EP1877209B1 - Method for the production of pigs, and pigs - Google Patents

Method for the production of pigs, and pigs Download PDF

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Publication number
EP1877209B1
EP1877209B1 EP06742695A EP06742695A EP1877209B1 EP 1877209 B1 EP1877209 B1 EP 1877209B1 EP 06742695 A EP06742695 A EP 06742695A EP 06742695 A EP06742695 A EP 06742695A EP 1877209 B1 EP1877209 B1 EP 1877209B1
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Prior art keywords
formation
melt
pigs
energy
temperature
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German (de)
French (fr)
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EP1877209B9 (en
EP1877209A1 (en
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Evgenij Sterling
Hugo Berger
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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
    • B22D1/00—Treatment of fused masses in the ladle or the supply runners before casting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D3/00—Pig or like casting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D46/00—Controlling, supervising, not restricted to casting covered by a single main group, e.g. for safety reasons

Definitions

  • the invention relates to methods for producing ingots of a metal alloy, in which a melt is formed in which a base material and one or more alloying constituents are in the liquid state from which the ingots are formed.
  • Aluminum or cast aluminum alloys are usually provided as semi-finished products in the form of two-piece or three-piece ingots for further processing by casting. To produce the pigs, a melt of the respective metal alloy is formed, which is then poured into ingots.
  • the invention according to claim 1 is based on the object to provide a method for the production of pigs, which lead in the further processing to cast workpieces with improved properties without changes to the previous casting machines must be made. Spesielle Ausfump forms said the untrangen to take.
  • This object is achieved by briefly introducing energy into the melt prior to forming the ingots during cooling by means of a variable physical field which increases the formation of mixed crystals.
  • mixed-crystal unit cells initially form, in which atoms of the base material are substituted by atoms of the additional constituent (s).
  • the formation of enriched mixed crystals is specifically achieved, whereby the saturation limit and the width of the concentration-temperature interval are controlled by means of the external variable physical field, so that oversaturated mixed crystals are formed with impurities.
  • the saturation limit and the increased diffusion of foreign atoms into the space lattice of the base material is not temperature-dependent. Upon further cooling, a fairly fine-grained microstructure of these mixed crystals is formed.
  • the supply of energy takes place at a temperature approximately at the liquidus line of this metal alloy.
  • the time for which the energy supply is to be carried out must be determined experimentally. It is dependent on the specific metal alloy and also on the means by which the energy supply is carried out.
  • the mixed crystal formation is detected by measuring the dynamic viscosity of the melt located in the treatment chamber. The invention assumes that an optimum of the solid solution formation manifests itself when the treated melt, despite the cooling, has reached a particularly low-viscosity state which remains approximately constant and then no longer changes significantly.
  • the formation of mixed crystals is determined by means of measurements of the liquidus temperature of samples taken from the treatment chamber.
  • the invention is based on the fact that the actual liquidus temperature proves to be a kink in the cooling curve due to the heat of crystallization arises. This actual liquidus temperature, if successfully treated, is below the liquidus line given for a state diagram for that metal alloy.
  • the short-term power supply by means of a varying, preferably pulsating electromagnetic field.
  • ingots produced in this way in the manner of a memory effect have the increased flowability produced by means of the treatment in the electromagnetic field even when they are re-melted and processed in a casting machine.
  • treated pigs have an increased flowability compared to the ingots produced by conventional methods, so that castings with complicated shapes and increased density can be produced.
  • the castings produced in this way have increased strength, improved stretch behavior and improved wear behavior. You can partially replace components that previously had to be forged.
  • a melting furnace which has a pouring opening 1, a melting channel 2 and an electric heater 3, the constituents of a metal or a metal alloy are heated to such an extent that all constituents are melted and form a melt 4.
  • This melt 4 is brought through a filling opening 19 into a treatment chamber.
  • This treatment chamber consists of a substantially cylindrical housing part 18, a hemispherical lower part 10 and an approximately hemispherical upper part 7.
  • the treatment chamber is associated with a preferably electric heater 6 in the form of heating coils, with which the treatment chamber to a temperature in the range and for example slightly below the liquidus line of the special metal alloy is heated, for example, to about the eutectic temperature of the metal alloy.
  • the treatment chamber is associated with a device 5 introducing energy, for example by generating a rotating electromagnetic field.
  • This electromagnetic field has, for example, a field strength of 6 to 20 mT and rotates at a frequency of about 60 Hz to 500 Hz.
  • the two-phase is shrinking continuously due to sinking liquidus temperature and simultaneously increasing solidus temperature, so that the Konode becomes shorter.
  • the melt 11 is removed by means of a removal robot 12 of the treatment chamber and filled in ingots 14, which are transported on a mass train 13.
  • the ingot molds 14 are emptied, so that then empty ingot molds 17 can again be supplied to the removal robot 12.
  • the highest flowability or lowest viscosity which is an indication of the increased solid solution formation, is measured by means of a viscometer 8 online in the treatment chamber, so that it can be determined at any time whether the desired state for the melt 11 has been reached.
  • the external energetic action changes the energetic state of the liquid crystalline base crystal. His space grid is loosened up, facilitating the process of building new atomic groupings.
  • the energy and the bonding forces between the atoms of individual components and structural units of the metal alloys emerge as one of the decisive factors.
  • the viscosity is one of these properties.
  • the construction and remodeling of atomic complexes leads to a release of strong compounds, which were rather closed inside the complexes. These compounds participate in the viscous flow and also in dislocations of structural units.
  • a decreasing viscosity is therefore attributed to an atomic complex having the weakened inner and starched outer compounds.
  • This creates the technological-physical prerequisites under which collective areas with a uniform orientation are built up in the liquid-crystalline system.
  • the new structuring and its energetic stability are enhanced by the variable electromagnetic field.
  • the result is the lower viscosity, which reflects the energetic state of the space lattice or microstructure units of the melt.
  • the fluidity can be displayed on a monitor 16, for example.
  • the maximum flowability is achieved when the fluidity no longer increases significantly, ie, has reached the approximately horizontal branch of the curve shown on the monitor 16 of the flowability ⁇ over time t.
  • samples of the melt 11 are taken from the treatment chamber and analyzed.
  • it can be displayed on another monitor 9 how the liquidus temperature T L changes and has approached the liquidus line of the specific metal alloy of the solidus temperature line Ts.
  • a picture of the temperature T over the time t can be displayed on a monitor 9.
  • the build-up process of the supersaturated mixed crystal, which had begun in the liquid-crystalline system, is completed during the cooling of the alloy, so that the preparation of a realistic state diagram is possible.
  • thermodynamic Representation covers a wide range of alloy properties, such as concentration indication, liquidus solidus line, saturation limit (solubility), etc., which allow to set the appropriate technological casting parameters for the alloy produced by the process of the present invention.
  • ingots which have been produced by the above process are further processed, resulting in advantageous conditions.
  • the increase in fluidity resulting from the treatment is not reversible because the mixed crystals are stable.
  • the melt produced during further processing from molten ingots has an improved flowability and a lower tendency to oxidation. As the pigs melt, less scabies appear on the surface of the bath.
  • the invention is based on the fact that the external energetic action, ie the interaction between an external electromagnetic field and an internal electromagnetic field of the crystal, influences an amplification of the diffusion process and interatomic compounds.
  • the result of this interaction is a construction of an alloy whose crystals in the molten state have a far-reaching order or distance order.
  • This interaction can also be controlled by having an alloying component is added, which differs from the base material by the magnetic susceptibility.
  • the invention is particularly suitable for metal alloys in which the base material is aluminum and the main additive component is silicon. In principle, however, the invention is applicable to all metal alloys, regardless of the magnetic susceptibility of the constituents.
  • the external energetic action takes place in the embodiment by means of a varying, pulsating electromagnetic field. However, other possibilities for external energetic action by means of a variable physical field are also readily given, for example an action by means of ultrasound. In this case, the field is designed so that the conditions resulting from the above-described electromagnetic field are also obtained.
  • the pigs according to the invention are suitable for all casting processes.
  • the high flowability is of particular advantage
  • die casting the excellent formability is of particular advantage. It is believed that, as the ingots melt, the new atomic arrangement in the space lattice obtained by the diffusion pretreatment is retained even when the ingots are melted, without the atoms of the alloying components giving up their places in the aluminum lattice.
  • pigs according to the invention not only the commercial forms of pigs are understood. Rather, it should be understood to mean any form in which a processed melt is poured off before re-melting for a casting process.

Description

Die Erfindung betrifft Verfahren zum Herstellen von Masseln aus einer Metalllegierung, bei welchem eine Schmelze gebildet wird, in welcher ein Basismaterial und ein oder mehrere Legierungsbestandteile sich in flüssigem Zustand befinden, aus welcher die Masseln geformt werden.The invention relates to methods for producing ingots of a metal alloy, in which a melt is formed in which a base material and one or more alloying constituents are in the liquid state from which the ingots are formed.

Aluminium oder Aluminiumgusslegierungen werden üblicherweise als Halbzeug in Form von zweiteiligen oder dreiteiligen Masseln für die Weiterverarbeitung durch Gießen zur Verfügung gestellt. Um die Masseln herzustellen, wird eine Schmelze aus der betreffenden Metalllegierung gebildet, die dann in Masselformen gegossen wird.Aluminum or cast aluminum alloys are usually provided as semi-finished products in the form of two-piece or three-piece ingots for further processing by casting. To produce the pigs, a melt of the respective metal alloy is formed, which is then poured into ingots.

Um die Qualität der Gussstücke, die aus derartigen Masseln hergestellt werden, zu verbessern, ist es auch bekannt ( DE 10002670 A1 ) die Masseln in einem Ofen aufzuschmelzen und dann die Schmelze in einer Behandlungskammer einem rotierenden elektromagnetischen Feld auszusetzen und die auf diese Weise behandelte Schmelze zu vergießen. Dieses Verfahren führt zu einer erheblichen Verbesserung der Gussteile.In order to improve the quality of castings made from such pigs, it is also known ( DE 10002670 A1 ) melt the pigs in an oven and then subject the melt to a rotating electromagnetic field in a treatment chamber and to pour the melt thus treated. This process leads to a significant improvement of the castings.

Der Erfindung gemäβ Auspruch 1 liegt die Aufgabe zugrunde, ein Verfahren zum Herstellen von Masseln zu schaffen, die bei der Weiterverarbeitung zu Gusswerkstücken mit verbesserten Eigenschaften führen, ohne dass Veränderungen an den bisherigen Gießmaschinen vorgenommen werden müssen. Spesielle Ausführump formen said den untransprüchen zu entnehmen.The invention according to claim 1 is based on the object to provide a method for the production of pigs, which lead in the further processing to cast workpieces with improved properties without changes to the previous casting machines must be made. Spesielle Ausfump forms said the untransprüchen to take.

Diese Aufgabe wird dadurch gelöst, dass in die Schmelze vor dem Formen der Masseln während des Abkühlens kurzzeitig Energie mittels eines variablen physikalischen Feldes eingebracht wird, die das Bilden von Mischkristallen steigert.This object is achieved by briefly introducing energy into the melt prior to forming the ingots during cooling by means of a variable physical field which increases the formation of mixed crystals.

Dokument D7 ( EP 1 077 098 A1 ) beschreibt ein Verfahren zum Herstellen von Masseln aus einer Metalllegierung, bei welchem zunächst eine Schmelze gebildet wird, in welcher ein Basismaterial und ein oder mehrere Legierungsbestandteile sich in flüssigem Zustand befinden, aus welcher die Masseln geformt werden.Document D7 ( EP 1 077 098 A1 ) describes a method for producing ingots of a metal alloy, in which first a melt is formed in which a base material and one or more alloying constituents are in the liquid state from which the ingots are formed.

Durch die Erfindung wird erreicht, dass zunächst Mischkristall-Elementarzellen entstehen, bei welchen Atome des Basismaterials durch Atome des oder der Zusatzbestandteile substituiert sind. Es wird gezielt die Bildung von angereicherten Mischkristallen erreicht, wobei die Sättigungsgrenze und die Breite des Konzentrations-TemperaturIntervalls mittels des äußeren variablen physikalischen Feldes kontrolliert wird, so dass mit Fremdatomen übersättigte Mischkristalle entstehen. Die Sättigungsgrenze und die gesteigerte Diffusion von Fremdatomen in das Raumgitter des Basismaterials ist nicht temperaturabhängig. Beim weiteren Abkühlen entsteht ein recht feinkörniges Gefüge aus diesen Mischkristallen.As a result of the invention it is achieved that mixed-crystal unit cells initially form, in which atoms of the base material are substituted by atoms of the additional constituent (s). The formation of enriched mixed crystals is specifically achieved, whereby the saturation limit and the width of the concentration-temperature interval are controlled by means of the external variable physical field, so that oversaturated mixed crystals are formed with impurities. The saturation limit and the increased diffusion of foreign atoms into the space lattice of the base material is not temperature-dependent. Upon further cooling, a fairly fine-grained microstructure of these mixed crystals is formed.

In Ausgestaltung der Erfindung wird vorgesehen, dass das Zuführen von Energie bei einer Temperatur etwa bei der Liquiduslinie dieser Metalllegierung erfolgt.In an embodiment of the invention it is provided that the supply of energy takes place at a temperature approximately at the liquidus line of this metal alloy.

Die Zeit, für die die Energiezufuhr durchgeführt werden soll, ist experimentell zu ermitteln. Sie ist von der speziellen Metalllegierung und auch von den Mitteln abhängig, mit welchen die Energiezufuhr durchgeführt wird. Um die Zeitspanne für die Beaufschlagung mit Energie zu bestimmen, wird gemäß einer ersten Ausführungsform vorgesehen, dass die Mischkristallbildung durch das Messen der dynamischen Viskosität der in der Behandlungskammer befindlichen Schmelze erfasst wird. Die Erfindung geht davon aus, dass ein Optimum der Mischkristallbildung sich dann zeigt, wenn die behandelte Schmelze trotz des Abkühlens einen besonders dünnflüssigen Zustand erreicht hat, der annähernd konstant bleibt und sich dann nicht mehr wesentlich ändert. Bei einer anderen Ausgestaltung der Erfindung wird vorgesehen, dass die Mischkristallbildung mittels Messungen der Liquidustemperatur von Proben festgestellt wird, die der Behandlungskammer entnommen werden. Dabei geht die Erfindung davon aus, dass die tatsächliche Liquidustemperatur sich als eine Knickstelle in der Abkühlkurve erweist, die aufgrund der Kristallisationswärme entsteht. Diese tatsächliche Liquidustemperatur liegt bei erfolgreicher Behandlung unterhalb der nach einem Zustandsdiagramm für diese Metalllegierung gegebenen Liquiduslinie.The time for which the energy supply is to be carried out must be determined experimentally. It is dependent on the specific metal alloy and also on the means by which the energy supply is carried out. In order to determine the time period for the application of energy, it is provided according to a first embodiment that the mixed crystal formation is detected by measuring the dynamic viscosity of the melt located in the treatment chamber. The invention assumes that an optimum of the solid solution formation manifests itself when the treated melt, despite the cooling, has reached a particularly low-viscosity state which remains approximately constant and then no longer changes significantly. In another embodiment of the invention, it is provided that the formation of mixed crystals is determined by means of measurements of the liquidus temperature of samples taken from the treatment chamber. The invention is based on the fact that the actual liquidus temperature proves to be a kink in the cooling curve due to the heat of crystallization arises. This actual liquidus temperature, if successfully treated, is below the liquidus line given for a state diagram for that metal alloy.

In weiterer Ausgestaltung der Erfindung wird vorgesehen, dass die kurzzeitige Energiezufuhr mittels eines variierenden, vorzugsweise pulsierenden Elektromagnetfeldes erfolgt.In a further embodiment of the invention it is provided that the short-term power supply by means of a varying, preferably pulsating electromagnetic field.

Es hat sich überraschend herausgestellt, dass auf diese Weise hergestellte Masseln in der Art eines Memory-Effektes die mit Hilfe der Behandlung in dem elektromagnetischen Feld hergestellte erhöhte Fließfähigkeit auch dann besitzen, wenn sie wieder aufgeschmolzen und in einer Gießmaschine verarbeitet werden. Derart aufbereitete Masseln haben gegenüber den nach konventionellen Verfahren hergestellten Masseln eine erhöhte Fließfähigkeit, so dass Gussstücke mit komplizierten Formen und erhöhter Dichte hergestellt werden können. Die auf diese Weise hergestellten Gussteile besitzen eine erhöhte Festigkeit, ein verbessertes Dehnverhalten und ein verbessertes Verschleißverhalten. Sie können dadurch teilweise Bauteile ersetzen, die bisher geschmiedet werden mussten.It has surprisingly been found that ingots produced in this way in the manner of a memory effect have the increased flowability produced by means of the treatment in the electromagnetic field even when they are re-melted and processed in a casting machine. Thus treated pigs have an increased flowability compared to the ingots produced by conventional methods, so that castings with complicated shapes and increased density can be produced. The castings produced in this way have increased strength, improved stretch behavior and improved wear behavior. You can partially replace components that previously had to be forged.

Gegenüber dem aus der DE 10002670 A1 bekannten Verfahren ergibt sich der wesentliche Vorteil, dass nicht jeder Gießmaschine eine entsprechende Behandlungskammer vorgeschaltet werden muss. Es können die gleichen Gießmaschinen eingesetzt werden, mit denen herkömmliche Masseln verarbeitet werden, ohne dass Änderungen an der Maschine vorgenommen werden müssen. Die Gießtemperatur kann herabgesetzt werden, sogar unter die Liquidustemperatur der betreffenden Legierung. Der Temperaturbereich, in welchem ein Gießen möglich ist, wird vergrößert, so dass die Gefahr des Entstehens von Ausschuss aufgrund ungünstiger Gießtemperaturen wesentlich verringert ist. Weitere Merkmale und Vorteile der Erfindung ergeben sich aus der nachfolgenden Beschreibung einer Anlage, die zum erfindungsgemäßen Herstellen von erfindungsgemäßen Masseln geeignet ist.Opposite that from the DE 10002670 A1 known method results in the significant advantage that not every casting a corresponding treatment chamber must be preceded. The same casting machines can be used with which conventional pigs are processed without having to make any changes to the machine. The casting temperature can be lowered, even below the liquidus temperature of the alloy in question. The temperature range in which pouring is possible is increased, so that the risk of rejects due to unfavorable pouring temperatures is substantially reduced. Further features and advantages of the invention will become apparent from the following description of a plant which is suitable for the inventive production of pigs invention.

In einem Schmelzofen, der eine Gießöffnung 1 eine Schmelzrinne 2 und eine elektrische Heizung 3 aufweist, werden die Bestandteile eines Metalls oder einer Metalllegierung soweit erhitzt, dass alle Bestandteile geschmolzen sind und eine Schmelze 4 bilden.In a melting furnace, which has a pouring opening 1, a melting channel 2 and an electric heater 3, the constituents of a metal or a metal alloy are heated to such an extent that all constituents are melted and form a melt 4.

Diese Schmelze 4 wird durch eine Füllöffnung 19 hindurch in eine Behandlungskammer gebracht. Diese Behandlungskammer besteht aus einem im Wesentlichen zylindrischen Gehäuseteil 18, einem halbkugelförmigen Unterteil 10 und einem etwa halbkugelförmigen Oberteil 7. Der Behandlungskammer ist eine vorzugsweise elektrische Heizung 6 in Form von Heizwendeln zugeordnet, mit welcher die Behandlungskammer auf eine Temperatur im Bereich der und beispielsweise etwas unterhalb der Liquiduslinie der speziellen Metalllegierung aufgeheizt wird, beispielsweise auf etwa die eutektische Temperatur der Metalllegierung. Zusätzlich ist der Behandlungskammer eine Einrichtung 5 Einbringen von Energie, beispielsweise durch Erzeugen eines rotierenden, elektromagnetischen Feldes zugeordnet. Dieses elektromagnetische Feld besitzt beispielsweise eine Feldstärke von 6 bis 20 mT und rotiert mit einer Frequenz von etwa 60 Hz bis 500 Hz. Dadurch entsteht ein hydrodynamischer Druck in der Größenordnung von 150 x 10-4 N/m2. Während der gemeinsamen Einwirkung des isotrophen magnetischen Druckes und der magnetischen Spannung, deren optimaler Bereich zwischen 15 und 80 mT liegt, entwickelt sich in der Schmelze der Effekt einer fluidelastischen Annomalie, die durch die höchste Fliessbarkeit der Metallschmelze geprägt ist. Sie hat dann die niedrigste dynamische Viskosität. Gemessen wurde eine dynamische Viskosität von 0,74 mPa/s bei einer Schmelzentemperatur von 580°C. Auch ist eine thermokinetische Annomalie der behandelten Schmelze beobachtbar, die durch die Schrumpfung des Bereiches zwischen Liquidustemperatur und Solidustemperatur auf einen Minimalwert bestimmt ist. Die vollkommene Löslichkeit von mehreren zulegierten Bestandteilen liegt auch noch bei der Solidustemperatur vor. Der zweiphasige wird aufgrund sinkender Liquidustemperatur und gleichzeitig steigender Solidustemperatur kontinuierlich geschrumpft, so dass die Konode kürzer wird. Wenn der angestrebte Zustand erreicht wird, wird die Schmelze 11 mittels eines Entnahmeroboters 12 der Behandlungskammer entnommen und in Masselformen 14 gefüllt, die auf einer Masselbahn 13 transportiert werden. An einer Ausleereinrichtung 15 werden die Masselformen 14 geleert, so dass dann leere Masselformen 17 wieder dem Entnahmeroboter 12 zugeführt werden können.This melt 4 is brought through a filling opening 19 into a treatment chamber. This treatment chamber consists of a substantially cylindrical housing part 18, a hemispherical lower part 10 and an approximately hemispherical upper part 7. The treatment chamber is associated with a preferably electric heater 6 in the form of heating coils, with which the treatment chamber to a temperature in the range and for example slightly below the liquidus line of the special metal alloy is heated, for example, to about the eutectic temperature of the metal alloy. In addition, the treatment chamber is associated with a device 5 introducing energy, for example by generating a rotating electromagnetic field. This electromagnetic field has, for example, a field strength of 6 to 20 mT and rotates at a frequency of about 60 Hz to 500 Hz. This results in a hydrodynamic pressure in the order of 150 x 10 -4 N / m 2 . During the combined action of the isotropic magnetic pressure and the magnetic stress whose optimum range is between 15 and 80 mT, the melt develops the effect of a fluid-elastic anomaly, which is characterized by the highest meltability of the molten metal. It then has the lowest dynamic viscosity. A dynamic viscosity of 0.74 mPa / s was measured at a melt temperature of 580 ° C. Also, a thermokinetic anomaly of the treated melt observed by the Shrinkage of the range between liquidus temperature and solidus temperature to a minimum value is determined. The perfect solubility of several alloyed ingredients is still present at the solidus temperature. The two-phase is shrinking continuously due to sinking liquidus temperature and simultaneously increasing solidus temperature, so that the Konode becomes shorter. When the desired state is reached, the melt 11 is removed by means of a removal robot 12 of the treatment chamber and filled in ingots 14, which are transported on a mass train 13. At a discharge device 15, the ingot molds 14 are emptied, so that then empty ingot molds 17 can again be supplied to the removal robot 12.

Das kurzzeitige Einbringen von Energie in die sich in der Abkühlphase befindliche Schmelze führt dazu, dass die Bildung von Mischkristallen gesteigert wird, bei welcher in den Elementarkristallen Atome des Basismaterials durch Atome des oder der Zusatzbestandteile ersetzt werden. Die Zufuhr von Energie kann dann beendet werden, wenn der Prozess der Mischkristallbildung ein Optimum erreicht hat und eine weitere Energiezufuhr die Mischkristallbildung nicht mehr entscheidend steigert. Dieses Optimum, das den neuen energetischen Zustand der Schmelze charakterisiert, wird bei einer Ausführungsform der Erfindung erfasst.The brief introduction of energy into the melt which is in the cooling phase leads to the fact that the formation of mixed crystals is increased, in which atoms of the base material in the elementary crystals are replaced by atoms of the additional constituent (s). The supply of energy can be stopped when the process of solid solution formation has reached an optimum and a further supply of energy no longer decisively increases solid-solution formation. This optimum, which characterizes the new energetic state of the melt, is detected in one embodiment of the invention.

Die höchste Fließfähigkeit oder niedrigste Viskosität, die ein Indiz für die gesteigerte Mischkristallbildung ist, wird mittels eines Viskosimeters 8 online in der Behandlungskammer gemessen, so dass jederzeit festgestellt werden kann, ob der gewünschte Zustand für die Schmelze 11 erreicht worden ist. Durch die äußere energetische Einwirkung wird der energetische Zustand des flüssig-kristallinischen Basiskristalls geändert. Sein Raumgitter wird aufgelockert, so dass sich der Vorgang erleichtert, bei dem neue atomare Gruppierungen gebaut werden. Die Energie und die Verbindungskräfte, die zwischen den Atomen von einzelnen Komponenten und Struktureinheiten der Metalllegierungen auftauchen, gehören zu den ausschlaggebenden Faktoren. Die Viskosität ist eine von diesen Eigenschaften. Der Auf- und Umbau von atomaren Komplexen führt zu einer Freisetzung von starken Verbindungen, die eher im Inneren der Komplexe geschlossen waren. Diese Verbindungen nehmen an dem viskosen Fließen und auch an Versetzungen von Struktureinheiten teil. Eine sinkende Viskosität wird deshalb auf einen atomaren Komplex zurückgeführt, der die geschwächten inneren und die gestärkten äußeren Verbindungen aufweist. Damit werden die technologisch-physikalischen Voraussetzungen geschaffen, unter denen im flüssig-kristallinischen System kollektive Bereiche mit einer einheitlichen Orientierung aufgebaut werden. Die neue Strukturierung und ihre energetische Stabilität werden durch das variable elektromagnetische Feld verstärkt. Das Ergebnis ist die geringere Viskosität, die den energetischen Zustand des Raumgitters bzw. der Mikrostruktureinheiten der Schmelze widerspiegelt. Die Fließfähigkeit kann beispielsweise auf einem Monitor 16 angezeigt werden. Die maximale Fließfähigkeit ist dann erreicht, wenn die Fließfähigkeit nicht mehr wesentlich ansteigt, d.h. den annähernd waagrechten Ast der auf dem Monitor 16 dargestellten Kurve der Fließfähigkeit ϕ über die Zeit t erreicht hat.The highest flowability or lowest viscosity, which is an indication of the increased solid solution formation, is measured by means of a viscometer 8 online in the treatment chamber, so that it can be determined at any time whether the desired state for the melt 11 has been reached. The external energetic action changes the energetic state of the liquid crystalline base crystal. His space grid is loosened up, facilitating the process of building new atomic groupings. The energy and the bonding forces between the atoms of individual components and structural units of the metal alloys emerge as one of the decisive factors. The viscosity is one of these properties. The construction and remodeling of atomic complexes leads to a release of strong compounds, which were rather closed inside the complexes. These compounds participate in the viscous flow and also in dislocations of structural units. A decreasing viscosity is therefore attributed to an atomic complex having the weakened inner and starched outer compounds. This creates the technological-physical prerequisites under which collective areas with a uniform orientation are built up in the liquid-crystalline system. The new structuring and its energetic stability are enhanced by the variable electromagnetic field. The result is the lower viscosity, which reflects the energetic state of the space lattice or microstructure units of the melt. The fluidity can be displayed on a monitor 16, for example. The maximum flowability is achieved when the fluidity no longer increases significantly, ie, has reached the approximately horizontal branch of the curve shown on the monitor 16 of the flowability φ over time t.

Alternativ oder eventuell auch zusätzlich wird vorgesehen, dass aus der Behandlungskammer Proben der Schmelze 11 entnommen und analysiert werden. Es lässt sich anhand dieser Analyse beispielsweise auf einem weiteren Monitor 9 anzeigen, wie sich die Liquidustemperatur TL ändert und gegenüber der Liquiduslinie der speziellen Metalllegierung der Solidustemperatur-Linie Ts angenähert hat. Hierbei kann auf einem Monitor 9 ein Bild der Temperatur T über der Zeit t angezeigt werden. Der Aufbauprozess des übersättigten Mischkristalls, der im flüssig-kristallinischen System angefangen hatte, vollendet sich während des Abkühlens der Legierung, so dass die Aufstellung eines realistischen Zustandsschaubildes möglich ist. Durch diese realistische, thermodynamische Darstellung wird ein großes Spektrum von Legierungseigenschaften abgedeckt, beispielsweise Konzentrationsangabe, Liquidus-Soliduslinienanordnung, Sättigungsgrenze (Löslichkeit) usw., die es ermöglichen, die geeigneten technologischen Gießparameter für die nach dem erfindungsgemäßen Verfahren hergestellte Legierung festzulegen.Alternatively or possibly additionally, it is provided that samples of the melt 11 are taken from the treatment chamber and analyzed. By means of this analysis, for example, it can be displayed on another monitor 9 how the liquidus temperature T L changes and has approached the liquidus line of the specific metal alloy of the solidus temperature line Ts. In this case, a picture of the temperature T over the time t can be displayed on a monitor 9. The build-up process of the supersaturated mixed crystal, which had begun in the liquid-crystalline system, is completed during the cooling of the alloy, so that the preparation of a realistic state diagram is possible. Through this realistic, thermodynamic Representation covers a wide range of alloy properties, such as concentration indication, liquidus solidus line, saturation limit (solubility), etc., which allow to set the appropriate technological casting parameters for the alloy produced by the process of the present invention.

Es hat sich überraschend gezeigt, wenn Masseln, die nach dem vorstehenden Verfahren hergestellt worden sind, weiterverarbeitet werden, sich vorteilhafte Verhältnisse ergeben. Die aufgrund der Behandlung erhaltene Erhöhung der Fließfähigkeit ist nicht reversibel, weil die Mischkristalle stabil sind. Die bei der Weiterverarbeitung aus aufgeschmolzenen Masseln hergestellte Schmelze hat eine verbesserte Fließfähigkeit und eine geringere Neigung zu Oxidation. Beim Aufschmelzen der Masseln entsteht weniger Krätze an der Badoberfläche.It has surprisingly been found that ingots which have been produced by the above process are further processed, resulting in advantageous conditions. The increase in fluidity resulting from the treatment is not reversible because the mixed crystals are stable. The melt produced during further processing from molten ingots has an improved flowability and a lower tendency to oxidation. As the pigs melt, less scabies appear on the surface of the bath.

Bei einer Metalllegierung mit dem Basismaterial Aluminium und dem Hauptlegierungsbestandteil Silizium ist es möglich gewesen, Zylinderköpfe noch mit einer Gießtemperatur von 637° C erfolgreich abzugießen die damit um etwa 100° C niedriger lag, als die für diese Maschine und diese Legierung vorgeschriebene Gießtemperatur. Trotz der geringeren Gießtemperatur gab es keine Qualitätsminderungen durch Lunker, Gasporosität oder Kaltlauf und keine grobe Gefügebildung.For a metal alloy with the base material aluminum and the main alloying constituent silicon, it has been possible to successfully cast off cylinder heads with a casting temperature of 637 ° C., which is about 100 ° C. lower than the casting temperature prescribed for this machine and alloy. Despite the lower casting temperature, there were no quality reductions due to voids, gas porosity or cold running and no coarse structure formation.

Die Erfindung geht davon aus, dass durch die äußere energetische Einwirkung, d.h. durch die Wechselwirkung zwischen einem äußeren elektromagnetischen Feld und einem inneren elektromagnetischen Feld des Kristalls, eine Verstärkung des Diffusionsprozesses und interatomare Verbindungen beeinflusst werden. Das Ergebnis dieser Wechselwirkung ist ein Aufbau einer Legierung, deren Kristalle im geschmolzenen Zustand eine weitreichende Ordnung bzw. Fernordnung besitzen. Diese Wechselwirkung kann auch dadurch gesteuert werden, dass ein Legierungsbestandteil zugegeben wird, das sich von dem Basismaterial durch die magnetische Suszeptibilität unterscheidet.The invention is based on the fact that the external energetic action, ie the interaction between an external electromagnetic field and an internal electromagnetic field of the crystal, influences an amplification of the diffusion process and interatomic compounds. The result of this interaction is a construction of an alloy whose crystals in the molten state have a far-reaching order or distance order. This interaction can also be controlled by having an alloying component is added, which differs from the base material by the magnetic susceptibility.

Die Erfindung eignet sich insbesondere für Metalllegierungen, bei welchen das Basismaterial Aluminium und der Hauptzusatzbestandteil Silizium ist. Grundsätzlich ist die Erfindung jedoch für alle Metalllegierungen anwendbar, unabhängig von der magnetischen Suszeptibilität der Bestandteile. Die äußere energetische Einwirkung erfolgt bei dem Ausführungsbeispiel mittels eines variierenden, pulsierenden elektromagnetischen Feldes. Es sind jedoch auch ohne weiteres andere Möglichkeiten zur äußeren energetischen Einwirkung mittels eines variablen physikalischen Feldes gegeben, beispielsweise eine Einwirkung mittels Ultraschall. Dabei wird das Feld so ausgelegt, dass sich die zu dem vorstehend erläuterten elektromagnetischen Feld ergebenden Bedingungen ebenfalls erhalten werden.The invention is particularly suitable for metal alloys in which the base material is aluminum and the main additive component is silicon. In principle, however, the invention is applicable to all metal alloys, regardless of the magnetic susceptibility of the constituents. The external energetic action takes place in the embodiment by means of a varying, pulsating electromagnetic field. However, other possibilities for external energetic action by means of a variable physical field are also readily given, for example an action by means of ultrasound. In this case, the field is designed so that the conditions resulting from the above-described electromagnetic field are also obtained.

Die erfindungsgemäßen Masseln eignen sich für alle Gießprozesse. Dabei ist bei einem Kokillenguss die hohe Fließfähigkeit von besonderem Vorteil, während beim Druckguss die hervorragende Verformbarkeit von besonderem Vorteil ist. Es wird angenommen, dass bei einem Aufschmelzen der Masseln die neue atomare Anordnung im Raumgitter, die durch die Vorbehandlung durch Diffusion erhalten wurde, auch bei dem Aufschmelzen der Masseln beibehalten wird, ohne dass die Atome der Legierungsbestandteile ihre Plätze im Aluminium-Raumgitter aufgeben.The pigs according to the invention are suitable for all casting processes. In the case of a chill casting, the high flowability is of particular advantage, while in die casting the excellent formability is of particular advantage. It is believed that, as the ingots melt, the new atomic arrangement in the space lattice obtained by the diffusion pretreatment is retained even when the ingots are melted, without the atoms of the alloying components giving up their places in the aluminum lattice.

Unter dem Ausdruck Masseln werden gemäß der Erfindung nicht nur die handelsüblichen Formen von Masseln verstanden. Vielmehr soll darunter jegliche Form verstanden werden, in die eine aufbereitete Schmelze vor einem Wiederaufschmelzen für einen Gießvorgang abgegossen wird.By the term pigs according to the invention not only the commercial forms of pigs are understood. Rather, it should be understood to mean any form in which a processed melt is poured off before re-melting for a casting process.

Claims (5)

  1. A Method for producing pigs made of a metal alloy, wherein initially a melt is formed in which a basic material and one or several alloy components are present in the liquid state, from which the pigs are formed, characterized in that prior to the formation of the pigs in the course of cooling, energy is introduced into the melt for a short time by means of a variable physical field which increases the formation of mixed crystals,
    upon reaching an optimum of the formation of mixed crystals, the supply of energy may be stopped, and further energy supply does not effect an essential increase in mixed crystal formation, and
    the formation of mixed crystals is detected by measuring the dynamic viscosity of the melt located in the treatment chamber.
  2. The method in accordance with claim 1, characterized in that the supply of energy takes place at a temperature at the liquidus level of this metal alloy.
  3. The method in accordance with claim 1 or 2, characterized in that the formation of mixed crystals is detected by means of measurements of the liquidus temperature of samples taken from the treatment chamber.
  4. The method in accordance with any of the claims 1 to 3, characterized in that the short-time energy supply takes place by means of a varying electromagnetic field.
  5. The method in accordance with claim 4, characterized in that the short-time energy supply takes place by means of a pulsating electromagnetic field.
EP06742695A 2005-05-04 2006-04-26 Method for the production of pigs, and pigs Not-in-force EP1877209B9 (en)

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DE102005021891A DE102005021891B4 (en) 2005-05-04 2005-05-04 Method of making pigs and pigs
PCT/EP2006/003853 WO2006117111A1 (en) 2005-05-04 2006-04-26 Method for the production of pigs, and pigs

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DE102005021891B4 (en) 2011-12-22
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