US20090166387A1 - Bottom Pour Ladle and Method of Transferring Liquid Metal with Same - Google Patents
Bottom Pour Ladle and Method of Transferring Liquid Metal with Same Download PDFInfo
- Publication number
- US20090166387A1 US20090166387A1 US12/341,118 US34111808A US2009166387A1 US 20090166387 A1 US20090166387 A1 US 20090166387A1 US 34111808 A US34111808 A US 34111808A US 2009166387 A1 US2009166387 A1 US 2009166387A1
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- Prior art keywords
- liquidus
- aperture
- alloy
- bowl
- stopper
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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
- B22D39/00—Equipment for supplying molten metal in rations
- B22D39/02—Equipment for supplying molten metal in rations having means for controlling the amount of molten metal by volume
- B22D39/026—Equipment for supplying molten metal in rations having means for controlling the amount of molten metal by volume using a ladler
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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
- B22D37/00—Controlling or regulating the pouring of molten metal from a casting melt-holding vessel
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D41/00—Casting melt-holding vessels, e.g. ladles, tundishes, cups or the like
- B22D41/08—Casting melt-holding vessels, e.g. ladles, tundishes, cups or the like for bottom pouring
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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
- B22D41/00—Casting melt-holding vessels, e.g. ladles, tundishes, cups or the like
- B22D41/14—Closures
- B22D41/16—Closures stopper-rod type, i.e. a stopper-rod being positioned downwardly through the vessel and the metal therein, for selective registry with the pouring opening
Definitions
- the present invention relates generally to a bottom pour ladle device. More particularly, the present invention relates to a bottom pour ladle device and method for transferring liquid metal with same.
- liquid metal In the casting industry, a supply of liquid metal is maintained at liquidus temperatures in a crucible or reservoir. Depending upon the particular method of casting, this liquidus metal is transferred from the crucible to a mold for casting an item. Certain automobile components are typically made via cast methods such as high pressure die casting (“HPDC”) or squeeze casting. In such high pressure devices, the liquidus metal is generally transferred to a hydraulic press or shot sleeve that injects the liquidus metal into the mold at high pressures.
- HPDC high pressure die casting
- squeeze casting In such high pressure devices, the liquidus metal is generally transferred to a hydraulic press or shot sleeve that injects the liquidus metal into the mold at high pressures.
- a ladle may be used to dip into the crucible and retrieve a measure of liquidus metal that is then poured into the shot sleeve.
- conventional ladles include elements that are not compatible with some alloys.
- these convention ladles are not capable of transferring liquidus metals without causing a great deal of turbulence. In some relatively reactive alloys, this turbulence may cause the formation of oxides or other such impurities that in turn adversely affect the quality of the casting.
- An embodiment of the present invention relates to a bottom pour ladle device for transferring liquidus metal from a crucible to a shot sleeve.
- the device includes a bowl, snout, aperture, stopper, actuator, and stopper rod.
- the snout is disposed below the bowl and is configured to fit into the shot sleeve.
- a distal end of the snout is configured to reach a bottom portion of the shot sleeve.
- the aperture is at the distal end of the snout.
- the stopper is to close the aperture in response to being urged against the aperture.
- the actuator is to urge the stopper.
- the stopper rod is to connect the stopper to the actuator.
- the bowl, snout, and aperture are comprised of materials compatible with liquidus alloy.
- the apparatus includes a means for disposing a bottom pour ladle in the crucible.
- the bottom pour ladle has a bowl and a snout disposed below the bowl.
- the snout has an aperture at a distal end.
- the apparatus includes a means for opening the aperture to allow an ingress of liquidus alloy, means for closing the aperture to retain the liquidus alloy, and means for disposing the distal end at a bottom portion of the shot sleeve.
- the apparatus includes a means for opening the aperture to allow the liquidus alloy to flow into the shot sleeve and means for raising the bottom pour ladle, wherein the aperture is raised at a rate coinciding with a rate the shot sleeve fills with liquidus alloy and the aperture is controlled to remain relatively below a fill level of the shot sleeve.
- Yet another embodiment of the present invention relates to a method of transferring liquidus alloy from a crucible to a shot sleeve.
- a bottom pour ladle is disposed in the crucible.
- the bottom pour ladle has a bowl and a snout disposed below the bowl.
- the snout has an aperture at a distal end.
- the aperture is opened to allow an ingress of liquidus alloy, the aperture is closed to retain the liquidus alloy, and the distal end is disposed at a bottom portion of the shot sleeve.
- the aperture is opened to allow the liquidus alloy to flow into the shot sleeve and the bottom pour ladle is raised.
- the aperture is raised at a rate coinciding with a rate the shot sleeve fills with liquidus alloy and the aperture is controlled to remain relatively below a fill level of the shot sleeve.
- FIG. 1 is a simplified view of a horizontal vertical squeeze casting apparatus according to an embodiment of the invention.
- FIG. 2 is a simplified view of the horizontal vertical squeeze casting apparatus during a shot sleeve filling operation.
- FIG. 3 is a cross sectional view of a bottom pour ladle during an initial stage of the shot sleeve filling operation.
- FIG. 4 is a cross sectional view of a bottom pour ladle during an intermediate stage of the shot sleeve filling operation.
- FIG. 5 is a cross sectional view of a bottom pour ladle during an intermediate stage of the shot sleeve filling operation.
- FIG. 6 is a cross sectional view of a bottom pour ladle during an end stage of the shot sleeve filling operation.
- the present invention provides, in some embodiments, a device to transfer liquidus alloy for making a squeeze cast product, a method of transferring liquidus alloy using the device, the cast product, and a system for making the cast product.
- Various embodiments of the invention are particularly suited for use in transferring liquidus magnesium and/or aluminum alloys.
- Squeeze casting is a term of art used to describe a process of introducing liquid or semi solid alloy into a die and pressurizing the alloy in the die.
- the relative benefits of squeeze casting over traditional die casting methods include less to no turbulence, less to no air entrapment, reduced shrink porosity, and more rapid solidification.
- Squeeze casting also offers dimensional control that is comparable to that available with high pressure die casting (“HPDC”).
- HPDC high pressure die casting
- Squeeze casting is suitable for the production of a variety of components.
- thick-walled components or components having a thickness of about 2.5 mm or greater benefit from being produced in various squeeze casting devices.
- squeeze casting imparts qualities to a metal that are difficult to achieve with conventional die casting, gravity permanent mold, or sand casting, including reduced or no porosity, higher mechanical integrity, improved wear resistance, and the ability to solution treat.
- squeeze casting devices include: horizontal vertical squeeze casting (“HVSC”), vertical casting devices, and the like.
- HVSC devices are so named because the die clamp opens horizontally and the molten alloy is inserted vertically.
- vertical casting devices the die clamp opens vertically and, generally, the molten alloy is inserted vertically as well.
- a great variety of variations and conformation of squeeze casting devices exist. Some such variations are described herein, however, any suitable device for squeeze casting is within the purview of the present invention.
- Components produced in a squeeze casting device are subjected to various optional post-casting procedures. These optional procedures include one or more of milling, finishing, chemical and thermal treatments, and the like.
- the component is subjected to a heat treatment, if desired, to enhance certain properties of the cast components, especially ductility. More particularly, mechanical properties of products generated by squeeze casting (squeeze casts) are generally enhanced by various heat treatments such as, for example, T6 tempering, T4 tempering, and the like.
- FIG. 1 is a horizontal vertical squeeze casting (“HVSC”) system 10 for squeeze casting an alloy according to an embodiment of the invention.
- the HVSC system 10 includes mold 12 , shot sleeve 14 , furnace or crucible 16 , bottom pour ladle 18 , and robotic system 20 .
- the HVSC system 10 may be utilized to cast an item 22 from a supply of liquidus alloy 24 .
- liquidus alloy refers to alloy held at a liquidus temperature.
- the liquidus temperature specifies the maximum temperature at which crystals can co-exist with the melt in thermodynamic equilibrium. Above the liquidus temperature the material is homogeneous. Below the liquidus temperature, crystals may begin to form in the melt, depending on the material.
- the liquidus temperature can be contrasted with the solidus temperature.
- the solidus temperature quantifies the point at which a material completely solidifies (crystallizes).
- the liquidus and solidus temperatures may overlap. In this overlapping temperature range, a slurry or semi-solid metal may be formed. In this regard, squeeze casting may be performed with semi-solid metal.
- the mold 12 includes a cavity corresponding to the item 22 .
- liquidus magnesium alloy may be introduced to the mold 12 in any suitable manner.
- the mold 12 includes an orifice configured to mate with the shot sleeve 14 to receive an injectant of liquidus alloy 24 .
- the shot sleeve 14 is configured to receive the injectant and introduce the injectant to the mold cavity.
- the shot sleeve 14 may include a hydraulically driven piston 26 or other such actuator to urge the injectant into the mold cavity. As shown herein, the shot sleeve 14 may be moved out from under the mold 12 and/or tilted to receive the injectant from the bottom pour ladle 16 .
- the crucible 16 is configured to heat and/or retain the supply of liquidus alloy 24 at the liquidus temperature.
- Magnesium alloy is a particularly suitable alloy for use with HVSC system 10 and/or the crucible 16 .
- the liquidus temperature of magnesium alloys varies widely depending upon the particular alloy composition. In a specific example, the liquidus temperature of the magnesium alloy AZ91D is about 1105° F. or 595° C. Typically, the alloy is heated somewhat beyond this temperature to allow for contact with relatively cooler surfaces without solidification of the alloy. Therefore, the casting temperature is about 1160° F. (625° C.) to about 1290° F. (700° C.).
- AZ91D magnesium alloys and or various aluminum alloys are suitable for use with the HVSC system 10 .
- aluminum alloys A356, A380, A383, ADC-12 and the like are suitable for use with the HVSC system 10 and bottom pour ladle 18 . Accordingly, the temperature of the crucible 16 and/or other components of the HVSC system 10 may vary depending upon the particular alloy utilized.
- the bottom pour ladle 18 is configured to transfer the liquidus alloy 24 from the crucible 16 to the shot sleeve 14 .
- the bottom pour ladle 18 includes a bowl 28 , snout 30 , aperture 32 , stopper 34 , and stopper shaft 36 .
- the snout 30 either alone or together with the bowl 28 is configured to contain a sufficient volume of the liquidus alloy 24 to fill the shot sleeve 14 . In this regard, all of the surfaces that come into contact with the liquidus alloy 24 are compatible with constituents of the liquidus alloy 24 and will not contaminate or otherwise react with the liquidus alloy 24 .
- one or more of the bowl 28 , snout 30 , stopper 34 , and stopper shaft 36 include surfaces of a stainless steel alloy Y06.
- Conventional ladles include ceramic components with a silica base. Silica reacts violently with liquidus magnesium and therefore silica can not be used to transfer liquidus magnesium.
- one or more of the bowl 28 , snout 30 , stopper 34 , and stopper shaft 36 include surfaces of other ferrous materials or non-ferrous materials that are compatible with constituents of the liquidus alloy 24 .
- the bowl 28 , snout 30 , stopper 34 , and stopper shaft 36 may include surfaces of any suitable material.
- the bottom pour ladle 18 may be positioned into the crucible 16 by the robotic system 20 .
- a controller 38 may control the robotic system 20 to place the bottom pour ladle 18 into the crucible 16 .
- the stopper 34 is configured to mate with the aperture 32 and form a seal.
- the bottom pour ladle 18 includes an actuator 40 connected to the stopper shaft 38 .
- the actuator 40 may be controlled to urge the stopper towards the aperture 32 or away from the aperture 32 .
- the aperture 32 may be closed.
- the actuator 40 may be controlled, by the controller 36 for example, to urge the stopper 34 away from the aperture 32 .
- the level to which the bottom pour ladle 18 is filled with the liquidus alloy 24 may depending upon the depth to which the bottom pour ladle 18 is placed in the crucible 16 and the level of the supply of liquidus alloy 24 .
- the fill level of the bottom pour ladle 18 may be reduced.
- the fill level may be increased.
- the robotic system 20 includes any suitable system of actuators that may be controlled to lift the bottom pour ladle 18 , move the bottom pour ladle 18 between the crucible 16 and the shot sleeve 14 , and as shown in FIG. 2 , place the snout 30 into the shot sleeve 14 .
- the snout 30 is configured to fit within the shot sleeve 14 . That is, the outside diameter of the snout 30 is less than the inside diameter of the shot sleeve 14 .
- the robotic system 20 and/or a system to move the shot sleeve 14 may be configured to retract the snout 30 from the shot sleeve 14 substantially at the rate at which the shot sleeve 14 is filled.
- FIG. 3 is a cross sectional view of the bottom pour ladle 18 at an initial stage of filling the shot sleeve 14 in accordance with an embodiment of the invention.
- the aperture 32 is placed at a bottom portion of the shot sleeve 14 .
- the aperture 32 is as close to the bottom of the shot sleeve 14 as possible without impeding the flow of the liquidus alloy 24 therefrom.
- the aperture 32 is placed in close proximity to the piston 26 .
- the shot sleeve 14 may be filled with a minimum about of splashing and turbulence. This relatively calm flow of the liquidus alloy 24 from the aperture 32 greatly improves the overall casting quality of cast products.
- the mechanical properties of the item 22 are improved by reducing the creation of oxides and other impurities.
- the bottom pour ladle 18 may optionally include one or more heaters 42 and 44 .
- the heater 42 may be disposed upon or around the bowl 28 and configured to impart heat to the bowl 28 and any contents therein.
- the heater 44 is included, it may be disposed in or around the stopper 34 and/or stopper shaft 36 .
- the heater 44 is configured to impart heat into the contents of the bowl 28 and/or snout 30 .
- the heaters 42 and 44 may include any suitable heating devices or elements.
- the heaters 42 and 44 may include a resistive metal element configured to generate heat in response to the application of current therethrough.
- the heaters 42 and/or 44 may be controlled to provide sufficient heat energy to maintain the liquidus temperature of the liquidus alloy 24 or to raise the temperature of the liquidus alloy 24 in preparation to fill the relatively cooler shot sleeve 14 .
- the bottom pour ladle 18 may include an optional nozzle 46 .
- the nozzle 46 may be connected to an inert gas source via a hose or pipe 48 .
- the nozzle 46 is configured to introduce a bath of inert gas into the bottom pour ladle 18 .
- the specific gas may be selected from suitable inert gasses.
- the inert gas may include Argon and/or SO 2 .
- the bottom pour ladle 18 may include a lid 50 .
- the lid 50 may be configured to cover a rim of the bowl 28 and form a seal thereon. In general, the lid 46 facilitates retention of the gasses within the bowl 28 , however, the lid need not provide a gas impermeable seal.
- FIG. 4 is a cross sectional view of the bottom pour ladle 18 at an intermediate stage of filling the shot sleeve 14 in accordance with an embodiment of the invention.
- the aperture 32 is opened in response to the actuator 40 urging the stopper 34 via the stopper shaft 36 away from the aperture 32 .
- liquidus alloy 24 is allowed to flow from the bottom pour ladle 18 into the shot sleeve 14 .
- FIGS. 5 and 6 the bottom pour ladle 18 and shot sleeve 14 are drawn away from one another during the shot sleeve filling operation.
- the bottom pour ladle 18 and shot sleeve 14 are drawn away from one another at approximately the rate at which the shot sleeve 14 fills with the liquidus alloy 24 .
- the rate at which the bottom pour ladle 18 and shot sleeve 14 are drawn away from one another is controlled to retain the aperture just below the level of the rising the liquidus alloy 24 within the shot sleeve 14 .
- the rate at which the shot sleeve 14 is filled—and thus the rate at which the snout 30 is drawn out of the shot sleeve 14 may be determined in any suitable manner.
- the fill rate may be calculated, determined empirically and/or sensed via sensors in or around the shot sleeve 14 .
- the aperture 32 may be closed in response to the completion of the shot sleeve filling operation.
- the actuator 40 may be controlled to urge the stopper 34 via the stopper shaft 36 against the aperture 32 .
- any of the liquidus alloy 24 remaining in the bottom pour ladle 18 may be prevented from entering the shot sleeve 14 and/or spilling out as the bottom pour ladle 18 is returned to the crucible 16 .
- the bottom pour ladle 18 may be filled from the crucible 16 to contain the correct amount of the liquidus alloy 24 to fill the shot sleeve 14 and thus, the aperture closing procedure may be omitted.
Abstract
Description
- This application claims priority to U.S. Provisional Application Ser. No. 61/017,073, filed on Dec. 27, 2007, titled “BOTTOM POUR LADLE AND METHOD OF TRANSFERRING LIQUID METAL WITH SAME,” the disclosure of which is incorporated herein by reference in its entirety.
- The present invention relates generally to a bottom pour ladle device. More particularly, the present invention relates to a bottom pour ladle device and method for transferring liquid metal with same.
- In the casting industry, a supply of liquid metal is maintained at liquidus temperatures in a crucible or reservoir. Depending upon the particular method of casting, this liquidus metal is transferred from the crucible to a mold for casting an item. Certain automobile components are typically made via cast methods such as high pressure die casting (“HPDC”) or squeeze casting. In such high pressure devices, the liquidus metal is generally transferred to a hydraulic press or shot sleeve that injects the liquidus metal into the mold at high pressures.
- Conventionally, a ladle may be used to dip into the crucible and retrieve a measure of liquidus metal that is then poured into the shot sleeve. Unfortunately, conventional ladles include elements that are not compatible with some alloys. In addition, these convention ladles are not capable of transferring liquidus metals without causing a great deal of turbulence. In some relatively reactive alloys, this turbulence may cause the formation of oxides or other such impurities that in turn adversely affect the quality of the casting.
- The foregoing needs are met, to a great extent, by the present invention, wherein in some embodiments a bottom pour ladle and method for transferring liquidus magnesium alloy are provided.
- An embodiment of the present invention relates to a bottom pour ladle device for transferring liquidus metal from a crucible to a shot sleeve. The device includes a bowl, snout, aperture, stopper, actuator, and stopper rod. The snout is disposed below the bowl and is configured to fit into the shot sleeve. A distal end of the snout is configured to reach a bottom portion of the shot sleeve. The aperture is at the distal end of the snout. The stopper is to close the aperture in response to being urged against the aperture. The actuator is to urge the stopper. The stopper rod is to connect the stopper to the actuator. The bowl, snout, and aperture are comprised of materials compatible with liquidus alloy.
- Another embodiment of the present invention pertains to an apparatus for transferring liquidus alloy from a crucible to a shot sleeve. The apparatus includes a means for disposing a bottom pour ladle in the crucible. The bottom pour ladle has a bowl and a snout disposed below the bowl. The snout has an aperture at a distal end. The apparatus includes a means for opening the aperture to allow an ingress of liquidus alloy, means for closing the aperture to retain the liquidus alloy, and means for disposing the distal end at a bottom portion of the shot sleeve. In addition, the apparatus includes a means for opening the aperture to allow the liquidus alloy to flow into the shot sleeve and means for raising the bottom pour ladle, wherein the aperture is raised at a rate coinciding with a rate the shot sleeve fills with liquidus alloy and the aperture is controlled to remain relatively below a fill level of the shot sleeve.
- Yet another embodiment of the present invention relates to a method of transferring liquidus alloy from a crucible to a shot sleeve. In this method, a bottom pour ladle is disposed in the crucible. The bottom pour ladle has a bowl and a snout disposed below the bowl. The snout has an aperture at a distal end. In addition, the aperture is opened to allow an ingress of liquidus alloy, the aperture is closed to retain the liquidus alloy, and the distal end is disposed at a bottom portion of the shot sleeve. Furthermore, the aperture is opened to allow the liquidus alloy to flow into the shot sleeve and the bottom pour ladle is raised. The aperture is raised at a rate coinciding with a rate the shot sleeve fills with liquidus alloy and the aperture is controlled to remain relatively below a fill level of the shot sleeve.
- There has thus been outlined, rather broadly, certain embodiments of the invention in order that the detailed description thereof herein may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional embodiments of the invention that will be described below and which will form the subject matter of the claims appended hereto.
- In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of embodiments in addition to those described and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein, as well as the abstract, are for the purpose of description and should not be regarded as limiting.
- As such, those skilled in the art will appreciate that the conception upon which this disclosure is based may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
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FIG. 1 is a simplified view of a horizontal vertical squeeze casting apparatus according to an embodiment of the invention. -
FIG. 2 is a simplified view of the horizontal vertical squeeze casting apparatus during a shot sleeve filling operation. -
FIG. 3 is a cross sectional view of a bottom pour ladle during an initial stage of the shot sleeve filling operation. -
FIG. 4 is a cross sectional view of a bottom pour ladle during an intermediate stage of the shot sleeve filling operation. -
FIG. 5 is a cross sectional view of a bottom pour ladle during an intermediate stage of the shot sleeve filling operation. -
FIG. 6 is a cross sectional view of a bottom pour ladle during an end stage of the shot sleeve filling operation. - The present invention provides, in some embodiments, a device to transfer liquidus alloy for making a squeeze cast product, a method of transferring liquidus alloy using the device, the cast product, and a system for making the cast product. Various embodiments of the invention are particularly suited for use in transferring liquidus magnesium and/or aluminum alloys.
- Squeeze casting is a term of art used to describe a process of introducing liquid or semi solid alloy into a die and pressurizing the alloy in the die. The relative benefits of squeeze casting over traditional die casting methods include less to no turbulence, less to no air entrapment, reduced shrink porosity, and more rapid solidification. Squeeze casting also offers dimensional control that is comparable to that available with high pressure die casting (“HPDC”).
- Squeeze casting is suitable for the production of a variety of components. In particular, thick-walled components or components having a thickness of about 2.5 mm or greater benefit from being produced in various squeeze casting devices. Additionally, there is less or no skin effect with squeeze casting as compared to traditional methods of casting, resulting in a component with higher integrity and less porosity. That is, squeeze casting imparts qualities to a metal that are difficult to achieve with conventional die casting, gravity permanent mold, or sand casting, including reduced or no porosity, higher mechanical integrity, improved wear resistance, and the ability to solution treat.
- Examples of squeeze casting devices include: horizontal vertical squeeze casting (“HVSC”), vertical casting devices, and the like. HVSC devices are so named because the die clamp opens horizontally and the molten alloy is inserted vertically. In vertical casting devices, the die clamp opens vertically and, generally, the molten alloy is inserted vertically as well. In addition, a great variety of variations and conformation of squeeze casting devices exist. Some such variations are described herein, however, any suitable device for squeeze casting is within the purview of the present invention.
- Components produced in a squeeze casting device are subjected to various optional post-casting procedures. These optional procedures include one or more of milling, finishing, chemical and thermal treatments, and the like. In a particular example, the component is subjected to a heat treatment, if desired, to enhance certain properties of the cast components, especially ductility. More particularly, mechanical properties of products generated by squeeze casting (squeeze casts) are generally enhanced by various heat treatments such as, for example, T6 tempering, T4 tempering, and the like.
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FIG. 1 is a horizontal vertical squeeze casting (“HVSC”)system 10 for squeeze casting an alloy according to an embodiment of the invention. As shown inFIG. 1 , theHVSC system 10 includesmold 12, shotsleeve 14, furnace orcrucible 16, bottom pourladle 18, androbotic system 20. In general, theHVSC system 10 may be utilized to cast anitem 22 from a supply ofliquidus alloy 24. For the purpose of this disclosure, the term, liquidus alloy refers to alloy held at a liquidus temperature. The liquidus temperature specifies the maximum temperature at which crystals can co-exist with the melt in thermodynamic equilibrium. Above the liquidus temperature the material is homogeneous. Below the liquidus temperature, crystals may begin to form in the melt, depending on the material. - The liquidus temperature can be contrasted with the solidus temperature. The solidus temperature quantifies the point at which a material completely solidifies (crystallizes). The liquidus and solidus temperatures may overlap. In this overlapping temperature range, a slurry or semi-solid metal may be formed. In this regard, squeeze casting may be performed with semi-solid metal.
- The
mold 12 includes a cavity corresponding to theitem 22. In general, liquidus magnesium alloy may be introduced to themold 12 in any suitable manner. In the particular embodiment shown inFIG. 1 , themold 12 includes an orifice configured to mate with theshot sleeve 14 to receive an injectant ofliquidus alloy 24. - The
shot sleeve 14 is configured to receive the injectant and introduce the injectant to the mold cavity. In various examples, theshot sleeve 14 may include a hydraulically drivenpiston 26 or other such actuator to urge the injectant into the mold cavity. As shown herein, theshot sleeve 14 may be moved out from under themold 12 and/or tilted to receive the injectant from the bottom pourladle 16. - The
crucible 16 is configured to heat and/or retain the supply ofliquidus alloy 24 at the liquidus temperature. Magnesium alloy is a particularly suitable alloy for use withHVSC system 10 and/or thecrucible 16. The liquidus temperature of magnesium alloys varies widely depending upon the particular alloy composition. In a specific example, the liquidus temperature of the magnesium alloy AZ91D is about 1105° F. or 595° C. Typically, the alloy is heated somewhat beyond this temperature to allow for contact with relatively cooler surfaces without solidification of the alloy. Therefore, the casting temperature is about 1160° F. (625° C.) to about 1290° F. (700° C.). - In addition to AZ91D other magnesium alloys and or various aluminum alloys are suitable for use with the
HVSC system 10. For example aluminum alloys A356, A380, A383, ADC-12 and the like are suitable for use with theHVSC system 10 and bottom pourladle 18. Accordingly, the temperature of thecrucible 16 and/or other components of theHVSC system 10 may vary depending upon the particular alloy utilized. - The bottom pour
ladle 18 is configured to transfer theliquidus alloy 24 from thecrucible 16 to theshot sleeve 14. The bottom pourladle 18 includes abowl 28,snout 30,aperture 32,stopper 34, andstopper shaft 36. Thesnout 30 either alone or together with thebowl 28 is configured to contain a sufficient volume of theliquidus alloy 24 to fill theshot sleeve 14. In this regard, all of the surfaces that come into contact with theliquidus alloy 24 are compatible with constituents of theliquidus alloy 24 and will not contaminate or otherwise react with theliquidus alloy 24. In a particular example, one or more of thebowl 28,snout 30,stopper 34, andstopper shaft 36 include surfaces of a stainless steel alloy Y06. Conventional ladles include ceramic components with a silica base. Silica reacts violently with liquidus magnesium and therefore silica can not be used to transfer liquidus magnesium. - In other embodiments, one or more of the
bowl 28,snout 30,stopper 34, andstopper shaft 36 include surfaces of other ferrous materials or non-ferrous materials that are compatible with constituents of theliquidus alloy 24. As such, depending upon theparticular liquidus alloy 24, thebowl 28,snout 30,stopper 34, andstopper shaft 36 may include surfaces of any suitable material. - To fill the
snout 30 and/orbowl 28, the bottom pourladle 18 may be positioned into thecrucible 16 by therobotic system 20. For example, acontroller 38 may control therobotic system 20 to place the bottom pourladle 18 into thecrucible 16. Thestopper 34 is configured to mate with theaperture 32 and form a seal. The bottom pourladle 18 includes anactuator 40 connected to thestopper shaft 38. - The
actuator 40 may be controlled to urge the stopper towards theaperture 32 or away from theaperture 32. By urging thestopper 34 into contact with the aperture, theaperture 32 may be closed. To open theaperture 34 and allow theliquidus alloy 24 to enter thesnout 30, theactuator 40 may be controlled, by thecontroller 36 for example, to urge thestopper 34 away from theaperture 32. The level to which the bottom pourladle 18 is filled with theliquidus alloy 24 may depending upon the depth to which the bottom pourladle 18 is placed in thecrucible 16 and the level of the supply ofliquidus alloy 24. In addition, by closing theaperture 34, the fill level of the bottom pourladle 18 may be reduced. Conversely, by applying a vacuum to the bottom pourladle 18, the fill level may be increased. - The
robotic system 20 includes any suitable system of actuators that may be controlled to lift the bottom pourladle 18, move the bottom pourladle 18 between thecrucible 16 and theshot sleeve 14, and as shown inFIG. 2 , place thesnout 30 into theshot sleeve 14. In this regard, thesnout 30 is configured to fit within theshot sleeve 14. That is, the outside diameter of thesnout 30 is less than the inside diameter of theshot sleeve 14. In addition, as shown inFIGS. 3-5 , therobotic system 20 and/or a system to move theshot sleeve 14, may be configured to retract thesnout 30 from theshot sleeve 14 substantially at the rate at which theshot sleeve 14 is filled. -
FIG. 3 is a cross sectional view of the bottom pourladle 18 at an initial stage of filling theshot sleeve 14 in accordance with an embodiment of the invention. As shown inFIG. 3 , theaperture 32 is placed at a bottom portion of theshot sleeve 14. In general, theaperture 32 is as close to the bottom of theshot sleeve 14 as possible without impeding the flow of theliquidus alloy 24 therefrom. In a particular example, theaperture 32 is placed in close proximity to thepiston 26. By placing theaperture 32 in close proximity to the bottom of theshot sleeve 14 prior to opening theaperture 32, theshot sleeve 14 may be filled with a minimum about of splashing and turbulence. This relatively calm flow of theliquidus alloy 24 from theaperture 32 greatly improves the overall casting quality of cast products. In particular the mechanical properties of theitem 22 are improved by reducing the creation of oxides and other impurities. - According to various embodiments of the invention, the bottom pour
ladle 18 may optionally include one ormore heaters heater 42 may be disposed upon or around thebowl 28 and configured to impart heat to thebowl 28 and any contents therein. If theheater 44 is included, it may be disposed in or around thestopper 34 and/orstopper shaft 36. Theheater 44 is configured to impart heat into the contents of thebowl 28 and/orsnout 30. Theheaters heaters heaters 42 and/or 44 may be controlled to provide sufficient heat energy to maintain the liquidus temperature of theliquidus alloy 24 or to raise the temperature of theliquidus alloy 24 in preparation to fill the relativelycooler shot sleeve 14. - In addition, according to an embodiment of the invention, the bottom pour
ladle 18 may include anoptional nozzle 46. If included, thenozzle 46 may be connected to an inert gas source via a hose orpipe 48. Thenozzle 46 is configured to introduce a bath of inert gas into the bottom pourladle 18. Depending upon the particular alloy utilized, the specific gas may be selected from suitable inert gasses. In a particular example, the inert gas may include Argon and/or SO2. To retain the bath of inert gas and/or facilitate heat retention and/or reduce spillage, the bottom pourladle 18 may include alid 50. Thelid 50 may be configured to cover a rim of thebowl 28 and form a seal thereon. In general, thelid 46 facilitates retention of the gasses within thebowl 28, however, the lid need not provide a gas impermeable seal. -
FIG. 4 is a cross sectional view of the bottom pourladle 18 at an intermediate stage of filling theshot sleeve 14 in accordance with an embodiment of the invention. As shown inFIG. 4 , theaperture 32 is opened in response to theactuator 40 urging thestopper 34 via thestopper shaft 36 away from theaperture 32. In response to opening theaperture 32,liquidus alloy 24 is allowed to flow from the bottom pourladle 18 into theshot sleeve 14. As shown inFIGS. 5 and 6 , the bottom pourladle 18 and shotsleeve 14 are drawn away from one another during the shot sleeve filling operation. In general, the bottom pourladle 18 and shotsleeve 14 are drawn away from one another at approximately the rate at which theshot sleeve 14 fills with theliquidus alloy 24. In a particular example, the rate at which the bottom pourladle 18 and shotsleeve 14 are drawn away from one another is controlled to retain the aperture just below the level of the rising theliquidus alloy 24 within theshot sleeve 14. The rate at which theshot sleeve 14 is filled—and thus the rate at which thesnout 30 is drawn out of theshot sleeve 14—may be determined in any suitable manner. For example, the fill rate may be calculated, determined empirically and/or sensed via sensors in or around theshot sleeve 14. - As shown in
FIG. 6 , theaperture 32 may be closed in response to the completion of the shot sleeve filling operation. For example, theactuator 40 may be controlled to urge thestopper 34 via thestopper shaft 36 against theaperture 32. In this manner, any of theliquidus alloy 24 remaining in the bottom pourladle 18 may be prevented from entering theshot sleeve 14 and/or spilling out as the bottom pourladle 18 is returned to thecrucible 16. In other examples, the bottom pourladle 18 may be filled from thecrucible 16 to contain the correct amount of theliquidus alloy 24 to fill theshot sleeve 14 and thus, the aperture closing procedure may be omitted. - The many features and advantages of the invention are apparent from the detailed specification, and thus, it is intended by the appended claims to cover all such features and advantages of the invention which fall within the true spirit and scope of the invention. Further, since numerous modifications and variations will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation illustrated and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.
Claims (27)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US12/341,118 US20090166387A1 (en) | 2007-12-27 | 2008-12-22 | Bottom Pour Ladle and Method of Transferring Liquid Metal with Same |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US1707307P | 2007-12-27 | 2007-12-27 | |
US12/341,118 US20090166387A1 (en) | 2007-12-27 | 2008-12-22 | Bottom Pour Ladle and Method of Transferring Liquid Metal with Same |
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Publication Number | Publication Date |
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US20090166387A1 true US20090166387A1 (en) | 2009-07-02 |
Family
ID=40796878
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US12/341,118 Abandoned US20090166387A1 (en) | 2007-12-27 | 2008-12-22 | Bottom Pour Ladle and Method of Transferring Liquid Metal with Same |
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US (1) | US20090166387A1 (en) |
Cited By (5)
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CN103394666A (en) * | 2013-05-31 | 2013-11-20 | 广东科达机电股份有限公司 | Slurry taking device |
CN104353811A (en) * | 2014-10-30 | 2015-02-18 | 广东科达洁能股份有限公司 | Vacuum quantifying tank |
US9005518B2 (en) | 2008-02-18 | 2015-04-14 | North American Refractories Co. | High yield ladle bottoms |
WO2016151119A1 (en) * | 2015-03-25 | 2016-09-29 | Bayerische Motoren Werke Aktiengesellschaft | Apparatus for filling a melt into a casting chamber, and method for filling melt into a casting chamber |
CN113275548A (en) * | 2021-05-24 | 2021-08-20 | 巢湖云海镁业有限公司 | Liquid control device used in magnesium alloy pouring and liquid transferring process |
-
2008
- 2008-12-22 US US12/341,118 patent/US20090166387A1/en not_active Abandoned
Cited By (7)
Publication number | Priority date | Publication date | Assignee | Title |
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US9005518B2 (en) | 2008-02-18 | 2015-04-14 | North American Refractories Co. | High yield ladle bottoms |
CN103394666A (en) * | 2013-05-31 | 2013-11-20 | 广东科达机电股份有限公司 | Slurry taking device |
CN104353811A (en) * | 2014-10-30 | 2015-02-18 | 广东科达洁能股份有限公司 | Vacuum quantifying tank |
WO2016151119A1 (en) * | 2015-03-25 | 2016-09-29 | Bayerische Motoren Werke Aktiengesellschaft | Apparatus for filling a melt into a casting chamber, and method for filling melt into a casting chamber |
CN107107179A (en) * | 2015-03-25 | 2017-08-29 | 宝马股份公司 | For the equipment of injection melt into casting room and the method for injecting melt into casting room |
US10537936B2 (en) | 2015-03-25 | 2020-01-21 | Bayerische Motoren Werke Aktiengesellschaft | Apparatus for filling a melt into a casting chamber, and method for filling melt into a casting chamber |
CN113275548A (en) * | 2021-05-24 | 2021-08-20 | 巢湖云海镁业有限公司 | Liquid control device used in magnesium alloy pouring and liquid transferring process |
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