568A1 (fr) 2020-01-01
US20210146431A1 (en) 2021-05-20
CN111742615B (zh) 2021-06-29
KR102226483B1 (ko) 2021-03-11
RU2736273C1 (ru) 2020-11-13
TWI727304B (zh) 2021-05-11
TW201944434A (zh) 2019-11-16
DE102018109592A1 (de) 2019-10-24
PL3586568T3 (pl) 2021-06-28
KR20200116154A (ko) 2020-10-08
US11370020B2 (en) 2022-06-28
WO2019202111A1 (fr) 2019-10-24
CN111742615A (zh) 2020-10-02
SI3586568T1 (sl) 2021-07-30

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