CN1265915C - Method and apparatus for making metal alloy castings - Google Patents
Method and apparatus for making metal alloy castings Download PDFInfo
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- CN1265915C CN1265915C CNB018140319A CN01814031A CN1265915C CN 1265915 C CN1265915 C CN 1265915C CN B018140319 A CNB018140319 A CN B018140319A CN 01814031 A CN01814031 A CN 01814031A CN 1265915 C CN1265915 C CN 1265915C
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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
- B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
- B22D11/10—Supplying or treating molten metal
- B22D11/11—Treating the molten metal
- B22D11/112—Treating the molten metal by accelerated cooling
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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
- B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
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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
- B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
- B22D11/06—Continuous casting of metals, i.e. casting in indefinite lengths into moulds with travelling walls, e.g. with rolls, plates, belts, caterpillars
- B22D11/0622—Continuous casting of metals, i.e. casting in indefinite lengths into moulds with travelling walls, e.g. with rolls, plates, belts, caterpillars formed by two casting wheels
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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
Abstract
A method and apparatus are provided for fabricating of continuous castings with fine and uniform microstructure, which can be used as feedstock for secondary processing routes, such as thixoforming, forging and machining or direct application in industry. An overheated liquid alloy is fed into a high shear device (for example, a twin-screw extruder) and sheared intensively to produce a sheared liquid alloy or a semisolid slurry, wherein the sheared liquid alloy is at a temperature close to its liquidus and the semisolid slurry is then transferred to a shaping device for production of continuous castings with fine and uniform microstructures through a solidification process. The shaping device is any device capable of forming continuous (i.e. infinite length) products, such as a direct chill (DC) caster (DC rheocasting) for production of continuous billets, an extrusion die (rheo-extrusion) for production of continuous bars or wires, or a twin-roll caster (twin-roll rheocasting) for producing of continuous strips. In all those cases, the cross-section of the continuous castings exhibits a microstructure in which a controlled volume fraction of fine and spherical primary particles are uniformly distributed in a fine structured matrix.
Description
Technical field
The application relates to and a kind ofly forms the method and apparatus of continuous product by liquid metal alloy, particularly makes can be used as secondary processes method (as thixotropic forming, forging and machining) raw material and have tiny and the continuous casting homogeneous microstructure.The application also relates to the goods that made by these methods, as square billet, bar, wire rod, tubing or band.
Background technology
In metal forming industry, continuous casting billet is made by direct chill (DC) casting technique usually.In this technology, overheated liquid alloy is by in the cylindrical mold of the water-cooled of packing into continuously, and the alloy that continuous then output is solidified is to form continuous casting billet.The final cross section of strand has three zones that feature is different, the chill zone on surface, the thick zone of equiaxial crystals at column district and center (coarse equiaxedzone).The inhomogeneity of this microstructure has limited the direct application of DC strand.
Many secondary treatment methods, as rolling, extrude and again crystallization be commonly used to make microstructure refinement and homogenising.Such after-treatment technology power consumption, time-consuming and cost is high.Therefore, be badly in need of that exploitation is a kind of not to be adopted these after-treatment technologies and can directly produce the continuous casting process of the continuous casting billet of the tiny and homogeneous of microstructure.
A kind of known employing DC strand is the bar of or compound section simple with expressing technique production as raw-material technology.Extruding of metal can be divided into two classes: cold-extruded goes out with hot-extrudable.In cold-extruded went out, cold metal was loaded in the open mold of a temperature near room temperature.Go out in the process at the metal cold-extruded, pass through module in order to force metal, it is necessary applying certain pressure, and this just causes the expensive of capital equipment, shortens die life and the capacity usage ratio reduction.Therefore in hot-extrudable, alloy preform is heated to its subsolidus, resembles to be extruded the cold extrusion process.In hot-extrudable, the life-span of mould can improve but energy utilization ratio still is restricted.Simultaneously, accurately extrusion pin (as thin wire) is very difficult with hot-extrudable technology.Therefore, a kind of expressing technique that can directly make bar and wire rod by liquid alloy of invention is very favourable.
Another adopts the DC strand is rolling mill practice as raw-material technology, and it produces band by the continuous rolling continuous casting billet to desired thickness.Compare with expressing technique, the cost of rolling mill practice is higher, because it consumes energy very much, capital equipment costs height and material output capacity are low.
Another technology of producing band is a twin roller casting technology, and this technology is effective to the different metal in the limited range.In twin roller casting technology, have the lateral shaft and a pair of roller location that is parallel to each other of rotation round about, and certain slit is arranged between them, in the slit upper rolls on annular surface form the liquid alloy molten bath, liquid alloy is continuously cast into alloy strip steel rolled stock then.
The problem that traditional twin roller casting technology relates to comprises, near the leakage of the liquid alloy side dam, and the damage on side dam, the formation of side, Cast Strip crackle, the roller life-span is short, the chemical segregation in technology controlling and process difficulty and the solid product.
Also having another kind of is the thixotropic forming technology that latest developments are got up with the DC strand as raw-material technology.It is two-stage process substantially.In the first step, the DC casting technique production thixotroping raw material that employing is transformed have non-dendroid microstructure with production strand.In second step, thixotroping base/raw material is reheated its semi-solid state (temperature is between its solidus and the liquidus curve), makes it form the hole with casting (thixotroping casting) or forging (thixotroping forging) then.Ideally, the raw material that is used for thixotropic forming should comprise an a certain amount of tiny spherical solid material at matrix.The present major limitation of thixotropic forming is the low quality of raw material and expensive.The technology that is used for the production of thixotropic forming raw material comprises the initial dendroid microstructure of simple mechanical agitation, electromagnetic agitation, alligatoring, increases a large amount of brilliant material fining agents and adopt sonic oscillations at casting process.Yet these technologies have certain shortcoming.A significant drawbacks of known method is the microstructure heterogeneity on the cross section, brings the mechanical performance of difficulty and final member relatively poor relatively for heating process again.Another shortcoming is owing to a non-sphere material form causes because the heat time heating time again that it need be grown with the nodularization solid particle, this will reduce the potential advantages of half solid techniques.Another shortcoming is raw-material cost height, and the ratio that raw-material cost accounts for final member cost has reached 50%.
A large amount of lists of references has disclosed the thixotroping mould pressing process, wherein at first solid or semisolid are packed into (such as, the material of packing into by heating when shearing liquefies it), then it is sprayed into mold to make member.These lists of references comprise: EP 0867246 A1 (Mazda MotorCorporation); WO 90/09251 (The Dow Chemical Company); US5,711,366 (Thixomat, Inc.); US 5,735,333 (The Japan Steel Works, Limited); US 5,685,357 (The Japan Steel Works, Limited); US4,694,882 (The Dow Chemical Company); With CA 2,164,759 (InventronicsLimited).
Yet, by heat solid material so that it changes thixotropic state (thixotroping mold pressing) into rather than becomes the shortcoming of thixotropic state (rheology mold pressing) by the cooling liquid metal is that particle size and particle size distribution in the substructure in the thixotroping ore pulp is difficult to control.Particularly the particle size of the ore pulp of thixotroping mold pressing is tending towards an order of magnitude greater than the particle size of the ore pulp of rheology mold pressing, and a wideer Size Distribution is arranged.This structural behaviour to the casting goods has potential adverse effect.
And above-mentioned list of references adopts the single screw extrusion machine of standard that the thixotroping ore pulp is sheared, and causes product quality lower.
Many lists of references have disclosed the rheology mould pressing process really.WO97/21509 (Thixomat for example, Inc.) relate to a kind of technology that forms metallic article, wherein alloy is heated to it more than liquidus temperature, when liquid metal is cooled to biphase equilibrium regional, adopts single screw extrusion machine to shear this liquid metal then.
US4,694,881 (The Dow Chemical Company) relate to a kind of technology, and wherein a kind of material with non-thixotroping type structure is packed into solid-state form in the single screw extrusion machine.Raw material is heated to it more than liquidus temperature, when carrying out shear action, it is cooled to it then below the liquidus temperature and it is more than solidus temperature.
WO95/34393 (Cornell Research Foundation, Inc.) also disclosed a kind of rheology mould pressing process, wherein overheated liquid metal is cooled to semi-solid state in the bucket of single screw extrusion machine before being injection moulded into foundry goods, and shear in cooling.
WO01/21343 (Brunel University) is the application that is disclosed in priority date of the present invention common pending trial afterwards.It has disclosed the method for liquid metal alloy being made formed product, for alloy is transformed into thixotropic state, when shearing alloy is cooled to it below liquidus curve.Alloy is delivered in the discontinuous mold to make formed product then.Wherein do not disclose the formation of continuous cast products.
WO01/23124 (Brunel University) is another patent that is disclosed in priority date of the present invention common pending trial afterwards.It has been particularly related to a kind of method of producing foundry goods with metal alloy (having two kinds of unmixing compositions at least), and product wherein is sheared and changes the semi-solid state ore pulp into, then ore pulp can be sent in the mold or preheating metal tape in.
There is not the list of references of thixotroping mold pressing or rheology mold pressing to describe the technology that can form continuous cast products with sufficiently high structural integrity.
Summary of the invention
According to a first aspect of the invention, it provides a kind of method of being made continuous product by liquid metal alloy, comprise the liquidus curve that alloy is cooled to be roughly liquidus curve or is cooled to alloy from the solidus of alloy, alloy is sheared alloy is transformed into the thixotroping attitude with sufficiently high shear rate and turbulence intensity, and will shear liquid metal or shear semi-solid ore pulp and be transported to building mortion to form solid product, building mortion wherein can form continuous product.
Because " product continuously " refers to the product of formation continuously,, just can form the product of random length as long as therefore provide enough raw materials.This is different with discontinuous (as forming in mold) product.
Former can be DC casting machine (a DC rheocasting), or extrusion die (rheology is extruded), or dual roll casting machine (two roller rheocasting).The material of handling according to the present invention can be the also unmixing alloy of alloy that dissolves each other, and when under the situation of unmixing alloy, this process is called rheology mixed process.
Have been found that, if the temperature of the liquid alloy of adorning is lower and near viscosity big (this can shear liquid alloy the liquidus temperature or between liquidus curve and solidus obtain), most of shortcoming of prior art thixotropic forming (traditional DC casting and twin roller casting technology and expressing technique) can overcome.Fully the liquid alloy of shearing or the high viscosity of semisolid ore pulp can shorten setting time, stop the leakage in the dual roll casting machine, reduce continuous casting and solidifying and extrude in chemical segregation and boost productivity.Low impouring/the temperature of packing into also can increase the quality of die life, energy efficiency and product.
A second aspect of the present invention provides a kind of method of being made continuous cast products by liquid metal alloy, its step comprise alloy is cooled near the liquidus curve or from the solidus of alloy to liquidus curve, alloy sheared with sufficiently high shear rate and turbulence intensity make it change thixotropic state into, the semi-solid ore pulp of shearing liquid alloy or shearing is transported in the former to form solid product, former wherein can form continuous product, and wherein alloy is formed by the composition that dissolves each other.
According to a third aspect of the invention we, a kind of method of being made continuous cast products by liquid metal alloy is provided, its step comprises alloy is cooled near the liquidus curve, alloy sheared with sufficiently high shear rate and turbulence intensity make it change thixotropic state into, will shear liquid alloy and be transported in the former to form solid product.Former wherein preferably can form continuous product, and wherein alloy can also can be formed by immiscible composition by the composition that dissolves each other.
Another aspect of the present invention provides a kind of method of being made continuous cast products by the liquid metal alloy with unmixing composition, its step comprises alloy is cooled to below the immiscibility gap, alloy sheared with sufficiently high shear rate and turbulence intensity make it change thixotropic state into, to shear liquid alloy or shear semi-solid ore pulp and be transported in the former to form solid product, former wherein can form continuous product, but former wherein is not the metal tape of a preheating.
Usually, shear is a high shear extruder, and its step comprises the bucket of liquid alloy being put into Controllable Temperature, and the screw rod that is fixed in the bucket with sufficiently high shear rate operation is transformed into its high-shear state and/or thixotropic state with liquid alloy.The external form of screw rod should design especially so that the end of liquid alloy from bucket is being transported to the process of the other end, provides high-rate of shear and high turbulence intensity to obtain forcing swabbing action.Extruder can be the extruder of any kind of, as long as have at least a screw rod to be positioned in the bucket.
Preferably, extruder is the double screw extruder that at least two screw rods are arranged, and it is to the small part interlock, and more preferably, it is whole interlocks basically.
Former can be for having the various moulds or the mold of auxiliary equipment (deciding according to the final products needs of making).(a) in DC rheocasting technology, mould/mold can be the simple circle cylinder that has optional startup substrate, and cylinder wherein has a cooling system.The alloy that solidifies pulls straight from mould/mold by starting substrate, thereby forms foundry goods continuously.(b) in two roller rheocasting technologies, mould/mold comprises a pair of rotation roller and a pair of side dam composition that is arranged in two ends of roll shaft, shears liquid alloy or semisolid ore pulp molten bath so that form one between roller and side dam.Two roller opposite spins are so that liquid alloy or semisolid ore pulp after shearing form solid shell with after coagulation, thereby these solid shell are extruded the formation continuous band mutually when the slit of passing between roller.(c) mould/mold can be the simple perforate on the cutter end in the rheology expressing technique.The pressure swabbing action of cutter forces liquid alloy after the shearing or semi-solid ore pulp to form bar or wire rod or other any suitable cross sectional shape by the open mold of preheating.
When liquid alloy after shearing or semi-solid ore pulp passed through mold, mold can be heated to or remain on a predetermined temperature, and the relation between mold temperature and the metal sheet slitting temperature is decided by individual other Technology Need.
Continuous cast method of the present invention and equipment preferably adopt an end that inlet is arranged, and the other end has the cutter of outlet, and the Controllable Temperature bucket links to each other above-mentioned inlet with the screw rod that above-mentioned outlet and at least one are positioned in the said bucket.
Described screw rod in the above-mentioned cutter preferably includes a shaft that has a blade on it at least, described blade forms a spiral at least on shaft peripheral part ground, to promote metal by described bucket, wherein said screw rod can be sheared above-mentioned liquid alloy enough to be suppressed at the speed that wherein is completed into dendritic structure, and described metal is a semi-solid state, and the rotation of described screw rod can also make described metal be transported to above-mentioned outlet by said bucket from above-mentioned inlet.
In one embodiment, adopt temperature-controlled process to the extruder bucket, screw rod and alloy temperature are adjusted so that the temperature of alloy remains near its liquidus curve or between liquidus curve and the solidus.One control valve can be arranged outlet of extruder so that the alloy in the extruder is transported to former.The available above-mentioned valve control of the amount of liquid alloy from the extruder to the former or semisolid ore pulp is to keep the continuity of semi-solid ore pulp in the former.
In a preferred embodiment, extrusion die directly is connected on the extruder to produce the continuous wire of different cross section.This technology is called rheology and extrudes.
As a kind of scheme that can substitute, except High shear device, also can adopt single screw extrusion machine, wherein shearing liquid alloy or semisolid ore pulp are poured out from above-mentioned High shear device, and the continuous rotation by above-mentioned single screw extrusion machine screw rod is to produce continuous casting billet such as bar or thin wire or square billet.
The continuous product of making according to the inventive method also can further be out of shape by traditional expressing technique.
Usually, can can be any metal alloy according to the material that the present invention handles, as Al, Mg, Zn, Cu, Fe base alloy etc., one group of important metal material can handling according to the present invention is to contain the material that does not mix the slit with liquid mutually, for example Al-Pb, Al-Bi, Al-In and Cu-Pb base alloy.
According to the significant advantage of the inventive method be that the microstructure of entire cross section of the strand that obtains is tiny and homogeneous wherein, is being evenly distributed the controlled tiny circular granular of content in the matrix.Therefore, made strand has very high thixotropy, is particularly suitable as the raw material of thixotropic forming.
Another advantage of technology of the present invention is such fact, and it need not carry out after-treatment technology for microstructure control, as extrudes and crystallization again microstructure homogeneous because the strand of making has contained tiny.Therefore, they can directly be used for carrying out solid-state processing, as machining and forging etc.
Cylindrical die/the mold that is used for the DC rheocasting can be made by any material, but mold is preferably made by graphite or acid bronze alloy.Cylindrical die/mold can have cooling system, so that shearing liquid alloy or semi-solid ore pulp solidify with suitable cooldown rate.The starting substrate can be in the initial use of casting.
The rotation roller of dual roll casting machine can have any profile that narrow slot can be provided when rotated, and the profile of roller is preferably flat.
Extrusion die cross section in the rheology expressing technique can be Any shape, comprise simple shape, as circle, triangle, rectangle or as the complicated shape of polygon or other any appropriate, sectional dimension can change in a big way one, this just means that product can be thin wire or bar more greatly.
Liquid alloy after said method can adopt temperature near the shearing of its liquidus curve, or adopt by temperature at the semi-solid ore pulp of shearing between liquidus curve and the solidus after liquid alloy has the shearing of tiny, homogeneous microstructure of different solid volume ratios (0% to 750%).When shearing when near its liquidus curve, carrying out, in the product that finally solidifies, generated meticulous uniform microstructure, this is because strengthened having the nucleation rate of liquid alloy of the high shear of uniform temperature and chemical composition effectively.When shearing when between liquidus curve and solidus, carrying out, under strong shear action, just can produce semi-solid ore pulp with tiny spheric granules, this ore pulp can be used for directly forming member or be configured as strand as the raw material of thixotroping technology.The said equipment and method also can be improved the mechanical performance of metal parts owing to effective improvement (particularly for the alloy near eutectic composition) of microstructure.
The said equipment and method preferably include following steps:
* provide the liquid alloy that exists with liquid state, and the inlet by being arranged in extruder one end is with pack into the extruder of a Controllable Temperature of described liquid alloy;
* with the extruder that contains a screw rod at least, shear described liquid alloy with sufficiently high shear rate and shear liquid alloy or semisolid ore pulp to form;
* above-mentioned shearing liquid alloy or semisolid ore pulp in the described extruder are sent into former, two roll-ins that this equipment can be the cylindrical mold that the DC rheocasting uses or is used for two roller rheocasting technologies are rolled or are fixed in extruder other end control valve by unlatching and carry out the open mold that rheology is extruded.
* shearing liquid alloy in the former or semisolid ore pulp are solidified the continuously cast that forms different cross section.Above-mentioned former can be DC casting machine or extrusion die or dual roll casting machine.
Generally, extruder is by a bucket, and one or more screw rods and a drive system are formed, and it is used for accepting the liquid alloy that passes through from the inlet that is positioned at extruder one end.In a single day liquid alloy enters the passage of extruder, will cool off or remain on a predetermined temperature.In another case, treatment temperature can be the temperature between near the temperature of liquidus curve or solidus and the liquidus curve.
According to the liquidus curve of alloy and solidus and fixed treatment temperature is different with the difference of alloy.What is that suitable temperature it will be apparent to those skilled in the art that.
The shearing of liquid alloy is also carried out in extruder.Shear rate will enough make the microstructure that obtains a spherical material and tiny homogeneous in the final products.Shear action is caused by the screw rod in the bucket, and is strengthened by the spirality screw rod flying object that screw rod forms on one's body.The shearing of strengthening is produced by the annular space between bucket and screw rod flying object and the screw rod flying object.Just moving in the extruder can make shears liquid alloy or semi-solid ore pulp and moves to outlet from the inlet of extruder, and draws off from here.
Roll in the rheocasting technology two, the pressure rolling of being made up of a pair of roller, an offside dam and drive system preferably is used for accepting to shear liquid alloy or semi-solid ore pulp by the top molten bath that is formed by two side dam inner surfaces and two roller upper surface.Shear liquid alloy or semi-solid ore pulp and in a single day enter molten bath in the dual roll casting machine, will cool off and form one deck shell at roller surface.Roller temperature is different with the difference of alloy.Suitable temperature is conspicuous to this area skill personnel, but it should be lower than the solidus of alloy usually.Equally in twin roller casting technology, shear liquid alloy or semi-solid ore pulp also will solidify, distortion, the connection of solidified shell and pulling straight of solid band.The speed of pulling out will be enough to keep the continuity of technology.The distortion and be connected effective connection that will be enough to the holding plate face portion.
In the rheology expressing technique, be used to shear the extrusion pressure of liquid alloy or semi-solid ore pulp by temperature and the shear rate control of principal component.Temperature difference between extruder bucket and the open mold can significantly reduce shears liquid alloy or the outside friction of semisolid ore pulp when extruding and between the open mold.Outside friction, the viscosity of shearing liquid alloy or semisolid ore pulp and extruder pressure suction pressure equilibrium of forces have determined the extruded velocity by open mold.The extrusion die of different cross section shape is used for the continuously cast of varying cross-section shape.
When adopting rheology to mix, be that temperature is in it and mixes the even liquid alloy on gap or mix the liquefied mixture that is pre-mixed in the gap extruder of all can packing in temperature and carry out high strength and mix to produce tiny liquefied mixture homogeneous.In extruder, liquid alloy cools off and high strength is sheared, extruder can be more than the monotectic temperature or following temperature carry out.Former can be extrusion die or dual roll casting machine.
Description of drawings
Below with reference to figure the preferred embodiments of the invention are described in detail, wherein:
Fig. 1 is that principle according to the present invention changes liquid alloy into embodiment sketch that high strength is sheared the equipment of liquid alloy or semi-solid ore pulp.
Fig. 2 is that principle according to the present invention changes liquid alloy into high strength shearing liquid alloy or semi-solid ore pulp, uses the embodiment sketch of the equipment of DC rheocasting explained hereafter metal strand then.
Fig. 3 is that principle according to the present invention changes liquid alloy into high strength shearing liquid alloy or semi-solid ore pulp, then with extrusion die another embodiment sketch by the equipment of rheocasting explained hereafter metal bar/wire rod.
Fig. 4 is used for the extrusion die device schematic diagram that expressing technique is extruded in rheology in another embodiment.
Fig. 5 is that principle according to the present invention changes liquid alloy into high strength shearing liquid alloy or semi-solid ore pulp, then with single screw extrusion machine another embodiment sketch by the equipment of rheocasting explained hereafter metal bar/wire rod.
Fig. 6 is that principle according to the present invention changes liquid alloy into high strength shearing liquid alloy or semi-solid ore pulp, uses the embodiment sketch of the equipment of two roller rheocasting explained hereafter sheet metal strips then.
The specific embodiment
In the preferred embodiment of describing subsequently, foundry goods is made by an extruder and a former of being made by the AZ91D liquid alloy.The present invention is not limited to the AZ91D manganese alloy, also comprises that applicable to the metal of other kind aluminium alloy, manganese alloy, kirsite, copper alloy, ferroalloy and other may be suitable for the smithcraft shearing-bring out and/or the alloy of semi solid metal technology.And specified temp of Miao Shuing and temperature range can only be used in the AZ91D manganese alloy in preferred embodiments, but those skilled in the art can principle according to the present invention to this modification so that it is adapted to other alloy, as Al, Mg, Zn and Cu base alloy.
Fig. 1 has provided extruder system according to embodiments of the present invention.The liquid alloy dispenser 10 of packing into.The periphery of dispenser 10 is provided with a series of heating element heaters 11, and heating element heater can be the type of any routine.The operation heating element heater has sufficiently high temperature so that liquid by the metal maintenance of dispenser 10 supplies to keep dispenser 10.To the AZ91D alloy, this temperature can be (liquidus curve of alloy) more than 600 ℃.Extruder has a plurality of cooling ducts 12 and heating element heater 13, and they distribute along its length direction.The cooling duct 12 and the heating element heater 13 of coupling can form a series of heating and cooling zone respectively mutually.The heating and cooling zone can make along extruding the Temperature Distribution that arbor keeps a complexity, and this can satisfy the specific (special) requirements in the semi-solid technical process.Each regional temperature control is by balance heating and cooling power (this power is by the central control system input of thermocouple 20).Heating means can be resistance heated, reduction heating or other any heating means.Cooling medium can be decided according to arts demand for water or gas or other any medium.Though Fig. 1 has only provided a heating/cooled region, extruder can assemble controlled heating/cooled region respectively between 1 to 10.
Extruder also has physics slope or gradient.Gradient is generally 0～90 ° with respect to metallic plate-plane of motion.The slope of design is with the next step of helping the liquid alloy after shearing or semisolid ore pulp are transported to different process from extruder.
Extruder also has two screw rods 14 that driven by speed changer 17 by electro-motor or hydraulic motor 16.Two screw rods 14 be positioned at bucket 15 inside and with end cap 18,19 in a straight line.Two screw rods 14 of design are used to provide high-rate of shear, and uniform solid particle is necessary to obtaining tiny for this.Certainly, the profile of used screw rod can be different.In addition, any equipment of high-rate of shear that can provide can replace double screw extruder.
Liquid alloy after the shearing in the extruder or semisolid ore pulp are transported in the former by the valve 21 that links to each other with end cap 19.Valve 21 is operated according to the signal that central control system sends.Valve 21 is used for continuously providing the regulated flow of semi-solid ore pulp so that provide suitable molten bath for next step of technology.The optional unlatching of valve 21 should match with the demand of technology.Valve 21 can the open continuously or discontinuous opening with a flow that limits with not having flow restriction.
Fig. 2 is a DC rheocasting system.There are two function assembling devices in this system: a double screw extruder 1 and a DC casting machine 2.Extruder 1 has been described in Fig. 1.DC casting machine 2 mainly comprises a cylindrical mold 31 and cooling medium 33.Mold is placed on extruder 1 to be had on the support 36 in a predetermined slit.Pack into and start substrate so that move continuously.Shearing liquid alloy of laying down or semisolid ore pulp are packed in the DC casting machine.Direct chill device 31 has been full of by entering the mouth and 32 has entered and pass through the cooling mediums 33 that outlet 34 is flowed out.Therefore shearing liquid alloy in the molten bath 30 or semisolid ore pulp can solidify and form strand 34 continuously, and it supports then output strand continuously by substrate 35 when technology begins.
Fig. 3 is the rheology extrusion system.This system is formed by extruder transformation shown in Figure 1.A temperature control extrusion die 8 directly is contained on the outlet valve 21.Extrusion die 8 have one independently thermocouple 9 to keep a required temperature of mould and an outlet 7 to extrude alloy.Variations in temperature around the open mold may reduce more greatly shearing the resistance of liquid alloy or semisolid flow of slurry.Shearing liquid alloy or semisolid ore pulp extrudes from extrusion die and forms bar or wire rod.
Fig. 4 is another extrusion die, and extrusion die 8 has wherein adopted other shape of cross section 7 to produce the product of varying cross-section shape.Usually, extrusion die ground cross section can also can be other any shape that is fit to extrude part for any simple or complicated shape.
Fig. 5 is another rheology extrusion system.There are two functional devices in this system: a double screw extruder and a single screw extrusion machine.Double screw extruder is described in Fig. 1.Single screw extrusion machine is used for shearing liquid alloy or semisolid ore pulp are produced rod/wire as former.Single screw extrusion machine is by bucket 42, screw rod 43, and nozzle 41 and the heating element heater 45 with bucket 42 of the thermocouple 46 that needs for satisfied temperature are formed.Shearing liquid alloy or semisolid ore pulp is discharged in the single screw extrusion machine by valve 22.The continuous rotation of screw rod 43 makes shearing liquid alloy or semisolid ore pulp move to nozzle 41 and form continuous product.Carry out temperature controlled bucket 42 by heating element heater 45 and may reduce to shear liquid alloy or semisolid ore pulp ground outflow resistance greatly.The shape of the cross sectional shape decision extruding part of nozzle 41.Nozzle can be for forming simple roundlet or other any possible shape of metal wire rod.The extruder of this prior art can be transformed by adopting wherein at least one open mold to be transformed into a difform alternate embodiment of the present invention.
Fig. 6 is an a pair of roller rheocasting system.This system comprises two functional devices: two screw extruders 1 and a dual roll casting machine 2.Extruder is described in Fig. 1.Dual roll casting machine 2 mainly comprises an a pair of roller 22 and an offside dam 23.The two roller levels and the placement that certain intervals is arranged is parallel to each other, one or two roller all have support so that roller directly make progress optional select mobile.The direction of rotation of roller 22 such as arrow indication.The inside of each roller 22 can constitute a cooling cover or a heating muff.Side dam 23 axially links to each other with roller roller 22.Between the inner surface on the upper surface of roller 22 opposite ends and dam, both sides 23, be formed for storing the molten bath 24 of semisolid ore pulp.With this understanding, roller 22 with the direction shown in the arrow in scheming rotation so that the solid shell 25 that form on roller 22 surfaces are left behind and then form continuous Cast Strip 26 owing to the effect of pressure bonds together.
As shown in Figure 6, the outer surface of roller is generally flat, as level and smooth column roller.Casting machine in this type of prior art can by adopt another embodiment of the present invention (wherein at least the part surface of roller for convex or concave surface or other any suitable surface) transform.
Usually, system also has a control device to realize all functions.Control device be preferably sequencing so that obtain the metal of desirable characteristics.The control device (not shown) may comprise that as miniature message handler it can be regrouped program easily and apace and change the fixed relevant parameter according to the final products type.
Also can contain an equipment that is connected in extruder and is used for improving bucket pressure in the embodiment.Also can contain one in the embodiment is connected in extruder and associated components and is used to provide protective gas to avoid the equipment of oxidation.This type of gas can be argon gas, nitrogen or other suitable gas.
Though particular of the present invention has given diagram and described in foregoing, clearly, the present invention also can have other different form in appended claims.For example bucket and screw rod can be modular design (modular design).
Claims (13)
1. method by the continuous product of liquid metal alloy manufacturing may further comprise the steps:
Alloy is cooled to such temperature, and this temperature is the temperature from the solidus of alloy to liquidus curve;
Alloy is sheared so that alloy changes its thixotroping attitude into sufficiently high shear rate and turbulence intensity; With
Liquid alloy of shearing or the semisolid ore pulp of shearing are transported in the former to form solid product;
Described former wherein can be made continuous product,
Wherein shearing is applied to alloy by having at least two double screw extruders to the screw rod of small part interlock.
2. method as claimed in claim 1, at least have a blade on wherein said at least two at least one screw rods to the screw rod of small part interlock, described blade defines spiral at least in part and passes through extruder to advance alloy around screw rod, wherein, when alloy was semi-solid state, described at least one screw rod can rotate enough to be suppressed at the speed that wherein is completed into dendritic structure sheared above-mentioned liquid alloy.
3. as the method for claim 1 or 2, wherein, screw rod is interlock fully basically.
4. as the method for above-mentioned claim 1 or 2, wherein, described former is direct chill casting machine, extrusion die or dual roll casting machine.
5. as above-mentioned the process of claim 1 wherein, described alloy comprises at least two kinds of unmixing compositions and wherein, and described composition provides with liquid condition separately, and carries out premix before shearing.
6. method as claimed in claim 5, wherein, described alloy is fully sheared to be transformed into liquid suspension, and wherein, less important unmixing composition is dispersed in the main unmixing composition mutually with liquid.
7. as the method in the claim 6, wherein, when described liquid suspension is sheared, should be cooled to below its monotectic temperature or the monotectic temperature to form semi-solid ore pulp.
8. method as claimed in claim 7, wherein, it is enough big to prevent the thick segregation of unmixing system that ore pulp viscosity is wanted.
9. as each method in the claim 1 to 2, wherein, alloy does not comprise any immiscible composition.
10. goods of being made by metal alloy, wherein, goods can be required that each method obtains among the 1-2 by aforesaid right.
11. device of liquid metal alloy being made continuous product, comprise: can give enough shearings of semi-solid metal alloy and turbulence intensity, it is transformed into the temperature controlled shear of its thixotropic state, with the building mortion that links to each other with shear with liquid form, wherein, this building mortion can be made continuous product, and wherein said shear is to have at least two double screw extruders to the screw rod of small part interlock.
12. device as claim 11, at least have a blade on wherein said at least two at least one screw rods to the screw rod of small part interlock, this blade passes through extruder at peripheral part definition spiral of screw rod to advance alloy at least, wherein, when alloy was semi-solid state, this at least one screw rod can wherein be completed into dendritic structure to be suppressed at enough above-mentioned liquid alloys of speed rotational shear.
13. as the device of claim 11 or 12, wherein, described screw rod is interlock fully basically.
Applications Claiming Priority (6)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB0019855A GB0019855D0 (en) | 2000-08-11 | 2000-08-11 | Method and apparatus for forming a metal sheet |
| GB0019855.6 | 2000-08-11 | ||
| GB0019856.4 | 2000-08-11 | ||
| GB0019856A GB0019856D0 (en) | 2000-08-11 | 2000-08-11 | Method and apparatus for making castings |
| GB0118289.8 | 2001-07-26 | ||
| GB0118289A GB0118289D0 (en) | 2001-07-26 | 2001-07-26 | Process for forming metal alloy articles |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN1446134A CN1446134A (en) | 2003-10-01 |
| CN1265915C true CN1265915C (en) | 2006-07-26 |
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|---|---|---|---|
| CNB018140319A Expired - Fee Related CN1265915C (en) | 2000-08-11 | 2001-08-09 | Method and apparatus for making metal alloy castings |
Country Status (8)
| Country | Link |
|---|---|
| US (1) | US20040089437A1 (en) |
| EP (1) | EP1307308B1 (en) |
| CN (1) | CN1265915C (en) |
| AT (1) | ATE284285T1 (en) |
| AU (2) | AU8227301A (en) |
| CA (1) | CA2417822C (en) |
| DE (1) | DE60107690T2 (en) |
| WO (1) | WO2002013993A1 (en) |
Cited By (2)
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|---|---|---|---|---|
| CN102615989A (en) * | 2006-10-11 | 2012-08-01 | 施乐公司 | Solid ink stick fabrication by extrusion, roll forming and swaging |
| CN103170606A (en) * | 2011-12-23 | 2013-06-26 | 北京有色金属研究总院 | Device for manufacturing metal paste in double forcing and homogenizing mode and machining forming method thereof |
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| GB2354471A (en) | 1999-09-24 | 2001-03-28 | Univ Brunel | Producung semisolid metal slurries and shaped components therefrom |
| AU784926B2 (en) * | 2001-03-26 | 2006-07-27 | Kiichi Miyazaki | Method and apparatus for production of platelike metal material |
| JP3867769B2 (en) * | 2001-03-26 | 2007-01-10 | 徹一 茂木 | Method and apparatus for manufacturing plate metal material |
| AU2003900971A0 (en) * | 2003-02-28 | 2003-03-13 | Commonwealth Scientific And Industrial Research Organisation | Magnesium alloy sheet and its production |
| US7509993B1 (en) | 2005-08-13 | 2009-03-31 | Wisconsin Alumni Research Foundation | Semi-solid forming of metal-matrix nanocomposites |
| CN100421841C (en) * | 2005-11-18 | 2008-10-01 | 北京有色金属研究总院 | Composite shearing semi-solid state metal rheological slurry preparation method |
| CN100509217C (en) * | 2006-09-20 | 2009-07-08 | 中国科学院金属研究所 | Equipment for preparing monotectic alloy shell type composite tissue powder and use method thereof |
| CN101049630B (en) * | 2007-01-23 | 2010-10-06 | 程思明 | Continuous casting product line process flow |
| CN101406925B (en) * | 2008-11-18 | 2011-08-24 | 浙江大学 | Method for device for forming metal micro-thixotropy in semi-solid state assistant by supersonic vibration |
| AT512229B1 (en) * | 2011-11-10 | 2014-10-15 | Mold Thix Consulting Bueltermann Gmbh | DEVICE, APPARATUS AND METHOD FOR THE PRESSURE GASING OF METALLIC MATERIAL IN THE THIXOTROPIC CONDITION |
| WO2014113894A1 (en) | 2013-01-25 | 2014-07-31 | Calaeris Energy & Environment Ltd. | Turbulent vacuum thermal separation methods and systems |
| AT518824A1 (en) * | 2016-05-31 | 2018-01-15 | Lkr Leichtmetallkompetenzzentrum Ranshofen Gmbh | Method for producing a profile from a metal alloy |
| CN107022731B (en) * | 2017-04-25 | 2023-05-12 | 昆明理工大学 | Device for preparing semi-solid slurry and carrying out surface coating |
| CN108246993A (en) * | 2018-01-18 | 2018-07-06 | 中北大学 | A kind of aluminium alloy semi-solid casting-rolling method |
| CN112371868B (en) * | 2020-10-26 | 2022-03-15 | 广州法思特精密五金有限公司 | Screw head forming process |
| CN113798464A (en) * | 2021-08-11 | 2021-12-17 | 昆明理工大学 | Split type totally-enclosed melt constraint flow induced nucleation semi-solid slurry preparation device |
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| US4694881A (en) * | 1981-12-01 | 1987-09-22 | The Dow Chemical Company | Method for making thixotropic materials |
| US4694882A (en) * | 1981-12-01 | 1987-09-22 | The Dow Chemical Company | Method for making thixotropic materials |
| US4494461A (en) * | 1982-01-06 | 1985-01-22 | Olin Corporation | Method and apparatus for forming a thixoforged copper base alloy cartridge casing |
| GB8305066D0 (en) * | 1983-02-23 | 1983-03-30 | Secretary Industry Brit | Casting of material |
| JPH07100216B2 (en) * | 1987-09-29 | 1995-11-01 | 石川島播磨重工業株式会社 | Thin plate manufacturing equipment |
| JPH01192447A (en) * | 1988-01-27 | 1989-08-02 | Agency Of Ind Science & Technol | Method and apparatus for continuously forming metallic slurry for continuous casting |
| GB9201364D0 (en) * | 1992-01-22 | 1992-03-11 | British Steel Plc | Liquid metal processing |
| JP3013226B2 (en) * | 1994-04-28 | 2000-02-28 | 株式会社日本製鋼所 | Manufacturing method of metal molded products |
| JP2976274B2 (en) * | 1995-05-29 | 1999-11-10 | 株式会社日本製鋼所 | Injection molding method and injection molding apparatus for low melting metal material |
| AU1287597A (en) * | 1995-12-12 | 1997-07-03 | Thixomat, Inc. | Apparatus for processing semisolid thixotropic metallic slurries |
| US5711366A (en) * | 1996-05-31 | 1998-01-27 | Thixomat, Inc. | Apparatus for processing corrosive molten metals |
| EP0839589A1 (en) * | 1996-11-04 | 1998-05-06 | Alusuisse Technology & Management AG | Method for producing a metallic profiled strand |
| DE19907118C1 (en) * | 1999-02-19 | 2000-05-25 | Krauss Maffei Kunststofftech | Injection molding apparatus for producing molded metal parts with dendritic properties comprises an extruder with screw system |
| GB2354471A (en) * | 1999-09-24 | 2001-03-28 | Univ Brunel | Producung semisolid metal slurries and shaped components therefrom |
| GB2354472A (en) * | 1999-09-24 | 2001-03-28 | Univ Brunel | Manufacturing castings from immiscible metallic liquids |
-
2001
- 2001-08-09 AU AU8227301A patent/AU8227301A/en active Pending
- 2001-08-09 AT AT01960880T patent/ATE284285T1/en not_active IP Right Cessation
- 2001-08-09 WO PCT/GB2001/003596 patent/WO2002013993A1/en active IP Right Grant
- 2001-08-09 EP EP01960880A patent/EP1307308B1/en not_active Expired - Lifetime
- 2001-08-09 CA CA002417822A patent/CA2417822C/en not_active Expired - Fee Related
- 2001-08-09 AU AU2001282273A patent/AU2001282273B2/en not_active Ceased
- 2001-08-09 CN CNB018140319A patent/CN1265915C/en not_active Expired - Fee Related
- 2001-08-09 DE DE60107690T patent/DE60107690T2/en not_active Expired - Lifetime
- 2001-08-09 US US10/344,209 patent/US20040089437A1/en not_active Abandoned
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102615989A (en) * | 2006-10-11 | 2012-08-01 | 施乐公司 | Solid ink stick fabrication by extrusion, roll forming and swaging |
| CN103170606A (en) * | 2011-12-23 | 2013-06-26 | 北京有色金属研究总院 | Device for manufacturing metal paste in double forcing and homogenizing mode and machining forming method thereof |
Also Published As
| Publication number | Publication date |
|---|---|
| AU8227301A (en) | 2002-02-25 |
| EP1307308B1 (en) | 2004-12-08 |
| AU2001282273B2 (en) | 2006-03-30 |
| ATE284285T1 (en) | 2004-12-15 |
| DE60107690T2 (en) | 2005-12-15 |
| US20040089437A1 (en) | 2004-05-13 |
| CA2417822A1 (en) | 2002-02-21 |
| WO2002013993A1 (en) | 2002-02-21 |
| DE60107690D1 (en) | 2005-01-13 |
| CN1446134A (en) | 2003-10-01 |
| CA2417822C (en) | 2009-09-15 |
| EP1307308A1 (en) | 2003-05-07 |
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