WO2010000209A1 - 环缝式电磁搅拌制备半固态合金浆料的装置及方法 - Google Patents

环缝式电磁搅拌制备半固态合金浆料的装置及方法 Download PDF

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Publication number
WO2010000209A1
WO2010000209A1 PCT/CN2009/072611 CN2009072611W WO2010000209A1 WO 2010000209 A1 WO2010000209 A1 WO 2010000209A1 CN 2009072611 W CN2009072611 W CN 2009072611W WO 2010000209 A1 WO2010000209 A1 WO 2010000209A1
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WIPO (PCT)
Prior art keywords
semi
solid
slurry
crucible
blank
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PCT/CN2009/072611
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English (en)
French (fr)
Inventor
徐骏
张志峰
白月龙
石力开
Original Assignee
北京有色金属研究总院
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Priority claimed from CN2008101161819A external-priority patent/CN101618438B/zh
Priority claimed from CN200810239964A external-priority patent/CN101745629A/zh
Application filed by 北京有色金属研究总院 filed Critical 北京有色金属研究总院
Publication of WO2010000209A1 publication Critical patent/WO2010000209A1/zh

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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
    • B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
    • B22D11/10—Supplying or treating molten metal
    • B22D11/11—Treating the molten metal
    • B22D11/114—Treating the molten metal by using agitating or vibrating means
    • B22D11/115—Treating the molten metal by using agitating or vibrating means by using magnetic fields
    • 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
    • B22D41/005—Casting melt-holding vessels, e.g. ladles, tundishes, cups or the like with heating or cooling means

Definitions

  • the invention belongs to the technical field of semi-solid metal processing and relates to a device and a method for preparing a semi-solid alloy rheological slurry or blank.
  • an apparatus and method are provided for preparing a large gauge semi-solid alloy rheological slurry or blank.
  • the electromagnetic stirring slurry preparation technology has the advantages of not polluting the alloy, the alloy slurry is pure, the control parameters are easy to adjust, and the rheological slurry can be continuously produced or continuously.
  • the advantages of ingot casting, etc. have been put into commercial production and have obtained a wide range of applications.
  • the semi-solid pulping industry generally regards the skin effect of electromagnetic induction as an unfavorable factor and tries to avoid it.
  • the method of reducing the electromagnetic stirring frequency and increasing the skin depth of the electromagnetic field is often used to overcome
  • the adverse effect of the skin effect on the texture of the slurry attempts to obtain a more ideal semi-solid slurry structure.
  • this will result in a large pulping equipment, high investment costs, and high slurry preparation costs.
  • U.S. Patent No. 4,344,837 and U.S. Patent No. 4,229,210 disclose various methods of preparing electromagnetic stirring of semi-solid metal and alloy slurries and billets. The principle is to break the primary dendrites by strong electromagnetic stirring, and inhibit the growth of primary crystal grains into dendritic crystals, thereby preparing semi-solid metal and alloy slurry of spherical or granular primary crystal grains.
  • the problem of cooling inside the slurry is not mentioned, and the internal cooling mechanism is not mentioned.
  • the distribution of the temperature field of the slurry is not uniform, the outer layer of the slurry dissipates quickly, and the inner heat dissipation of the slurry is slow, resulting in the primary crystal grains in space and time.
  • the primary crystal grains of the outer layer of the slurry are precipitated first, and the primary crystal grains inside the slurry are precipitated, which will eventually lead to unevenness of the slurry structure, for large size and large size slurry or The billet is even more so.
  • the magnetic field strength decreases exponentially from the outer edge to the center of the slurry, resulting in a strong agitation of the outer layer of the slurry, and a weak agitation at the center of the slurry.
  • the microstructure distribution is very uneven, the outer layer is fine, the inner layer is coarse, and the microstructure is different, and the primary crystal grains of the outer layer are spherical or granular, and the center It is dendritic or rose-like, so the size of the semi-solid slurry or blank prepared by the above method is also limited, and it is difficult to prepare high-quality large-size and large-sized semi-solid metal and alloy pastes or blanks.
  • Solid metal or alloy bars generally not exceeding 150 in diameter, so how to overcome the above shortcomings of electromagnetic stirring, to prepare uniform and fine semi-solid metal and alloy slurry or blank, especially to prepare large-size and large-size semi-solid Metal and alloy pastes or billets will be of great significance and practical value.
  • Chinese Patent 200420112702.0 also proposes a device and a method for continuously preparing a semi-solid metal slurry by a composite electromagnetic stirring method.
  • the main structure and principle of the device are: electromagnetic stirring is applied in the tundish to uniformly cool the liquid of the tundish overheated. At the liquidus temperature, strong electromagnetic stirring is applied outside the draft tube, and the metal liquid flow can be sufficiently rapidly cooled, so that the number of nucleation is greatly increased, and the solidified structure is remarkably refined.
  • the preparation of the semi-solid metal slurry by the above-mentioned equipment and method can solve the problem that in the prior art, the liquidity of the pouring metal liquid is close to the liquidus temperature due to the simple static insulation, and the liquidity of the metal liquid is too low.
  • the technical problem of variation can also avoid the problem of uneven cooling and uneven solidification structure due to the large size of the crucible prepared in the prior art and the uneven stirring of the metal liquid.
  • a composite electromagnetic stirring technique is employed, and the internal cooling mechanism of the slurry is not mentioned.
  • a strong composite electromagnetic stirring technique is used to facilitate the flow of the semi-solid alloy slurry, but the unevenness of the slurry temperature field and the unevenness of the slurry structure.
  • it can only produce semi-solid metal paste or blank with small size, can not produce large-size semi-solid alloy slurry or blank, and the electromagnetic stirring equipment of the equipment adopts frequency conversion device, and the purchase cost is high.
  • the structure is complex, which also limits the promotion and application of the device.
  • Electromagnetic stirring technology is the key to the application range of semi-solid metal paste.
  • an object of the present invention is to provide a device and method for preparing a semi-solid metal rheological slurry or blank by annular seam electromagnetic stirring, the device and method
  • the skin effect of electromagnetic stirring is fully utilized, and the semi-solid slurry obtained by the device and method has uniform microstructure, small size and good shape, and is favorable for producing qualified high-quality semi-solid metal or alloy blank or slurry.
  • An apparatus for preparing a semi-solid metal rheological slurry or billet comprising a preparation crucible, wherein an outer cooling controller, an insulation system, and a magnetic stirrer are disposed in order from the inside to the outside of the preparation crucible;
  • the top of the crucible is provided with a stationary crucible which is connected to the preparation crucible through a heat insulating cover on the preparation crucible through a draft tube at the bottom thereof, and a melting crucible is disposed on the upper portion of the stationary crucible; and is provided at the bottom of the preparation crucible a draft tube, the draft tube for preparing the bottom of the crucible and the bottom tube of the melting crucible each having a valve;
  • the middle portion of the preparation crucible is provided with an internal cooling controller, and
  • the outer wall of the internal cooling controller forms an annular gap with the inner side wall of the preparation crucible.
  • the device for preparing a semi-solid metal rheological slurry or blank of the invention fully utilizes the skin effect of electromagnetic stirring, and the main principle thereof is:
  • the principle of electromagnetic induction the magnetic field strength decreases from the surface of the slurry to the inward exponential curve, the closer On the surface of the slurry, the greater the magnetic induction, the closer to the inside of the slurry, the smaller the magnetic induction, and the magnetic induction is small at the part larger than the skin depth, that is, in order to make the slurry to have a strong stirring force, the inside of the slurry
  • the magnetic induction intensity of the region should be sufficiently large.
  • all of the semi-solid alloy melt can be placed in a region from the surface of the slurry to the inner width not exceeding the skin depth, that is, the agitation region is a narrow slit.
  • the slurry is formed by a "film" which can be appropriately adjusted in thickness, and the width of the slit is at most the skin depth.
  • the width of the slit can be adjusted and narrowed, and the smaller the gap, penetrates into the interior of the slurry. The stronger the magnetic induction, the more vigorous the stirring, the more uniform the agitation, and then the semi-solid alloy slurry obtained by stirring. Rheological survive shaping, or made into billets touch performance.
  • the present invention provides an internal cooling controller that can be passed through a cooling medium in the preparation of the crucible, and the semi-solid alloy melt can be obtained by adjusting the annular gap formed between the outer wall of the internal cooling controller and the inner side wall of the preparation crucible. Strong agitation is carried out in the gap under the action of electromagnetic stirring force, and the cooling medium introduced in the internal cooling controller and the external cooling controller can make the heat dissipation of the slurry more uniform and the temperature field distribution is more uniform. Got The distribution of the resulting slurry is also more desirable.
  • the shortcomings of the current electromagnetic stirring device adopting the frequency conversion system are large and complicated, and the investment cost is high, and the electromagnetic stirring can be performed in the production as long as the power frequency is used, without using the low frequency stirring, nor
  • the need for a frequency conversion system is of great practical significance and practical value for reducing the investment cost of the enterprise and reducing the production cost of the semi-solid components, and expanding the application range of the semi-solid.
  • the draft tube of the apparatus for preparing a semi-solid rheological slurry or blank of the present invention can be connected to a die casting machine, an extruder, a continuous casting machine, a forging machine, and subjected to rheological die casting, rheological extrusion casting, rheological continuous casting, For rheological forging, the connection is as follows:
  • the structure of the draft tube connecting die casting machine of the apparatus for preparing a semi-solid rheological slurry or blank of the present invention is as follows: the draft tube for preparing the bottom of the crucible is connected to the injection chamber of the die casting machine, on one side of the shot chamber A punch is arranged inside, and the other side of the injection chamber is connected to a die-casting fixed mold and a die-casting movable mold.
  • the structure of the draft tube connecting extruder of the apparatus for preparing a semi-solid rheological slurry or blank of the present invention is as follows: the draft tube for preparing the bottom of the crucible is connected to the extrusion barrel of the extruder, and one of the extrusion tubes The extrusion rod is arranged in the side, and the other side of the extrusion barrel is connected to the extrusion mold right type and the extrusion mold left type.
  • the structure of the draft tube connecting continuous casting machine for preparing the semi-solid rheological slurry or blank of the present invention is as follows: the draft tube for preparing the bottom of the crucible is connected to the tundish of the continuous casting machine, and the tundish is connected to the crystallizer, A plurality of cooling water nozzles are uniformly distributed around the outlet of the crystallizer, and a lowering device outside the outlet of the crystallizer has a traction mechanism.
  • the structure of the draft tube connection forging machine of the apparatus for producing a semi-solid rheological slurry or blank of the present invention is as follows:
  • the draft tube for preparing the bottom of the crucible is connected to the forged mold cavity in the forging mold.
  • the internal cooling controller is a cooling passage through which a cooling medium is passed, and the cooling passage is composed of a central tube and an outer sleeve thereof, the central tube
  • the upper port is the cooling medium input port
  • the lower port of the center pipe is in communication with the outer casing, and the center pipe constitutes a cooling medium input passage
  • the upper port of the outer casing is a cooling medium output port
  • the outer casing constitutes a cooling medium output passage.
  • the shape of the cooling medium input passage along the radial direction that is, the cross section of the central tube is circular, elliptical, square or trapezoidal;
  • the shape of the cooling medium input passage, that is, the center tube, in the axial direction is a straight tube shape or a curved tube shape.
  • the appearance of the cooling medium output passage along the radial direction that is, the outer cross section of the outer sleeve is circular, elliptical, square or
  • the shape of the cooling medium output passage, that is, the outer sleeve along the axial direction is a straight tube shape, a serpentine tube shape, a spiral tube shape, a wave tube shape or other curved tube shape; or the inner wall of the outer sleeve is along
  • the shape in the axial direction is a straight pipe wall shape
  • the shape of the outer wall in the axial direction is spiral or wavy.
  • the outer sleeve is formed into a serpentine tube shape, a spiral tube shape, a wave tube shape or other curved tube shape, the situation is complicated and the manufacturing process is difficult; from the viewpoint of ease of manufacture, it is preferable to make the inner wall of the outer sleeve along the shaft.
  • the shape in the direction of the direction is a straight pipe wall shape, and the outer wall thereof is formed in a spiral shape or a wave shape in the axial direction.
  • the cooling medium input passage is made of austenitic stainless steel, titanium, molybdenum, cobalt, chromium, nickel, copper or the like.
  • Non-metallic materials such as graphite, ceramics, corundum
  • the output channels of the cooling medium are austenitic stainless steel, non-magnetic metal materials such as titanium, molybdenum, cobalt, chromium, nickel, copper, or non-metallic materials such as graphite, ceramics, and corundum.
  • the material of the cooling medium input channel and the cooling medium output channel must be non-magnetic metal or non-metal material, mainly to prevent it from affecting the electromagnetic field.
  • the inner passage of the cooling medium input passage that is, the inner tube is 2 to 1000 mm
  • the inner diameter of the cooling medium output passage that is, the outer sleeve
  • the cross-sectional shape of the crucible is round, elliptical or square; and the longitudinal cross-sectional shape of the crucible is square or broad and narrow.
  • an outer wall of the internal cooling controller that is, an outer wall of the cooling medium output passage and an inner side wall of the preparation crucible, form an annular gap, and the cross-sectional shape of the annular slit It is circular, elliptical or square; the width of the annular slit shown by the longitudinal section of the annular slit is equal to the width of the upper part and the lower part, or the width of the upper width and the lower part having a gradient; the width of the annular gap is 0.
  • the outer wall of the cooling medium output passage has a spiral shape in the axial direction, and has a pitch of 5 to 100 mm and a high thread. It is 2 ⁇ 100mm.
  • the outer wall of the cooling medium output passage has a wave shape along the axial direction, and has a wave pitch of 5 to 100 mm and a corrugation height of 2 ⁇ 100mm.
  • the cooling medium introduced into the cooling passage is air, nitrogen, argon, tap water or other cooling liquid, and the temperature of the cooling medium is room temperature.
  • the inlet pressure is 0. 001MP a
  • the inlet pressure is 0. 001MP a . -1 2MP a;. in the case where the case where the cooling medium to the external cooling gas controller, which inlet pressure of 0. 001MPa-0 5MPa, cooled when the cooling medium of the external controller is liquid, imports The pressure is 0. 001MPa-l. 2MPao
  • a method for preparing a slurry or a blank of a semi-solid metal or alloy using the apparatus of the present invention pouring a liquid metal or alloy liquid higher than a liquidus temperature of 5 to 200 ° C into a crucible inner wall and an internal cooling controller Between outer walls In the annular gap, and open the electromagnetic stirrer to stir the liquid metal or alloy liquid in the annular gap, prepare the semi-solid slurry, and simultaneously pass the room temperature to the external cooling controller and the internal cooling controller respectively.
  • the cooling medium has a cooling rate of l ⁇ 150 ° C / min, so that the prepared semi-solid slurry temperature field is more uniform, thereby obtaining a fine and uniform semi-solid slurry structure, and controlling the temperature of the semi-solid slurry below Its liquidus temperature is higher than its solidus temperature.
  • the temperature range of the semi-solid slurry is the temperature interval between the solidus and liquidus of the metal or alloy melt, that is, the temperature of the semi-solid slurry is lower than the liquidus temperature and higher than the solidus temperature.
  • the determination of the temperature of the semi-solid slurry is determined according to the complexity of the formed part and the specific conditions during the operation. If the part is complicated, the temperature of the semi-solid slurry required is higher for filling. The parts are simple and the required semi-solid slurry can be cooler. Therefore, the temperature of the semi-solid slurry is determined according to the complexity of the part and the specific conditions during the operation. For different alloys of different parts, the temperature of the semi-solid slurry is different.
  • the flow rate of the cooling medium introduced into the internal cooling controller and the external cooling controller is a flow rate of the cooling medium of 0 to 200 liters / min, and ⁇ 0.
  • the electromagnetic stirrer uses an induction alternating current rotating electromagnetic stirrer, and the frequency is 5 to 100 Hz.
  • the temperature difference between the inside and the outside of the semi-solid slurry is controlled within ⁇ 3 ° C, and the temperature difference between the inside and the outside of the semi-solid slurry is a semi-solid slurry on the outer wall of the internal cooling controller.
  • the prepared semi-solid slurry is a semi-solid aluminum-based alloy slurry, a semi-solid magnesium-based alloy slurry, a semi-solid zinc-based alloy slurry, a semi-solid copper-based alloy slurry, and a semi-solid nickel.
  • the semi-solid slurry is completely solidified in the preparation crucible to obtain a semi-solid aluminum alloy billet, a semi-solid magnesium alloy billet, a semi-solid zinc alloy billet, a semi-solid copper alloy billet, and a semi-solid nickel.
  • the above-mentioned blank material can be used as a semi-solid thixotropic Formed raw blank.
  • the inner side wall and the internal cooling control are prepared A protective gas is formed in the annular gap formed between the outer walls of the vessel to prevent or reduce oxidation of the metal or alloy, which is argon, nitrogen or helium.
  • the materials for preparing the crucible, the internal cooling controller and the external cooling controller are all non-metallic or non-magnetic metals.
  • the present invention provides an internal cooling controller that can be passed through the cooling medium in the preparation crucible, and an annular gap is formed between the outer wall of the internal cooling controller and the inner side wall of the preparation crucible.
  • the solid alloy melt is strongly stirred in the gap under the action of electromagnetic stirring force, and the cooling medium introduced in the internal cooling controller can make the heat dissipation of the slurry more uniform and the temperature field distribution is more uniform.
  • the slurry distribution is also more ideal.
  • a certain degree of superheated liquid metal and alloy can be poured into the annular space, and the metal and alloy melt are strongly stirred under the action of electromagnetic stirring force.
  • the temperature field of the slurry is more uniform under the co-cooling action of the internal cooling controller and the preparation crucible, so that the agitating force field and temperature field of the slurry will be more uniform, thereby obtaining a high quality semi-solid slurry, and then
  • the semi-solid slurry is directly transferred to a die casting machine or a forging machine or an extruder to form; or the obtained semi-solid slurry is completely solidified into a billet, and then the billet is reheated to a semi-solid section, and then the billet is transferred to a die casting machine or Forging machine and extruder forming.
  • the preparation process is simple, the operation is convenient, the semi-solid structure is excellent in morphology and the preparation cost is low, and is very suitable for preparation of semi-solid metal and alloy slurry or blank.
  • a metal and alloy melt having a certain degree of superheat The temperature of the melt is controlled at a temperature of 5 to 200 ° C above the liquid phase temperature, and the melt is poured between the inner wall of the crucible and the outer wall of the internal cooling controller. Inside the annular gap.
  • the shape of the preparation crucible is cylindrical
  • the shape of the internal cooling controller is a hollow bottom sealed straight tubular shape
  • the shape of the external cooling controller is a spiral tube.
  • the preparation ⁇ , internal cooling controller and external cooling controller are made of non-metallic or non-magnetic metal.
  • the annular gap formed between the inner wall of the preparation crucible and the outer wall of the inner cooling tube is 3 to 200 mm.
  • the electromagnetic stirrer uses an induction AC rotating electromagnetic stirrer with a frequency of 5 ⁇ 100Hz.
  • Externally set external cooling controller Externally set external cooling controller.
  • the external cooling controller and internal cooling controller are supplied with cooling medium at room temperature, nitrogen, argon or room temperature cold water at a flow rate of 0 ⁇ 200 liters/min and ⁇ 0.
  • the metal and alloy slurry are strongly stirred in the annular gap, and the slurry temperature is gradually lowered under the cooling effect of the internal cooling controller and the external cooling controller, and the flow rate of the cooling medium is adjusted to make the slurry
  • the cooling rate is l ⁇ 150 °C/min, and ⁇ 0.
  • the temperature field of the semi-solid metal or alloy slurry is made uniform, and the temperature difference between the inside and the outside of the semi-solid slurry is controlled to not exceed ⁇ 3 °C.
  • the shielding gas may be introduced to avoid or reduce the oxidation of metals and alloys.
  • the shielding gas may be a shielding gas such as argon gas, nitrogen gas or helium gas.
  • the slurry temperature reaches the predetermined temperature, the slurry is immediately transferred to a die casting machine or a forging machine, an extruder to form, or the slurry is completely solidified in the preparation crucible to obtain a special semi-solid metal and An alloy blank that can be used as a semi-solid thixoforming original blank.
  • the invention avoids the adverse effects of the electromagnetic induction skin effect, and the slurry is subjected to a more uniform stirring force and temperature field.
  • the invention concentrates all the slurry in the narrow inner region of the gap for agitation, the slurry is more vigorously stirred, the strength is greater, the agitation of the slurry is more uniform, and the internal and external stirring of the slurry is overcome by the conventional electromagnetic stirring. Uneven, uneven organization and other issues.
  • the temperature field of the semi-solid alloy melt is uniform, and the obtained semi-solid slurry is uniform, small, and well-formed, and the radial size of the internal cooling controller can be freely selected.
  • the distance between the internal cooling controller and the inner wall of the preparation crucible ie, the thickness of the slurry
  • the thickness of the slurry can be freely adjusted, which is advantageous for obtaining a larger shear rate of the slurry and obtaining a fine and uniform structure.
  • the invention can produce large-size semi-solid alloy slurry or blank.
  • the invention provides an internal and external cooling controller, which can not only obtain strong electromagnetic stirring of the slurry, but also obtain uniform stirring force inside the slurry, obtain uniform slurry structure, and balance the temperature field of the semi-solid alloy melt, and promote The alloy melt nucleates in a large amount, inhibits the formation or growth of dendrites, and finally forms a semi-solid structure.
  • the internal cooling controller will a certain agitating effect on the agitated alloy melt, which will promote the breaking and dissociation of the primary crystal grains.
  • the alloy melt in the preparation of the crucible is in a relatively closed state, which prevents the entrainment of the semi-solid alloy melt, and the static standing argon provided can also effectively prevent the external gas from being caught in the alloy melt prepared in the crucible, and further provided
  • the internal cooling controller can effectively prevent the movement of the electromagnetic stirring magnetic field from causing vortex in the alloy melt, and the surface of the alloy melt is gentle and prevents the gas from being blown.
  • the self-cleaning property of the melt is good.
  • the alloy melt is gradually collected to the bottom of the crucible, which can effectively avoid the alloy melt.
  • the equipment is simple and compact, with simple installation, simple process, convenient operation, low investment cost, strong practicability and wide application range. Compared with other semi-solid forming methods and conventional electromagnetic stirring methods currently used, the device is small in size, simple in equipment, and low in investment cost.
  • the enterprise can perform electromagnetic stirring in the production process by using a power frequency without using low-frequency stirring.
  • a frequency conversion system which overcomes the shortcomings of the current electromagnetic stirring device using a variable frequency system, such as large structure and high complexity, and high investment cost, which can significantly reduce the preparation cost of semi-solid alloy slurry or blank, and ultimately reduce the production cost of semi-solid castings. Reinforce the competitiveness of semi-solid castings and expand the application range of semi-solid castings.
  • the invention is suitable for the preparation of semi-solid pastes or blanks of aluminum-based alloys and composites thereof, and also for magnesium-based alloys, copper-based alloys, zinc. Preparation of semi-solid slurries or blanks of base alloys, iron-based alloys and other non-ferrous metal alloys and composites thereof.
  • Figure 1 is a schematic view of a device for preparing a semi-solid metal rheological slurry or blank.
  • Fig. 2 is a schematic view showing the structure of an internal cooling controller in which the outer wall of the cooling medium output passage has a linear shape in the axial direction.
  • Fig. 3 is a schematic view showing the structure of an internal cooling controller in which the outer wall of the cooling medium output passage is wavy in the axial direction.
  • Fig. 4 is a schematic view showing the structure of an internal cooling controller in which the outer wall of the cooling medium output passage has a spiral shape in the axial direction.
  • Figure 5 is a schematic view of a device for preparing a semi-solid metal rheological slurry or blank equipped with a die casting machine.
  • Figure 6 is a schematic view of an apparatus for preparing a semi-solid metal rheological slurry or blank equipped with an extruder.
  • Figure 7 is a schematic view of a device for preparing a semi-solid metal rheological slurry or blank equipped with a continuous casting machine.
  • Figure 8 is a schematic view of a device for preparing a semi-solid metal rheological slurry or blank equipped with a forging machine.
  • Figure 9 is a quenched structure of the side of the semi-solid A357 aluminum alloy slurry prepared by the present invention, and the light-colored region is a spherical primary "-A/, and the dark region is a solidified eutectic liquid.
  • Figure 10 is a quenched structure of the middle portion of a semi-solid ⁇ 357 aluminum alloy slurry prepared by the present invention.
  • the light-colored region is a spherical primary "-A/, and the dark region is a solidified eutectic liquid.
  • Figure 11 is a quenched structure of a semi-solid ⁇ 357 aluminum alloy slurry center prepared by the present invention, wherein the light-colored region is a spherical primary - ⁇ /, and the dark region is a solidified eutectic liquid.
  • FIG. 1 is a schematic view of a device for preparing a semi-solid metal rheological slurry or blank. As shown in FIG. 1, the device includes a preparation crucible 6, and an external cooling controller 3 is disposed in the outer periphery of the preparation crucible 6 from the inside to the outside.
  • insulation system 2 a magnetic stirrer 1; a static raft 11 is disposed on the upper portion of the preparation crucible 6, and the stationary crucible 11 is passed through a heat-guiding cover 8 on the preparation crucible 6 through a guide tube 9 at the bottom thereof to communicate with the preparation crucible 6
  • the upper portion of the crucible 11 is provided with a melting crucible 12; and at the bottom of the preparation crucible 6, a draft tube 5 is provided, and the draft tube 5 for preparing the bottom of the crucible 6 and the draft tube 9 for the bottom portion of the crucible 12 are formed.
  • Each has a valve 4, 10; the middle portion of the preparation crucible is provided with an internal cooling controller 14, the internal cooling controller 14 is a cooling passage through which a cooling medium is passed, and the cooling passage is composed of a central tube and an outer sleeve thereof.
  • the upper port of the central pipe is a cooling medium input port, the lower port of the center pipe is connected to the outer casing, the central pipe constitutes a cooling medium input passage; the upper port of the outer casing is a cooling medium output port, and the internal cooling controller 14 can be cooled inside. medium.
  • the external cooling controller 3 is a spiral tube having a plurality of uniformly distributed small holes which are placed inside the external thermal insulation system 2 for preparing the crucible 4 and at a certain distance from the outer wall of the preparation crucible, and the external cooling controller 3 is also inside.
  • the cooling medium can be supplied.
  • the crucible 6 is a cylindrical container which is placed inside the thermal insulation system to form a closed cavity.
  • the internal cooling controller 14 is placed in the center of the preparation crucible 6. An annular gap is formed between the outer side wall of the inner cooling controller 14 and the inner side wall of the preparation crucible 6.
  • the electromagnetic stirrer 1 is placed outside the thermal insulation system 2. And a thermocouple 13 is provided in the preparation crucible 6.
  • FIG. 2 to FIG. 4 are schematic diagrams showing the structure of the internal cooling controller 14.
  • the internal cooling controller 14 is composed of a cooling passage and a cooling medium.
  • the cooling passage is composed of a cooling medium input passage 14-1 and a cooling medium.
  • the output channel 14-2 is composed.
  • the cooling medium input channel 14-1 is a central tube with a hollow bottom opening, and the upper end of the central tube is a cooling medium input port, and the central tube can be circular, elliptical, square, or trapezoidal in the radial direction (cross section). Or other various shapes, the shape of the center tube in the axial direction is a straight tube shape or a curved tube shape, wherein the curved tube shape is a serpentine tube shape.
  • the cooling medium output passage 14-2 is a hollow bottom sealed outer sleeve which is sleeved outside the center tube, and the center tube communicates with the outer sleeve through the bottom opening, and the upper opening of the outer sleeve is a cooling medium outlet.
  • the bottom and the side wall of the outer sleeve may be integrally formed or sealed by welding and other methods, and the outer shape of the cooling medium output passage 14-2 in the radial direction (cross section), that is, the outer shape of the cross section of the outer sleeve may be a circle Shape, ellipse, square, trapezoid or other various shapes, the cooling medium output channel, that is, the shape of the outer sleeve along the axial direction is a straight tube shape, a serpentine tube shape, a spiral tube shape, a wave tube shape or other curved tube shape Or the inner wall of the outer sleeve is shaped like a straight tube wall in the axial direction and the outer wall has a spiral or wave shape along the axial direction.
  • the shape of the outer sleeve along the axial direction is a straight tube shape; in FIG. 3, the inner wall of the outer sleeve has a straight tube wall shape along the axial direction and the outer wall along the axial direction.
  • the shape of the outer sleeve is wavy; in Fig. 4, the inner wall of the outer sleeve has a straight tube wall shape in the axial direction and the outer wall has a spiral shape in the axial direction.
  • the material of the cooling medium input passage 14-1 may be a non-magnetic metal material such as steel, copper, titanium, tungsten, molybdenum aluminum or zinc or a non-metal material such as graphite or ceramic.
  • the cooling medium output channel 14-2 can be made of non-metallic materials such as graphite or ceramic. Material.
  • the cooling medium input channel 14-1 is placed in the cooling medium output channel 14-2 to form a cooling medium cooling channel, and the cooling medium input channel 14-1 and the cooling medium output channel 14-2 may be connected by bolting, welding or other methods.
  • the cooling medium may be air, nitrogen, argon or the like, or the temperature of the cooling medium is room temperature.
  • the inner diameter of the cooling medium input channel 14-1 is 2 200.
  • the inner diameter of the cooling medium output channel 14-2 is 5 300.
  • the pitch 1 ⁇ is 5 100!11 1 11 ! ! for? ⁇ !!, as shown in Figure 3;
  • the pitch L' is 5 100 and the thread height h' is 2 100 mm, as shown in Figure 4.
  • the main function of the external cooling controller 3 is to pass a cooling medium into the cooling pipe to cool the alloy melt to the required temperature. It is mainly composed of a cooling pipe and a cooling medium.
  • the cooling pipe is a hollow cooling pipe, and the cooling pipe section
  • the shape may be circular, elliptical, square, trapezoidal or other shape, and the shape of the cooling tube along the axial direction is a straight tube shape, a serpentine tube shape, a spiral tube shape, a wave tube shape or other curved tube shape;
  • the shape of the inner wall of the cooling pipe in the axial direction is a straight pipe wall shape and the shape of the outer wall thereof in the axial direction is a spiral shape or a wave shape.
  • the material of the cooling channel may be a metal-based material such as steel, copper, aluminum, zinc or magnesium or a non-metallic material such as ceramic.
  • the cooling medium may be a gas such as air, nitrogen or argon, and the temperature of the cooling medium is room temperature.
  • the external cooling controller 11 is placed inside the insulation system, around the preparation ⁇ and at a distance from the preparation 10 (10 mm 300 mm).
  • the main function of the valve 4 and the valve 10 is to control the flow of the alloy melt, the valve 4 controls the flow of the semi-solid alloy melt 7 to the flow tube 5, and the valve 10 controls the alloy melt in the stationary crucible 11.
  • the valve 4 and the valve 10 can be controlled manually or mechanically.
  • the main function of the draft tube 5 and the draft tube 9 is to introduce an alloy melt or a semi-solid alloy slurry, and the upper portion of the draft tube 5 is connected to the preparation crucible 6; the upper portion of the draft tube 9 is static The lower portion is connected to the semi-solid alloy melt 7 in the preparation crucible 6, and the outside of the draft tubes 5 and 9 is wound around the heater to control the temperature of the draft tube.
  • the main function of preparing crucible 6 is to hold the alloy melt.
  • the cross-sectional shape of the crucible can be round, square or elliptical.
  • the material of the crucible can be graphite, copper or other non-magnetic metal or non-metal.
  • the main function of the electromagnetic stirrer 1 is to generate a strong electromagnetic force to agitate the alloy melt, so that the alloy melt is strongly stirred.
  • the electromagnetic stirrer can be a rotating electromagnetic stirrer, a traveling wave electromagnetic stirrer, a composite electromagnetic stirrer and Other forms of electromagnetic stirrers.
  • FIG. 5 is a schematic diagram of a semi-solid metal and alloy slurry rheology die-casting equipment, which is obtained by directly placing or fixing a semi-solid rheological slurry preparation device as shown in FIG. 1 above a die casting machine.
  • the die casting machine is composed of a die-casting fixed mold 15, a die-casting movable mold 16, a shot chamber 17, and a punch 19.
  • the draft tube 5 is placed above the shot chamber 17 for convenience The rheological slurry flows into the shot chamber 17.
  • Figure 6 is a schematic diagram of a semi-solid metal and alloy slurry rheological extrusion equipment, which is formed by directly placing or fixing a semi-solid rheological slurry preparation device as shown in Fig. 1 above the extruder.
  • the extruder consists of an extrusion die right type 20, an extrusion die left type 21, a squeeze barrel 22, and a squeeze bar 23.
  • the draft tube 5 is placed above the extrusion barrel 22 to facilitate the flow of the rheological slurry into the extrusion barrel 22.
  • FIG. 7 is a schematic diagram of a semi-solid metal and alloy slurry continuous casting equipment, which is a device in which a semi-solid rheological slurry preparation device as shown in Fig. 1 is directly placed or fixed on top of a continuous casting machine.
  • the continuous casting equipment consists of a tundish 24, a crystallizer 25, a cooling water nozzle 26 and a traction mechanism 27.
  • the draft tube 5 is placed above the tundish 24 to facilitate the flow of the rheological slurry into the tundish 24,
  • FIG. 8 is a schematic diagram of a semi-solid metal and alloy slurry rheological forging equipment, which is obtained by directly placing or fixing a semi-solid rheological slurry preparation device as shown in FIG. 1 above a forging machine.
  • the forging equipment consists of a forging die 30 and a forging die cavity 29 therein, wherein a draft tube 5 is placed over the forging die cavity 29 to facilitate flow of the rheological slurry into the forging die cavity 29.
  • the superheated ZL101A aluminum alloy melt is melted by melting ⁇ 12, and the enthalpy 12 is an electromagnetic induction heating furnace.
  • the heat preservation performance is good, and the ZL101A alloy melt can ensure high temperature control precision, and the temperature control precision is ⁇ 10°C.
  • the stationary crucible 11 is a crucible having excellent heat preservation performance, and the lower end opening is connected to the draft tube 9, and the bottom of the crucible 11 is opened and a valve 10 is provided to control the flow of the molten alloy in the stationary crucible to the preparation crucible 6.
  • the static enthalpy 11 can provide a sufficient amount of alloy liquid for preparing ⁇ 6, and the static enthalpy 11 can ensure that the temperature of the alloy melt is 5 to 200 V above the liquidus, and the temperature control precision is ⁇ 10.
  • the upper part of the draft tube 9 is connected to the stationary crucible 11, and the lower opening is opened into the alloy melt in the preparation crucible 6.
  • the outside of the draft tube 9 is wound with an electric resistance heater which heats the temperature of the draft tube to 400.
  • the preparation crucible 6 is placed inside the thermal insulation system 2, and the inner diameter of the crucible 6 is prepared to be 8O X 16Omm, and the crucible cover 8 having excellent heat insulation performance is prepared on the upper part of the crucible, and the cooling medium output pipe 14-2 of the internal cooling controller 14 is prepared.
  • the outer diameter is 06Omm
  • the material is graphite
  • the preheating temperature is 300 °C.
  • the outer wall of the cooling medium output pipe 14-2 of the internal cooling controller 14 is spaced from the inner side wall of the preparation crucible 11 by a distance of 10 mm.
  • the bottom of the internal cooling controller cooling medium output pipe 14-2 is 40 mm from the inner wall of the bottom of the preparation crucible.
  • the cooling medium input pipe 14-1 of the internal cooling controller 14 has an outer diameter of 025, a pipe thickness of 3 mm, a material of stainless steel, and a temperature of room temperature.
  • the thermal insulation system 2 is a nearly closed cylindrical structure that is hollow and has a top connected to the lid 8. It is surrounded by a good insulation material. This insulation system ensures the slow cooling of the alloy melt in the preparation of the crucible.
  • the cooling rate is 1 ⁇ 150. °C/min
  • the external cooling controller 3 surrounds the outside of the preparation crucible 6 and is 20 mm away from the outer wall of the preparation crucible.
  • a small ventilation hole is formed in the wall of the cooling duct of the external cooling controller 3, and the diameter of the small hole is 4 mm, and the external cooling controller is adjusted.
  • the cooling medium flow rate of 3 can make the outer wall of the preparation crucible cool at a temperature of l ⁇ 150 ° C / min, and the cooling medium is room temperature air.
  • the die casting machine is composed of a die-casting type mold 15, a die-casting type mold 16, a shot chamber 17, and an injection punch 19.
  • the draft tube 5 is connected to the lower port of the preparation crucible 6, and a valve 4 is arranged at the lower end of the crucible 6 to control the flow of the semi-solid alloy melt to the shot chamber.
  • a certain amount of 670 ° C ZL101A alloy liquid is poured into the stationary crucible 11 , covered with a lid 8 , allowed to stand for 10 to 20 s, the valve 10 is opened, and the superheated ZL101A alloy liquid flows into the draft tube 9 to prepare the crucible.
  • the valve 10 is closed, the electromagnetic stirrer 1 is turned on, the nominal power of the electromagnetic stirrer is set to 1300 W, and the internal and external cooling controllers are controlled.
  • the flow rate of the cooling medium in 14, 3 is such that the cooling rate of the melt is 5 ° C / min, and the temperature indicated by the thermocouple 13 is 580 to 600 ° C, and the semi-solid ZL101A aluminum alloy slurry can be obtained.
  • the electromagnetic stirrer 1 and the internal and external cooling controllers 14, 3 are closed, the valve 4 is opened, and the semi-solid ZL101A aluminum alloy slurry 7 flows into the injection chamber 17 through the draft tube 5, and the temperature of the draft tube 5 is controlled at 500°.
  • the preheating temperature of the injection chamber 17 and the injection punch 19, the die-casting mold 15 and the die-casting mold 16 are 250 ° C, and the valve 4 is to be opened for about 5 seconds, and the semi-solid slurry 7 is completely discharged, and the valve is closed. 4.
  • the die casting machine punch 19 presses the semi-solid slurry 7 into the die-casting cavity. Press forming for about 4 ⁇ 8s, then take out the die casting, complete the rheological die casting of a semi-solid ZL101A aluminum alloy slurry, open the valve 10 at the same time of rheological die casting, and flow the superheated ZL101A alloy liquid into the preparation crucible 6, and enter the next time. Rheological die casting.
  • the superheated ZL101A aluminum alloy melt is melted by melting ⁇ 12, and the enthalpy 12 is an electromagnetic induction heating furnace.
  • the heat preservation performance is good, and the ZL101A alloy melt can ensure high temperature control precision, and the temperature control precision is ⁇ 10°C.
  • the stationary crucible 11 is a crucible having excellent heat preservation performance, and the lower end opening is connected to the draft tube 9, and the bottom of the crucible 11 is opened and a valve 10 is provided to control the flow of the molten alloy in the stationary crucible to the preparation crucible 6.
  • the static enthalpy 11 can provide a sufficient amount of alloy liquid for preparing ⁇ 6, and the static enthalpy 11 can ensure that the temperature of the alloy melt is 5 to 200 V above the liquidus, and the temperature control precision is ⁇ 10.
  • the upper part of the draft tube 9 is connected to the stationary crucible 11, and the lower opening is opened into the alloy melt in the preparation crucible 6.
  • the outside of the draft tube 9 is wound with an electric resistance heater which heats the temperature of the draft tube to 400. °C, the preparation crucible 6 is placed inside the thermal insulation system 2, and the inner diameter of the crucible 6 is prepared to be 8O X 16Omm, and the crucible cover 8 having excellent heat insulation performance is prepared.
  • the cooling medium output pipe 14-2 of the internal cooling controller 14 has a structure as shown in Fig. 2, an outer diameter of 06Omm, a material of graphite, and a preheating temperature of 300 °C.
  • the outer wall of the internal cooling controller cooling medium output pipe 14-2 is 10 mm away from the inner side wall of the preparation crucible.
  • the bottom of the internal cooling controller cooling medium output pipe 14-2 is 40 mm from the inner wall of the preparation crucible bottom.
  • Cooling medium input tube for internal cooling controller Lane 14-1 has an outer diameter of 025 and a pipe thickness of 3 mm.
  • the material is stainless steel and the temperature is room temperature.
  • the thermal insulation system 2 is a nearly closed cylindrical structure that is hollow and has a top connected to the lid 8. It is surrounded by a good thermal insulation material.
  • the external cooling controller 3 surrounds the outside of the preparation crucible 6 and is spaced apart.
  • the outer wall of the crucible is prepared to be 20 mm, and a small air hole is formed in the cooling duct wall of the external cooling controller 3, and the diameter of the small hole is 4 mm.
  • the cooling medium flow rate of the external cooling controller 3 can be adjusted to make the outer wall cooling speed of the preparation crucible l ⁇ 150 °C/ Min, the cooling medium is room temperature air.
  • the extruder consists of an extrusion die right type 20, an extrusion die left type 21, a squeeze barrel 22, and a squeeze bar 23.
  • the draft tube 5 is connected to the lower port of the preparation crucible 6, and a valve 4 is arranged at the lower end of the crucible 6 to control the flow of the semi-solid alloy melt to the shot chamber.
  • a certain amount of 670 ° C ZL101A alloy liquid is poured into the stationary crucible 11 , covered with a lid 8 , allowed to stand for 10 to 20 s, the valve 10 is opened, and the superheated ZL101A alloy liquid flows into the draft tube 9 to prepare the crucible.
  • the valve 10 In the middle 6, when the amount of alloy melt to be inflow reaches about 2/3 of the volume of the prepared crucible 6, the valve 10 is closed, the electromagnetic stirrer 1 is turned on, the nominal power of the electromagnetic stirrer is set to 1300 W, and the internal and external cooling controllers are controlled.
  • the flow rate of the cooling medium in the middle 14 and 3 is such that the cooling rate of the melt is 5 ° C /min, and the temperature indicated by the thermocouple 13 is 580 to 600 ° C, and the semi-solid ZL101A aluminum alloy slurry can be obtained.
  • the electromagnetic stirrer 1 and the internal and external cooling controllers 14, 3 are closed, the valve 4 is opened, and the semi-solid ZL101A aluminum alloy slurry 7 is introduced into the extrusion cylinder 22 through the draft tube 5, and the temperature of the draft tube 5 is controlled at 500°. C, the extrusion mold right type 20, the extrusion mold left type 21, the extrusion barrel 22 and the extrusion rod 23 are preheated at a temperature of 250 ° C, and the valve 4 to be opened is closed for about 5 seconds after the semi-solid slurry is completely discharged.
  • Valve 4 while the extrusion rod 23 presses the semi-solid slurry 7 into the extrusion mold right type 20 and the extrusion mold left The cavity between 21, press forming for about 4 ⁇ 8s, then take out the extrusion to complete the rheological extrusion casting of a semi-solid ZL101A aluminum alloy slurry, and open the valve 10 while rheologically pressing, which will overheat The ZL101A alloy liquid flows into the preparation crucible 6 and enters the next rheological extrusion casting.
  • the superheated ZL101A aluminum alloy melt is melted by melting ⁇ 12, and the enthalpy 12 is an electromagnetic induction heating furnace.
  • the heat preservation performance is good, and the ZL101A alloy melt can ensure high temperature control precision, and the temperature control precision is ⁇ 10°C.
  • the stationary crucible 11 is a crucible with excellent heat preservation performance, and the lower end opening is connected with the draft tube 9, and the bottom of the crucible 11 is open and a valve 10 is provided to control the flow of the alloy melt in the stationary crucible to the preparation crucible 6.
  • the static enthalpy 11 can provide a sufficient amount of alloy liquid for preparing the crucible 6, and the static enthalpy 11 can ensure that the temperature of the alloy melt is 5 to 200 ° C above the liquidus, and the temperature control precision is ⁇ 10.
  • the upper part of the draft tube 9 is connected to the stationary crucible 11, and the lower opening is opened into the alloy melt in the preparation crucible 6.
  • the outside of the draft tube 9 is wound around a resistance heater which heats the temperature of the draft tube to 400.
  • the preparation crucible 6 is placed inside the thermal insulation system 2, and the top cover 8 is provided with excellent heat insulation performance, the inner diameter of the preparation crucible 6 is 08O X 480 mm, and the cooling medium output pipe 14_2 of the internal cooling controller 14 adopts a spiral mechanism.
  • the material For graphite is 300 ° C
  • the pitch is high L' is 10 mm
  • the thread height h' is 5 mm
  • the distance between the outer wall of the thread and the inner side wall of the preparation is 10 mm.
  • the distance between the bottom of the internal cooling controller cooling medium output pipe 14-2 and the inner wall of the preparation crucible is 40.
  • the outer diameter of the cooling medium input pipe 14-1 of the internal cooling controller is 025, the pipe thickness is 3, the material is stainless steel, and the temperature is Room temperature.
  • the thermal insulation system 2 is a nearly closed cylindrical structure that is hollow and has a top connected to the lid 8. It is surrounded by a good insulation material. This insulation system ensures that the alloy melt in the preparation crucible is slowly cooled at a cooling rate of l-150 ° C / min.
  • the external cooling controller 3 surrounds the outside of the preparation crucible 6 and is spaced apart.
  • the ventilation duct wall of the external cooling controller 3 is provided with a ventilation hole, the diameter of the small hole is 4, and the cooling medium flow rate of the external cooling controller 3 is adjusted to make the outer wall cooling rate of the preparation crucible is l-150 ° C / min,
  • the cooling medium is room temperature air.
  • the continuous casting equipment consists of a tundish 24, a crystallizer 25, a cooling water nozzle 26 and a traction mechanism 27.
  • the draft tube 5 is placed above the tundish 24, the diameter of the draft tube 5 is 072 mm, the inner dimension of the tundish is 240 X 120 X 80 mm, and the draft tube 5 is connected to the lower port of the preparation crucible 6 to prepare the lower mouth of the crucible 6
  • a valve 4 is provided to control the flow of the semi-solid alloy melt to the injection chamber.
  • the ZL101A alloy liquid at 670 ° C is poured into the stationary crucible 11 , covered with a lid 8 , left to stand for 10 20 s, and the valve 10 is opened, so that the superheated ZL101A alloy liquid flows into the guide tube 9 to prepare the crucible 6 and internal cooling.
  • the controller cools the gap between the threads of the medium output pipe 14-2, simultaneously opens the electromagnetic stirrer 1, sets the nominal power of the electromagnetic stirrer to 1300W, and controls the flow rate of the cooling medium in the internal and external cooling controllers.
  • the cooling rate of the melt is 5 ° C / min, so that the alloy melt will be subjected to strong electromagnetic stirring while flowing in the gap.
  • the temperature of the alloy slurry indicated by the thermocouple 13 is lowered to 60 CTC, the semi-solid can be obtained.
  • the superheated ZL101A aluminum alloy melt is melted by melting ⁇ 12, and the enthalpy 12 is an electromagnetic induction heating furnace.
  • the heat preservation performance is good, and the ZL101A alloy melt can ensure high temperature control precision, and the temperature control precision is ⁇ 10°C.
  • the stationary crucible 11 is a crucible with excellent heat preservation performance, and the lower end opening is connected with the draft tube 9, and the bottom of the crucible 11 is open and a valve 10 is provided to control the flow of the alloy melt in the stationary crucible to the preparation crucible 6.
  • the static enthalpy 11 can provide a sufficient amount of alloy liquid for the preparation of ⁇ 6, which ensures that the temperature of the alloy melt is 5 200 V above the liquidus, and the temperature control accuracy is ⁇ 10.
  • the upper part of the draft tube 9 is connected to the stationary crucible 11, and the lower opening is opened into the alloy melt in the preparation crucible 6.
  • the outside of the draft tube 9 is wound with an electric resistance heater which heats the temperature of the draft tube to 400.
  • °C Preparation crucible 6 is placed inside the thermal insulation system 2, and the inner diameter of the crucible 6 is prepared to be 8O X 16Omm, and the crucible cover 8 having excellent heat insulation performance is prepared.
  • the cooling medium output pipe 14-2 of the internal cooling controller 14 is as shown in the figure
  • the structure shown in 2 has an outer diameter of 06Omm, is made of graphite, and has a preheating temperature of 300 °C.
  • the outer wall of the internal cooling controller cooling medium output pipe 14-2 is 10 mm away from the inner side wall of the preparation crucible.
  • the bottom of the internal cooling controller cooling medium output pipe 14-2 is 40 mm from the inner wall of the bottom of the preparation crucible.
  • the cooling medium input pipe 14-1 of the internal cooling controller has an outer diameter of 025, a pipe thickness of 3 mm, a material of stainless steel, and a temperature of room temperature.
  • the thermal insulation system 2 is a nearly closed cylindrical structure that is hollow and has a top connected to the lid 8.
  • the external cooling controller 3 is wound around the outside of the preparation crucible 6 and is prepared. 20mm outer wall of the crucible, a small ventilation hole is formed in the cooling duct wall of the external cooling controller 3, the diameter of the small hole is 4mm, and the cooling medium flow rate of the external cooling controller 3 can be adjusted to make the outer wall cooling rate of the outer wall of the preparation crucible 150°C/min.
  • the cooling medium is room temperature air.
  • the upper end of the draft tube 5 is connected to the lower port of the preparation crucible 6, and a valve 4 is arranged at the lower end of the preparation crucible 6, and the flow of the semi-solid alloy melt to the forging model chamber 29 is controlled.
  • a certain amount of ZL101A alloy liquid of 670 ° C is poured into the stationary crucible 11 , covered with a lid 8 , left to stand for 10 20 s, the valve 10 is opened, and the superheated ZL101A alloy liquid flows into the preparation crucible along the draft tube 9 . 6.
  • the electromagnetic stirrer When the amount of alloy melt to be flowed reaches about 2/3 of the volume of the prepared crucible 6, close the valve 10, turn on the electromagnetic stirrer 1, set the nominal power of the electromagnetic stirrer to 1300W, and control the internal and external cooling controllers.
  • the flow rate of the cooling medium in 14 3 is such that the cooling rate of the melt is 5 ° C / min, and the temperature indicated by the thermocouple 13 is 590 ° C, and the semi-solid ZL101A aluminum alloy slurry can be obtained.
  • the electromagnetic stirrer is turned off.
  • valve 4 open the valve 4, the semi-solid ZL101A aluminum alloy slurry 7 flows into the forging model cavity 29 through the draft tube 5, the temperature of the draft tube 5 is controlled at 500 ° C, forging the model cavity
  • the preheating temperature of 29 is 250 ° C, and after the valve 4 is opened for about 5 s, the semi-solid slurry 7 is completely discharged, the valve 4 is closed, and the mold of the forging machine is started to form a semi-solid metal and an alloy slurry, and pressure forming is performed.
  • the apparatus for carrying out the invention is suitable for preparation and molding of semi-solid slurry of aluminum-based alloy, and is also suitable for magnesium-based alloy, zinc-based alloy, copper-based alloy, nickel-based alloy, cobalt-based alloy and iron-based alloy and Preparation and shaping of semi-solid slurries of composite materials.
  • the melt of the A357 aluminum alloy was melted by melting the crucible 12, and the liquidus temperature of the A357 aluminum alloy was 613. C.
  • the melt temperature was controlled at 650 °C.
  • the crucible 6 is prepared as a cylindrical stainless steel vessel, the internal cooling controller 14 is made of high-purity graphite, the outer diameter of the internal cooling controller is 40 mm, and the inner wall diameter of the crucible 6 is 80.
  • the annular gap formed between the outer walls of 14 has a size of 20 mm.
  • the valve 10 is opened, and the superheated A357 aluminum alloy melt flows along the draft tube 9 into the ring formed in the crucible. Strong agitation in the gap, the input power of the stirrer is 1200W, and the stirring frequency is 50Hz.
  • the cooling medium input to the internal cooling controller 14 and the external cooling controller 3 is room temperature air, the flow rate is 30 liters/min, and the temperature difference between the inside and the outside of the slurry can be controlled at ⁇ 3 °C.
  • FIG. 9, FIG. 10 and FIG. Figure 9 is a quenched structure of the side of the semi-solid A357 aluminum alloy slurry prepared by the present invention, wherein the light-colored region is spherical nascent - ⁇ /, the dark region is a solidified eutectic liquid;
  • Figure 10 is a semi-solid prepared by the present invention; Quenched structure in the middle of ⁇ 357 aluminum alloy slurry, the light-colored area is spherical and the dark area is solidified eutectic liquid;
  • Figure 11 is the quenched structure of the semi-solid ⁇ 357 aluminum alloy slurry center prepared by the present invention, light-colored area It is a globular nascent ⁇ /, and the dark area is a solidified eutectic liquid.
  • the apparatus and method of the present invention are suitable for preparation of aluminum-based alloys and composite semi-solid pastes or blanks thereof, and also for magnesium-based alloys, copper-based alloys, zinc-based alloys, iron-based alloys and other non-ferrous metal alloys and Preparation of composite semi-solid slurry or blank.

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Description

环缝式电磁搅拌制备半固态合金浆料的装置及方法 技术领域
本发明属于半固态金属加工技术领域，涉及一种制备半固态合金流变浆料或坯料的 装置和方法。特别提供了一种可用来制备大规格半固态合金流变浆料或坯料的装置和方 法。
背景技术
自从二十世纪七十年代美国麻省理工学院的 Flemings教授发明了半固态金属成形技 术以来，半固态金属浆料的制备和成形技术作为一种新型的技术立即引起了世界各国的 广泛关注， 纷纷投入大量的人力、 物力和财力对此技术进行相关的研究和开发， 目前许 多金属浆料的制备方法已经发明出来， 目前见诸于相关报道的主要有： 电磁搅拌法； 机 械搅拌法； 双螺旋搅拌法， 单螺旋搅拌法； 低过热度浇注和弱电磁搅拌法； 气泡法， 低 过热度倾斜板浇注法， 熔体混合法等制浆方法。 同样的也开发出许多半固态合金的成形 技术， 主要的有： 传统的机械搅拌式流变成形技术； 双螺旋机械搅拌式流变成形技术； 近液相线浇注式流变成形技术； 低过热度倾斜板浇注式流变成形技术； 低过热度浇注和 弱电磁搅拌式流变成形技术； 低过热度浇注和弱机械搅拌式流变成形技术等。 而在上述 发明的半固态浆料制浆方法和流变成形方法中， 电磁搅拌浆料制备技术具有不污染合 金、 合金浆料纯净， 控制参数易于调节， 可以连续生产流变浆料或连续铸锭等优点， 因此 已经投入商业化生产且获得了较大范围的应用， 成为目前生产半固态金属及合金浆料主要 的制备方式， 但是由于电磁感应趋肤效应的存在， 使浆料内部所受的电磁搅拌力存在明显 的区别， 浆料表层受到的搅拌力大而内部小， 导致制备的半固态浆料组织分布不均匀， 浆 料表层温度低而内部温度高。 这些因素导致制备的半固态浆料组织分布不均匀， 表层为较 小的粒状或蔷薇状， 而内部往往为较为粗大的蔷薇晶或树枝晶， 浆料或坯料组织较差。 影 响了该技术应用范围的进一步扩大或竞争力的提高。 因此目前半固态制浆行业普遍将电磁 感应存在的趋肤效应看作为一种不利的因素而极力加以避免， 制浆生产中也往往采用降低 电磁搅拌频率、 增加电磁场的趋肤深度的手段来克服趋肤效应对浆料组织的不利影响， 试 图获得较为理想的半固态浆料组织。 但是这会造成制浆设备庞大， 投资成本很高， 浆料制 备成本也很高。
在电磁搅拌制备半固态金属及合金浆料或坯料的方法和设备中， 美国 4434837号专 利和 4229210都公开了几种制备半固态金属及合金浆料和坯料的电磁搅拌方法， 其主要 原理是利用强烈的电磁搅拌打碎初生枝晶， 抑制初生晶粒向枝晶状生长， 从而制备出球 状或粒状初生晶粒的半固态金属及合金浆料。在上述专利公开的有关电磁搅拌方法和设 备中， 未提到浆料内部的冷却问题， 也未提到内部冷却机构。 但是在采用上述专利公开 的电磁搅拌方法制备半固态浆料时， 浆料温度场的分布不均匀， 浆料的外层散热快， 而 浆料内部中心散热慢， 导致初生晶粒在空间和时间上的产生存在明显的差别， 浆料外层 初生晶粒先析出， 而浆料内部初生晶粒后析出， 这样最终会导致浆料组织的不均匀性， 对于大尺寸和大规格的浆料或坯料更为如此。 而且由于电磁感应磁场的趋肤效应， 使磁 场强度从浆料的外缘到中心呈指数式递减， 导致浆料的外层受到的搅拌作用强， 而在浆 料的中心受到的搅拌作用很弱， 因此在采用此方法得到的浆料或坯料组织中， 组织分布 很不均匀， 外层细小， 而内层粗大， 且组织形态也不相同， 外层的初生晶粒呈球状或粒 状， 而中心呈树枝晶或蔷薇状， 因此采用上述方法制备的半固态浆料或坯料的尺寸也受 到了限制， 很难制备出优质的大尺寸和大规格的半固态金属及合金浆料或坯料， 对于半 固态金属或合金棒料， 直径一般不超过 150， 因此如何克服电磁搅拌的上述缺点、 制备 出组织均匀、 细小的半固态金属及合金浆料或坯料， 尤其是制备出大规格大尺寸的半固 态金属及合金浆料或坯料， 将具有十分重要的意义和现实价值。
中国专利 200420112702.0也提出了一种复合电磁搅拌法连续制备半固态金属浆料的 装置及方法， 该装置的主要结构和原理是： 在中间包内施加电磁搅拌， 使中间包过热的 液体整体均匀降温到液相线温度， 在导流管外均施加强烈电磁搅拌， 金属液流可获得充 分快速的冷却， 使形核数量大幅增加， 凝固组织明显细化。 采用上述设备及方法制备半 固态金属浆料，可解决现有技术中由于单纯静置保温控制浇注金属液体接近液相线温度 难操作性以及由此带来的金属液体过热度太低时流动性变差的技术难题，也可避免了由 于现有技术中制备坩埚尺寸较大、金属液体搅拌不均匀导致冷却不均匀及凝固组织不均 匀的问题。 在该设备中， 采用了复合电磁搅拌技术， 未提及到浆料的内部冷却机构。 但 是在采用该装置制备半固态金属浆料时，虽采用了强烈的复合电磁搅拌技术有助于半固 态合金浆料的流动， 但是浆料温度场的不均匀性和浆料组织的不均匀性仍然明显存在， 同样也只能生产尺寸不大的半固态金属浆料或坯料，无法生产大规格的半固态合金浆料 或坯料， 而且该设备的电磁搅拌装备采用了变频装置， 购置成本较高， 结构复杂， 因此 也限制了该设备的推广应用。
总之， 目前国内外采用的电磁搅拌方法制备半固态金属及合金浆料或坯料的装置及 方法中，即使采用低频搅拌等多种措施，也由于趋肤效应和浆料固有的散热特性的存在， 浆料的温度场分布和组织的分布仍存在较大的不均匀性，不易生产出优质的半固态浆料 或坯料， 限制了该技术的进一步发展和应用， 因此如何克服这些问题就成为目前扩大电 磁搅拌技术制备半固态金属浆料应用范围的关键。
发明内容
与前述专利和目前采用的电磁搅拌方法中试图避免趋肤效应相反，本发明的目的是 提供一种环缝式电磁搅拌制备半固态金属流变浆料或坯料的装置及方法，该装置及方法 充分利用了电磁搅拌的趋肤效应，通过该装置及方法得到的半固态浆料组织均匀，细小， 形态好， 有利于生产出合格优质的半固态金属或合金坯料或浆料。
为了实现上述目的， 本发明采取以下技术方案：
一种制备半固态金属流变浆料或坯料的装置， 该装置包括有制备坩埚， 在该制备坩 埚的外周由里到外依次设置有外部冷却控制器、 保温***、 电磁搅拌器； 在该制备坩埚 上部设置静置坩埚，该静置坩埚通过其底部的导流管穿过制备坩埚上的保温盖与制备坩 埚相通， 在该静置坩埚上部设置有熔化坩埚； 并在制备坩埚的底部设有导流管， 所述的 制备坩埚的底部的导流管和所述的熔化坩埚的底部的导流管均具有阀门； 其特征在于： 所述的制备坩埚的中部设有一内部冷却控制器，且内部冷却控制器的外壁与制备坩埚的 内侧壁形成环形缝隙。
本发明的制备半固态金属流变浆料或坯料的装置充分利用了电磁搅拌的趋肤效应， 其主要原理是： 根据电磁感应原理， 磁场强度从浆料表面向里按指数曲线递减， 越靠近 浆料表面， 磁感应强度越大， 越靠近浆料内部， 磁感应强度越小， 在大于趋肤深度的部 位， 磁感应强度很小， 也就是说为了使浆料受到较强的搅拌力， 浆料内部区域的磁感应 强度应足够的大， 为此， 可以将全部半固态合金熔体置于从浆料表面向里宽度不超过趋 肤深度的区域内进行搅拌， 也即搅拌区域为一狭长缝隙， 使浆料形成一层厚度可适当调 整的 "薄膜"进行搅拌， 该缝隙宽度最大为趋肤深度， 当然为了达到强的搅拌强度， 可 进行调整縮小缝隙的宽度，缝隙越小，渗透入浆料内部的磁感应强度越强，搅拌越剧烈， 搅拌也越均匀， 然后将搅拌得到的半固态合金浆料储存下来进行流变成形， 或制成坯料 进行触变成性能。
根据该原理， 本发明在制备坩埚中设置可通入冷却介质的内部冷却控制器， 通过调 整内部冷却控制器的外壁与制备坩埚的内侧壁之间形成的环形缝隙，可使半固态合金熔 体在电磁搅拌力的作用下在此缝隙中进行较为强烈的搅拌， 同时内部冷却控制器和外部 冷却控制器中通入的冷却介质可使浆料的散热更加均匀， 温度场的分布也更加均匀， 得 到的浆料组织分布也更为理想。
采用本发明的装置，可以克服目前的电磁搅拌装置采用变频***带来的结构庞大复 杂， 投资成本高等缺点， 在生产中只要采用工频就可进行电磁搅拌， 而不需要采用低频 搅拌， 也不需要变频***， 这对降低企业的投资成本和降低半固态零部件的生产成本， 扩大半固态的应用范围具有很大的现实意义和实用价值。
本发明的制备半固态流变浆料或坯料的装置的导流管可以连接压铸机、挤压机、 连 铸机、 锻造机， 进行流变压铸、 流变挤压铸造、 流变连铸、 进行流变锻造， 其连接方式 如下：
本发明的制备半固态流变浆料或坯料的装置的导流管连接压铸机的结构如下：所述 的制备坩埚底部的导流管连通压铸机的压射室， 在压射室的一侧内设置冲头， 压射室的 另一侧连接压铸型定模和压铸型动模。
本发明的制备半固态流变浆料或坯料的装置的导流管连接挤压机的结构如下：所述 的制备坩埚底部的导流管连通挤压机的挤压筒， 挤压筒的一侧内设置挤压杆， 挤压筒的 另一侧连接挤压模右型和挤压模左型。
本发明的制备半固态流变浆料或坯料的装置的导流管连接连铸机的结构如下：所述 的制备坩埚底部的导流管连通连铸机的中间包， 中间包连通结晶器， 在结晶器的出口外 的四周均布若干个冷却水喷嘴， 并在结晶器的出口外的下部装置有牵引机构。
本发明的制备半固态流变浆料或坯料的装置的导流管连接锻造机的结构如下：所述 的制备坩埚底部的导流管连通锻造模中的锻造模型腔。
在本发明的制备半固态金属流变浆料或坯料的装置中，所述的内部冷却控制器为其 内通有冷却介质的冷却通道， 冷却通道是由中心管和其外套管组成， 中心管的上口为冷 却介质输入口， 中心管的下口与外套管相通， 中心管构成冷却介质输入通道； 外套管的 上口为冷却介质输出口， 外套管构成冷却介质输出通道。
在本发明的制备半固态金属流变浆料或坯料的装置中，所述的冷却介质输入通道沿 着径向方向的形状即中心管的横截面为圆形、 椭圆形、 方形或梯形； 所述的冷却介质输 入通道即中心管沿着轴向方向的形状为直管形状或弯曲管形状。
在本发明的制备半固态金属流变浆料或坯料的装置中，所述的冷却介质输出通道沿 着径向方向的外观形状即外套管的横截面的外形为圆形、 椭圆形、 方形或梯形； 所述的 冷却介质输出通道即外套管沿着轴向方向的形状为直管形状、蛇形管形状、螺旋管形状、 波浪管形状或其他弯曲管形状； 或是外套管的内壁沿着轴向方向的形状为直管壁形状而 其外壁沿着轴向方向的形状为螺旋形或波浪形。考虑到外套管制成蛇形管形状、 螺旋管 形状、 波浪管形状或其他弯曲管形状， 情况比较复杂， 制作加工难度大； 从制作方便上 考虑， 还是优选将外套管的内壁制成沿着轴向方向的形状为直管壁形状， 而其外壁制成 沿着轴向方向的形状为螺旋形或波浪形。
在本发明的制备半固态金属流变浆料或坯料的装置中，所述的冷却介质输入通道的 材质为奥氏体不锈钢、 钛、 钼、 钴、 铬、 镍、 铜等非磁金属材料或石墨、 陶瓷、 刚玉等 非金属材料； 冷却介质输出通道的材质为奥氏体不锈钢、 钛、 钼、 钴、 铬、 镍、 铜等非 磁金属材料或石墨、 陶瓷、 刚玉等非金属材料。 在此说明， 冷却介质输入通道和冷却介 质输出通道的材质必须为无磁金属或非金属材料， 主要是为了防止其对电磁场产生影 响。
在本发明的制备半固态金属流变浆料或坯料的装置中，所述的冷却介质输入通道即 中心管的内径为 2〜1000mm， 冷却介质输出通道即外套管的内径为 5〜1000mm。
在本发明的制备半固态金属流变浆料或坯料的装置中，制备坩埚的横截面形状为圆 形、 椭圆形或方形； 制备坩埚的纵截面形状为方形或上宽下窄的梯形。
在本发明的制备半固态金属流变浆料或坯料的装置中， 内部冷却控制器的外壁即冷 却介质输出通道的外壁与制备坩埚的内侧壁之间形成环形缝隙，此环形缝隙的横截面形 状为圆形、椭圆形或方形； 此环形缝隙的纵截面所示的环形缝隙的宽度为上部与下部均 相等的宽度， 或者是上宽下窄具有梯度的宽度； 环形缝隙的宽度尺寸为 0. 5〜300mm 在本发明的制备半固态金属流变浆料或坯料的装置中，所述的冷却介质输出通道的 外壁沿着轴向方向的形状为螺旋形， 其螺距为 5〜100mm， 螺纹高为 2〜100mm。
在本发明的制备半固态金属流变浆料或坯料的装置中，所述的冷却介质输出通道的 外壁沿着轴向方向的形状为波浪形， 其波距为 5〜100mm， 波纹高为 2〜100mm。
在本发明的制备半固态金属流变浆料或坯料的装置中冷却通道内通入的冷却介质 为空气、 氮气、 氩气、 自来水或其他冷却液体， 冷却介质的温度为室温。
当内部冷却控制器中的冷却介质为气体的情况下，其进口压力为 O. OOlMPa-0. 5MPa, 当内部冷却控制器中的冷却介质为液体的情况下， 其进口压力为 0. 001MPa-1. 2MPa ; 当 外部冷却控制器中的冷却介质为气体的情况下，其进口压力为 0. 001MPa-0. 5MPa,当外部 冷却控制器中的冷却介质为液体的情况下， 其进口压力为 0. 001MPa-l. 2MPao
一种使用本发明装置制备半固态金属或合金的浆料或坯料的方法，将高于其液相线 温度 5〜200 °C的液态金属或合金液浇入制备坩埚内侧壁和内部冷却控制器外壁之间形 成的环形缝隙中， 并开启电磁搅拌器对环形缝隙中的液态金属或合金液进行搅拌， 进行 半固态浆料制备， 同时分别向外部冷却控制器和内部冷却控制器中通入的室温温度的冷 却介质， 其冷却速度为 l〜150°C/min， 使得制备的半固态浆料温度场更加均匀， 从而得 到细小均匀的半固态浆料组织， 并使半固态浆料的温度控制在低于其液相线温度而高于 其固相线温度之间。
半固态浆料的温度区间是金属或合金熔体的固相线和液相线之间的温度区间，也即 半固态浆料的温度是低于液相线温度而高于固相线温度的，半固态浆料温度的确定是根 据所成形的零件的复杂程度和操作过程中的具体情况来决定的， 如果零件复杂， 为了充 填完整， 则所需的半固态浆料的温度较高； 如果零件简单， 所需的半固态浆料的温度可 低一点。因此半固态浆料的温度是根据零件的复杂程度和操作过程中的具体情况来确定 的， 对于不同的零件不同的合金， 半固态浆料的温度是不同的。
在本发明的方法中，所述的内部冷却控制器和外部冷却控制器中通入的冷却介质的 流量为冷却介质的流量为 0〜200升 /min， 且≠0。
在本发明的方法中， 所述的电磁搅拌器采用感应交流旋转电磁搅拌器， 频率为 5〜 100Hz。
在本发明的方法中， 在半固态浆料制备过程中， 半固态浆料内外温差控制在 ± 3°C 以内，所述的半固态浆料内外温差为处于内部冷却控制器外壁的半固态浆料的温度和处 于制备坩埚内侧壁的半固态浆料的温度之差。
在本发明的方法中， 所制备的半固态浆料为半固态铝基合金浆料、 半固态镁基合金 浆料、 半固态锌基合金浆料、 半固态铜基合金浆料、 半固态镍基合金浆料、 半固态钴基 合金浆料和半固态铁基合金浆料中的任意一种； 或半固态铝基复合材料浆料、 半固态镁 基复合材料浆料、 半固态锌基复合材料浆料、 半固态铜基复合材料浆料、 半固态镍基复 合材料浆料、 半固态钴基复合材料浆料和半固态铁基复合材料浆料中的任意一种。
在本发明的方法中， 将上述半固态浆料在制备坩埚内完全凝固， 即可获得半固态铝 合金坯料、 半固态镁合金坯料、 半固态锌合金坯料、 半固态铜合金坯料、 半固态镍合金 坯料、 半固态钴合金坯料和半固态铁基合金坯料中的任意一种坯料； 或半固态铝基复合 材料的坯料、 半固态镁基复合材料的坯料、 半固态锌基复合材料的坯料、 半固态铜基复 合材料的坯料、 半固态镍基复合材料的坯料、 半固态钴基复合材料的坯料和半固态铁基 复合材料的坯料中的任意一种坯料， 上述坯料可作为半固态触变成形的原始坯料。
在本发明的方法中， 在制备半固态浆料过程中， 向制备坩埚内侧壁和内部冷却控制 器外壁之间形成的环形缝隙中通入避免或减少金属或合金氧化的保护气体，该保护气体 为氩气、 氮气或氦气。
在本发明的方法中， 所述的制备坩埚、 内部冷却控制器和外部冷却控制器的材质均 为非金属或无磁金属。
为了克服电磁感应趋肤效应的不利影响，本发明在制备坩埚内设置可通入冷却介质 的内部冷却控制器， 内部冷却控制器的外壁与制备坩埚的内侧壁之间形成环形间隙， 可 使半固态合金熔体在电磁搅拌力的作用下在此缝隙中进行较为强烈的搅拌， 同时内部冷 却控制器中通入的冷却介质可使浆料的散热更加均匀， 温度场的分布也更加均匀， 得到 的浆料组织分布也更为理想。
为此可将一定过热度的液态金属及合金浇入环形空隙内，金属及合金熔体在电磁搅 拌力的作用下进行强烈的搅拌。 同时， 在内部冷却控制器和制备坩埚的共同冷却作用下 浆料的温度场更加均匀， 这样浆料受到的搅拌力场和温度场将更加均匀， 从而得到优质 的半固态浆料， 然后将此半固态浆料直接移送到压铸机或锻造机、 挤压机成形； 或将得 到的半固态浆料完全凝固成坯料， 再将该坯料重新加热至半固态区间， 然后将坯料移送 至压铸机或锻造机、 挤压机成形。 该制备工艺简单， 操作方便， 半固态组织形态优良、 制备成本低， 非常适合半固态金属及合金浆料或坯料的制备。
本发明具体的制备工艺如下：
1、产生一定过热度的金属及合金熔体， 该熔体的温度控制在液相相温度以上 5~200 °C， 将该熔体浇入制备坩埚内壁和内部冷却控制器外壁之间形成的环形空隙内。
2、制备坩埚的形状为圆筒形， 内部冷却控制器的形状为中空的底部密封的直管状， 外部冷却控制器的形状为螺旋管。制备坩埚、 内部冷却控制器和外部冷却控制器的材质 为非金属或无磁金属。 制备坩埚内壁和内部冷却管外壁之间形成的环形空隙宽度为 3~200mm。
3、 电磁搅拌器采用感应交流旋转电磁搅拌器， 频率为 5~100Hz。
4、 制备坩埚外部设置外部冷却控制器， 外部冷却控制器和内部冷却控制器通入的 冷却介质为室温空气、 氮气、 氩气或室温冷水， 流量为 0~200升 /min， 且≠0。
5、 浇注后， 金属及合金浆料在环形缝隙中进行强烈的搅拌， 同时在内部冷却控制 器和外部冷却控制器的冷却作用下浆料温度逐渐降低， 调节冷却介质的流量， 使浆料的 冷却速度为 l~150°C/min， 且≠0。 使半固态金属或合金浆料的温度场均匀， 控制半固态 浆料的内外温度差不超过 ± 3 °C。 6、 在制备过程中， 可通入保护气体避免或减少金属及合金的氧化， 该保护气体可 为氩气、 氮气、 氦气等保护气体。
7、 待浆料温度达到预定的温度后， 立即将此浆料移送到压铸机或锻造机、 挤压机 成形， 或将浆料在制备坩埚内完全凝固， 即可获得特制的半固态金属及合金坯料， 该坯 料可作为半固态触变成形的原始坯料。
与现有技术相比， 本发明的优点是：
1.充分利用了电磁感应的趋肤效应。 与常规的电磁搅拌方法相比， 该发明避免了电 磁感应趋肤效应带来的不利影响， 浆料受到的搅拌力和温度场更加均匀。 该发明将浆料 全部集中在较窄的缝隙内域进行搅拌， 浆料受到的搅拌更为剧烈， 强度更大， 浆料受到 的搅拌更为均匀， 克服常规的电磁搅拌导致的浆料内外搅拌不均， 组织不均匀等问题。 此外通过设置内部冷却控制器与外部冷却控制器， 使半固态合金熔体的温度场均匀， 得 到的半固态浆料组织均匀，细小，形态好，而且内部冷却控制器的径向大小可自由选择， 这样可自由调整内部冷却控制器和制备坩埚内壁之间的距离 （即浆料厚度）， 有利于浆 料获得更大的剪切速率， 获得细小均匀的组织。
2.可生产大规格的半固态合金浆料或坯料。本发明设置了内外部冷却控制器， 既可 使浆料得到强烈的电磁搅拌， 浆料内部受到的搅拌力均匀， 得到的浆料组织均匀， 又可 均衡半固态合金熔体的温度场， 促进合金熔体大量形核， 抑制树枝晶的形成或长大， 最 终形成半固态组织。同时，内部冷却控制器对受到搅动的合金熔体中起一定的搅拌作用， 会促进初生晶粒的破碎、 游离。 通过上述措施， 可使合金熔体的内部和外部均得到细小 均匀的半固态组织， 有利于生产出合格优质的大规格半固态合金坯料或浆料。
3.半固态合金浆料纯净。 由于采用电磁搅拌器作为搅拌源， 搅拌磁场产生的搅拌力 作用在合金熔体上搅拌， 可避免合金熔体的污染。
4.防止半固态合金熔体卷气。制备坩埚中的合金熔体处于相对密闭的状态， 可防止 半固态合金熔体的卷气，且设置的静置坩埚也可有效防止外界气体卷入制备坩埚中的合 金熔体中，此外设置的内部冷却控制器可有效防止电磁搅拌磁场的运动导致合金熔体产 生漩涡， 合金熔体表面平缓， 防止卷气。
5.熔体的自洁净性好，通过将内部冷却控制器冷却介质输出管道设置为螺旋型等形 状， 在电磁搅拌力的作用下， 合金熔体逐步向坩埚底部汇集， 可有效避免合金熔体在内 部冷却控制器外壁和制备坩埚内壁的粘挂， 减少清理工作量， 提高合金利用率和制备坩 埚、 内部冷却控制器的寿命。 6.设备简单、 紧凑， 安装、 工艺简单、 操作方便， 投资成本低， 实用性强， 应用范 围广。 与其他半固态成形方法和目前采用的常规的电磁搅拌法比较， 该装置体积小， 设 备简单， 投资成本低， 企业在生产中只要采用工频就可进行电磁搅拌， 而不需要采用低 频搅拌， 也不需要变频***， 克服目前的电磁搅拌装置采用变频***带来的结构庞大复 杂， 投资成本高等缺点， 可显著降低半固态合金浆料或坯料的制备成本， 最终会降低半 固态铸件的生产成本， 增强半固态铸件的竞争力和扩大半固态铸件的应用范围， 该发明 既适合于铝基合金及其复合材料半固态浆料或坯料的制备， 也适合于镁基合金、 铜基合 金、 锌基合金、 铁基合金和其他有色金属合金及其复合材料半固态浆料或坯料的制备。 附图说明
图 1是制备半固态金属流变浆料或坯料的装置示意图。
图 2是冷却介质输出通道的外壁沿着轴向方向的形状为直线形的内部冷却控制器的 结构示意图。
图 3是冷却介质输出通道的外壁沿着轴向方向的形状为波浪形的内部冷却控制器的 结构示意图。
图 4是冷却介质输出通道的外壁沿着轴向方向的形状为螺旋形的内部冷却控制器的 结构示意图。
图 5是装有压铸机的制备半固态金属流变浆料或坯料的装置示意图。
图 6是装有挤压机的制备半固态金属流变浆料或坯料的装置示意图。
图 7是装有连铸机的制备半固态金属流变浆料或坯料的装置示意图。
图 8是装有锻造机的制备半固态金属流变浆料或坯料的装置示意图。
图 9是本发明制备的半固态 A357铝合金浆料边部的淬火组织， 浅色区域为球状初生 的《- A/， 深色区域为凝固的共晶液体。
图 10是本发明制备的半固态 Α357铝合金浆料中部的淬火组织， 浅色区域为球状初生 的《- A/， 深色区域为凝固的共晶液体。
图 11是本发明制备的半固态 Α357铝合金浆料中心的淬火组织， 浅色区域为球状初生 的 - Α/， 深色区域为凝固的共晶液体。
具体实施方式
图 1是制备半固态金属流变浆料或坯料的装置示意图， 如图 1所示， 该装置包括有 制备坩埚 6， 在该制备坩埚 6的外周由里到外依次设置有外部冷却控制器 3、 保温*** 2、 电磁搅拌器 1 ; 在该制备坩埚 6上部设置静置坩埚 11， 该静置坩埚 11通过其底部的导流管 9穿过制备坩埚 6上的保温盖 8与制备坩埚 6相通， 在该静置坩埚 11上部设置有熔化坩埚 12； 并在制备坩埚 6的底部设有导流管 5， 所述的制备坩埚 6的底部的导流管 5和所述的熔 化坩埚 12的底部的导流管 9均具有阀门 4、 10； 所述的制备坩埚的中部设有一内部冷却控 制器 14， 内部冷却控制器 14为其内通有冷却介质的冷却通道， 冷却通道是由中心管和其 外套管组成， 中心管的上口为冷却介质输入口， 中心管的下口与外套管相通， 中心管构 成冷却介质输入通道； 外套管的上口为冷却介质输出口， 内部冷却控制器 14内部可通入 冷却介质。 外部冷却控制器 3是一螺旋管， 管上开有多个分布均匀的小孔， 其置于制备 坩埚 4的外部保温*** 2的内部且距制备坩埚外壁一定距离， 外部冷却控制器 3内部也可 通入冷却介质。 制备坩埚 6是圆筒形的容器， 其放置于保温***内部形成一个封闭的空 腔。 内部冷却控制器 14置于制备坩埚 6的中心。 内部冷却控制器 14的外侧壁和制备坩埚 6 的内侧壁之间形成一个环形的缝隙。 电磁搅拌器 1置于保温*** 2的外部。 且在制备坩埚 6中设有热电偶 13。
如图 2〜图 4所示， 图 2〜图 4为内部冷却控制器 14的结构示意图， 内部冷却控制器 14 由冷却通道和冷却介质组成， 冷却通道由冷却介质输入通道 14-1和冷却介质输出通道 14-2组成。冷却介质输入通道 14-1为一中空底部开口的中心管， 中心管的上口为冷却介 质输入口， 中心管沿着径向方向 （截面） 的形状可为圆形、 椭圆形、 方形， 梯形或其他 各种形状， 中心管沿着轴向方向的形状为直管形状或弯曲管形状， 其中， 弯曲管形状如 蛇形管形状。冷却介质输出通道 14-2为一中空的底部密封的外套管， 该外套管套在中心 管的外部， 中心管通过底部开口与外套管相通， 外套管的上口为冷却介质输出口。 外套 管底部与侧壁可以制造为一体或通过焊接和其他方法等密封连接， 冷却介质输出通道 14-2沿着径向方向（截面）的外观形状即外套管的横截面的外形形状可为圆形、椭圆形、 方形， 梯形或其他各种形状， 冷却介质输出通道即外套管沿着轴向方向的形状为直管形 状、 蛇形管形状、 螺旋管形状、 波浪管形状或其他弯曲管形状； 或是外套管的内壁沿着 轴向方向的形状为直管壁形状而其外壁沿着轴向方向的形状为螺旋形或波浪形。 其中， 在图 2中， 外套管沿着轴向方向的形状为直管形状； 在图 3中， 外套管的内壁沿着轴向方 向的形状为直管壁形状而其外壁沿着轴向方向的形状为波浪形； 在图 4中， 外套管的内 壁沿着轴向方向的形状为直管壁形状而其外壁沿着轴向方向的形状为螺旋形。
冷却介质输入通道 14-1的材质可为钢、 铜、 钛、 钨、 钼铝或锌等非磁性金属材料或 者石墨或陶瓷等非金属材料。冷却介质输出通道 14-2的材质可为石墨或陶瓷等非金属材 料。 冷却介质输入通道 14-1置于冷却介质输出通道 14-2内， 形成冷却介质冷却通道， 冷 却介质输入通道 14-1与冷却介质输出通道 14-2可采用螺栓连接、焊接或其他方法连接成 一体。 冷却介质可为空气、 氮气、 氩气等气体或水，冷却介质的温度为室温。 冷却介质 输入通道 14-1的内径在 2 200 冷却介质输出通道 14-2的内径为 5 300 对于形 状为波浪型的冷却介质输出管道， 其波距 1^为5 100!11111， 波纹高！！为？〜^^!!!!!!， 如图 3所 示； 对于形状为螺旋形的冷却介质输出管道， 其螺距 L' 为 5 100 螺纹高 h' 为 2 100mm, 如图 4所示。
外部冷却控制器 3的主要功能是在冷却管道内通入冷却介质使合金熔体冷却到所需 的温度， 它主要由冷却管道和冷却介质组成， 冷却管道为一中空的冷却管， 冷却管截面 形状可为圆形、 椭圆形、 方形、 梯形或其他形状， 冷却管沿着轴向方向的形状为直管形 状、 蛇形管形状、 螺旋管形状、 波浪管形状或其他弯曲管形状； 或是冷却管的内壁沿着 轴向方向的形状为直管壁形状而其外壁沿着轴向方向的形状为螺旋形或波浪形。冷却通 道的材质可为钢、 铜、 铝、 锌或镁等金属基材料或者陶瓷等非金属材料。 冷却介质可为 空气、 氮气或氩气等的气体， 冷却介质的温度为室温。 外部冷却控制器 11置于保温系 统内部， 环绕制备坩埚并距离制备坩埚一定距离 （10 mm 300 mm)。
如图 1所示， 阀门 4和阀门 10的主要功能就是控制合金熔体的流动， 阀门 4控制 半固态合金熔体 7向导流管 5的流动， 而阀门 10控制静置坩埚 11中合金熔体向制备坩 埚 6的流动， 阀门 4和阀门 10可采用手动或机械控制。
如图 1所示， 导流管 5和导流管 9的主要功能是导入合金熔体或半固态合金浆料， 导流管 5的上部与制备坩埚 6连接； 导流管 9的上部与静置坩埚 11连接， 下部通入制 备坩埚 6中的半固态合金熔体 7中， 导流管 5和 9的外部缠绕加热器来控制导流管的温 度。
制备坩埚 6的主要功能是盛放合金熔体， 制备坩埚的截面形状可为圆形、 方形或椭 圆形等各种形状， 制备坩埚的材质可为石墨， 铜或其他非磁金属或非金属。
电磁搅拌器 1的主要功能是产生很强的电磁力搅动合金熔体，使合金熔体发生强烈 的搅拌， 电磁搅拌器可为旋转的电磁搅拌器、 行波电磁搅拌器、 复合电磁搅拌器和其他 形式的电磁搅拌器。
如图 5所示的是半固态金属和合金浆料流变压铸装备示意图，是将如图 1所示的半固 态流变浆料制备装置直接放置或固定在压铸机的上方连接而成的装备。压铸机由压铸型 定模 15、 压铸型动模 16、 压射室 17和冲头 19组成。 导流管 5置于压射室 17的上方以方便 流变浆料流进压射室 17。
如图 6所示的是半固态金属和合金浆料流变挤压装备示意图，是将如图 1所示的半固 态流变浆料制备装置直接放置或固定在挤压机的上方连接而成的装备。挤压机由挤压模 右型 20、 挤压模左型 21、 挤压筒 22和挤压杆 23组成。 导流管 5置于挤压筒 22的上方以方 便流变浆料流进挤压筒 22。
如图 7所示的是半固态金属和合金浆料连铸装备示意图，是将如图 1所示的半固态流 变浆料制备装置直接放置或固定在连铸机的上方连接而成的装备。 连铸装备由中间包 24、 结晶器 25、 冷却水喷嘴 26和牵引机构 27组成。 导流管 5置于中间包 24的上方以方便 流变浆料流进中间包 24，
如图 8所示的是半固态金属和合金浆料流变锻造装备示意图，是将如图 1所示的半固 态流变浆料制备装置直接放置或固定在锻造机的上方连接而成的装备。锻造装备是由锻 造模 30及其内的锻造模具型腔 29组成， 其中导流管 5置于锻造模具型腔 29的上方以方便 流变浆料流进锻造模具型腔 29。
本发明的制备半固态金属流变浆料或坯料的装置的主要实施方式为：
参照图 1、 图 2、 图 5， 这是按上述技术特点提供的工艺流程及装置。过热的 ZL101A 铝合金熔体通过熔化坩埚 12熔化， 熔化坩埚 12为电磁感应加热炉， 保温性能良好， 可 保证 ZL101A合金熔体有具有较高的控温精度， 控温精度为 ± 10°C， 静置坩埚 11为一保 温性能优良的坩埚， 下端开口与导流管 9相连， 静置坩埚 11的底部开口且设置一阀门 10， 可控制静置坩埚内合金熔体向制备坩埚 6中的流动， 静置坩埚 11可为制备坩埚 6 中提供足量的合金液， 该静置坩埚 11可保证合金熔体的温度在液相线以上 5〜200 V， 控温精度在 ± 10。 导流管 9的上部与静置坩埚 11相连， 下部开口通入制备坩埚 6中的 合金熔体中，导流管 9的外部缠绕电阻加热器，该加热器将导流管的温度加热到 400°C， 制备坩埚 6置于保温*** 2内部， 制备坩埚 6的内径尺寸为 8O X 16Omm， 制备坩埚上部 设置隔热性能优良的坩埚盖 8， 内部冷却控制器 14的冷却介质输出管道 14-2采用如图 2所示的结构， 外径为 06Omm， 材质为石墨， 预热温度 300°C。 内部冷却控制器 14的冷 却介质输出管道 14-2的外壁与制备坩埚 11的内侧壁距离为 10mm。 内部冷却控制器冷 却介质输出管道 14-2的底部与制备坩埚底部的内壁距离为 40mm。 内部冷却控制器 14 的冷却介质输入管道 14-1的外径为 025， 管道厚为 3mm， 材质为不锈钢， 温度为室温。 保温*** 2是一中空且顶部与坩埚盖 8连接的近乎密闭的筒式结构。其四周由良好的绝 热材料组成，这一保温***可保证制备坩埚中的合金熔体缓慢冷却，冷却速度为 1〜150 °C/min, 外部冷却控制器 3环绕在制备坩埚 6的外部且距制备坩埚外壁 20mm， 外部冷 却控制器 3的冷却管道壁上开设通气小孔， 小孔直径为 4mm， 调节外部冷却控制器 3的 冷却介质流量可使制备坩埚外壁冷却速度为 l〜150°C/min，冷却介质采用室温空气。压 铸机由压铸型定模 15、 压铸型动模 16、 压射室 17和压射冲头 19组成。 导流管 5与制 备坩埚 6下口相连，制备坩埚 6下口设一阀门 4，控制半固态合金熔体向压射室的流动。 将一定量的 670°C的 ZL101A合金液浇入静置坩埚 11中， 盖上坩埚盖 8， 静置 10〜20s， 打开阀门 10， 使过热的 ZL101A合金液顺着导流管 9流入制备坩埚中 6， 待流入的合金 熔体量达到制备坩埚 6容积的约 2/3时， 关闭阀门 10， 开启电磁搅拌器 1， 设置电磁搅 拌器的名义功率为 1300W, 同时控制内部、外部冷却控制器 14、 3中的冷却介质的流量， 使熔体的冷却速度为 5°C/min， 待热电偶 13指示的温度为 580〜600°C， 即可得到半固 态 ZL101A铝合金浆料， 此时关闭电磁搅拌器 1和内部、外部冷却控制器 14、 3， 打开阀 门 4， 将半固态 ZL101A铝合金浆料 7通过导流管 5流入压射室 17， 导流管 5的温度控 制在 500°C， 压射室 17和压射冲头 19、 压铸型定模 15和压铸型动模 16的预热温度为 250 °C , 待开启阀门 4约 5s半固态浆料 7全部流出后， 关闭阀门 4， 同时压铸机冲头 19 将半固态浆料 7压入压铸型型腔， 加压成形约 4〜8s， 然后取出压铸件， 完成一次半固 态 ZL101A铝合金浆料的流变压铸，流变压铸的同时开启阀门 10，将过热的 ZL101A合金 液流入制备坩埚 6中， 进入下一次流变压铸。
参照图 1、 图 2、 图 6， 这是按上述技术特点提供的工艺流程及装置。过热的 ZL101A 铝合金熔体通过熔化坩埚 12熔化， 熔化坩埚 12为电磁感应加热炉， 保温性能良好， 可 保证 ZL101A合金熔体有具有较高的控温精度， 控温精度为 ± 10°C， 静置坩埚 11为一保 温性能优良的坩埚， 下端开口与导流管 9相连， 静置坩埚 11的底部开口且设置一阀门 10， 可控制静置坩埚内合金熔体向制备坩埚 6中的流动， 静置坩埚 11可为制备坩埚 6 中提供足量的合金液， 该静置坩埚 11可保证合金熔体的温度在液相线以上 5〜200 V， 控温精度在 ± 10。 导流管 9的上部与静置坩埚 11相连， 下部开口通入制备坩埚 6中的 合金熔体中，导流管 9的外部缠绕电阻加热器，该加热器将导流管的温度加热到 400°C， 制备坩埚 6置于保温*** 2内部， 制备坩埚 6的内径尺寸为 8O X 16Omm， 制备坩埚上部 设置隔热性能优良的坩埚盖 8。 内部冷却控制器 14的冷却介质输出管道 14-2采用如图 2所示的结构， 外径为 06Omm， 材质为石墨， 预热温度 300°C。 内部冷却控制器冷却介 质输出管道 14-2的外壁与制备坩埚内侧壁距离为 10mm。内部冷却控制器冷却介质输出 管道 14-2的底部与制备坩埚底部内壁距离为 40mm。内部冷却控制器的冷却介质输入管 道 14-1的外径为 025， 管道厚为 3mm， 材质为不锈钢， 温度为室温。 保温*** 2是一中 空且顶部与坩埚盖 8连接的近乎密闭的筒式结构。其四周由良好的绝热材料组成， 这一 保温***可保证制备坩埚中的合金熔体缓慢冷却，冷却速度为 l〜150°C/min，外部冷却 控制器 3环绕在制备坩埚 6的外部且距制备坩埚外壁 20mm， 外部冷却控制器 3的冷却 管道壁上开设通气小孔， 小孔直径为 4mm， 调节外部冷却控制器 3的冷却介质流量可使 制备坩埚外壁冷却速度为 l〜150°C/min，冷却介质采用室温空气。挤压机由挤压模右型 20、挤压模左型 21、 挤压筒 22和挤压杆 23组成。 导流管 5与制备坩埚 6下口相连， 制 备坩埚 6下口设一阀门 4， 控制半固态合金熔体向压射室的流动。 将一定量的 670°C的 ZL101A合金液浇入静置坩埚 11中， 盖上坩埚盖 8， 静置 10〜20s， 打开阀门 10， 使过 热的 ZL101A合金液顺着导流管 9流入制备坩埚中 6，待流入的合金熔体量达到制备坩埚 6容积的约 2/3时，关闭阀门 10，开启电磁搅拌器 1，设置电磁搅拌器的名义功率为 1300W, 同时控制内部、 外部冷却控制器中 14、 3的冷却介质的流量， 使熔体的冷却速度为 5°C /min, 待热电偶 13指示的温度为 580〜600°C， 即可得到半固态 ZL101A铝合金浆料， 此 时关闭电磁搅拌器 1和内部、 外部冷却控制器 14、 3， 打开阀门 4， 将半固态 ZL101A铝 合金浆料 7通过导流管 5流入挤压筒 22，导流管 5的温度控制在 500°C，挤压模右型 20、 挤压模左型 21、 挤压筒 22和挤压杆 23的预热温度为 250°C， 待开启阀门 4约 5s半固 态浆料 Ί全部流出后， 关闭阀门 4， 同时挤压杆 23将半固态浆料 7压入挤压模右型 20 和挤压模左型 21 之间的型腔， 加压成形约 4〜8s， 然后取出挤压件， 完成一次半固态 ZL101A铝合金浆料的流变挤压铸造， 流变挤压的同时开启阀门 10， 将过热的 ZL101A合 金液流入制备坩埚 6中， 进入下一次流变挤压铸造。
参照图 1、 图 4、 图 7， 这是按上述技术特点提供的工艺流程及装置。 过热的 ZL101A 铝合金熔体通过熔化坩埚 12熔化， 熔化坩埚 12为电磁感应加热炉， 保温性能良好， 可保 证 ZL101A合金熔体有具有较高的控温精度， 控温精度为 ± 10°C， 静置坩埚 11为一保温性 能优良的坩埚， 下端开口与导流管 9相连， 静置坩埚 11的底部开口且设置一阀门 10， 可 控制静置坩埚内合金熔体向制备坩埚中 6的流动，静置坩埚 11可为制备坩埚 6中提供足量 的合金液， 该静置坩埚 11可保证合金熔体的温度在液相线以上 5〜200 °C， 控温精度在 ± 10。 导流管 9的上部与静置坩埚 11相连， 下部开口通入制备坩埚 6中的合金熔体中， 导 流管 9的外部缠绕电阻加热器， 该加热器将导流管的温度加热到 400°C， 制备坩埚 6置于 保温*** 2内部， 上部设置隔热性能优良的坩埚盖 8， 制备坩埚 6的内径尺寸为 08O X 480mm, 内部冷却控制器 14的冷却介质输出管道 14_2采用螺旋形机构， 如图 4所示， 材质 为石墨， 预热温度为 300°C， 螺距高 L' 为 10mm， 螺纹高 h' 为 5mm， 螺纹外壁与制备坩埚 内侧壁距离为 10mm。 内部冷却控制器冷却介质输出管道 14-2的底部与制备坩埚底部的内 壁距离为 40 内部冷却控制器的冷却介质输入管道 14-1的外径为 025， 管道厚为 3 材质为不锈钢， 温度为室温。 保温*** 2是一中空且顶部与坩埚盖 8连接的近乎密闭的筒 式结构。其四周由良好的绝热材料组成， 这一保温***可保证制备坩埚中的合金熔体缓 慢冷却， 冷却速度为 l-150°C/min， 外部冷却控制器 3环绕在制备坩埚 6的外部且距制备 坩埚外壁 20 外部冷却控制器 3的冷却管道壁上开设通气小孔， 小孔直径为 4 调 节外部冷却控制器 3的冷却介质流量可使制备坩埚外壁冷却速度为 l-150°C/min，冷却介 质采用室温空气。 连铸装备由中间包 24、 结晶器 25、 冷却水喷嘴 26和牵引机构 27组成。 导流管 5置于中间包 24的上方， 导流管 5的直径为 072mm， 中间包的内部尺寸为 240 X 120 X 80mm, 导流管 5与制备坩埚 6下口相连， 制备坩埚 6下口设一阀门 4， 控制半固态合金熔 体向压射室的流动。将 670°C的 ZL101A合金液浇入静置坩埚 11中，盖上坩埚盖 8，静置 10 20s , 打开阀门 10， 使过热的 ZL101A合金液顺着导流管 9流入制备坩埚 6与内部冷却控制 器冷却介质输出管道 14-2螺纹之间的间隙中， 同时开启电磁搅拌器 1， 设置电磁搅拌器 的名义功率为 1300W, 控制内部、 外部冷却控制器中 14 3中冷却介质的流量， 使熔体的 冷却速度为 5°C/min， 这样合金熔体在间隙中流动的同时将受到强烈的电磁搅拌作用， 待热电偶 13指示的合金浆料温度降低到 60CTC时， 即可得到半固态 ZL101A铝合金浆料 7 这些铝合金浆料 7通过导流管 5流入中间包 24， 然后在连铸机的结晶器 25、 冷却水喷嘴 26 、 牵引机构 27的共同作用下连铸成半固态金属和合金坯料 28。 通过上述反复动作， 将不断的得到半固态坯料 28， 这些坯料可作为触变成形用的半固态坯料。
参照图 1、 图 2、 图 8， 这是按上述技术特点提供的工艺流程及装置。过热的 ZL101A 铝合金熔体通过熔化坩埚 12熔化， 熔化坩埚 12为电磁感应加热炉， 保温性能良好， 可 保证 ZL101A合金熔体有具有较高的控温精度， 控温精度为 ± 10°C， 静置坩埚 11为一保 温性能优良的坩埚， 下端开口与导流管 9相连， 静置坩埚 11的底部开口且设置一阀门 10， 可控制静置坩埚内合金熔体向制备坩埚中 6的流动， 静置坩埚 11可为制备坩埚 6 中提供足量的合金液， 该静置坩埚 11可保证合金熔体的温度在液相线以上 5 200 V， 控温精度在 ± 10。 导流管 9的上部与静置坩埚 11相连， 下部开口通入制备坩埚 6中的 合金熔体中，导流管 9的外部缠绕电阻加热器，该加热器将导流管的温度加热到 400°C 制备坩埚 6置于保温*** 2内部， 制备坩埚 6的内径尺寸为 8O X 16Omm， 制备坩埚上部 设置隔热性能优良的坩埚盖 8。 内部冷却控制器 14的冷却介质输出管道 14-2采用如图 2所示的结构， 外径为 06Omm， 材质为石墨， 预热温度 300°C。 内部冷却控制器冷却介 质输出管道 14-2的外壁与制备坩埚内侧壁距离为 10mm。内部冷却控制器冷却介质输出 管道 14-2的底部与制备坩埚底部的内壁距离为 40mm。内部冷却控制器的冷却介质输入 管道 14-1的外径为 025， 管道厚为 3mm， 材质为不锈钢， 温度为室温。 保温*** 2是一 中空且顶部与坩埚盖 8连接的近乎密闭的筒式结构。其四周由良好的绝热材料组成， 这 一保温***可保证制备坩埚中的合金熔体缓慢冷却，冷却速度为 l 150°C/min，外部冷 却控制器 3环绕在制备坩埚 6的外部且距制备坩埚外壁 20mm， 外部冷却控制器 3的冷 却管道壁上开设通气小孔， 小孔直径为 4mm， 调节外部冷却控制器 3的冷却介质流量可 使制备坩埚外壁冷却速度为 l 150°C/min，冷却介质采用室温空气。导流管 5置于锻造 模的上方利于浆料顺利流入锻造模 30的型腔 29。 导流管 5的上端与制备坩埚 6下口相 连， 制备坩埚 6下口设一阀门 4， 控制半固态合金熔体向锻造模型腔 29的流动。将一定 量的 670°C的 ZL101A合金液浇入静置坩埚 11中， 盖上坩埚盖 8， 静置 10 20s， 打开阀 门 10， 使过热的 ZL101A合金液顺着导流管 9流入制备坩埚中 6， 待流入的合金熔体量 达到制备坩埚 6容积的约 2/3时， 关闭阀门 10， 开启电磁搅拌器 1， 设置电磁搅拌器的 名义功率为 1300W, 同时控制内部、 外部冷却控制器中 14 3中冷却介质的流量， 使熔 体的冷却速度为 5°C/min， 待热电偶 13指示的温度为 590°C， 即可得到半固态 ZL101A 铝合金浆料， 此时关闭电磁搅拌器 1和内部、 外部冷却控制器 3 14， 打开阀门 4， 将 半固态 ZL101A铝合金浆料 7通过导流管 5流入锻造模型腔 29， 导流管 5的温度控制在 500°C，锻造模型腔 29的预热温度为 250°C，待开启阀门 4约 5s半固态浆料 7全部流出 后， 关闭阀门 4， 同时锻造机的模具开始合型将半固态金属和合金浆料成形， 加压成形 约 4 8s， 然后取出锻造件， 完成一次半固态 ZL101A铝合金浆料的流变锻造， 流变锻造 的同时开启阀门 10，将过热的 ZL101A合金液流入制备坩埚 6中，进入下一次流变锻造。
为实施该发明的装置既适合于铝基合金的半固态浆料的制备与成型，也适合于镁基 合金、 锌基合金、 铜基合金、 镍基合金、 钴基合金和铁基合金及其复合材料的半固态浆 料的制备与成形。
本发明的制备半固态金属流变浆料或坯料的方法的主要实施方式为：
如图 1所示， 利用熔化坩埚 12熔化 A357铝合金熔体， A357铝合金的液相线温度是 613 。C。 将熔体温度控制在 650°C。 制备坩埚 6为圆筒形不锈钢容器， 内部冷却控制器 14采用 高纯石墨制作， 内部冷却控制器的外直径为 40mm， 制备坩埚 6的内壁直径为 80 这样 制备坩埚 6内侧壁和内部冷却控制器 14外壁之间形成的环形缝隙尺寸为 20mm。 将制备坩 埚 6和内部冷却控制器 14置于保温炉中预热至 200°C并快速取出安放完毕后， 打开阀门 10，使过热的 A357铝合金熔体顺着导流管 9流入制备坩埚中的环形缝隙内进行强烈搅拌， 搅拌器的输入名义功率为 1200W, 搅拌频率为 50Hz。 内部冷却控制器 14和外部冷却控制 器 3中输入的冷却介质为室温空气， 流量均为 30升 /min， 浆料内外温差可控制在 ± 3 °C。 当浆料温度冷却至 600 °C时， 则可得到固相分数约为 0. 35的半固态 A357铝合金浆料， 浆 料组织如图 9、 图 10和图 11所示。 图 9是本发明制备的半固态 A357铝合金浆料边部的淬火 组织， 浅色区域为球状初生的 - Α/， 深色区域为凝固的共晶液体； 图 10是本发明制备 的半固态 Α357铝合金浆料中部的淬火组织，浅色区域为球状初生的 ，深色区域为 凝固的共晶液体； 图 11是本发明制备的半固态 Α357铝合金浆料中心的淬火组织， 浅色区 域为球状初生的 Α/，深色区域为凝固的共晶液体。此时可将该浆料直接移送到压铸 机或锻造机、挤压机成形。或在制备坩埚内完全凝固下来，作为触变成形用的原始坯料。 工业上的应用
本发明的装置和方法既适合于铝基合金及其复合材料半固态浆料或坯料的制备，也 适合于镁基合金、 铜基合金、 锌基合金、 铁基合金和其他有色金属合金及其复合材料半 固态浆料或坯料的制备。

Claims

权 利 要 求
1、 一种环缝式电磁搅拌制备半固态金属流变浆料或坯料的装置， 该装置包括有制 备坩埚， 在该制备坩埚的外周由里到外依次设置有外部冷却控制器、 保温***、 电磁搅 拌器； 在该制备坩埚上部设置静置坩埚， 该静置坩埚通过其底部的导流管穿过制备坩埚 上的保温盖与制备坩埚相通， 在该静置坩埚上部设置有熔化坩埚； 并在制备坩埚的底部 设有导流管，所述的制备坩埚的底部的导流管和所述的熔化坩埚的底部的导流管均具有 阀门； 其特征在于： 所述的制备坩埚的中部设有一内部冷却控制器， 且内部冷却控制器 的外壁与制备坩埚的内侧壁形成环形缝隙。
2、 按照权利要求 1所述的环缝式电磁搅拌制备半固态金属流变浆料或坯料的装置， 其特征在于： 所述的制备坩埚底部的导流管连通压铸机的压射室， 在压射室的一侧内设 置冲头， 压射室的另一侧连接压铸型定模和压铸型动模。
3、 按照权利要求 1所述的环缝式电磁搅拌制备半固态金属流变浆料或坯料的装置， 其特征在于： 所述的制备坩埚底部的导流管连通挤压机的挤压筒， 挤压筒的一侧内设置 挤压杆， 挤压筒的另一侧连接挤压模右型和挤压模左型。
4、 按照权利要求 1所述的环缝式电磁搅拌制备半固态金属流变浆料或坯料的装置， 其特征在于： 所述的制备坩埚底部的导流管连通连铸机的中间包， 中间包连通结晶器， 在结晶器的出口外的四周均布若干个冷却水喷嘴， 并在结晶器的出口外的下部装置有牵 引机构。
5、 按照权利要求 1所述的环缝式电磁搅拌制备半固态金属流变浆料或坯料的装置， 其特征在于： 所述的制备坩埚底部的导流管连通锻造模中的锻造模型腔。
6、按照权利要求 1-5中的任意一项所述的环缝式电磁搅拌制备半固态金属流变浆料 或坯料的装置， 其特征在于： 所述的内部冷却控制器为其内通有冷却介质的冷却通道， 冷却通道是由中心管和其外套管组成， 中心管的上口为冷却介质输入口， 中心管的下口 与外套管相通， 中心管构成冷却介质输入通道； 外套管的上口为冷却介质输出口， 外套 管构成冷却介质输出通道。
7、 按照权利要求 1所述的环缝式电磁搅拌制备半固态金属流变浆料或坯料的装置， 其特征在于： 制备坩埚的横截面形状为圆形、 椭圆形或方形。
8、 按照权利要求 6所述的环缝式电磁搅拌制备半固态金属流变浆料或坯料的装置， 其特征在于： 所述的冷却介质输入通道沿着径向方向的形状即中心管的横截面为圆形、 椭圆形、 方形或梯形； 所述的冷却介质输入通道即中心管沿着轴向方向的形状为直管形 状或弯曲管形状。
9、 按照权利要求 8所述的环缝式电磁搅拌制备半固态金属流变浆料或坯料的装置， 其特征在于：所述的冷却介质输出通道沿着径向方向的外观形状即外套管的横截面的外 形为圆形、 椭圆形、 方形或梯形； 所述的冷却介质输出通道即外套管沿着轴向方向的形 状为直管形状、 蛇形管形状， 螺旋管形状、 波浪管形状或其他弯曲管形状； 或是外套管 的内壁沿着轴向方向的形状为直管壁形状而其外壁沿着轴向方向的形状为螺旋形或波 浪形。
10、按照权利要求 6所述的环缝式电磁搅拌制备半固态金属流变浆料或坯料的装置， 其特征在于： 所述的冷却介质输入通道的材质为奥氏体不锈钢、 钛、 钼、 钴、 铬、 镍或 铜等非磁金属材料， 或者石墨、 陶瓷或刚玉等非金属材料； 冷却介质输出通道的材质为 奥氏体不锈钢、 钛、 钼、 钴、 铬、 镍或铜等非磁金属材料， 或者石墨、 陶瓷或刚玉等非 金属材料； 所述的制备坩埚的材质为奥氏体不锈钢、 钛、 钼、 钴、 铬、 镍或铜等非磁金 属材料， 或者石墨、 陶瓷或刚玉等非金属材料。
11、按照权利要求 6所述的环缝式电磁搅拌制备半固态金属流变浆料或坯料的装置， 其特征在于： 所述的冷却介质输入通道即中心管的内径为 2 1000 冷却介质输出通 道即外套管的内径为 5 1000
12、按照权利要求 6或 7所述的环缝式电磁搅拌制备半固态金属流变浆料或坯料的装 置， 其特征在于： 内部冷却控制器的外壁即冷却介质输出通道的外壁与制备坩埚的内侧 壁之间形成环形缝隙， 此环形缝隙的横截面形状为圆形、 椭圆形或方形； 环形缝隙的宽 度尺寸为 0. 5 300
13、按照权利要求 6所述的环缝式电磁搅拌制备半固态金属流变浆料或坯料的装置， 其特征在于： 所述的冷却介质输出通道的外壁沿着轴向方向的形状为螺旋形， 其螺距为 5 100mm， 螺纹高为 2 100mm
14、按照权利要求 6所述的环缝式电磁搅拌制备半固态金属流变浆料或坯料的装置， 其特征在于： 所述的冷却介质输出通道的外壁沿着轴向方向的形状为波浪形， 其波距为
5 100mm， 波纹高为 2 100mm
15、按照权利要求 6所述的环缝式电磁搅拌制备半固态金属流变浆料或坯料的装置， 其特征在于： 冷却通道内通入的冷却介质为空气、氮气、氩气、 自来水或其他冷却液体， 冷却介质的温度为室温。
16、 一种使用权利要求 1所述的装置制备半固态金属或合金的浆料或坯料的方法， 其特征在于： 使用权利要求 1所述的装置， 将高于其液相线温度 5〜200°C的液态金属或 合金液浇入制备坩埚内侧壁和内部冷却控制器外壁之间形成的环形缝隙中， 并开启电磁 搅拌器对环形缝隙中的液态金属或合金液进行搅拌， 进行半固态浆料制备， 同时分别向 外部冷却控制器和内部冷却控制器中通入的室温温度的冷却介质，其冷却速度为 1〜150 °C/min,使得制备半固态浆料的温度场更加均匀，从而得到细小均匀的半固态浆料组织， 并使半固态浆料的温度控制在低于其液相线温度而高于其固相线温度之间。
17、 按照权利要求 16所述的方法， 其特征在于： 所述的内部冷却控制器和外部冷却 控制中通入的冷却介质的流量为 0〜200升 /min， 且≠0。
18、 按照权利要求 16所述的方法， 其特征在于： 所述的电磁搅拌器采用感应交流旋 转电磁搅拌器， 频率为 5〜100Hz。
19、 按照权利要求 16所述的方法， 其特征在于： 在半固态浆料制备过程中， 半固态 浆料内外温差控制在 ± 3°C以内， 所述的半固态浆料内外温差为处于内部冷却控制器外 壁的半固态浆料的温度和处于制备坩埚内侧壁的半固态浆料的温度之差。
20、 按照权利要求 16所述的方法， 其特征在于： 所制备的半固态浆料为半固态铝 基合金浆料、 半固态镁基合金浆料、 半固态锌基合金浆料、 半固态铜基合金浆料、 半固 态镍基合金浆料、 半固态钴基合金浆料和半固态铁基合金浆料中的任意一种； 或半固态 铝基复合材料浆料、 半固态镁基复合材料浆料、 半固态锌基复合材料浆料、 半固态铜基 复合材料浆料、 半固态镍基复合材料浆料、 半固态钴基复合材料浆料和半固态铁基复合 材料浆料中的任意一种。
21、 按照权利要求 20所述的方法， 其特征在于： 将上述半固态浆料在制备坩埚内完 全凝固， 即可获得半固态铝合金坯料、 半固态镁合金坯料、 半固态锌合金坯料、 半固态 铜合金坯料、 半固态镍合金坯料、 半固态钴合金坯料和半固态铁基合金坯料中的任意一 种坯料； 或半固态铝基复合材料的坯料、 半固态镁基复合材料的坯料、 半固态锌基复合 材料的坯料、 半固态铜基复合材料的坯料、 半固态镍基复合材料的坯料、 半固态钴基复 合材料的坯料和半固态铁基复合材料的坯料中的任意一种坯料，上述坯料可作为半固态 触变成形的原始坯料。
22、 按照权利要求 16所述的方法， 其特征在于： 在制备半固态浆料过程中， 向制备 坩埚内侧壁和内部冷却控制器外壁之间形成的环形缝隙中通入避免或减少金属或合金 氧化的保护气体， 该保护气体为氩气、 氮气或氦气。
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