CN1718317A - Electromagnetic semicontinuous casting method of aluminium alloy pipe material and its casting device - Google Patents
Electromagnetic semicontinuous casting method of aluminium alloy pipe material and its casting device Download PDFInfo
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Abstract
An electromagnetic semi-conticasting method for casting Al-alloy tube features that its casting temp is 710-770 deg.C, its casting speed is 60-180 mm/min, its electromagnetic field is 10000-20000 ampere-turn and 1-100 Hz for internal coil and 2000-8000 ampere-turn and 1-100 Hz for external coil, and the phase difference between said two coils is 0-359 deg., Its apparatus is composed of semi-conticaster, internal and external crystallizers, two water-cooled coils, etc.
Description
Technical field
The invention belongs to the aluminium alloy pipe casting technology field, relate in particular to aluminium alloy pipe electromagnetism D.C.casting method and casting device.
Background technology
High performance aluminium alloy pipe is used widely in every profession and trades such as electric power, buildings, and its production method mainly contains two kinds:
1, be cast as excellent base, rolling then or be squeezed into tubing, but operation is many like this, using rate of metal is low;
2, be cast as hollow bloom earlier, apply less deflection and make tubing, the using rate of metal height.Being cast with of common aluminum alloy hollow pipe: sand casting, centrifugal casting and semi-continuous casting.
Sand casting: small investment, adaptability are strong, can produce the product of different shape, specification.But production efficiency is low, and labour intensity is big; And cooling velocity is slow in the casting, and nucleation rate is low, and crystal grain is thick; Shrinkage porosite, pore, be mingled with, blemish such as microscopic structure defective such as segregation and depression, crackle is more.
Centrifugal casting: equipment is simple, and product variety is flexible, is widely used, and can produce in batches.In the casting, molten metal pours into type tube, rotates the type tube moulding.Because molten metal at the centrifugal action compacted under, is easy to produce segregation; And the inner surface of centrifugal casting is Free Surface, and surface quality is general; Surfaces externally and internally cooling condition difference (inner surface is an air cooling), so solidified structure is generally all inhomogeneous, but centrifugal casting has special advantages aspect the production functionally gradient material (FGM).Electromagnetic centrifugal casting is the technology that applies magnetic field on the basis of centrifugal casting, has the beneficial functional that changes dendritic growth direction, crystal grain thinning.
Semi-continuous casting: be liquid metal moulding in the die cavity of inside and outside crystallizer and dummy ingot base composition, with the mobile pipe that is drawn into of dummy ingot base, process equipment is simple, small investment.In the casting, even along the field distribution of tube wall peripheral force, there is not the segregation problem of centrifugal force.But in the process of setting, liquid metal solidification is shunk, the first scull of ingot casting increases sharply with the pressure that contacts of interior crystallizer, surperficial drawing crack often occurs, even produces " embracing core " phenomenon of ingot casting and the direct locking of interior crystallizer.Crystal grain is thick, has the relatively more flourishing mechanical property that influences ingot casting of arborescent structure of directionality.A large number of experiments show that to apply the advantage that magnetic field has crystal grain thinning, improves surface smoothness in the solid ingot D.C.casting, is simple and direct, the effective process that improves the ingot blank quality.Solid ingot electromagnetic casting method has containerless casting (US Patent No 3,467,166), power frequency electromagnetic casting (US Patent No 4,523,628), low frequency electromagnetic casting (Chinese patent No02133270.3) etc. at present.The electromagnetism semi-continuous casting of hollow pipe is except outside the early stage hollow pipe containerless casting (US Patent No 4,126,175), all belongs to blank in the research of the each side such as power frequency electromagnetic casting, low frequency electromagnetic casting and electromagnetic viscosimeter of hollow pipe.Because containerless casting is low to requirement height, the lumber recovery of control system, therefore never see the industrial production report of hollow pipe containerless casting.In recent years, the research relevant with the electromagnetism semi-continuous pipe casting has only the unicoil electromagnetic continuous pipe-casting of H.Harada, Li Qiulin, though at crystal grain thinning, improving the outer surface quality aspect has good result, has certain industrial production and is worth.But the magnetic field that produces because of coil makes liquid metal, first scull be subjected to radially inside electromagnetic force, and produces following problem:
1, inner surface quality: interior crystallizer and inner surface initial set shell joint touch closely, conduct heat, and metal freezing shrinks strong, and interior crystallizer is big with the frictional force of first scull, influences the ingot casting inner surface quality; When the tensile strength of frictional force greater than first scull, inner surface then can drawing crack.
2, embrace core: the electromagnetic force that applies behind the magnetic field is radially inside, and liquid metal, first scull not only do not reduce on the contrary for the contact pressure of interior crystallizer and increase, and have therefore increased the probability of " embracing core ".
3, Tissue distribution inequality: the ingot casting surfaces externally and internally is different with the contact tightness degree of inside and outside crystallizer, and intensity of cooling is also different, makes the solidified structure skewness.
Summary of the invention
Weak point at existing aluminium alloy pipe foundry engieering the invention provides a kind of aluminium alloy pipe electromagnetism D.C.casting method and casting device.
Aluminium alloy pipe electromagnetism D.C.casting casting device of the present invention, be on semicontinuous casting machine, the non-magnetic stainless steel crystallizer is set, comprise outer crystallizer and interior crystallizer, interior crystallizer is a little more than outer crystallizer, and two full built-in water-cooling coils are set, i.e. exterior loop and interior loop, two coils are the high temperature resistant magnet wire that scribbles insulated paint.In casting device when work,, the magnetic field that two coils produce acts on the Al-alloy metal melt simultaneously, compares with unicoil that Distribution of Magnetic Field is complicated more, the magnetic field adjustable range is wideer.The non-magnetic stainless steel crystallizer reduces the loss of magnetic field on crystallizer, more effective the acting on the aluminium alloy melt in magnetic field that coil is produced.Interior crystallizer and outer crystallizer all are provided with the high heat top of 50～200mm, realize the effective insulation to aluminium alloy melt, aluminum melt is fully flowed reduce the radial temperature difference of melt.Upper end, interior heat top at interior crystallizer is provided with the formula chute that drenches with rain, the formula cast that realizes drenching with rain, thus make the circumferential temperature of pipe more evenly can cast out the more pipe of high-quality.
In the casting, vibration and forced convertion take place in metal bath under the electromagnetic force effect, aluminum melt is played the concise effect of degasification.Forced convertion impels the thermograde of ingot casting wall thickness center and limit portion to reduce, and reduces thermal stress; Because the temperature field of metal bath is even, can two-phase section near liquid phase region very on a large scale in explosion type forming core simultaneously, form and wait a fine grained texture uniformly; Forced convertion simultaneously and vibration make dendrite fusing, fracture and suppressed the growth of dendrite, increase equiax crystal quantity; Make the two-phase section bottom, reduce near the effect crystal region width of solidus, the feeding capacity in having strengthened solidifying has reduced defectives such as loose, shrinkage cavity; Forced convertion enters the nucleus disengaging wall that forms on the crystallizer wall becomes the nucleating center in the melt, increase forming core quantity, crystal grain thinning.Electromagnetic force promotes metal bath and first scull in addition, the effect that has balance static pressure and control surface to be shaped, and effect is obviously under the high frequency.Under the twin coil condition, can make the direction of electromagnetic force radially outside, realize the electro-magnetic forming of inner surface.Because electromagnetic force equilibrium or weakened melt static pressure has suppressed the formation of segregation knurl; Electromagnetic force promotes ingot casting inner surface scull just, makes just scull and the separative trend of interior crystallizer, has weakened hot conduction and solidification shrinkage, has reduced crackle and has taken place with " embracing core "; Electromagnetic force effect metal bath forms meniscus, reduced melt and interior crystallizer contact length and pressure, weakened intensity of cooling one time, improved ingot surface quality.
Aluminium alloy pipe electromagnetism D.C.casting technology of the present invention adopts aforesaid aluminium alloy pipe electromagnetism D.C.casting device to finish, and method is as follows:
Connect the cooling water of interior loop and exterior loop, connect the power supply of interior loop and exterior loop, after interior loop and exterior loop feed electric current, cast aluminum water, aluminium water are entered by the hole that drenches with rain under the formula chute that drenches with rain and solidify die cavity, form scull just, move down the dummy ingot base, carry out the casting of hollow ingot.710～770 ℃ of casting temperatures of the present invention, casting speed is 60～180mm/min, because in the casting, effective function in ingot casting electromagnetic field be the outer measuring magnetic field of interior loop and the inboard magnetic field of exterior loop, therefore the electromagnetic field that applies is interior loop 10000～20000 numbers of ampere turns, and frequency is 1～100Hz, and exterior loop is 2000～8000 numbers of ampere turns, frequency is 1～100Hz, and phase difference lags behind 0 °～359 ° of interior loop current phases for the exterior loop current phase.
Adopt the inventive method, can realize difference phase power frequency continuous casting electromagnetic, low frequency electromagnetic continuous casting by intensity, frequency, the phase place of adjusting loading current.
Difference phase power frequency continuous casting electromagnetic cast temperature is 710～770 ℃, casting speed is 60～180mm/min, the electromagnetic field that applies is interior loop 10000～20000 numbers of ampere turns, frequency is 50Hz, exterior loop 2000～8000 numbers of ampere turns, frequency is 50Hz, and phase difference lags behind 1 °～90 ° of interior loop current phases for the exterior loop current phase.Under the effect of difference phase power frequency magnetic field, Distribution of Magnetic Field is even in the ingot casting, and near metal bath interior graphite annulus, the outer graphite annulus and first scull are subjected to very strong electromagnetic repulsion force effect; Fully suppress the formation of segregation knurl, obtained all smooth bright and clean ingot casting of surfaces externally and internally; The flowing velocity of wall thickness middle part metal bath is obviously accelerated, and flow regime becomes the big circulation that involves whole molten bath by the little whirlpool of bilateral symmetry in no magnetic field; Liquidus curve moves up, and it is smooth that solidus becomes, and two-phase section enlarges, and temperature is even in the molten bath, makes metal bath under less degree of supercooling, can form the forming core of explosion type, and nucleus collides mutually, rubs, and makes the dendritic growth difficulty, and it is closely spherical that crystal grain becomes; The wall thickness middle part reduces with the temperature difference of surfaces externally and internally simultaneously, has reduced the thermal stress of ingot casting, has suppressed the formation of crackle.
Low frequency electromagnetic continuous casting process casting temperature is 710～770 ℃, casting speed is 60～180mm/min, the electromagnetic field that applies is interior loop 10000～20000 numbers of ampere turns, frequency is 1～50Hz, exterior loop 2000～8000 numbers of ampere turns, frequency is 1～50Hz, and exterior loop electric current and interior loop current and phase difference are 0 °.Under the low frequency magnetic field effect, Distribution of Magnetic Field is even in the ingot casting, and near metal bath the inside/outside graphite annulus and first scull are subjected to certain electromagnetic repulsion force effect; Can suppress the formation of segregation knurl, obtain the smooth ingot casting of surfaces externally and internally; The flowing velocity of wall thickness middle part metal bath is obviously accelerated, and forms a big circulation in the molten bath, flow direction and difference mutually under the magnetic field on the contrary; Liquidus curve moves up, and it is smooth that solidus becomes, and two-phase section enlarges, and thermograde reduces, and produces the forming core of explosion type in the melt, and forming core quantity is increased sharply, and makes the abundant refinement of crystal grain, and crystal grain collides mutually, rubs simultaneously, suppresses dendritic growth, makes crystal grain become closely spherical; And under the low frequency magnetic field, the low frequency pulsating amount of electromagnetic force, the inertia response that more approaches the intergranular melt is interval, can cause intergranular melt generation forced oscillation in the two-phase section, change the type of flow of intergranular melt, thereby avoid dendrite too to grow up, the effect of playing crystal grain thinning and improving proportion of equiaxed grain; Because the wall thickness middle part reduces with the surfaces externally and internally temperature difference, has reduced the thermal stress in the tube wall, has suppressed the formation of crackle.
Adopt electromagnetism D.C.casting method of the present invention and casting device, can make the nodularization of pipe crystal grain, refinement, even tissue, effectively improve the inside and outside surface quality of aluminium alloy pipe, realize the nearly end form shape casting of tubing; And can solve " embracing core " problem.The inventive method technology is simple, can realize multiple casting technique by intensity, frequency, the phase place of adjusting loading current, except that power frequency continuous casting electromagnetic, difference phase power frequency continuous casting electromagnetic, low frequency electromagnetic continuous casting, also can implement electromagnetic viscosimeter, high-frequency electromagnetic continuous casting, list (inside/outside) coil electromagnetism continuous casting etc., so the present invention has very strong industrial utility value.
Description of drawings
Fig. 1 is an aluminium alloy pipe electromagnetism D.C.casting casting device structural representation of the present invention, comprising: 1 support, 2 drench with rain heat tops in the formula chute, 3,4 glands, 5 outer crystallizer overcoats, 6 dummy ingot bases, 7 nuts, 8 interior crystallizers inlet water pipe, 9 interior crystallizer loam cakes, 10 intercrystalline bodies, 11 outer heat tops, 12 outer crystallizers enter the mouth water pipes, 13 exterior loop, the interior cover of 14 outer crystallizers, 15 stone mill rings, 16 aluminium alloy cast tubes, 17 interior loop.
What Fig. 2～Fig. 5 represented is the distribution of magnetic induction in the ingot casting, wherein Fig. 2 be under the difference phase magnetic field condition in ingot casting the real part schematic diagram of magnetic induction, Fig. 3 be under the difference phase magnetic field condition in ingot casting the imaginary part schematic diagram of magnetic induction, Fig. 4 be under the low frequency magnetic field condition in ingot casting the real part schematic diagram of magnetic induction, Fig. 5 be under the low frequency magnetic field condition in ingot casting the imaginary part schematic diagram of magnetic induction.
What Fig. 6～Fig. 7 represented is the distribution of electromagnetic force in the ingot casting, wherein Fig. 6 be under the difference phase magnetic field condition in ingot casting the distribution schematic diagram of electromagnetic force, Fig. 7 be under the low frequency magnetic field condition in ingot casting the distribution schematic diagram of electromagnetic force.
What Fig. 8～Figure 10 represented is the distribution of velocity field, and wherein Fig. 8 is the distribution schematic diagram of velocity field under the no magnetic field condition, and Fig. 9 is a velocity field distribution schematic diagram under the difference phase magnetic field condition, and Figure 10 is a velocity field distribution schematic diagram under the low frequency magnetic field condition.
What Figure 11～13 were represented is the distribution in temperature field, and wherein Figure 11 is the distribution schematic diagram in temperature field under the no magnetic field condition, and Figure 12 is a temperature field distribution schematic diagram under the difference phase magnetic field condition, and Figure 13 is a temperature field distribution schematic diagram under the low frequency magnetic field condition.
What Figure 14～Figure 17 represented is the macrostructure and the crackle of ingot casting, wherein Figure 14 is the macroscopic cracking photo under the no magnetic field condition, Figure 15 is the macrograph under the no magnetic field condition, Figure 16 is the macrograph under the difference phase magnetic field condition, and Figure 17 is the macrograph under the low frequency magnetic field condition.
Figure 18～Figure 24 is the microstructure photo of ingot casting, wherein Figure 18 is the microstructure photo of portion of no magnetic field condition bottom ingot casting, Figure 19 is a middle part microstructure photo under the no magnetic field condition, Figure 20 is portion of a difference phase magnetic field condition bottom microstructure photo, Figure 21 is a difference phase magnetic field condition middle part microstructure photo down, Figure 22 is portion of a low frequency magnetic field condition bottom microstructure photo, Figure 23 is a middle part microstructure photo under the low frequency magnetic field condition, and Figure 24 is the arborescent structure photo of portion of no magnetic field condition bottom prosperity.
Figure 25～Figure 27 is the photo of expression ingot surface quality, wherein Figure 25 is the surface picture of the aluminium ingot of casting under the no magnetic field condition, Figure 26 is the difference phase magnetic field condition surface picture of the aluminium ingot of casting down, and Figure 27 is the surface picture of the aluminium ingot cast under the low frequency magnetic field condition.
The specific embodiment
As shown in Figure 1, aluminium alloy pipe electromagnetism D.C.casting casting device of the present invention comprises: 1 support, 2 drench with rain formula chute, enter the mouth water pipes, 13 exterior loop, the interior cover of 14 outer crystallizers, 15 stone mill rings, 16 aluminium alloy cast tubes, 17 interior loop of heat tops, 4 glands, 5 outer crystallizer overcoats, 6 dummy ingot bases, 7 nuts, 8 interior crystallizers inlet water pipe, 9 interior crystallizer loam cakes, 10 intercrystalline bodies, 11 outer heat tops, 12 outer crystallizers in 3.In the outer crystallizer cover 14 and outer crystallizer overcoat 5 involutory after, fix with gland 4, form outer crystallizer waterway, exterior loop 13 places outer crystallizer waterway; Cover 14 is embedded with outer heat top 11, stone mill ring 15 in the outer crystallizer; Intercrystalline body 10, interior crystallizer loam cake 9 are in conjunction with constituting the interior crystallizer waterway, and interior loop 17 places the interior crystallizer waterway.Heat top 3 in being embedded with on the intercrystalline body 10.Interior crystallizer is a little more than outer crystallizer.1 on support is on outer crystallizer, interior crystallizer inlet water pipe 8 passes in the middle of support 1, and is fixing with nut 7, and the interior crystallizer cooling water is entered by interior crystallizer inlet water pipe 8, cool off interior loop 17 on the one hand, the secondary cooling water of aluminium alloy cast tube 16 is provided on the other hand; Outer crystallizer cooling water is entered by outer crystallizer inlet water pipe 12, cools off exterior loop 13 on the one hand, and the secondary cooling water of aluminium alloy cast tube 16 is provided on the other hand.The dummy ingot base 6 of bottom cooperates formation to solidify die cavity with interior crystallizer, outer crystallizer; The formula that drenches with rain chute 2 is arranged at 3 upper ends, interior heat top of interior crystallizer.
Following examples 2 and embodiment 3 are example with the electromagnetism D.C.casting of 6063 aluminium alloys, adopt difference phase power frequency continuous casting electromagnetic, low frequency electromagnetic continuous casting to cast respectively.
Embodiment 2
Difference phase power frequency continuous casting electromagnetic
Ingot casting size: φ 290mm * 35mm, stainless steel dummy ingot base
Magnetic field condition: interior loop: number of ampere turns 14400AT; Exterior loop: number of ampere turns 6000AT; Frequency 50Hz; The exterior loop electric current
Phase place lags behind 50 ° of interior loop
Technological parameter: casting temperature is 750 ℃, and casting speed is 140mm/min.
Ingot quality is compared as follows:
| Casting method | Surface quality | Grain shape | Crystallite dimension/μ m | Crackle |
| The tradition D.C.casting | The segregation knurl is serious, the surface is rough and uneven in surface | Limit portion: dendrite or radial dendrite middle part: thick equiax crystal | Limit portion: 100～1000 middle parts: 100～200 | Longitudinal crack |
| Difference phase power frequency D.C.casting | Smooth bright and clean | Limit, middle part are less equiax crystal | Limit portion: 30～50 middle parts: 40～80 | Do not have |
Embodiment 3
The low frequency electromagnetic continuous casting
Ingot casting size: φ 290mm * 35mm, stainless steel dummy ingot base
Magnetic field condition: interior loop: number of ampere turns 12000AT; Exterior loop: number of ampere turns 5000AT; Frequency 30Hz; The exterior loop electric current
Phase place lags behind 0 ° of interior loop
Technological parameter: 750 ℃ of casting temperatures, casting speed are 140mm/min.
Ingot quality is compared as follows:
| Casting method | Surface quality | Grain shape | Crystallite dimension/μ m | Crackle |
| The tradition D.C.casting | The segregation knurl is serious, the surface is rough and uneven in surface | Limit portion: dendrite or radial dendrite middle part: thick equiax crystal | Limit portion: 100～1000 middle parts: 100～200 | Longitudinal crack |
| The low frequency D.C.casting | Smooth, a small amount of segregation knurl arranged | Limit, middle part are tiny equiax crystal | Limit portion: 20～40 middle parts: 30～60 | Do not have |
Claims (7)
1, a kind of aluminium alloy pipe electromagnetism D.C.casting casting device, comprise support, the formula that drenches with rain chute, interior heat top, gland, outer crystallizer overcoat, the dummy ingot base, nut, interior crystallizer inlet water pipe, the interior crystallizer loam cake, the intercrystalline body, outer heat top, outer crystallizer inlet water pipe, exterior loop, cover in the outer crystallizer, the stone mill ring, interior loop, it is characterized in that on semicontinuous casting machine, outer crystallizer and interior crystallizer are set, and two full built-in water-cooling coils are set, be exterior loop and interior loop, and heat top in being provided with, outer heat top, the stone mill ring and the formula chute that drenches with rain, after interior cover of outer crystallizer and outer crystallizer overcoat are involutory, with the outer crystallizer waterway of the fixing formation of gland, exterior loop places the waterway of outer crystallizer, intercrystalline body and interior crystallizer loam cake are in conjunction with constituting the interior crystallizer waterway, interior loop places the interior crystallizer waterway, cover is embedded with outer heat top and stone mill ring in the outer crystallizer, be embedded with Nei Reding on the intercrystalline body, the formula chute that drenches with rain be set in the upper end, interior heat top of interior crystallizer.
2, according to the described aluminium alloy pipe electromagnetism of claim 1 D.C.casting casting device, it is characterized in that outer crystallizer, interior crystallizer are the non-magnetic stainless steel crystallizer, interior crystallizer is higher than outer crystallizer.
3, according to the described aluminium alloy pipe electromagnetism of claim 1 D.C.casting casting device, it is characterized in that interior loop and exterior loop are the high temperature resistant magnet wire that scribbles insulated paint.
4,, it is characterized in that the height on Nei Reding and outer heat top is 50～200mm according to the described aluminium alloy pipe electromagnetism of claim 1 D.C.casting casting device.
5, adopt the method for the described aluminium alloy pipe electromagnetism of claim 1 D.C.casting casting device Birmasil tubing, it is characterized in that casting technique is: the cooling water of connecting interior loop and exterior loop, connect the power supply of interior loop and exterior loop, after interior loop and exterior loop feed electric current, cast aluminum water, aluminium water is entered by the hole that drenches with rain under the formula chute that drenches with rain and solidifies die cavity, form scull just, move down the dummy ingot base, carry out the casting of aluminium alloy hollow ingot, casting temperature is 710～770 ℃, casting speed is 60～180mm/min, the electromagnetic field that applies is interior loop 10000～20000 numbers of ampere turns, frequency is 1～100Hz, exterior loop 2000～8000 numbers of ampere turns, and frequency is 1～100Hz, phase difference lags behind 0 °～359 ° of interior loop current phases for the exterior loop current phase, by adjusting the intensity of loading current, frequency, phase place realizes difference phase power frequency continuous casting electromagnetic, the low frequency electromagnetic continuous casting.
6, according to the method for the described Birmasil tubing of claim 5, it is characterized in that difference phase power frequency continuous casting electromagnetic cast temperature is 710～770 ℃, casting speed is 60～180mm/min, the electromagnetic field that applies is interior loop 10000～20000 numbers of ampere turns, frequency is 50Hz, exterior loop 2000～8000 numbers of ampere turns, frequency are 50Hz, and phase difference lags behind 1 °～90 ° of interior loop current phases for the exterior loop current phase.
7, according to the method for the described Birmasil tubing of claim 5, it is characterized in that low frequency electromagnetic continuous casting process casting temperature is 710～770 ℃, casting speed is 60～180mm/min, the electromagnetic field that applies is interior loop 10000～20000 numbers of ampere turns, frequency is 1～50Hz, exterior loop 2000～8000 numbers of ampere turns, frequency are 1～50Hz, and exterior loop electric current and interior loop current and phase difference are 0 °.
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| CN106238716A (en) * | 2016-09-19 | 2016-12-21 | 东北大学 | Aluminium alloy stratiform cloth plane of flow solidified cast device and casting method thereof |
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| CN106925736B (en) * | 2017-04-01 | 2018-12-28 | 东北大学 | The Electromagnetic Treatment device and its working method of a kind of semi-continuous casting liquid cave melt |
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| CN108284213B (en) * | 2018-01-26 | 2024-01-26 | 江苏星火特钢集团有限公司 | Device for preventing ingot-drawing type hollow electroslag remelting inner crystallizer from locking by online dynamic monitoring and adjusting method thereof |
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