US20190001407A1 - Injection tip for casting machine, casting machine and method using such a tip - Google Patents

Injection tip for casting machine, casting machine and method using such a tip Download PDF

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Publication number
US20190001407A1
US20190001407A1 US16/060,341 US201616060341A US2019001407A1 US 20190001407 A1 US20190001407 A1 US 20190001407A1 US 201616060341 A US201616060341 A US 201616060341A US 2019001407 A1 US2019001407 A1 US 2019001407A1
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US
United States
Prior art keywords
liquid metal
conduit
tip
mould
reservoir
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
US16/060,341
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English (en)
Inventor
Victor Shribman
Ori Ben David
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.)
ADM28 SARL
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ADM28 SARL
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 ADM28 SARL filed Critical ADM28 SARL
Assigned to ADM28 s.àr.l. reassignment ADM28 s.àr.l. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: BEN DAVID, ORI, SHRIBMAN, VICTOR
Publication of US20190001407A1 publication Critical patent/US20190001407A1/en
Abandoned legal-status Critical Current

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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/20Accessories: Details
    • B22D17/2015Means for forcing the molten metal into the die
    • B22D17/2023Nozzles or shot sleeves
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/02Hot chamber machines, i.e. with heated press chamber in which metal is melted
    • B22D17/04Plunger machines
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/20Accessories: Details
    • B22D17/2015Means for forcing the molten metal into the die
    • B22D17/2038Heating, cooling or lubricating the injection unit
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/20Accessories: Details
    • B22D17/30Accessories for supplying molten metal, e.g. in rations
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/02Hot chamber machines, i.e. with heated press chamber in which metal is melted

Definitions

  • the invention relates to an injection tip with a magnetic pinch for a machine for casting metal under pressure, and more particularly to such a tip which can be used for the metal moulding under pressure of metal pieces.
  • the invention also relates to a casting machine and method using this tip.
  • Machines for casting metal under pressure are generally used for metal moulding under pressure of metal pieces made of aluminium, zinc, magnesium, etc. and alloys thereof.
  • This moulding method permits high production rates and a high level of precision in the pieces obtained.
  • One of the most important parameters of the method is the pressure at which the molten metal in the liquid state is injected into the mould, particularly at the end of injection. This pressure is from 5 to 30 MPa for machines named hot chamber machines and from 25 to 200 MPa, or even 350 MPa for machines named cold chamber machines.
  • liquid metal will be used to designate a molten metal in the liquid state, without prejudging the nature and/or melting temperature of said metal.
  • WO02/30596 a machine for injecting under pressure is known, comprising a tubular injection tip comprising a resistor wound on the major part of this tip in order to maintain the temperature of the molten metal.
  • JP2005-28429 also describes a similar injection machine comprising a heating sleeve in which metal bars are inserted and melted by a resistive coil surrounding the sleeve.
  • a stopper fixedly attached to the mould can be actuated to close the supply channel.
  • the injection pressure depends on the general supply pressure of the machine.
  • FR 2 668 967 therefore proposed machines in which the supply of liquid metal is effected by an electromagnetic pump.
  • the performance of these machines in terms of injection pressure, in particular at the end of injection, is relatively poor.
  • the invention thus relates to the provision of an injection tip suitable for association with a casting machine, which permits easy adjustment of the quantity of metal injected and high pressure at the end of injection.
  • the invention also relates to a casting machine comprising such a tip, particularly suitable for permitting high levels of performance to be achieved.
  • the invention further relates to a method for casting metal, carried out by a casting machine fitted with an injection tip according to the invention, the method being particularly suitable to metal moulding under pressure.
  • the invention relates to a tip for injecting metal under pressure, being tubular in shape, made from electrically insulating refractory material, suitable for being inserted between a conduit for supplying liquid metal and an injection opening of a mould, comprising an injection channel suitable for the flow of liquid metal between a first end, named upstream end, suitable for being connected to said conduit and a second end, named downstream end, suitable for being connected to the mould, characterised in that said tip comprises an electromagnetic coil placed between said ends, having an axis merged with at least one axis portion of the channel, suitable for being supplied with a current pulse from a high-voltage generator and generating an electromagnetic pinch in the injection channel.
  • this tip By virtue of this tip and in particular of the channel in which the liquid metal flows it is possible to fill the mould placed at the downstream end of the tip. Furthermore, since the material of the tip is refractory, e.g. of ceramic, the heat of the metal flowing in the channel has little degrading effect thereon. Furthermore, by virtue of the electromagnetic coil which surrounds this conduit, when a high-amperage electric current pulse passes through it, the liquid metal flowing in the channel is subjected on the one hand to a magnetic field oriented axially with respect to the coil and to the channel and on the other hand to an induced current opposite to the direction of the current in the coil. The combination of these two phenomena generates Lorentz forces orientated radially with respect to the conduit, in the direction of the axis thereof.
  • the coil is suitable for being connected to the terminals of a current pulse generator.
  • a generator e.g. a Marx generator
  • Such a generator is capable—using one or more spark gaps discharging a bank of capacitors—of developing an electric current of the order of several tens of thousands of amps at a voltage of several thousands of volts in a very short time, of the order of some milliseconds.
  • the channel has a diameter comprising a narrowing between the upstream end and the coil.
  • this narrowing which forms a converging nozzle, the velocity of the liquid metal leaving the conduit for supplying the metal is increased at right angles to the electromagnetic coil owing to the narrowing of the cross-section of the channel.
  • the coil is embedded in the material of the tip.
  • the electromagnetic coil is placed closest to the flow stream of the liquid metal by embedding it in the refractory material forming the tip. Furthermore, being thus held on all sides, the electromagnetic coil is less subjected to the reaction forces acting on its turn(s) upon pinching. It remains possible nevertheless, particularly when the conditions for injection of the metal (temperature, pressure . . . ) permit, to use a tip comprising a thinner wall and thus to place the electromagnetic coil around and on the outside of the nozzle of the tip. In this variation, the holding of the coil is facilitated.
  • the coil has multiple turns.
  • the coil has a single turn.
  • the electromagnetic coil is preferentially produced so as to present a plurality of turns extending from the narrow end of the narrowing of the channel in the direction of its downstream end connected to the injection opening of the mould in order to increase the width of the pinch zone of the liquid metal in the tip and thus the volume of metal propelled towards the mould.
  • the coil can be a single-turn coil which makes it possible to achieve, for a single output stage of the current pulse generator, higher frequencies (or shorter pulses), thus increasing the momentary power of the pulse, a better transfer of the energy and extended service life.
  • the invention also relates to a casting machine comprising a liquid metal reservoir, a conduit for the supply of liquid metal connected to said reservoir and fitted with an electromagnetic pump suitable for causing the liquid metal to flow in the conduit in the direction of a mould, characterised in that the machine comprises a tip having at least one of the above-mentioned features, between said conduit and an injection opening of said mould.
  • a tip renders the casting machine more reliable and easier to maintain. In fact, it is within the tip that the greatest variations in pressure and thus wear phenomena take place. Consequently, a detachable tip renders possible reduced down times during maintenance.
  • the electromagnetic pump comprises a plurality of induction coils coaxial to the conduit and suitable for induction heating of the metal flowing in the conduit.
  • the induction coils are supplied with polyphase current so as to generate a moving magnetic field and to drive the liquid metal in the direction of the tip.
  • the induction coils supplied with alternating currents for induction heating can form an induction magnetohydrodynamic accelerator when they are supplied with currents having phase difference from one coil to the other. Consequently, apart from the heating of the liquid metal in the supply conduit, the coils make it possible to generate an axial magnetic field in the conduit and to communicate a movement of the liquid metal in the direction of the tip.
  • the machine comprises a device for cooling the induction coils which is interposed between said coils and the conduit.
  • a device for cooling the induction coils which is interposed between said coils and the conduit.
  • these coils are insulated from the conduit by an air or water cooling device, e.g. for cooling using water, by a circulation of cooling liquid within a copper tube serving as a winding.
  • the invention relates to a method for casting liquid metal under pressure in a metal mould, wherein:
  • the resulting flow velocity in the direction of the conduit is further reduced by the presence of the divergent area formed by the narrowing of the cross-section of the channel which is passed through in the reverse direction. It is thus possible to achieve an at least temporary halt to the flow of the liquid metal in the supply conduit.
  • the invention also relates to a tip, a casting machine and a casting method which are characterised in combination by all or some of the features mentioned above or below.
  • FIG. 1 shows a schematic, cross-sectional view of a casting machine in accordance with the invention
  • FIG. 2 is schematic, cross-sectional view of tip in accordance with the invention.
  • FIG. 3 is a cross-sectional view of a tip in accordance with the invention during pinching of the flow of the metal.
  • FIG. 1 shows a longitudinal cross-sectional view of a casting machine 10 comprising a reservoir 11 suitable for containing liquid metal to be injected into a mould 30 .
  • the reservoir 11 can comprise heating means (not shown) to maintain the metal at its melting temperature, or be shaped into the form of a hopper in which the liquid metal is poured from a crucible.
  • the liquid metal is then channelled in a conduit 12 for supplying the metal in the direction of a tip 20 fixed between the conduit 12 and the mould 30 .
  • the conduit 12 is fitted with an electromagnetic pump 50 comprising a plurality of induction coils 51 regularly spaced along the conduit 12 .
  • Each of the induction coils 51 is connected to a power inverter 53 adapted to supply the coils 51 with alternating current.
  • the induction coils 51 fulfil a dual role: on the one hand, they operate as induction heating coils permitting the stream of liquid metal flowing in the conduit 12 to be kept in the liquid state and, on the other hand, being supplied with polyphase alternating current adapted to the number and the order of the coils 51 , they generate a moving magnetic field going from the reservoir 11 in the direction of the tip 20 , this magnetic field making it possible to cause the liquid metal to flow in the conduit in the direction of the mould 30 at a velocity V 0 .
  • the induction coils are supplied with three-phase current at a voltage of 400V at a frequency of the order of 50 Hz to 10 kHz with a current variable between 50 A and 10 000 A.
  • the coils 51 also comprise a cooling circuit 52 , e.g. using a cooling liquid circulating in copper tubes forming the coils 51 , making it possible to limit heating thereof.
  • a cooling circuit 52 e.g. using a cooling liquid circulating in copper tubes forming the coils 51 , making it possible to limit heating thereof.
  • an air cooling system with forced convection employing one or more fans and cooling fins fixedly attached to the windings can also be contemplated.
  • the tip 20 is fixed by means of flanges 25 to the end of the conduit 12 by its upstream end 23 (thus designated in relation to the direction of flow of the liquid metal in the conduit and in the tip).
  • the tip 20 is also fixed to the mould 30 by flanges 25 at its opposite end, named downstream end 24 .
  • the tip 20 comprises a body 21 of refractory and electrically insulating material, preferably ceramic, and more particularly zirconium/aluminium nitride.
  • Other refractory materials can also be used, e.g. alumina-based, zirconium-based, yttrium-based, titanium-based or nickel oxide-based ceramics, or even a mixture of these constituents in various proportions.
  • the body 21 of the tip is traversed by a channel 22 extending from the upstream end 23 to the downstream end 24 where the channel 22 issues into the injection opening 33 of the mould 30 .
  • the channel 22 is preferably of a revolutional cylindrical shape and comprises, at the upstream end 23 , a conical part forming a narrowing 27 between a large cross-section with a diameter corresponding to the end of the conduit 12 and a smaller cross-section of the channel 22 corresponding to the cross-section of the injection opening 33 of the mould 30 .
  • the body 21 also comprises, downstream of the narrowing 27 , an electromagnetic coil 26 surrounding the channel 22 and over-moulded in the body 21 .
  • the coil 26 is preferably a multi-turn coil of copper or other highly conductive material, e.g. aluminium, cupro-beryllium, copper-chromium-zirconium alloy, tungsten or tungsten-copper alloy . . . .
  • the coil 26 is suitable for connection to a current pulse generator 40 generally comprising a bank 41 of capacitors, which are charged by an external continuous supply source (not shown), and is discharged in the electromagnetic coil 26 via a spark gap 42 .
  • the coil 26 can also be formed by a single turn.
  • the coil 26 is a multi-turn or single-turn coil it has an axis of rotation substantially merged with at least a portion of the axis of the channel 21 over the part thereof which it surrounds. In the channel 21 , the coil 26 thus defines a zone, named pinch zone 28 , within which develops the electromagnetic field created by the coil 26 when this coil is supplied by the generator 40 .
  • the coil 26 around the body 21 .
  • a tip of non-magnetic austenitic refractory stainless steel which permits satisfactory resistance with thicknesses reduced to a few millimetres.
  • a single-turn or multi-turn electromagnetic coil 26 can thus be threaded onto the body 21 and fixed by any suitable means. This variation permits easy removal of the coil while retaining the body 21 of the tip.
  • FIGS. 1 and 3 describe the operation of the machine 10 and of the tip 20 as well as the casting method of the invention.
  • the reservoir 11 is filled with a liquid metal, e.g. an alloy of zinc or magnesium.
  • the liquid metal flows from the reservoir 11 into the conduit 12 .
  • the power inverter 53 supplies the induction coils 51 with a polyphase (e.g. three-phase) alternating current so as to induction heat the liquid metal in the conduit 12 to avoid any initiation of solidification or the formation of lumps.
  • Each induction coil 51 also develops a magnetic field, the field lines of which are orientated along the axis of the induction coils and of the conduit 12 .
  • the phase difference in the magnetic field of the induction coils generates a moving magnetic field in the conduit 12 which displaces the liquid metal contained therein towards its end opposite to the reservoir 11 at a substantially constant velocity V 0 .
  • the flow cross-section of the liquid metal is reduced in the narrowing 27 and thus the velocity of displacement of the metal increases as a function of the cross-section ratio between the upstream end 23 of the tip and the cross-section of the channel 22 to reach a velocity V 1 at the end of the narrowing, at the inlet into the pinch zone 28 located under the electromagnetic coil 26 .
  • the liquid metal progresses at the velocity V 1 in the channel 22 then in the injection opening 33 of the mould 30 to fill one or more cavities 32 formed between the dies 31 of the mould 30 .
  • the cavities 32 are filled, e.g.
  • the pulse generator 40 is activated and delivers a current pulse, e.g. of an intensity of the order of 20 kA to 1 MA, a duration of 40 ⁇ s to 2 ms which flows in the coil 26 .
  • a current pulse e.g. of an intensity of the order of 20 kA to 1 MA, a duration of 40 ⁇ s to 2 ms which flows in the coil 26 .
  • the liquid metal 13 is thus radially compressed and, owing to its incompressibility, is ejected axially on both sides of the pinch zone 28 at an ejection velocity V 2 .
  • the combination of this ejection velocity V 2 with the flow velocity V 1 of the liquid metal in the direction of the mould 30 imparts to the metal a velocity corresponding to V 1 +V 2 .
  • this velocity V 1 +V 2 is manifested as an increase in the injection pressure in the mould 30 .
  • a single-turn coil 26 of aluminium having a working zone (pinch zone 28 ) of a length of 15 mm, supplied by a current pulse Imax 500 kA to 500 Hz (2 ms), the coil generates a magnetic field of 40 T.
  • this metal can achieve a maximum velocity (V 1 +V 2 ) of the order of 30 m/s in the tip and a maximum pressure of 700 MPa.
  • the flow velocity of the metal following the combination of the flow and ejection velocities is V 1 -V 2 .
  • the ejection velocity V 2 is higher in absolute value than the flow velocity V 1 which imparts a movement to the liquid metal in the direction of the conduit 12 of the machine.
  • the narrowing 27 which behaves as a diverging area in this direction, the velocity of the liquid metal is decreased in the ratio of the cross-sections and does not generate a large shock wave in the conduit 12 likely to damage the machine, but simply a pressure wave which promotes the mixing of the metal in the conduit.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Continuous Casting (AREA)
  • Casting Support Devices, Ladles, And Melt Control Thereby (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)
US16/060,341 2015-12-11 2016-12-09 Injection tip for casting machine, casting machine and method using such a tip Abandoned US20190001407A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
FR1562245 2015-12-11
FR1562245A FR3044943B1 (fr) 2015-12-11 2015-12-11 Embout d'injection pour machine de coulee, machine et procede de coulee faisant usage d'un tel embout
PCT/EP2016/080396 WO2017097961A1 (fr) 2015-12-11 2016-12-09 Embout d'injection pour machine de coulée, machine et procédé de coulée faisant usage d'un tel embout

Publications (1)

Publication Number Publication Date
US20190001407A1 true US20190001407A1 (en) 2019-01-03

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US16/060,341 Abandoned US20190001407A1 (en) 2015-12-11 2016-12-09 Injection tip for casting machine, casting machine and method using such a tip

Country Status (6)

Country Link
US (1) US20190001407A1 (fr)
EP (1) EP3386659B1 (fr)
JP (1) JP6840166B2 (fr)
CN (1) CN108367344A (fr)
FR (1) FR3044943B1 (fr)
WO (1) WO2017097961A1 (fr)

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CN115863125A (zh) * 2022-10-31 2023-03-28 西北核技术研究所 一种一体化高压真空绝缘堆栈

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* Cited by examiner, † Cited by third party
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CN113927014A (zh) * 2021-09-09 2022-01-14 仁兴机械(佛山)有限公司 一种射料装置及其压铸机及其压铸方法

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Publication number Priority date Publication date Assignee Title
US2224982A (en) * 1939-03-10 1940-12-17 Whitehall Patents Corp Method of die casting by electrical induction
US3917896A (en) * 1972-10-11 1975-11-04 Nat Res Inst Metals Induction melting furnace
US4786237A (en) * 1981-10-21 1988-11-22 Interatom International Atomreaktorbau Gmbh Induction immersion pump, particularly for aluminum
US5282608A (en) * 1992-12-03 1994-02-01 Cmi International Induction heated metal pouring apparatus
US5960854A (en) * 1995-08-24 1999-10-05 Oskar Frech Gmbh & Co. Hot chamber die-casting machine
US20140369375A1 (en) * 2012-01-23 2014-12-18 Apple Inc. Boat and coil designs
US20150013932A1 (en) * 2012-10-15 2015-01-15 Crucible Intellectual Property, Llc Unevenly spaced induction coil for molten alloy containment
US20140238633A1 (en) * 2013-02-27 2014-08-28 Schuler Pressen Gmbh Casting device and casting method

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN115863125A (zh) * 2022-10-31 2023-03-28 西北核技术研究所 一种一体化高压真空绝缘堆栈

Also Published As

Publication number Publication date
FR3044943A1 (fr) 2017-06-16
FR3044943B1 (fr) 2020-12-04
JP6840166B2 (ja) 2021-03-10
EP3386659B1 (fr) 2020-12-02
WO2017097961A1 (fr) 2017-06-15
CN108367344A (zh) 2018-08-03
JP2018537296A (ja) 2018-12-20
EP3386659A1 (fr) 2018-10-17

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