WO2018068526A1 - 一种铝合金半固态成型方法及装置 - Google Patents

一种铝合金半固态成型方法及装置 Download PDF

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Publication number
WO2018068526A1
WO2018068526A1 PCT/CN2017/089596 CN2017089596W WO2018068526A1 WO 2018068526 A1 WO2018068526 A1 WO 2018068526A1 CN 2017089596 W CN2017089596 W CN 2017089596W WO 2018068526 A1 WO2018068526 A1 WO 2018068526A1
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WO
WIPO (PCT)
Prior art keywords
mold
aluminum alloy
semi
stator
rotor
Prior art date
Application number
PCT/CN2017/089596
Other languages
English (en)
French (fr)
Inventor
朱丽娟
陈亮
陈宇杰
贾萍
Original Assignee
福建省瑞奥麦特轻金属有限责任公司
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from CN201621116135.5U external-priority patent/CN206083826U/zh
Priority claimed from CN201621132093.4U external-priority patent/CN206083784U/zh
Priority claimed from CN201621131822.4U external-priority patent/CN206083782U/zh
Priority claimed from CN201621132117.6U external-priority patent/CN206159007U/zh
Priority claimed from CN201621178211.5U external-priority patent/CN206153543U/zh
Priority claimed from CN201621178212.XU external-priority patent/CN206153538U/zh
Priority claimed from CN201621178120.1U external-priority patent/CN206153542U/zh
Priority claimed from CN201621179229.7U external-priority patent/CN206153544U/zh
Priority claimed from CN201621179618.XU external-priority patent/CN206153547U/zh
Priority to EP17860182.9A priority Critical patent/EP3527303A4/en
Priority to US16/341,258 priority patent/US20200038946A1/en
Application filed by 福建省瑞奥麦特轻金属有限责任公司 filed Critical 福建省瑞奥麦特轻金属有限责任公司
Publication of WO2018068526A1 publication Critical patent/WO2018068526A1/zh

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/007—Semi-solid pressure die casting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/06—Permanent moulds for shaped castings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/002—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure using movable moulds
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/20—Accessories: Details
    • B22D17/22—Dies; Die plates; Die supports; Cooling equipment for dies; Accessories for loosening and ejecting castings from dies
    • B22D17/2218—Cooling or heating equipment for dies
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/20—Accessories: Details
    • B22D17/26—Mechanisms or devices for locking or opening dies
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D21/00—Casting non-ferrous metals or metallic compounds so far as their metallurgical properties are of importance for the casting procedure; Selection of compositions therefor
    • B22D21/002—Castings of light metals
    • B22D21/007—Castings of light metals with low melting point, e.g. Al 659 degrees C, Mg 650 degrees C
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
    • B22D27/04—Influencing the temperature of the metal, e.g. by heating or cooling the mould

Definitions

  • the invention is a light alloy forming process, in particular a semi-solid forming.
  • the semi-solid slurry is strongly stirred during the solidification of the metal to break the dendrites, and a solid-liquid mixed slurry in which some spherical solid phase particles are uniformly suspended is obtained. It has good fluidity and can be used for semi-solid die casting, semi-solid extrusion casting, and semi-solid die forging.
  • the gas is not easily entangled during filling, its forming temperature is low, the die life is long, the deformation resistance is small, and the production efficiency is high; the high pressure is applied during the forming to cause the solidified metal to undergo sag deformation, and the unsolidified solidification continues under high pressure.
  • the shrinkage hole shrinkage is small, the structure is compact, the mechanical performance is higher than that of ordinary castings, and the heat treatment, no riser feeding, and high metal utilization rate can be obtained. It is suitable for the production of thin, thick-walled parts and for the formation of any alloy material with a wide range of crystallization temperatures.
  • the semi-solid forming method of the invention comprises semi-solid die casting, semi-solid extrusion casting, semi-solid die forging, and comprises the following six parts: a mold, a main machine (supporting a fixed anti-lifting mold), a shot system (pressure chamber, an injection rod, Power system, etc.), pulping machine, quantitative feeding system, holding furnace, combining injection system (pressure chamber, pressure rod, power system, etc.), pulping machine, and quantitative feeding system are called integrated pulping pressure.
  • the system is placed and placed in a holding furnace, and the mold is provided with a heat insulating structure.
  • the present invention provides a novel mold for semi-solid slurry molding, the mold is provided with a cavity and a gate for casting, and the mold is provided with at least an outer layer from the outside to the inside. , middle and inner layers.
  • the wall thickness dimension of the inner layer is in a positive correlation with the slurry flow.
  • the inner layer is divided into at least two sections on each module along the flow direction, and the division of each section is calculated by a computer according to different casting requirements.
  • the novel host for the semi-solid slurry forming of the present invention is an additional device provided with an internal force that changes the mold-up force into a mold.
  • the additional device includes two clamping molds on both sides of the split upper mold and the lower mold, and the clamping device includes two U-shaped clamping clamps symmetrically placed, and the clamping clamps are driven by a cylinder Relative movement, the direction of motion is perpendicular to the mold opening and closing direction.
  • the two clamping clamps are respectively driven by the cylinder drive on both sides of the mold, and the clamping force counteracts the mold growth force generated when the liquid metal fills the mold.
  • the opposite two cylinders can be used to drive the square type and the annular clamping cylinder to lock the mold on the side of the mold.
  • the convex and concave inserts of the front and rear or left and right side molds can be inserted into the top and bottom of the bottom film to lock the upper and lower molds or the upper and lower left and right side molds are used to project the bottom and top molds.
  • the card is locked, and the side mold is sleeved and locked by the ring or square frame driven by the cylinder on the moving template.
  • the mold of the three-open mold can be changed into a four-open mold by using a dummy mold, and the mold of the five-open mold can be changed into a six-open mold by using a dummy mold, and the dummy mold does not participate in the forming of the part, and only the upper and lower molds are locked. .
  • the invention provides a circulation refining device for continuously preparing an aluminum alloy semi-solid slurry for refining a slurry, comprising a driving mechanism and a refining mechanism, wherein the refining part of the refining mechanism protrudes into the slurry Refining the slurry, the refining mechanism includes a rotor and a stator, the stator is hollow inside, the rotor is disposed inside the stator, the driving mechanism drives the rotor to rotate inside the stator; and the stator is immersed in the slurry to perform
  • the refining portion of the refining function is provided with a refining cavity, the rotor in the refining cavity is provided with a blade, and the bottom of the stator is provided with a suction port communicating with the refining cavity, and in the refining space a jet hole is defined in the sidewall of the stator in the cavity; the driving mechanism drives the rotor to rotate, and the blade rotates to form a negative pressure, so
  • the driving mechanism comprises a motor, a rotating wheel, a driving belt and a rotating shaft, the output end of the motor is connected to the rotating wheel, the driving belt is respectively connected to the rotating wheel and the rotating shaft, the rotating shaft is fixedly connected with the top of the rotor; the motor working drives the rotating wheel to rotate, Thereby, the power is transmitted to the rotating shaft through the transmission belt, and the rotating shaft is rotated, thereby driving the rotor to rotate relative to the stator.
  • the invention provides a constant current pump for continuously conveying an aluminum alloy semi-solid slurry for conveying aluminum liquid, comprising a driving mechanism and an aluminum liquid conveying mechanism, the aluminum liquid conveying mechanism comprising a rotor and a stator, the stator
  • the aluminum liquid conveying mechanism comprising a rotor and a stator
  • the stator The inside is hollow, the rotor is disposed inside the stator, the driving mechanism drives the rotor to rotate inside the stator; the stator is placed inside the slurry, and the infusion portion that performs the aluminum liquid conveying function is provided with a pump chamber, and the pump chamber is in the pump chamber
  • the rotor is provided with a curved or rectangular rotating piece, and the side wall of the stator is provided with a liquid suction port and a liquid discharge port which communicate with the aluminum liquid container and the guide cylinder, and the liquid discharge port is connected with a guide cylinder.
  • the driving mechanism comprises a motor, a rotating wheel, a driving belt and a rotating shaft, the output end of the motor is connected to the rotating wheel, the driving belt is respectively connected to the rotating wheel and the rotating shaft, the rotating shaft is fixedly connected with the top of the rotor; the motor working drives the rotating wheel to rotate, Thereby, the power is transmitted to the rotating shaft through the transmission belt, and the rotating shaft is rotated, thereby driving the rotor to rotate relative to the stator.
  • the invention provides a holding furnace for continuously preparing an aluminum alloy semi-solid slurry, comprising a furnace body, a crucible and a heater, wherein the crucible and the heater are both disposed in the furnace body, and the heater is in a vertical direction Arranging at least two independent heating elements; these heating elements are powered by separate external power sources, so that the heaters are heated to each other, and the operating temperature of each heating element is set to rise from bottom to top, thereby The liquid forms a temperature gradient which gradually rises from the bottom to the top.
  • a silicon carbon rod or the like to reflect the heated aluminum water from the upper portion to cause an upper and lower temperature field to meet the needs of the pulping.
  • Figure 1 is a schematic view showing the structure of a novel mold for semi-solid slurry molding of the present invention.
  • FIG. 2 is a schematic view showing the structure of a semi-solid molding machine of a two-open mold of the present invention.
  • Figure 2-1 is a schematic view showing the structure of a semi-solid molding machine for a 4-open mold of the present invention.
  • FIG. 3 is a schematic structural view of a circulation refining device for continuously preparing an aluminum alloy semi-solid slurry according to the present invention
  • FIG. 4 is a schematic view showing the structure of a constant current pump for continuously preparing an aluminum alloy semi-solid slurry according to the present invention
  • Figure 5 is a schematic view showing the structure of a holding furnace for continuously preparing an aluminum alloy semi-solid slurry according to the present invention
  • FIG. 1 is a novel mold for semi-solid slurry molding as a preferred embodiment of the present invention.
  • the mold 1 is provided with a cavity and a gate 15 for casting molding, and the mold is sequentially from the outside to the inside.
  • An outer layer 11, an intermediate layer 12 and an inner layer 13 are provided.
  • the outer layer 11 is used for load bearing and ordinary cast iron or steel is used
  • the intermediate layer 12 is used for controlling the heat flux and the heat resistant material is used
  • the inner layer 13 is used for restraining the size of the casting 14 and using heat resistant steel.
  • Graphite paper, stainless steel sheets, aluminum silicate fibers or asbestos paper are attached to the intermediate layer 12, or the intermediate layer 12 is a shelter layer.
  • the wall thickness dimension of the inner layer 13 is in a positive correlation with the slurry flow.
  • the inner layer 13 is divided into at least two sections on each module along the flow direction, and the division of each section is calculated by the computer according to different casting requirements.
  • the mold 1 of the present invention is provided with three layers of outer, middle and inner layers, and the layered and variable wall thickness in the flow direction, so that the new mold has small heat capacity, large temperature gradient and high pressure bearing capacity for semi-solid extrusion.
  • the outer layer can be made of ordinary steel, which is beneficial to reduce the mold cost, the mold has small thermal stress, small deformation and long service life.
  • the novel host for the semi-solid slurry forming of the present invention is an additional device 2 provided with an internal force that changes the mold-increasing force into a mold.
  • the attachment device 2 includes two clamping molds on both sides of the upper mold 71 and the lower mold 72, and the clamping device includes two U-shaped clamping jaws 21 symmetrically placed.
  • the clamping jaws 21 are each driven by a cylinder 22 for relative movement, and the direction of movement is perpendicular to the opening and closing direction of the mold 7.
  • the two clamping jaws 21 are respectively driven by the oil cylinder 22 to be engaged on both sides of the mold 7, and the clamping force counteracts the mold growth force generated when the liquid metal is filled into the mold.
  • the clamping force counteracts the mold growth force generated when the liquid metal is filled into the mold. The same is true for the four open molds and the six open molds.
  • the attachment device 3 includes a clamping device disposed on the four sides of the four-open mold 8 including the upper mold 81, the lower mold 84, the left mold 82 and the right mold 83, and the clamping device includes symmetrically placed
  • the two locking frames 31 are respectively driven by a cylinder 32 for relative movement, and the moving direction is perpendicular to the opening and closing direction of the mold 8. After the mold 8 is closed, the two locking frames 31 are respectively composed of the oil cylinder 32.
  • the driving card is attached to the front and rear sides of the mold 8, and the clamping force counteracts the mold-increasing force generated when the liquid metal is filled into the mold.
  • the huge mold-increasing force generated during liquid die forging and semi-solid extrusion molding becomes the internal force of the mold system, which greatly reduces the tonnage of the forming host and improves the rapidity.
  • the cost of liquid die forging and semi-solid extrusion molding will be greatly reduced, paving the way for the promotion of liquid die forging and semi-solid extrusion molding.
  • a cycle refining device 4 for continuously preparing an aluminum alloy semi-solid slurry for refining a slurry, including a driving mechanism and a refining mechanism is a preferred embodiment of the present invention.
  • the refining portion of the refining mechanism protrudes into the crucible where the slurry is placed to refine the slurry.
  • the refining mechanism includes a rotor 41 and a stator 42.
  • the stator 42 is hollow inside, and the rotor 41 is disposed inside the stator 42, and the driving mechanism drives the rotor. 41 rotates inside the stator 42.
  • the refining portion of the stator 42 invading the slurry to perform the refining function is provided with a refining cavity
  • the rotor 41 in the refining cavity is provided with a blade 411
  • the bottom of the stator 42 is provided with a suction port communicating with the refining cavity
  • a jet hole 421 is formed in a sidewall of the stator 42 in the refining cavity.
  • the driving mechanism drives the rotor 41 to rotate, and the blades 411 rotate to form a negative pressure to cause the slurry to enter the refining cavity from the suction port to be refined, and then ejected from the jet hole 421 to the outside of the stator 42.
  • the minimum gap between the rotor 41 and the stator 42 is 1-2000 micrometers, and a large number of fine streams (aluminum liquid in which solid phase particles are suspended) sprayed by the scattering pump are cut by a small gap, thereby continuously preparing an aluminum alloy semi-solid slurry device pair.
  • the refinement efficiency of suspended grains is high.
  • the number of the jet holes 421 can be set as needed, and it is preferable to provide two or more, and the two or more jet holes 421 are symmetrical with each other with the rotation axis of the rotor 41 as a central axis to uniformly and sufficiently eject the slurry.
  • the orifice 421 has an aperture of 0.1-20 mm, and the aperture axis forms an angle of 20-90° downward with the axis of rotation of the rotor 41.
  • the specific aperture and angle can be set according to the size of the crucible to adjust the slurry to be ejected from the jet orifice. The range is to ensure that the slurry in the crucible is sufficiently refined.
  • the driving mechanism includes a motor 43, a driving wheel 44, a driven wheel 46, a driving belt 45 and a rotating shaft 47.
  • the output end of the motor 43 is connected to the driving wheel 44.
  • the driven wheel 46 is disposed on the rotating shaft 47, and the driving belt 45 is tensioned on the driving wheel 44 and the driven wheel. Between 46, the shaft 47 is fixedly coupled to the top of the rotor 41.
  • the operation of the motor 43 drives the driving wheel 44 to rotate, thereby transmitting power to the rotating shaft 47 through the belt 45, causing the rotating shaft 47 to rotate, thereby driving the blades 411 of the rotor 41 to rotate relative to the stator 42.
  • the blade 411 can be provided as needed, preferably 2-16 pieces.
  • the driving mechanism drives the blade 411 to rotate a large amount of fine flow from the jet hole 421, and tilts downward to impact the bottom of the heat exchanger, and is sucked back by the bottom hole of the scattering pump to be re-cut and then injected, that is, the heat exchange intensity is increased. (Advantageous control of solid phase comparison) further strengthens the refining effect on suspended grains.
  • the present invention utilizes the rotation of the rotor blade 411 to form a negative pressure to draw the slurry into the refined cavity of the stator 42 for refinement, and ejects the slurry from the jet hole 421 to return the slurry to the slurry.
  • the crucible it is continuously sucked from the suction port, repeated circulation, and refinement; thus, the refining efficiency of the suspended crystal grains is higher, and the difference in specific gravity causes the prepared slurry to accumulate in the bottom of the crucible for continuous collection. delivery.
  • FIG. 4 is a constant current pump 5 for continuously preparing an aluminum alloy semi-solid slurry, which is used for conveying aluminum liquid, including a driving mechanism and an aluminum liquid conveying mechanism, and an aluminum liquid, as a preferred embodiment of the present invention.
  • the conveying mechanism includes a rotor 51 and a stator 52.
  • the stator 52 is hollow inside, and the rotor 51 is disposed inside the stator 52.
  • the driving mechanism drives the rotor 51 to rotate inside the stator 52.
  • the infusion portion of the stator 52 disposed inside the slurry for performing the aluminum liquid conveying function is provided with a pump chamber, and the rotor 51 in the pump chamber is provided with a curved or rectangular rotating piece 511, and the side wall of the stator 52 is provided with an aluminum bearing liquid container, The liquid suction port and the liquid discharge port of the guide cylinder 53 are connected, and the liquid discharge port is connected with the guide cylinder 53.
  • the liquid suction port and the liquid discharge port are placed at an angle of 45 degrees from the point where the rotor 51 and the stator 52 are tangent.
  • a high temperature resistant seal 541 and a gasket 542 are disposed between the rotor 51 and the stator 52 at the upper portion of the pump chamber.
  • the high temperature resistant sealing ring 541 is a U-shaped, V-shaped or square high temperature sealing ring
  • the gasket 542 is a square gasket in cross section.
  • the driving mechanism includes a motor 55, a driving wheel 56, a driven wheel 58, a driving belt 57 and a rotating shaft 59.
  • the output end of the motor 55 is connected to the driving wheel 56.
  • the driven wheel 58 is disposed on the rotating shaft 59.
  • the driving belt 57 is tensioned on the driving wheel 56 and the driven wheel. Between 58, the shaft 59 is fixedly coupled to the top of the rotor 51.
  • the operation of the motor 55 drives the driving wheel 56 to rotate, thereby transmitting power to the rotating shaft 59 through the belt 57, thereby rotating the rotating shaft 59, thereby driving the rotor 51 to rotate relative to the stator.
  • the pump seal is provided with high temperature resistant sealing rings and gaskets, which are made of graphite, carbon fiber and high temperature resistant composite materials.
  • the rectangular rotary vane in the pump can be replaced by an arc-shaped rotary vane, the number of which is 2-15, the thickness is 2-15 mm, the length is 5-100 mm, and the inner bearing of the original rotary vane pump is cancelled.
  • the closing angle between the suction port of the rotary vane pump and the liquid discharge port is larger than the angle of the rotor.
  • the root of the blade is provided with a pressure equalization groove. The low pressure side and the low pressure port of the pressure equalization groove are connected, and the high pressure side and the high pressure port are connected.
  • the rotor 51, the stator 52 and the rotary vane 511 of the pump are made of graphite, C-C fiber, ceramic material, metal molybdenum, tungsten, metal alloy surface coating, molybdenum or tungsten plating and aluminum water corrosion resistant composite material.
  • the present invention adopts a volumetric pump, which has a constant flow characteristic, and thus the filling speed of the liquid metal is substantially reduced when the horizontal section of the liquid metal is suddenly expanded, thereby overcoming the uncontrollable level of the liquid pressure control system of the conventional pressure control.
  • the shortcomings of the flow rate improve the intrinsic quality of the casting, and the operation of placing the filter in each casting can be eliminated.
  • the new semi-solid forming process of aluminum alloy is capable of timely and automatically completing a large pressure rise when the cavity is full, which is of great significance for improving the intrinsic quality of aluminum alloy semi-solid molded parts.
  • FIG. 5 is a holding furnace 6 for continuously preparing an aluminum alloy semi-solid slurry, which comprises a furnace body, a crucible and a heater, and a crucible 61 and a heater 62 are provided as a preferred embodiment of the present invention.
  • the heater 62 arranges at least two independent heating elements in a vertical direction; these heating elements are powered by external independent power sources, so that the heater 62 heats the crucible 61, and the operating temperature of each heating element is set to It gradually rises from the bottom to the top, thereby forming a temperature gradient for the crucible 61 which gradually rises from the bottom to the top.
  • the cooling device comprises a heat conductive graphite paper 631, a heat conducting ring 632 and a water cooling ring 633.
  • the heat conductive graphite paper 631 is adhered to the bottom of the crucible 61.
  • the heat conducting ring 632 is disposed in the furnace body, and the top thereof is closely attached to the bottom of the heat conductive graphite paper 631, and the bottom portion thereof and the furnace body
  • the furnace bottom 64 is connected, and the cooling ring 633 is disposed on the furnace bottom 64.
  • a heat shield 65 is disposed on the outside of the furnace body, and the heat shield 65 covers the top and the periphery of the furnace body.
  • the heating element includes a resistance wire, a resistance band, a silicon carbon rod, and an induction coil.
  • the heating element is arranged in the vertical direction of 2-5 segments.
  • the aluminum carbon water can be reflected from the upper part by using a silicon carbon rod or the like to cause an upper and lower temperature field to meet the needs of pulping.
  • the cooling ring 633 conducts heat in the form of water cooling, air cooling or oil cooling.
  • the heat conducting ring 632 is heat resistant steel or graphite.
  • the ratio of the height of the crucible 61 to its diameter is 1.0-2.5.
  • the present invention continuously prepares a semi-solid slurry under the protection of an inert gas, and has less oxidized slag in the slurry, which can further improve the intrinsic quality of the casting;
  • the depth of use of the new semi-solid forming process of the aluminum alloy Large, silicon carbide or graphite crucible, less pollution to aluminum liquid than knotting furnace lining, easy to clean, small heat capacity of liquid carrier (silicon carbide or graphite crucible), flexible and convenient temperature control; furnace body and furnace cover 66 are shielded and insulated The energy-saving effect is good; the aluminum leakage has an automatic processing and alarm device 67.
  • the semi-solid forming method of the present invention can provide a systemic slurry having continuous preparation, storage, transportation and forming, and has low cost, excellent quality and less pollution.

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  • Mechanical Engineering (AREA)
  • Manufacture And Refinement Of Metals (AREA)

Abstract

半固态成形新工艺也包括传统的六部分模具（1）、主机、压射***、制浆机、定量送料***、保温炉（6），把压射***、制浆机、定量送料***组合放在保温炉中，为了适应半固态浆料携带的热量少充入壁厚大的模具中成形困难，将半固态模具按照功能分成三层，极大的减少了模具的吸热能力，由于恒流量泵的特性造成充满型后的保压压力可达0.01MPa---30MPa之间，因此可将低压铸造、高压铸造、差压铸造、液态模锻、半固态挤压铸造统一在一种主机上进行生产。

Description

一种铝合金半固态成型方法及装置 技术领域
本发明属于轻合金成型方法，特别是半固态成型。
背景技术
半固态浆料是在金属凝固过程中进行强烈搅拌使其枝晶破碎，得到一种均匀悬浮一些近似球形固相颗粒的固液混合浆料。其流动性良好，可用于半固态压铸、半固态挤压铸造、半固态模锻。 填充时气体不易卷入，它的成形温度低，模具寿命长，变形阻力小，生产效率高；成形时施以高压使已凝固的金属产生朔性变形，未凝固的在高压下继续凝固因而制件缩孔缩松少、组织致密、机械性能高于普通铸件接近锻件、可进行热处理、无冒口补缩、金属利用率高。它适合薄、厚壁件的生产也适合各种结晶温度间隔较宽的任何合金材料的成形。
尽管用半固态成形技术生产出的铸件有很多优点，浆料的制备方法也很多，但是低成本优质浆料的连续制备、保存、输送、成形一直是难题，严重制约该技术的推广及应用。本发明就是为***、全方位解决上述问题。
发明内容
本发明的半固态成形方法包括半固态压铸、半固态挤压铸造、半固态模锻，包括以下六部分：模具、主机（支撑固定防涨模）、压射***（压室、压射杆、动力***等）、制浆机、定量送料***、保温炉，将压射***（压室、压射杆、动力***等）、制浆机、定量送料***组合在一起称做集成式制浆压射***并将它放在保温炉中，所述的模具设有保温结构。
这样半固态成形的三大难题都得到解决（模具庞大无法适应已经半固态的浆料流动时对热量的需求、大吨位的挤压铸造机快速性差难与半固态浆料的快速凝固匹配、连续制浆、定量运送、快速压射三者本身就很复杂再让它们协调起来就更难更复杂）为更清楚阐述发明内容下面分五个方面说明。
1 ）模具
本发明为解决上述技术问题，提供了一种用于半固态浆料成型的新型模具，该模具设有用于铸件成型的型腔和浇口，所述模具由外到内依次至少设有外层、中间层和内层。所述内层的壁厚尺寸与浆料流程成正相关的关系。所述内层沿着流程方向的每个模块上至少分为2段，各段的划分由计算机根据不同铸件要求计算得出。
2) 主机
本发明用于半固态浆料成形的新型主机是设有把漲模力变成模具的内力的附加装置。该附加装置对两开式模具包括对开的上模和下模两旁设有的锁模装置，锁模装置包括，对称放置的两个U形卡紧钳，卡紧钳各由一油缸驱动进行相对运动，其运动方向与模具开、合模方向垂直。上模和下模具合模后，两卡紧钳分别由油缸驱动卡接在模具两侧，该锁模力对液态金属填充模具时生的涨模力进行抵消。对四开模的模具可用相对的两油缸带动方型、环形卡紧筒在模具的侧面将模锁紧详见图2-1
对六开的模具可用前后或左右侧模的凸或凹***顶、底膜内的凹凸将上下模锁紧或用前后左右侧模上下高出的向里伸出的台阶把底膜及顶模卡锁紧，用动模板上油缸带动的环或方框下落把侧模套住锁紧。
可以把三开模的模具通过用假模变成四开模，把五开模的模具通过用假模可以变成六开模处理，假模不参与零件的成形，只起上下模锁紧作用。
3 ）连续制浆机
本发明提供了一种用于连续制备铝合金半固态浆料的循环细化装置，用于细化浆料，包括驱动机构和细化机构，该细化机构的细化部伸入到浆料中对浆料进行细化，所述细化机构包括转子和定子，所述定子内部中空，所述转子设于定子内部，所述驱动机构带动转子在定子内部旋转；所述定子浸入浆料执行细化功能的细化部设有细化空腔，在该细化空腔中的转子设有叶片，所述定子底部设有与细化空腔连通的吸料口，并在该细化空腔中的定子侧壁上开设有射流孔；所述驱动机构带动转子转动，其叶片旋转形成负压使浆料从吸料口进入细化空腔进行细化后，并从射流孔射出到定子外部。
所述驱动机构包括马达、转轮、传动带和转轴，所述马达的输出端连接转轮，所述传动带分别连接转轮和转轴，所述转轴与转子顶部固定连接；马达工作带动转轮转动，从而通过传动带向转轴传输动力，使转轴旋转，进而带动转子相对定子转动。
4 ）压射***、浆料输送
本发明提供了一种用于连续输送铝合金半固态浆料的恒流泵，用于输送铝液，包括驱动机构和铝液输送机构，所述铝液输送机构包括转子和定子，所述定子内部中空，所述转子设于定子内部，所述驱动机构带动转子在定子内部旋转；所述定子置于浆料内部，执行铝液输送功能的输液部设有泵腔，在该泵腔中的转子设有弧形或矩形旋片，所述定子侧壁设有与承铝液容器、导料筒连通的吸液口和排液口，所述排液口连接有导料筒。
所述驱动机构包括马达、转轮、传动带和转轴，所述马达的输出端连接转轮，所述传动带分别连接转轮和转轴，所述转轴与转子顶部固定连接；马达工作带动转轮转动，从而通过传动带向转轴传输动力，使转轴旋转，进而带动转子相对定子转动。
5 ）保温炉
本发明提供了一种用于连续制备铝合金半固态浆料的保温炉，包括炉体、坩埚和加热器，所述坩埚和加热器均设于炉体中，所述加热器沿竖直方向排布至少2段独立的加热元件；这些加热元件由外部各自独立的电源供电，从而使加热器对坩埚加热，各加热元件的工作温度设置为从下往上逐渐升高，从而对坩埚内铝液形成从下往上逐渐升高的温度梯度，对打结炉也可用硅碳棒等从上部反射加热铝水造成上高下低的温度场以满足制浆的需要。
附图说明
下面参照附图结合实施例对本发明作进一步的说明。
图1是本发明的用于半固态浆料成型的新型模具的结构示意图。
图2是本发明的两开式模具的半固态成型机结构示意图。
图2-1是本发明的4开式模具的半固态成型机结构示意图。
图3是本发明的用于连续制备铝合金半固态浆料的循环细化装置的结构示意图
图4是本发明的用于连续制备铝合金半固态浆料的恒流泵的结构示意图
图5是本发明的用于连续制备铝合金半固态浆料的保温炉的结构示意图
具体实施方式
1 ）模具
请参阅图1，是作为本发明的最佳实施例的一种用于半固态浆料成型的新型模具，该模具1设有用于铸件成型的型腔和浇口15，模具由外到内依次设有外层11、中间层12和内层13。外层11用于承重并采用普通铸铁或钢材，中间层12用于控制热流通量并采用热阻材料，内层13用于约束铸件14尺寸并采用耐热钢。中间层12上贴有石墨纸、不锈钢片、硅酸铝纤维或石棉纸，或者中间层12为避空层。内层13的壁厚尺寸与浆料流程成正相关的关系。内层13沿着流程方向在每个模块上至少分为两段，各段的划分由计算机根据不同铸件要求计算得出。
综上所述，本发明的模具1设有外、中、内三层，加之在流动方向上分层、变壁厚因而新型模具热容量小、温度梯度大、承压能力高适合半固态挤压成型的需要，当产品有不大的改型时只要更换内层这对降低更新换代成本有利，外层可以用普通钢制作有利于降低模具成本，模具热应力小、变形小、寿命长。
2) 主机
本发明用于半固态浆料成形的新型主机是设有把漲模力变成模具的内力的附加装置2。请参阅图2该附加装置2对两开式模具7包括相互对开的上模71和下模72两旁设有锁模装置，锁模装置包括对称放置的两个U形卡紧钳21，卡紧钳21各由一油缸22驱动进行相对运动，其运动方向与模具7开、合模方向垂直。上模71和下模72合模后，两卡紧钳21分别由油缸22驱动卡接在模具7两侧，该锁模力对液态金属填充模具时生的涨模力进行抵消。同理四开模、六开模也是如此。
详见图2-1，附加装置3对四开式模具8包括相互对开的上模81、下模84、左模82、右模83两旁设有锁模装置，锁模装置包括对称放置的两个矩形锁紧框31，锁紧框31各由一油缸32驱动进行相对运动，其运动方向与模具8开、合模方向垂直，模具8合模后，两锁紧框31分别由油缸32驱动卡接在模具8前后两侧，该锁模力对液态金属填充模具时生的涨模力进行抵消。
本发明通过设置合适的锁模机构，将液态模锻、半固态挤压成型时产生的巨大涨模力变成模具***的内力这将使成型主机的吨位大大减小、快速性也得以提高，将使液态模锻、半固态挤压成型的成本大大降低，为液态模锻、半固态挤压成型的推广铺平道路。
3 ）连续制浆机
请参阅图3，是作为本发明的最佳实施例的一种用于连续制备铝合金半固态浆料的循环细化装置4，用于细化浆料，包括驱动机构和细化机构，该细化机构的细化部伸入到放置浆料的坩埚中对浆料进行细化，细化机构包括转子41和定子42，定子42内部中空，转子41设于定子42内部，驱动机构带动转子41在定子42内部旋转。定子42侵入浆料执行细化功能的细化部设有细化空腔，在该细化空腔中的转子41设有叶片411，定子42底部设有与细化空腔连通的吸料口，并在该细化空腔中的定子42侧壁上开设有射流孔421。驱动机构带动转子41转动，其叶片411旋转形成负压使浆料从吸料口进入细化空腔进行细化后，并从射流孔421射出到定子42外部。转子41与定子42之间的最小间隙为1-2000微米，通过很小间隙切割散射泵喷射出的大量细流（悬浮着固相颗粒的铝液）因而连续制备铝合金半固态浆料装置对悬浮晶粒的细化效率高。射流孔421的数量可根据需要进行设置，优选设置两个以上，并两个以上射流孔421以转子41旋转轴线为中轴相互对称，以均匀、充分的射出浆料。射流孔421的孔径为0.1-20毫米，其孔径轴线与转子41旋转的轴线向下形成20-90°夹角，具体孔径和角度可根据坩埚大小进行设置，以调整浆料从射流孔射出的范围，从而保证坩埚中的浆料均得到充分细化。
驱动机构包括马达43、主动轮44、从动轮46、传动带45和转轴47，马达43的输出端连接主动轮44，从动轮46设置在转轴47上，传动带45张紧在主动轮44与从动轮46之间，转轴47与转子41顶部固定连接。马达43工作带动主动轮44转动，从而通过传动带45向转轴47传输动力，使转轴47旋转，进而带动转子41的叶片411相对定子42转动。叶片411可根据需要设置，优选2-16片。由驱动机构带动叶片411转动从射流孔421射出的大量细流，向下倾斜冲击换热器上部的坩埚底，又被散射泵底部孔吸回重新切割破碎后又被射出，即提高换热强度（有利控制固相比例）又进一步强化对悬浮晶粒的细化效果。
综上所述，本发明利用转子叶片411转动形成负压将浆料吸入到定子42的细化空腔中进行细化，并从射流孔421将浆料射出，使浆料回到放置浆料的坩埚中，再从吸料口不断吸入，反复循环，不断细化；因而对悬浮晶粒的细化效率更高，并由于温度造成的比重差使制备好的浆料积聚在坩埚底便于连续采集输送。
4 ）压射***、浆料输送
请参阅图4，是作为本发明的最佳实施例的一种用于连续制备铝合金半固态浆料的恒流泵5，用于输送铝液，包括驱动机构和铝液输送机构，铝液输送机构包括转子51和定子52，定子52内部中空，转子51设于定子52内部，驱动机构带动转子51在定子52内部旋转。定子52置于浆料内部执行铝液输送功能的输液部设有泵腔，在该泵腔中的转子51设有弧形或矩形旋片511，定子52侧壁设有与承铝液容器、导料筒53连通的吸液口和排液口，排液口连接有导料筒53。吸液口与排液口放置在距转子51与定子52相切点的45度角之外。泵腔上部的转子51与定子52之间设有耐高温密封圈541和垫片542。耐高温密封圈541为U形、V形或方形耐高温密封圈，垫片542是截面为方形垫片。驱动机构包括马达55、主动轮56、从动轮58、传动带57和转轴59，马达55的输出端连接主动轮56，从动轮58设置在转轴59上，传动带57张紧在主动轮56与从动轮58之间，转轴59与转子51顶部固定连接；马达55工作带动主动轮56转动，从而通过传动带57向转轴59传输动力，使转轴59旋转，进而带动转子51相对定子转动。泵的密封设有耐高温密封圈和垫片，其材质为石墨、碳纤维、耐高温的复合材料。
其泵内的矩形旋片可换成弧形旋片其数量为2-15个，其厚度为2-15毫米，其长度为5-100毫米，把原旋片泵内轴承都取消，所述旋片泵吸液口与排液口之间的封闭角要大于转子的平分角，叶片的根部要设有均压槽，均压槽的低压侧和低压口连通，高压侧和高压口连通。
泵的转子51、定子52、旋片511的材质为石墨、C-C纤维、陶瓷材料、金属钼、钨、金属合金表面涂、镀钼或钨及耐铝水腐蚀的复合材料。
综上所述，本发明采用体积泵，它有恒流量特性因而在液态金属填充水平截面突扩的时候，其充型速度自然降低，这就克服传统压力控制的液面加压控制***不能控制水平流速的缺点，提高铸件内在质量，又可以取消每铸一件放置过滤网的操作。铝合金半固态成形新工艺在模腔充满时由泵的特性造成能及时、自动完成幅度很大的压力跃升，这对提高铝合金半固态成型制品件的内在质量意义十分巨大。
5 ）保温炉
请参阅图5，是作为本发明的最佳实施例的一种用于连续制备铝合金半固态浆料的保温炉6，包括炉体、坩埚和加热器，坩埚61和加热器62均设于炉体中，加热器62沿竖直方向排布至少两段独立的加热元件；这些加热元件由外部各自独立的电源供电，从而使加热器62对坩埚61加热，各加热元件的工作温度设置为从下往上逐渐升高，从而对坩埚61形成从下往上逐渐升高的温度梯度。坩埚61底部设有冷却装置。冷却装置包括导热石墨纸631、导热环632和水冷环633，导热石墨纸631与坩埚61底部贴合，导热环632设于炉体内，其顶部紧贴导热石墨纸631底部，其底部与炉体的炉底64连接，冷却环633设于炉底64。炉体外部设有遮热屏65，该遮热屏65覆盖炉体的顶部及四周。加热元件包括电阻丝、电阻带、硅碳棒和感应线圈。加热元件沿竖直方向排布2-5段，对打结炉也可用硅碳棒等从上部反射加热铝水造成上高下低的温度场以满足制浆的需要。冷却环633采用水冷、风冷或油冷形式进行导热。导热环632为耐热钢或石墨。坩埚61的高度与其直径比为1.0-2.5。
综上所述，本发明在惰性气体的保护下连续制备半固态浆料其浆料内的氧化夹渣更少，可进一步提高铸件的内在质量；铝合金半固态成形新工艺的炉体使用深度大、碳化硅或石墨坩埚，对铝液的污染比打结炉衬少、清理方便、载液容器（碳化硅或石墨坩埚）热容量小控温灵活方便；炉体、炉盖66均采用屏蔽绝热技术，节能效果好；坩埚漏铝有自动处理、报警装置67。
上面结合附图对本发明行了示例性描述，显然本发明实现并不受上述方式的限制，只要采用了本发明方法构思和技术方案进行的各种非实质性的改进，或未经改进将发明构思和技术方案直接应用于其它场合的，均在本发明保护范围之内。
工业实用性
本发明采用半固态成形方法能够提供具有连续制备、保存、输送、成形 的***性的浆料，成本低，质量优，污染少。

Claims (21)

  1. 一种铝合金半固态成形装置，包括模具、主机、压射***、制浆机、定量送料***、保温炉，将压射***、制浆机、定量送料***放在保温炉中，所述的模具设有保温、冷却结构。
  2. 根据权利要求1所述的一种铝合金半固态成形装置，其特征在于，适用于半固态高压铸、半固态挤压铸造、半固态真空低压铸造、半固态调压铸造、半固态差压铸造、半固态低压铸造。
  3. 根据权利要求1所述的一种铝合金半固态成形装置，其特征在于，所述模具至少设有外层、中间层和内层，外层刚度大用于承重；内层薄用于约束铸件尺寸；中间层用于控制热流通量。
  4. 根据权利要求3所述的一种铝合金半固态成形装置，其特征在于，所述内层的壁厚尺寸与浆料流程有成正比的相关关系。
  5. 根据权利要求3所述的一种铝合金半固态成形装置，其特征在于，所述内层沿着流程方向在每个模块上至少分为两段。
  6. 根据权利要求1所述的一种铝合金半固态成形装置，其特征在于，所述的主机，其上设有把漲模力变成模具的内力的附加装置。
  7. 根据权利要求6所述的一种铝合金半固态成形装置，其特征在于，所述的附加装置对两开模是用U形卡钳 。
  8. 根据权利要求6所述的一种铝合金半固态成形装置，其特征在于，所述的附加装置，对四开模是用方框锁紧 。
  9. 根据权利要求6所述的一种铝合金半固态成形装置，其特征在于，所述的附加装置，对六开的模具可用前后或左右侧模的凸或凹***顶、底膜内的凹或凸将上下模锁紧或用前后左右侧模上下高出的向里伸出的台阶把底膜及顶模卡锁紧，用动模板上油缸带动的环或方框下落把侧模套住锁紧。
  10. 根据权利要求6所述的一种铝合金半固态成形装置，其特征在于，所述的附加装置，把三开模的模具通过用不参与成形只起锁紧作用的假模变成四开模，把五开模的模具通过用假模变成六开模处理。
  11. 根据权利要求1所述的一种铝合金半固态成形装置，其特征在于，所述的制浆机用于细化浆料，包括驱动机构和细化机构，该细化机构的细化部伸入到浆料中对浆料进行细化，所述细化机构包括转子和定子，所述定子内部中空，所述转子置于定子内部，所述驱动机构带动转子在定子内部旋转； 所述定子浸入浆料执行细化功能的细化部设有细化空腔，在该细化空腔中的转子设有叶片，所述定子底部设有与细化空腔连通的吸料口，并在该细化空腔中的定子侧壁上开设有射流孔；所述驱动机构带动转子转动，其叶片旋转形成负压使浆料从吸料口进入细化空腔进行细化后，并从射流孔射出到定子外部。
  12. 根据权利要求11所述的一种铝合金半固态成形装置，其特征在于，所述的制浆机用于细化浆料，所述转子与定子之间的最小间隙为 1-2000 微米，转子直径为3厘米-50厘米，转子的叶片为2-17个，叶片的形状可以是直的、也可以是前弯、也可以是后弯。
  13. 根据权利要求11所述的一种铝合金半固态成形装置，其特征在于，所述的制浆机用于细化浆料，所述射流孔的孔径为 0.1-20 毫米，射流孔的孔所占的空间高度为2厘米到d(转子的直径)。
  14. 根据权利要求11所述的一种铝合金半固态成形装置，其特征在于，所述射流孔的孔径轴线与转子旋转的轴线向下形成 90-45°夹角。
  15. 根据权利要求11所述的一种铝合金半固态成形装置，其特征在于，所述的制浆机其吸料口可以是单面的也可以是双面的，可以是全开的也可以是半开的。
  16. 根据权利要求1所述的一种铝合金半固态成形装置，其特征在于，所述压射***及浆料输送选用容积泵、旋片泵、齿轮泵、螺杆泵或罗氏泵。
  17. 根据权利要求16所述的一种铝合金半固态成形装置，其特征在于，所述旋片泵包括驱动机构和铝液输送机构，所述铝液输送机构包括转子和定子，所述定子内部中空，所述转子设于定子内部，所述驱动机构带动转子在定子内部旋转；所述定子置于浆料内部执行铝液输送功能的输液部设有铝液容纳腔，在该铝液容纳腔中的转子设有弧形旋片或矩形旋片，其数量为2-15个，其厚度为2-15毫米，其长度为5-100毫米，所述定子侧壁设有与铝液容纳腔连通的吸液口和排液口，所述排液口连接有导料筒。
  18. 根据权利要求17所述的一种铝合金半固态成形装置，其特征在于，所述吸液口与排液口之间的封闭角要大于转子的平分角，叶片的根部要设有均压槽，均压槽的低压侧和低压口连通，高压侧和高压口连通。
  19. 根据权利要求17所述的一种铝合金半固态成形装置，其特征在于，所述所述铝液容纳腔上部的转子与定子之间设有耐高温密封圈和垫片，其材质为石墨、碳纤维、耐高温的复合材料。
  20. 根据权利要求1所述的一种铝合金半固态成形装置，其特征在于，压射***、制浆机的材质为石墨、C-C纤维、陶瓷材料、金属钼、钨、金属合金表面涂、镀钼或钨及耐铝水腐蚀的复合材料。
  21. 根据权利要求1所述的一种铝合金半固态成形装置，其特征在于，所述的保温炉的加热带分2-5层独立控温以确保炉温上高下低，对打结炉也可用硅碳棒等从上部反射加热铝水造成上高下低的温度场以满足制浆的需要，坩埚的底部设有冷却装置，坩埚的高度与直径比为1.2-3。
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