US20080060779A1 - Sod, slurry-on-demand, casting method and charge - Google Patents

Sod, slurry-on-demand, casting method and charge Download PDF

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Publication number
US20080060779A1
US20080060779A1 US11/520,829 US52082906A US2008060779A1 US 20080060779 A1 US20080060779 A1 US 20080060779A1 US 52082906 A US52082906 A US 52082906A US 2008060779 A1 US2008060779 A1 US 2008060779A1
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US
United States
Prior art keywords
alloy
solid
fraction
constituent
sod
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.)
Abandoned
Application number
US11/520,829
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English (en)
Inventor
Adam E. Kopper
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.)
Brunswick Corp
Original Assignee
Brunswick Corp
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Brunswick Corp filed Critical Brunswick Corp
Priority to US11/520,829 priority Critical patent/US20080060779A1/en
Assigned to BRUNSWICK CORPORATION reassignment BRUNSWICK CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: KOPPER, ADAM E.
Priority to CA002587816A priority patent/CA2587816A1/en
Priority to EP07013338A priority patent/EP1900455A1/en
Priority to JP2007211485A priority patent/JP2008068321A/ja
Priority to AU2007216614A priority patent/AU2007216614A1/en
Publication of US20080060779A1 publication Critical patent/US20080060779A1/en
Abandoned legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/007—Semi-solid pressure die casting
    • 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
    • B22D21/002—Castings of light metals
    • B22D21/007—Castings of light metals with low melting point, e.g. Al 659 degrees C, Mg 650 degrees C
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/12—Making non-ferrous alloys by processing in a semi-solid state, e.g. holding the alloy in the solid-liquid phase

Definitions

  • the invention relates to SOD (slurry-on-demand) casting systems.
  • the present invention enables application of the above noted SOD technology to a wide array of die cast alloys and die casting applications.
  • FIG. 1 is a schematic sectional view illustrating slurry apparatus for implementing the SOD casting method in accordance with the invention.
  • FIG. 2 shows the vessel of FIG. 1 .
  • FIG. 3 is a top view of the vessel of FIG. 2 .
  • vessel 10 contains a semi-solid casting alloy 12 and is carried on a fixture 14 on a transfer device such as robotic arm 16 .
  • the alloy is heated, e.g. in a furnace as in the above incorporated SOD patents, to a molten liquid state, and then poured or discharged into vessel 10 , which is surrounded by an optional cooling sleeve or jacket 18 , and may be separated therefrom by air gaps such as 20 for controlled cooling, which jacket 18 is disposed within electromagnetic stirring device 22 , e.g. a stator, supported by base plate 24 which may or may not be cooled.
  • electromagnetic stirring device 22 e.g. a stator
  • the alloy After cooling and magnetic stirring, the alloy is transferred while in a partial solid/liquid phase to a casting machine, all as is known and disclosed in the above noted and incorporated SOD patents.
  • the noted transfer may be facilitated by a pouring spout 26 formed in the upper collar or lip of vessel 10 , FIGS. 2 , 3 .
  • a SOD (slurry-on-demand) casting method casts a low-solid-fraction, namely 10 to 30% by weight solid-fraction alloy.
  • This is in contrast to prior solid-fraction ratios of 40 to 60%.
  • the noted prior 40 to 60% solid-fraction ratio provides an ice cream-like or jello-like billet
  • a 10 to 30% solid-fraction ratio provides a soupy milkshake-like or oatmeal-like charge or billet. It is has been found that the latter ratio, namely a low-solid-fraction, namely 10 to 30% solid-fraction, enables usage of a wider array of die cast alloys, including 380, 383, 360, and Mercalloy (commercially produced under such Trademark by Mercury Marine Division, Brunswick Corporation) alloys.
  • the present method provides a SOD, slurry-on-demand, casting method for casting a low-solid-fraction, namely 10 to 30% solid-fraction, alloy, including the steps of heating the alloy to a molten liquid state, e.g. in vessel 10 as above, cooling and stirring the alloy to nucleate and create a partial solid phase of the noted low-solid-fraction, and transferring the alloy while in the partial solid phase of the noted low-solid-fraction to a casting machine, as in the above noted incorporated SOD patents.
  • the alloy includes a pair of constituents of different melting point including a first constituent of a first melting point, and a second constituent of a second lower melting point.
  • the preferred embodiment of the present method cools the alloy below the first melting point but above the second melting point, whereafter the noted transferring step is performed.
  • the first and second melting points are preferably selected close enough to each other such that during the cooling and stirring step, the solidification of the first constituent is limited to the noted low-solid-fraction until the second constituent begins to solidify, and then the transferring step is performed when the temperature of the alloy is between the noted first and second melting points.
  • the alloy is provided by aluminum as the first constituent and silicon as the second constituent.
  • the silicon content in the molten state increase from 9% to 12% ⁇ 1% (in one preferred embodiment the latter being 12.6%) during the noted cooling step between the first and second melting temperatures whereby the amount of aluminum transitioning in phase from liquid to solid state is limited to the noted low-solid-fraction, wherein the eutectic composition of the alloy is at the noted 12.6% silicon.
  • the noted first constituent is nucleated and solidified by magnetic stirring, as in the above noted incorporated SOD patents. Further in the preferred embodiment, the first constituent is nucleated and solidified without introducing a foreign object into the molten alloy. This is in contrast to prior art systems incorporating a rotating cooled rod, e.g. a graphite rod, introduced into a crucible of alloy to initiate the nucleation of solid phase particles.
  • a rotating cooled rod e.g. a graphite rod
  • the alloy is transferred while in the molten liquid state to vessel 10 , and then the cooling and magnetic stirring step is performed while the alloy is in vessel 10 , and then the alloy is transferred in the noted partial solid phase of the noted low-solid-fraction from the vessel to the casting machine.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Continuous Casting (AREA)
US11/520,829 2006-09-13 2006-09-13 Sod, slurry-on-demand, casting method and charge Abandoned US20080060779A1 (en)

Priority Applications (5)

Application Number Priority Date Filing Date Title
US11/520,829 US20080060779A1 (en) 2006-09-13 2006-09-13 Sod, slurry-on-demand, casting method and charge
CA002587816A CA2587816A1 (en) 2006-09-13 2007-05-07 Sod, slurry-on-demand, casting method and charge
EP07013338A EP1900455A1 (en) 2006-09-13 2007-07-07 Semi-solid casting method and charge
JP2007211485A JP2008068321A (ja) 2006-09-13 2007-08-14 Ｓｏｄ（スラリー・オンデマンド）鋳造方法及び充填物
AU2007216614A AU2007216614A1 (en) 2006-09-13 2007-08-30 Sod. Slurry-on-demand, casting method and charge

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US11/520,829 US20080060779A1 (en) 2006-09-13 2006-09-13 Sod, slurry-on-demand, casting method and charge

Publications (1)

Publication Number Publication Date
US20080060779A1 true US20080060779A1 (en) 2008-03-13

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Family Applications (1)

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US11/520,829 Abandoned US20080060779A1 (en) 2006-09-13 2006-09-13 Sod, slurry-on-demand, casting method and charge

Country Status (5)

Country Link
US (1) US20080060779A1 (ja)
EP (1) EP1900455A1 (ja)
JP (1) JP2008068321A (ja)
AU (1) AU2007216614A1 (ja)
CA (1) CA2587816A1 (ja)

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP5032422B2 (ja) * 2008-09-11 2012-09-26 有限会社ティミス 電磁撹拌式鋳造方法とその装置
JP5965890B2 (ja) * 2013-12-16 2016-08-10 東芝機械株式会社 成形装置、半凝固金属の製造装置、成形方法及び半凝固金属の製造方法

Citations (16)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4049248A (en) * 1971-07-16 1977-09-20 A/S Ardal Og Sunndal Verk Dynamic vacuum treatment
US4434837A (en) * 1979-02-26 1984-03-06 International Telephone And Telegraph Corporation Process and apparatus for making thixotropic metal slurries
US4832112A (en) * 1985-10-03 1989-05-23 Howmet Corporation Method of forming a fine-grained equiaxed casting
US6399017B1 (en) * 2000-06-01 2002-06-04 Aemp Corporation Method and apparatus for containing and ejecting a thixotropic metal slurry
US6402367B1 (en) * 2000-06-01 2002-06-11 Aemp Corporation Method and apparatus for magnetically stirring a thixotropic metal slurry
US6432160B1 (en) * 2000-06-01 2002-08-13 Aemp Corporation Method and apparatus for making a thixotropic metal slurry
US6443216B1 (en) * 2000-06-01 2002-09-03 Aemp Corporation Thermal jacket for a vessel
US6611736B1 (en) * 2000-07-01 2003-08-26 Aemp Corporation Equal order method for fluid flow simulation
US6645323B2 (en) * 2000-09-21 2003-11-11 Massachusetts Institute Of Technology Metal alloy compositions and process
US6742567B2 (en) * 2001-08-17 2004-06-01 Brunswick Corporation Apparatus for and method of producing slurry material without stirring for application in semi-solid forming
US6795362B2 (en) * 2001-08-27 2004-09-21 Elpida Memory, Inc. Power controlling method for semiconductor storage device and semiconductor storage device employing same
US6845809B1 (en) * 1999-02-17 2005-01-25 Aemp Corporation Apparatus for and method of producing on-demand semi-solid material for castings
US6918427B2 (en) * 2003-03-04 2005-07-19 Idraprince, Inc. Process and apparatus for preparing a metal alloy
US20050161127A1 (en) * 1995-05-29 2005-07-28 Ube Industries, Ltd. Method for shaping semisolid metals
US7024342B1 (en) * 2000-07-01 2006-04-04 Mercury Marine Thermal flow simulation for casting/molding processes
US7140419B2 (en) * 1999-07-26 2006-11-28 Alcan Internatinoal Limited Semi-solid concentration processing of metallic alloys

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5531261A (en) * 1994-01-13 1996-07-02 Rheo-Technology, Ltd. Process for diecasting graphite cast iron at solid-liquid coexisting state
SE528376C2 (sv) * 2004-12-10 2006-10-31 Magnus Wessen Förfarande och anordning för framställning av en flytande- fast metallkomposition

Patent Citations (19)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4049248A (en) * 1971-07-16 1977-09-20 A/S Ardal Og Sunndal Verk Dynamic vacuum treatment
US4434837A (en) * 1979-02-26 1984-03-06 International Telephone And Telegraph Corporation Process and apparatus for making thixotropic metal slurries
US4832112A (en) * 1985-10-03 1989-05-23 Howmet Corporation Method of forming a fine-grained equiaxed casting
US20050161127A1 (en) * 1995-05-29 2005-07-28 Ube Industries, Ltd. Method for shaping semisolid metals
US6845809B1 (en) * 1999-02-17 2005-01-25 Aemp Corporation Apparatus for and method of producing on-demand semi-solid material for castings
US7140419B2 (en) * 1999-07-26 2006-11-28 Alcan Internatinoal Limited Semi-solid concentration processing of metallic alloys
US6402367B1 (en) * 2000-06-01 2002-06-11 Aemp Corporation Method and apparatus for magnetically stirring a thixotropic metal slurry
US6637927B2 (en) * 2000-06-01 2003-10-28 Innovative Products Group, Llc Method and apparatus for magnetically stirring a thixotropic metal slurry
US6443216B1 (en) * 2000-06-01 2002-09-03 Aemp Corporation Thermal jacket for a vessel
US6432160B1 (en) * 2000-06-01 2002-08-13 Aemp Corporation Method and apparatus for making a thixotropic metal slurry
US6932938B2 (en) * 2000-06-01 2005-08-23 Mercury Marine Method and apparatus for containing and ejecting a thixotropic metal slurry
US6991670B2 (en) * 2000-06-01 2006-01-31 Brunswick Corporation Method and apparatus for making a thixotropic metal slurry
US6399017B1 (en) * 2000-06-01 2002-06-04 Aemp Corporation Method and apparatus for containing and ejecting a thixotropic metal slurry
US6611736B1 (en) * 2000-07-01 2003-08-26 Aemp Corporation Equal order method for fluid flow simulation
US7024342B1 (en) * 2000-07-01 2006-04-04 Mercury Marine Thermal flow simulation for casting/molding processes
US6645323B2 (en) * 2000-09-21 2003-11-11 Massachusetts Institute Of Technology Metal alloy compositions and process
US6742567B2 (en) * 2001-08-17 2004-06-01 Brunswick Corporation Apparatus for and method of producing slurry material without stirring for application in semi-solid forming
US6795362B2 (en) * 2001-08-27 2004-09-21 Elpida Memory, Inc. Power controlling method for semiconductor storage device and semiconductor storage device employing same
US6918427B2 (en) * 2003-03-04 2005-07-19 Idraprince, Inc. Process and apparatus for preparing a metal alloy

Also Published As

Publication number Publication date
AU2007216614A1 (en) 2008-04-03
EP1900455A1 (en) 2008-03-19
CA2587816A1 (en) 2008-03-13
JP2008068321A (ja) 2008-03-27

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AS Assignment

Owner name: BRUNSWICK CORPORATION, ILLINOIS

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:KOPPER, ADAM E.;REEL/FRAME:018421/0941

Effective date: 20060911

STCB Information on status: application discontinuation

Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION