Background of the Invention
[0001] This invention relates to a method of shaping semisolid metals , in which a liquid
alloy crystal nuclei at a temperature not lower than a is fed into an insulated vessel
having heat insulateing effect, holding the alloy for a period from 5 seconds to 60
minutes as it is cooled to the molding temperature where a specified fraction liquid
is established, thereby generating fine primary crystals in the alloy solution and
the alloy is shaped under pressure. The invention also relates to an apparatus for
implementing this method.
[0002] Various methods for shaping semisolid metals are known in the art. A thixo-casting
process is attracting researcher's attention these days since it involves a fewer
molding defects and segregations,produces uniform metallographic structures and features
longer mold lives but shorter molding cycles than the existing casting techniques.
The billets used in this molding method (A) are characterized by spheroidized structures
obtained by either performing mechanical or electromagnetic agitation in temperature
ranges that produce semisolid metals or by taking advantage of recrystallization of
worked metals. On the other hand, raw materials cast by the existing methods may be
molded in a semisolid state. There are three examples of this approach; the first
two concern magnesium alloys that will easily produce an equiaxed microstructure and
Zr is added to induce the formation of finer crystals [method (B)] or a carbonaceous
refiner is added for the same purpose [method (C)]; the third approach concerns aluminum
alloy and a master alloy comprising an Al-5% Ti-1% B system is added as a refiner
in amounts ranging from 2 - 10 times the conventional amount [method (D)]. The raw
materials prepared by these methods are heated to temperature ranges that produce
semisolid metals and the resulting primary crystals are spheroidized before molding.
It is also known that alloys within a solubility limit are heated fairly rapidly up
to a temperature near the solidus line and, thereafter, in order to ensure a uniform
temperature profile through the raw material while avoiding local melting, the alloy
is slowly heated to an appropriate temperature beyond the solidus line so that the
material becomes sufficiently soft to be molded [method (E)].
[0003] EP-A-0 719 606 discloses a method of shaping a semi-solid metal, in which a partially
solid, partially liquid alloy is brought into contact with a cooling unit in the form
of an inclined passage and the molten metal flows down on the inclined cooling unit
to be fed into an insulated vessel where it is held for a given time whereafter the
metallic slurry is shaped under pressure. An essential feature of this known process
is the cooling step carried out by means of an inclined cooling unit. ,
[0004] EP-A-0 392 998 discloses a method for making semi-liquid cast aluminium alloys which
comprises heating the aluminium alloy to a temperature of about 700°C in a melting
oven, generating a laminar flow of aluminium alloy and conveying the said fused alloy
onto a tiltable surface so as to adjust the alloy flow falling rate, cooling this
surface by a refrigerating medium circulating therein, collecting the semi-liquid
aluminium alloy in a vessel and cooling the alloy. This method also requires the use
of a cooling jig consisting of a tiltable surface and it is therefore difficult to
achieve a uniform temperature of the melt when it is poured into a holding vessel.
[0005] These methods in which billets are molded after they are heated to temperatures that
produce semisolid metals are in sharp contrast with a rheo-casting process (F), in
which molten metals containing spherical primary crystals are produced continuously
and molded as such without being solidified to billets.
[0006] However, the above-described conventional methods have their own problems. method
(A) is cumbersome and the production cost is high irrespective of whether the agitation
or recrystallization technique is utilized. When applied to magnesium alloys, method
(B) is economically disadvantageous since Zr is an expensive element and speaking
of method (C), in order to ensure that carbonaceous refiners will exhibit their function
to the fullest extent, the addition of Be as an oxidation control element has to be
reduced to a level as low as about 7 ppm but then the alloy is prone to burn by oxidation
during the heat treatment just prior to molding and this is inconvenient in operations.
[0007] In the case of aluminum alloys, about 500 µm is the size that can be achieved by
the mere addition of refiners and it is not easy to obtain crystal grains . finer
than 100 µm. To solve this problem, increased amounts of refiners are added in method
(D) but this is industrially difficult to implement because the added refiners are
prone to settle on the bottom of the furnace; furthermore, the method is costly. Method
(E) is a thixo-casting process which is characterized by heating the raw material
slowly after the temperature has exceeded the solidus line such that the raw material
is uniformly heated and spheroidized. In fact, however, an ordinary dendritic microstructure
will not transform to a thixotropic structure (in which the primary dendrites have
been spheroidized). What is more, thixo-casting methods (A) - (E) have a common problem
in that they are more costly than the existing casting methods because in order to
perform molding in the semisolid state, the liquid phase must first be solidified
to prepare a billet, which is heated again to a temperature range that produces a
semisolid metal. In contrast, method (F) which continuously generates and supplies
a molten metal containing spherical primary crystals is more advantageous than the
thixocasting approach from the viewpoint of cost and energy but, on the other hand,
the machine to be installed for producing a metal material consisting of a spherical
structure and a liquid phase requires cumbersome procedures to assure effective operative
association with the casting machine to yield the final product.
[0008] The present invention has been accomplished under these circumstances and has as
an object providing a method that does not use billets or any cumbersome procedures
but which ensures convenience and ease in the production of semisolid metals having
fine primary crystals and shaping them under pressure.
[0009] Another object of the invention is to provide an apparatus that can implement this
method.
Summary of the Invention
[0010] The object of the invention can be attained by the method of shaping a semisolid
metal recited in claim 1, in which a molten aluminum alloy or magnesium alloy containing
an element for promoting the generation of crystal nuclei held superheated to less
than 100°C above the liquidus temperature is directly poured without using a cooling
jig into an insulated vessel made of a material having a thermal conductivity of at
least 1.0 kcal/hr·m·°C (at room temperature), held in said insulated vessel for a
period from 5 seconds to 60 minutes as it is cooled to the molding temperature where
a specified liquid fraction is established wherein said specified liquid fraction
ranges from 20% to 90% in the case of high pressure casting operations and from 0.1%
to 70% in the case of extruding and forging operations, thereby crystallising fine
primary crystals in the alloy solution, and the alloy solution is fed into a forming
mold, where it is shaped under pressure.
[0011] According to claim 2, said alloy is an aluminum alloy of a composition within the
maximum solubility limit or a hypoeutectic aluminum alloy of a composition at or above
the maximum solubility limit.
[0012] According to claim 3, said alloy is a magnesium alloy of a composition within the
maximum solubility limit.
[0013] According to claim 4, said aluminum alloy has 0.001% - 0.01% B and 0.005% - 0.3%
Ti added thereto.
[0014] According to claim 5, said magnesium alloy has 0.005% - 0.1% Sr added thereto or
0.01% - 1.5% Si and 0.005% - 0.1% Sr added thereto or 0.05% - 0.30% Ca added thereto.
[0015] According to claim 6, in the method of claim 1 the liquid alloy that has been superheated
by a degree (X°C) of less than 10°C above the liquidus line is held in the insulated
vessel for a period from 5 seconds to 60 minutes as it is cooled to a molding temperature
where a specified liquid fraction, which ranges from 20% to 90% in the case of high
pressure casting operations and from 0.1% to 70% in the case of extruding and forging
operations, is established, such that the cooling from the initial temperature at
which said alloy is held in said insulated vessel to its liquidus temperature is completed
within a time shorter than the time Y (in minutes) calculated by the relation Y=10-X
and that the period of cooling from said initial temperature to a temperature 5°C
lower than said liquidus temperature is not longer than 15 minutes, whereby fine primary
crystals are crystallised in the alloy solution, which is then fed into a forming
mold, where it is shaped under pressure.
[0016] Claim 7 relates to the method according to claim 1, wherein the molten alloy is cooled
to a temperature at which a solid fraction appropriate for shaping, which is 10%-80%
in the case of high pressure casting operations or 30%-99,9% in the case of extruding
and forging operations, is established and wherein the step of cooling said alloy
is performed with the top and bottom portions of the vessel being heated by a greater
degree than the middle portion or heat-retained with a heat-retaining material having
a thermal conductivity of less than 1.0 kcal/hr · m · °C or with either the top or
bottom portion of the vessel being heated while the remainder is heat-retained, and
said alloy, after being cooled, is fed into a forming mold, where it is shaped under
pressure.
[0017] Claim 8 relates for an embodiment of the method according to claim 7, wherein the
step of cooling said alloy is performed with the vessel holding said alloy being accommodated
in an outer vessel that is capable of accommodating said alloy holding vessel and
that has a smaller thermal conductivity than said holding vessel, or that has a thermal
conductivity equal to or greater than that of said holding vessel and which has a
higher initial temperature than said holding vessel, or that is spaced from said holding
vessel by a gas-filled gap, at a rapid cooling rate to obtain a uniform temperature
through the alloy in said holding vessel no later than the start of the shaping steep.
[0018] Claim 9 relates to the method according to claim 1, wherein the pressure forming
is accomplished with the alloy being inserted into a container on an extruding machine.
[0019] Claim 10 relates to the method according to claim 9, wherein the extruding machine
is of either a horizontal or a vertical type or of such a horizontal type in which
the container changes position from being vertical to horizontal before shaping and
wherein the method of extrusion is either direct or indirect.
[0020] Claim 11 relates to the method according to claim 1, wherein the crystal nuclei are
generated by a method in which two or more liquid alloys having different melting
points that are held superheated to less than 50°C above the liquidus temperature
are mixed directly within the insulated vessel made of a material having a thermal
conductivity of at least 1.0 kcal/hr ·m· °C (at room temperature) such that the temperature
of the metal as mixed is either just above or below the liquidus temperature.
[0021] Claim 12 relates to the method according to claim 8, wherein the outer vessel is
heated either from inside or outside or by induction heating, with such heating being
performed only before or after the insertion of the holding vessel into the outer
vessel or continued throughout the period not only before but also after said insertion.
The process of this invention may be performed using an apparatus for managing the
temperature of a semisolid metal slurry to be used in molding equipment in which a
molten metal containing a large number of crystal nuclei is poured from a melt holding
furnace into a vessel, where it is cooled to produce a semisolid metal slurry containing
both a solid and a liquid phase in specified amounts and in which said slurry is directly
fed into a molding machine for shaping under pressure, which apparatus is further
characterized by compriseing the vessel for holding said molten metal, a vessel temperature
control section for managing the temperature of said vessel, a semisolid metal cooling
section for managing the temperature of the as-poured molten metal such that it is
cooled at an intended rate, and a vessel transport mechanism comprising basically
a robot for gripping, moving and transporting said vessel and a conveyor for carrying,
moving and transporting said vessel.
[0022] The vessel temperature control section mentioned above 20 comprises a vessel cooling
furnace for cooling the vessel in an ambient temperature not higher than a target
temperature for the vessel and a vessel heat-retaining furnace for holding the vessel
at an ambient temperature equal to said target temperature.
[0023] The semisolid metal cooling section mentioned above comprises a semisolid metal cooling
furnace and a semisolid metal annealing furnace for managing the temperature in itself
to be higher than the temperature in said semisolid metal cooling furnace.
[0024] The above mentioned semisolid metal cooling furnace in the semisolid metal cooling
section mentioned is such that the area around the vessel carried on the conveyor
device moving to pass trough said furnace is partitioned into three regions, the upper,
middle and lower parts, by means of two pairs of heat insulating plate, one pair consisting
of an upper right and an upper left plate and the other pair consisting of a lower
right and a lower left plate, with a heater being installed in both said upper and
lower parts for heating said two parts at a higher temperature than hot air to be
supplied to said central part.
[0025] A preheating furnace is installed at a stage prior to the above mentioned semisolid
metal cooling furnace to ensure that both a plinth having a lower thermal conductivity
than the vessel and which carries said vessel before it is directed to said semisolid
metal cooling furnace and a lid having a lower thermal conductivity than said vessel
and which is to be placed to cover it after it accommodate, said molten metal are
preheated by being moved to pass through said preheating furnace in advance.
[0026] According to one embodiment the semisolid metal cooling furnace is equipped with
a control unit with which the temperature or the velocity of hot air to be supplied
into said semisolid metal cooling furnace is controlled to vary with the lapse of
time.
[0027] According to one embodiment, the semisolid metal cooling furnace comprises an array
of housings each accommodating the vessel as it contains the molten metal and being
equipped with an openable cover and hot air feed/exhaust pipes, as well as a mechanism
by which a receptacle for carrying said vessel is rotated about a vertical shaft.
[0028] According to one embodiment, a vibrator for vibrating the receptacle mentioned above
is provided for each housing.
[0029] According to one embodiment, the semisolid metal cooling furnace for treating the
molten metal as poured into a vessel having a thermal conductivity of at least 1.0
kcal/hr·m·°C is supplied with hot air having a temperature in the range from 150°C
to 350°C for aluminum alloys and from 200°C to 450°C for magnesium alloys.
[0030] According to one embodiment, the semisolid metal cooling furnace for treating the
molten metal as poured into a vessel having a thermal conductivity of less than 1.0
kcal/hr·m·°C is supplied with hot air having a temperature in range from 50°C to 200°C
for aluminum alloys and from 100°C to 250°C for magnesium alloys.
[0031] According to one embodiment, the molten metal as poured into the insulated vessel
is isolated from the ambient atmosphere by closing the top surface of said vessel
with an insulating lid having a heat insulating effect as long as said molten metal
is held within said vessel until the molding temperature is reached.
[0032] According to one embodiment the alloy is specified to a hypereutectic Al-Si alloy
having 0.005% - 0.03% P added thereto or a hypereutectic Al-Si alloy containing 0.005%
- 0.03% P having either 0.005% - 0.03% Sr or 0.001% - 0.01% Na or both added thereto.
[0033] According to one embodiment the alloy in claim 1 or 2 is specified to a hypoeutectic
Al-Mg alloy containing Mg in an amount not exceeding a maximum solubility limit and
which has 0.3% - 2.5% Si added thereto.
[0034] The pressure forming may be accomplished with the alloy being inserted into a container
on an extruding machine.
[0035] According to one embodiment the extruding machine is of either a horizontal or a
vertical type or of such a horizontal type in which the container changes position
from being vertical to horizontal and the method of extrusion is either direct or
indirect.
[0036] According one embodiment, the outer vessel of claim 8 is heated either from inside
or outside or by induction heating, with such heating being performed only or before
or after the insertion of the holding vessel into the outer vessel or continued throughout
the period not only before but also after the insertion.
[0037] With these methods of the invention, liquid alloys (as exemplified by molten Al and
Mg alloys) are charged into an insulated vessel having a heat insulating effect and
held there for a period from 5 seconds to 60 minutes as they are cooled to a molding
temperature, whereby fine and spherical primary crystals are generated in the solution
and the resulting semisolid alloy is fed into a mold, where it is pressure formed
to produce a shaped part having a homogeneous microstructure.
Brief Description of the Drawings
[0038] In these drawings a part of the figures shows embodiments of a method of shaping
a semisolid metal in which - different from the present invention - a cooling jig
is used.
The process using a cooling jig is not included in the present invention.
Fig. 1 is a diagram showing a process sequence for the semisolid forming of a hypoeutectic
aluminum alloy having a composition at or above a maximum solubility limit;
Fig. 2 is a diagram showing a process sequence for the semisolid forming of a magnesium
or aluminum alloy having a composition within a maximum solubility limit;
Fig. 3 shows a process flow starting with the generation of spherical primary crystals
and ending with the molding step (not according to this invention);
Fig. 4 shows diagrammatically the metallographic structures obtained in the respective
steps shown in Fig. 3;
Fig. 5 is an equilibrium phase diagram for an Al-Si alloy as a typical aluminum alloy
system;
Fig. 6 is an equilibrium phase diagram for a Mg-Al alloy as a typical magnesium alloy
system;
Fig. 7 is a diagrammatic representation of a micrograph showing the metallographic
structure of a shaped part according to the invention;
Fig. 8 is a diagrammatic representation of a micrograph showing the metallographic
structure of a shaped part according to the prior art;
Fig. 9 is a diagram showing a process sequence for the semisolid forming of hypoeutectic
aluminum alloys having a composition at or above a maximum solubility limit according
to examples of the invention.
Fig. 10 is a diagram showing a process sequence for the semisolid forming of magnesium
or aluminum alloys having a composition within a maximum solubility limit according
to examples of the invention ;
Fig. 11 is an equilibrium phase diagram for Al-Si alloys as a typical aluminum alloy
system according to the invention (as recited in claims 11 - 13 and 18);
Fig. 12 is an equilibrium phase diagram for Mg-Al alloys as a typical magnesium alloy
system according to the invention;
Fig. 13 is a diagrammatic representation of a micrograph showing the metallographic
structure of a shaped part according to the invention
Fig. 14 is a diagrammatic representation of a micrograph showing the metallographic
structure of a shaped part according to the prior art (for comparison with the invention);
Fig. 15 is a graph showing how the holding time affects the crystal grain size of
a prior art alloy (AZ91);
Fig. 16 is a graph showing how the holding time affects the crystal grain size of
a prior art alloy (AC4CH);
Fig. 17 is a graph showing how the degree of superheating of the prior art alloy AZ91
(above the liquidus line) and the holding time (from the initial temperature within
an insulated vessel to the liquidus temperature) affect the crystal grain size of
the alloy;
Fig. 18 is a graph showing how the degree of superheating of the prior art alloy AC4H
(above the liquidus line) and the holding time (from the initial temperature within
the insulated vessel to the liquidus temperature) affect the crystal grain size of
the alloy;
Fig. 19 is a graph showing how the holding time (from the initial temperature within
the insulated vessel to the liquidus temperature minus 5°C) affects the crystal grain
size of the prior art alloy AZ91;
Fig. 20 is a graph showing how the holding time (from the initial temperature within
the insulated vessel to the liquidus temperature minus 5°C) affects the crystal grain
size of the prior art alloy AC4CH;
Fig. 21 is a side view of an apparatus for producing a semisolid forming metal;
Fig. 22 is a perspective view of a cooling jig as part of the nucleus generating section
of the apparatus shown in Fig. 21;
Fig. 23 shows in cross section two types of a cooling jig as part of the nucleus generating
section of an apparatus for producing a semisolid forming metal;
Fig. 24 is a sectional side view of a cooling jig as part of the nucleus generating
section of an apparatus for producing a semisolid forming metal;
Fig. 25 is a plan view showing the general layout of an apparatus for producing a
semisolid forming metal;
Fig. 26 is a longitudinal section A-A of Fig. 25;
Fig. 27 is a longitudinal section B-B of Fig. 25;
Fig. 28 is a longitudinal section of an insulated vessel;
Fig. 29 shows a process flow starting with the generation of spherical primary crystals
and ending with the molding step ;
Fig. 30 compares two graphs plotting the temperature changes in the metal being cooled
within a vessel
Fig. 31 illustrates four methods of managing the temperature within a vessel according
to the invention ;
Fig. 32 shows a process flow starting with the generation of spherical primary crystals
and ending with the molding step;
Fig. 33 compares the temperature profiles through two semisolid metals one being held
within a vessel according to an example of the method of the invention and the other
treated by the prior art;
Fig. 34 is a diagrammatic representation of a micrograph showing the metallographic
structure of a shaped part according to the prior art;
Fig. 35 is a diagrammatic representation of a micrograph showing the metallographic
structure of a shaped part obtained according to an example of the method of the invention
(as recited in claim 8);
Fig. 36 is a plan view showing the general layout of molding equipment (its first
embodiment) according to an example of the method of the invention
Fig. 37 is a plan view of a temperature management unit (its first embodiment) according
to an example of the method of the invention
Fig. 38 is a graph showing the specific positions of temperature measurement within
a vessel according to an example of the method of the invention
Fig. 39 is a graph showing the temperature history of cooling within the vessel according
to an example of the method of the invention ;
Fig. 40 is a graph showing the temperature history of cooling within the vessel according
to another example of the method of the invention
Fig. 41 is a graph showing the temperature history of cooling within the vessel according
to another example of the method of the invention;
Fig. 42 is a longitudinal section of a semisolid metal cooling furnace according to
another example of the method of the invention;
Fig. 43 is a plan view of a temperature management unit (its second embodiment) according
to other examples of the method of the invention;
Fig. 44 is a longitudinal section A-A of Fig. 43;
Fig. 45 shows the temperature profiles in the vessel fitted with heat insulators according
to an example of the method of the invention as compared with the temperature profile
in the absence of such heat insulators;
Fig. 46 is a plan view of a temperature management unit (its third embodiment) according
to another example of the method of the invention;
Fig. 47 shows schematically the composition of a temperature controller (its first
embodiment) for a semisolid metal cooling furnace according to an example of the method
of the invention;
Fig. 48 shows schematically the composition of a temperature controller (its second
embodiment) for a semisolid metal cooling furnace according to another example of
the method of the invention;
Fig. 49 is a longitudinal section of a vessel rotating unit according to an example
of the method of the invention;
Fig. 50 is a plan view showing the general layout of molding equipment according to
an example of the method of the invention;
Fig. 51 is a longitudinal sectional view showing in detail the position of temperature
measurement within the holding vessel in the example shown in Fig. 50;
Fig. 52 is a graph showing the temperature history of cooling within the holding vessel
in the example shown in Fig. 50;
Fig. 53 is a longitudinal section of a semisolid metal cooling furnace (equipped with
a vessel vibrator) according to the third embodiment of the method of the invention
Fig. 54 shows a process flow starting with the generation of spherical primary crystals
and ending with the molding step;
Fig. 55 is a diagram showing a process sequence for the semisolid forming of a zinc
alloy of a hypoeutectic composition ;
Fig. 56 is an equilibrium phase diagram for a binary Zn-Al alloy as a typical zinc
alloy system according to the invention
Fig. 57 is a diagrammatic representation of a micrograph showing the metallographic
structure of a shaped part according to the method of the invention
Fig. 58 is a diagrammatic representation of micrograph showing the metallographic
structure of a shaped part according to the prior art (for comparison with the method
of the invention);
Fig. 59 is a diagram showing a process sequence for the semisolid forming of a hypereutectic
Al-Si alloy according to an example of the method of the invention;
Fig. 60 shows a process flow starting with the generation of spherical primary crystals
and ending with the molding step according to the example shown in Fig. 59;
Fig. 61 shows diagrammatically the metallographic structures obtained in the respective
steps shown in Fig. 60;
Fig. 62 is an equilibrium phase diagram for a binary Al-Si alloy according to another
example of the method of the invention ;
Fig. 63 is a diagrammatic representation of a micrograph showing the metallographic
structure of a shaped part according to the method of the invention;
Fig. 64 is a diagrammatic representation of a' micrograph showing the metallographic
structure of a shaped part according to the prior art (for comparison with the method
of the invention);
Fig. 65 is an equilibrium phase diagram for a binary Al-Mg alloy according to the
method of the invention
Fig. 66 is a diagrammatic representation of a micrograph showing the metallographic
structure of a shaped part according to an example of the method of the invention;
Fig. 67 is a diagrammatic representation of a micrograph showing the metallographic
structure of a shaped part according to the prior art (for comparison with the method
of the invention;
Fig. 68 shows process flow starting with the generation of spherical primary crystals
and ending with the molding step
Fig. 69 shows two process sequences for the semisolid forming of a hypoeutectic aluminum
alloy;
Fig. 70 shows a process flow starting with the generation of spherical primary crystals
and ending with the molding step according to the example shown in Fig. 69;
Fig. 71 shows diagrammatically the metallographic structures obtained in the respective
steps shown in Fig. 70;
Fig. 72 is a diagrammatic representation of a micrograph showing the metallographic
structure of a shaped part according to the example shown in Fig. 69;
Fig. 73 is a diagrammatic representation of a micrograph showing the metallographic
structure of a shaped part according to the prior art (for comparison with the method
of the invention); and
Fig. 74 shows a process flow starting with the generation of spherical primary crystals
and ending with the molding step.
Detailed Description of the Invention
[0039] A molten aluminum alloy or magnesium alloy containing an element for promoting the
generation of crystal nuclei held superheated to less than 100°C above the liquidus
temperature is directly poured without using a cooling jig ... into an insulated vessel
having a heat insulating effected, and the alloys are held in that vessel for a period
from 5 seconds to 60 minutes as they are cooled to the molding temperature, thereby
generating fine and spheroidized primary crystals in the alloy solution and the resulting
semisolid alloy is fed into a mold, where it is pressure formed into a shaped part
having a homogeneous microstructure.
Example 1
[0040] An example of the invention will now be described in detail with reference to accompanying
Figs. 1-8, in which: Fig. 1 is a diagram showing a process sequence for the semisolid
forming of a hypoeutectic aluminum alloy having a composition at or above a maximum
solubility limit; Fig. 2 is a diagram showing a process sequence for the semisolid
forming of a magnesium or aluminum alloy having a composition within a maximum solubility
limit; Fig. 3 shows a process flow starting with the generation of spherical primary
crystals and ending with the molding step; Fig. 4 shows diagrammatically the metallographic
structures obtained in the respective steps shown in Fig. 3; Fig. 5 is an equilibrium
phase diagram for an Al-Si alloy as a typical aluminum alloy system; Fig. 6 is an
equilibrium phase diagram for a Mg-Al alloy as a typical magnesium alloy system; Fig.
7 is a diagrammatic representation of a micrograph showing the metallographic structure
of a shaped part according to the invention; and Fig. 8 is a diagrammatic representation
of a micrograph showing the metallographic structure of a shaped part according to
the prior art.
[0041] As shown in Figs. 1, 2, 5 and 6 the first step of the process according to the invention
comprises:
superheating the melt of am aluminum or magnesium alloy containing an element for
promoting the generation of crystal nuclei, holding the melt superheated to less than
100°C above the liquidus temperature.
[0042] The melt is directly poured into the insulated vessel without being cooled with a
jig. The melt is held within the insulated vessel for a period from 5 seconds to 60
minutes at a temperature not higher than the liquidus temperature but higher than
the eutectic or solidus temperature, whereby a large number of fine spherical primary
crystals are generated in the alloy, which is then shaped at a specified fraction
liquid.
[0043] The term "jig" (cooling jig) as used herein means any device that provides a cooling
action on the melt as it flows down.
[0044] The term "a specified fraction liquid" means a relative proportion of the liquid
phase which is suitable for pressure forming. In high-pressure casting operations
such as die casting and squeeze casting, the fraction liquid ranges from 20% to 90%,
preferably from 30% to 70%. If the fraction liquid is less than 30%, the formability
of the raw material is poor; above 70%, the raw material is so soft that it is not
only difficult to handle but also less likely to produce a homogeneous microstructure.
In extruding and forging operations, the fraction liquid ranges from 0.1% to 70%,
preferably from 0.1% to 50%, beyond which an inhomogeneous structure can potentially
occur.
[0045] The "insulated vessel" as used in the invention is a metallic or nonmetallic vessel,
or a metallic vessel having a surface coated with nonmetallic materials or semiconductors,
or a metallic vessel compounded of nonmetallic materials or semiconductor, which vessels
are adapted to be either heatable or coolable from either inside or outside.
[0046] According to the invention, semisolid metal forming will proceed by the following
specific procedure. In step (1) of the process shown in Figs. 3 and 4, a complete
liquid form of metal M is contained in a ladle 10. In step (2), the metal is treated
by the following method to produce an alloy having a large number of crystal nuclei
which is of a composition just below the liquidus line: the low-temperature melt of
a composition just above the melting point which contains an element to promote the
generation of a fine structure is directly poured into the insulated vessel (or a
ceramics-coated metallic vessel 30A) having a heat insulating effect. In subsequent
step (3) the alloy is held partially molten within the insulated vessel 30 (or 30A).
In the meantime, very fine, isotropic dendritic primary crystals result from the introduced
crystal nuclei [step (3)-a] and grow into spherical primary crystals as the fraction
solid increases with the decreasing temperature of the melt [steps (3)-b and (3)-c].
Metal M thus obtained at a specified fraction liquid is inserted into a die casting
injection sleeve 40 [step (3)-d] and thereafter pressure formed within a mold cavity
50a on a die casting machine to produce a shaped part [step (4)].
[0047] The semisolid metal forming process of the invention shown in Figs. 1 - 4 has obvious
differences from the conventional thixocasting and rheocasting methods. In the inventive
method, the dendritic primary crystals that have been crystallized within a temperature
range for the semisolid state are not ground into spherical grains by mechanical or
electromagnetic agitation as in the prior art but the large number of primary crystals
that have been crystallized and grown from the introduced crystal nuclei with the
decreasing temperature in the range for the semisolid state are spheroidized continuously
by the heat of the alloy itself (which may optionally be supplied with external heat
and held at a desired temperature). In addition, the semisolid metal forming method
of the invention is very convenient since it does not involve the step of partially
melting billets by reheating in the thixocasting process.
[0048] The casting, spheroidizing and molding conditions that are respectively set for the
step of generating and spheroidizing primary crystals and the forming step, are set
forth below more specifically. Also discussed below is the criticality of the numerical
limitations.
[0049] Insulated vessel 30 for holding the melt the temperature of which has dropped to
just below the liquidus line shall have a heat insulating effect in order to ensure
that the primary crystals generated will spheroidize and have the desired fraction
liquid after the passage of a specified time. The constituent material of the insulated
vessel is in no way limited and those which have a heat-retaining property and which
wet with the melt only poorly are preferred. If a gas-permeable ceramic container
is to be used as the insulated vessel 30 for holding magnesium alloys which are prone
to oxidize and burn, the exterior to the vessel is preferably filled with a specified
atmosphere (e.g. an inert or vacuum atmosphere). For preventing oxidation, it is desired
that Be or Ca is preliminarily added to the molten metal. The shape of the insulated
vessel 30 is by no means limited to a tubular form and any other shapes that are suitable
for the subsequent forming process may be adopted. The molten metal need not be poured
into the insulated vessel but it may optionally be charged directly into a ceramic
injection sleeve. If the holding time within the insulated vessel 30 is less than
5 seconds, it is not easy to attain the temperature for the desired fraction liquid
and it is also difficult to generate spherical primary crystals. If the holding time
exceeds 60 minutes, the spherical primary crystals and eutectic structure generated
are so coarse that deterioration in mechanical properties will occur. Hence, the holding
time within the insulated vessel is controlled to lie between 5 seconds and 60 minutes.
If the fraction liquid in the alloy which is about to be shaped by high-pressure casting
processes is less than 20%, the resistance to deformation during the shaping is so
high that it is not easy to produce shaped parts of good quality. If the fraction
liquid exceeds 90%, shaped parts having a homogeneous structure cannot be obtained.
Therefore, as already mentioned, the fraction liquid in the alloy to be shaped is
preferably controlled to lie between 20% and 90%. By adjusting the effective fraction
liquid to range from 30% to 70%, shaped parts having a more homogeneous structure
and higher quality can be easily obtained by pressure forming. If, in the case of
shaping Al-Si alloy systems having a near eutectic composition, it is necessary to
generate eutectic Si within the insulated vessel while reducing the fraction liquid
to 80% or below, Na or Sr may be added as an Si modifying element and this is advantageous
for refining the eutectic Si grains, thereby providing improved ductility. The means
of pressure forming are in no way limited to high-pressure casting processes typified
by squeeze casting and die casting and various other methods of pressure forming may
be adopted, such as extruding and casting operations.
[0050] In order to generate more crystal nuclei so as to produce a homogeneous structure
comprising fine spherical grains or to ensure that a semisolid alloy containing a
large number of crystal nuclei and which has a temperature not higher than the liquidus
line is produced from a melt that has been superheated to less than 100°C above the
liquidus line and which is not contacted with any jig, various elements may be added
to the melt, as exemplified by Ti and B for the case where the melt is an aluminum
alloy, and Sr, Si and Ca for the case where the melt is a magnesium alloy. If the
Ti addition is less than 0.005%, the intended refining effect is not attained; beyond
0.30%, a coarse Ti compound will form to cause deterioration in ductility. Hence,
the Ti addition is controlled to lie between 0.005% and 0.30%. Boron (B) cooperates
with Ti to promote the refining of crystal grains but its refining effect is small
if the addition is less than 0.001%; on the other hand, the effect of B is saturated
at 0.02% and no further improvement is expected beyond 0.02%. Hence, the B addition
is controlled to lie between 0.001% and 0.02%. If the Sr addition is less than 0.005%,
the intended refining effect is not attained; on the other hand, the effect of Sr
is saturated at 0.1% and no further improvement is expected beyond 0.1%. Hence, the
Sr addition is controlled to lie between 0.005% and 0.1%. If 0.01% - 1.5% of Si is
added in combination with 0.005% - 0.1% of Sr, even finer crystal grains will be formed
than when Sr is added alone. If the Ca addition is less than 0.05%, the intended refining
effect is not attained; on the other hand, the effect of Ca is saturated at 0.30%
and no further improvement is expected beyond 0.30%. Hence, the Ca addition is controlled
to lie between 0.05% and 0.30%.
[0051] To obtain fine spherical primary crystals without employing jig 20, the degree of
superheating above the liquidus line is set to be less than 100°C and this is to ensure
that the molten alloy poured into the insulated vessel 30 having a heat insulating
effect is brought to either a liquid state having crystal nuclei or a partially solid,
partially liquid state having crystal nuclei at a temperature not lower than the molding
temperature. If the melt poured into the insulated vessel 30 is unduly hot, so much
time will be taken for the temperature of the melt to decrease to establish a specified
fraction liquid that the operating efficiency becomes low. Another inconvenience is
that the poured melt M is oxidized or burnt at the surface.
[0052] Table 1 shows the conditions of various samples of semisolid metal to be shaped,
as well as the qualities of shaped parts. As shown in Fig. 3, the shaping operation
consisted of inserting the semisolid metal into an injection sleeve and subsequent
forming on a squeeze casting machine. The forming conditions were as follows: pressure,
950 kgf/cm
2; injection speed, 1.5 m/s; mold cavity dimensions, 100 x 150 x 10; mold temperature,
230°C.
[0053] With Comparative Sample 7, the jig 20 was not used; the starting alloy did not contain
any grain refiners, so the number of crystal nuclei generated was insufficient.
[0054] In each of Invention Samples 12, 17 and 18 a homogeneous microstructure comprising
fine (<150µm) spherical primary crystals was obtained to enable the production of
a shaped part having good appearance.
Example 2
[0055] An example of the invention will now be described in detail with reference to accompanying
drawings. As shown in Figs. 9 - 12, the invention is such that:
the melt of an aluminum or magnesium alloy that is held superheated to less than 100°C
above the liquidus temperature is directly poured into an insulated vessel without
using any jig, thereby generating crystal nuclei in the liquid alloy.
[0056] Subsequently, the liquid alloy having crystal nuclei that has been superheated by
a degree (X°C) of less than 10°C above the liquidus temperature is held in the insulated
vessel for a period from 5 seconds to 60 minutes as said alloy is cooled to a molding
temperature that is higher than the eutectic or solidus temperature and where a specified
fraction liquid is established, such that the cooling to the liquidus temperature
of said alloy is completed within a time shorter than the time Y (in minutes) calculated
by the relation Y=10-X and that the period of cooling from the initial temperature
at which said alloy is held in the insulated vessel to a temperature 5°C lower than
the liquidus temperature is not longer than 15 minutes, whereby fine spherical primary
crystals are crystallized in the alloy solution, which is then fed into a forming
mold, where it is shaped under pressure.
[0057] The specific procedure of semisolid metal forming to be performed in Example 2 is
essentially the same as described in Example 1.
[0058] The casting, spheroidizing and molding conditions that are respectively set for the
steps shown in Fig. 3, namely, the step of pouring the molten metal on to the ceramic
jig 20, a process step not according to this invention the step of generating and
spheroidizing primary crystals and the forming step, are set forth below more specifically.
Also discussed below is the criticality of the numerical limitations set forth in
subclaims.
[0059] If the alloy to be held within the insulated vessel 30 is superheated such that its
initial temperature is at least 10°C above the liquidus line, only unspherical primary
crystals of a size of 300µm and larger will form and fine, spherical primary crystals
cannot be obtained no matter what conditions are used to cool the alloy to the molding
temperature where a specified fraction liquid is established with a view to introducing
crystal nuclei into the melt. To avoid this problem, the initial temperature of the
alloy held within the insulated vessel 30 is controlled to be less than 10°C above
the liquidus line.
[0060] If the alloy to be held within the insulated vessel 30 is superheated such that its
initial temperature is less than 10°C above the liquidus line, the alloy must be cooled
to the liquidus temperature within a shorter time than the period calculated by the
relation Y=10-X , where Y is the time (in minutes) taken for the alloy temperature
to drop to the liquidus temperature and X is the degree of superheating (in °C). Otherwise,
unspherical primary crystals of a size of 300µm and larger will form as is the case
where the degree of superheating is 10°C or more above the liquidus line. To avoid
this problem, the alloy is cooled to the liquidus temperature within a shorter time
than the period calculated by the relation Y=10-X .
[0061] Even if the alloy is cooled from the initial temperature to the liquidus temperature
within a shorter time than the period determined by the relation Y=10-X , unspherical
primary crystals of a size of 300µm and larger will form or the size of spherical
crystals to be obtained tends to be larger than 200µm if the cooling from the initial
temperature to the temperature 5°C lower than the liquidus temperature is completed
within 15 minutes. Therefore, the period of cooling from the initial temperature to
the temperature 5°C lower than the liquidus temperature should not be longer than
15 minutes.
[0062] Figs. 15 and 16 show how the holding time affects the crystal grain sizes of AZ91
and AC4CH which respectively are typical magnesium and aluminum alloys. The "holding
time" is the time for which the metal as poured into the insulated vessel is held
until the molding temperature is reached. The "molding temperature" is a typical value
at which about 50% fraction liquid is established and it is 570°C for AZ91 and 585t
for AC4CH. Obviously, the dependency of the crystal grain size on the holding time
differs with the alloy type but in both cases the grain size tends to be greater than
200µm if the holding time exceeds 60 minutes. On the other hand, primary crystals
finer than 200µm are prone to occur in the present invention. Figs. 17 and 18 show
how the degree by which the AZ91 and AC4CH within the holding vessel are superheated
above the liquidus temperature and the holding time from the initial temperature within
the insulated vessel to the liquidus temperature will affect the crystal grain sizes
of the respective alloys.
[0063] In the area of each graph where the degree of superheating (°C) and the holding time
(min) are below the line connecting two points (10, 0) and (0, 10), fine (<200µm)
primary crystals are generated in accordance with the invention as shown diagrammatically
in Fig. 13. In the area above the line, coarse (>300µm) unspherical primary crystals
occur as shown diagrammatically in Fig. 14. Even finer and more homogeneous primary
crystals are obtained under the conditions for the holding time and the degree of
superheating that are represented by area (C) in Fig. 17 and 18 [the region bound
by points (0,6), (5,5) and (6,0) in Fig. 17 and the region bound by points (0,7),
(5,5) and (5,0) in Fig. 18]. Figs. 19 and 20 show how the holding time (from the initial
temperature within the insulated vessel to the liquidus temperature minus 5°C) affects
the crystal grain sizes of AZ91 and AC4CH, respectively. Obviously, the crystal grain
size increases with the holding time and if the latter exceeds 15 minutes, there is
a marked tendency for the crystal grain size to exceed 200µm and coarse unspherical
primary crystals occur. In the present invention where the holding time is less than
15 minutes, there is a marked tendency for the primary crystals to be generated in
small sizes less than 200µ m.
Example 3
[0064] An example of the invention will now be described with reference to accompanying
Figs. 1, 2, 4 - 8 and 29 - 31, in which: Fig. 1 is a diagram showing a process sequence
for the semisolid forming of a hypoeutectic aluminum alloy having a composition at
or above a maximum solubility limit; Fig. 2 is a diagram showing a process sequence
for the semisolid forming of a magnesium or aluminum alloy having a composition within
a maximum solubility limite; Fig. 29 shows a process flow starting with the generation
of spherical primary crystals and ending with the molding step; Fig. 4 shows diagrammatically
the metallographic structures obtained in the respective steps shown in Fig. 29; Fig.
30 compares two graphs plotting the temperature changes in the metal being cooled
within a vessel during step 3 shown in Fig. 29; Fig. 31 illustrates four methods of
managing the temperature within a vessel according to the invention; Fig. 5 is an
equilibrium phase diagram for an Al-Si alloy as a typical aluminum alloy system; Fig.
6 is an equilibrium phase diagram for a Mg-Al alloy as a typical magnesium alloy system;
Fig. 7 is a diagrammatic representation of a micrograph showing the metallographic
structure of a shaped part according to the invention; and Fig. 8 is a diagrammatic
representation of a micrograph showing the metallographic structure of a shaped part
according to the prior art.
[0065] As shown in Figs 1, 2, 5 and 6, the invention is such that:
the melt of an aluminum or magnesium alloy that is held superheated to less than 100°C
above the liquidus temperature as it contains an element to promote the generation
of crystal nuclei is directly poured into the vessel 30 without using the jig 20.
The vessel 30 of a specified wall thickness is adapted to be heatable or coolable
from either inside or outside, is made of a material having a thermal conductivity
of at least 1.0 kcal/hr·m·°C (at room temperature) and is held at a temperature not
higher than the liquidus temperature of said alloy prior to its pouring, and the melt
is subsequently cooled to a temperature at which a fraction solid appropriate for
shaping is established, such that while the alloy is poured into the vessel 30, its
top and bottom portions are heated by a greater degree than the middle portion or
that the top or bottom portion is heat-retained with a heat-retaining material having
a thermal conductivity of less than 1.0 kcal/hr·m·°C or that the top portion of the
vessel is heated by a greater degree than the middle portion while the bottom portion
is heat-retained or that the top portion is heat-retained while the bottom portion
is heated by a greater degree than the middle portion, whereby nondendritic fine primary
crystals are crystallized in the alloy solution while, at the same time, the alloy
is cooled at a sufficiently rapid rate to provide a uniform temperature profile through
the alloy in the vessel 30, with the cooled alloy being subsequently supplied into
a forming mold 50, where it is pressure formed to a shape.
[0066] Four methods of managing the temperature of the vessel 30 and that of the alloy within
the vessel 30 are collectively shown in Fig. 31, wherein (a) -(d) correspond to the
methods of temperature management.
[0067] The wall thickness of the vessel 30 is desirably such that after pouring of the molten
metal, no dendritic primary crystals will result from the metal in contact with the
inner surface of the' vessel and yet no solidified layer will remain in the vessel
at the stage where the semisolid metal has been discharged from within the vessel
just before shaping. The exact value of the wall thickness of the vessel is appropriately
determined in consideration of the alloy type and the weight of the alloy in the vessel
30.
[0068] The term "fraction solid appropriate for shaping" means a relative proportion of
the solid phase which is suitable for pressure forming. In high-pressure casting operations
such as die casting and squeeze casting, the fraction solid ranges from 10% to 80%,
preferably from 30% to 70%. If the fraction solid is more than 70%, the formability
of the raw material is poor; below 30%, the raw material is so soft that it is not
only difficult to handle but also less likely to produce a homogeneous structure.
In extruding and forging operations, the fraction solid ranges from 30% to 99.9%,
preferably from 50% to 99.9%; if the fraction solid is less than 50%, an inhomogeneous
structure can potentially occur.
[0069] The "temperature not higher than the liquidus temperature" means such a temperature
that even if the temperature of the metal within the vessel is rapidly lowered to
the level equal to the molding temperature, no dendritic primary crystals will result
from the melt in contact with the inner surface of the vessel and yet no solidified
layer will remain in the vessel at the stage where the semisolid metal is discharged
from within the vessel just before shaping. The exact value of the "temperature not
higher than the liquidus temperature" varies with the alloy type and the weight of
the alloy within the vessel.
[0070] The "vessel" as used in the invention is a metallic or nonmetallic vessel, or a metallic
vessel having a surface coated with nonmetallic materials or semiconductors, or a
metallic vessel compounded of nonmetallic materials or semiconductors. Coating the
surface of the metallic vessel with a nonmetallic material is effective in preventing
the sticking of the metal. To heat the vessel, its interior or exterior may be heated
with an electric heater; alternatively, induction heating with high-frequency waves
may be employed if the vessel is electrically conductive.
[0071] The specific procedure of semisolid metal forming to be performed in Example 3 is
essentially the same as described in Example 1.
[0072] Vessel 30 is used to hold the molten metal until it is cooled to a specified fraction
solid after its temperature has dropped just below the liquidus line. If the thermal
conductivity of the vessel 30 is less than 1.0 kcal/hr·m·°C at room temperature, it
has such a good heat insulating effect that an unduly prolonged time will be required
for the molten metal M in the vessel 30 to be cooled to the temperature where a specified
fraction solid is established, thereby reducing the operational efficiency. In addition,
the generated spherical primary crystals become coarse to deteriorate the formability
of the alloy. It should, however, be mentioned that if the vessel contains a comparatively
small quantity of the melt, the holding time necessary to achieve the intended cooling
becomes short even if the thermal conductivity of the vessel is less than 1.0 kcal/hr·m·°C
at room temperature. If the temperature of the vessel 30 is higher than the liquidus
temperature, the molten metal M as poured into the vessel is higher than the liquidus
temperature, so that only a few crystal nuclei will remain in the liquid phase to
produce large primary crystals. If the top and bottom portions of the vessel are neither
heated nor heat-retained as the molten metal M is cooled until the fraction solid
in the metal reaches the value appropriate for shaping, dendritic primary crystals
may occur at the site in the top or bottom portion of the vessel that is contacted
by the metal M or a solidified layer will grow at that site, thereby creating a nonuniform
temperature profile through the metal in the vessel which makes the subsequent shaping
operation difficult to accomplish on account of the remaining solidified layer within
the vessel. To avoid these difficulties, it is preferred to heat the top or bottom
portion of the vessel by a greater degree than the middle portion while the bottom
or top portion is heat-retained during the cooling process after the pouring of the
metal; if necessary, the top or bottom portion of the vessel may be heated not only
during the cooling process following the pouring of the metal but also prior to its
pouring and this is another preferred practice in the invention.
[0073] The constituent material of the vessel 30 is in no way limited except on the thermal
conductivity and those which are poorly wettable with the molten metal are preferred.
[0074] Table 2 shows the conditions of various samples of semisolid metal to be shaped,
as well as the qualities of shaped parts. As shown in Fig. 29, the shaping operation
consisted of inserting the semisolid metal into an injection sleeve and subsequent
forming on a squeeze casting machine. The forming conditions were as follows: pressure,
950 kgf/cm
2; injection speed, 1.0 m/s; casting weight (including biscuits), 30 kg; mold temperature,
230°C.
[0075] In Comparative Sample 1, the thermal conductivity of the holding vessel was small
and, in addition, the vessel was heated or heat-retained inappropriately after the
pouring of the metal so that the holding time to the shaping temperature was unduly
long; what is more, the formation of a solidified layer within the vessel prevented
the discharge of the semisolid metal, thus making it impossible to perform shaping.
In Comparative Sample 2, the thermal conductivity of the holding vessel was so small
that the holding time to the shaping temperature was unduly prolonged. In Comparative
Sample 3, the holding vessel was heated or heat-retained inappropriately after the
pouring of the metal so that a solidified layer formed within the vessel to prevent
the discharge of the semisolid metal; thus making it impossible to start the shaping
step. In Comparative Sample 4, the wall thickness of the holding vessel was unduly
great and, in addition, the vessel was heated or heat-retained inappropriately after
the pouring of the metal so that unspherical primary crystals were generated; what
is more, the formation of a solidified layer within the vessel prevented the discharge
of the semisolid metal, thus making it impossible to perform shaping. In Comparative
Sample 5, the casting temperature was so high that very few crystal nuclei remained
within the vessel to yield only coarse unspherical primary crystals as shown in Fig.
8. In Comparative Sample 6, the cooling jig had such a high temperature that the number
of crystal nuclei formed was insufficient to produce fine spherical primary crystals
and, instead, only coarse unspherical primary grains formed as in Comparative Sample
5. In Comparative Sample 7, the fraction solid in the metal was so small that many
segregations occurred within the shaped part.
[0076] In Invention Sample 13 , the metal in the vessel 30 was rapidly cooled with its temperature
profile being maintained sufficiently uniform that semisolid metal having nondendritic
fine primary crystals was produced in a convenient and easy way. Such alloy was then
fed into a forming mold and pressure formed to produce shaped parts of a homogeneous
structure having fine (<200µm) spherical primary crystals.
Example 4
[0077] An example of the invention (as recited in claim 8 ) will now be described with reference
to the accompanying Figs. 4, 9, 10 and 32 - 35, in which: Fig. 9 is a diagram showing
a process sequence for the semisolid forming of hypoeutectic aluminum alloys having
a composition at or above a maximum solubility limit; Fig. 10 is a diagram showing
a process sequence for the semisolid forming of magnesium or aluminum alloys having
a composition within a maximum solubility limit; Fig. 32 shows a process flow starting
with the generation of spherical primary crystals and ending with the molding step;
Fig. 4 shows diagrammatically the metallographic structures obtained in the respective
steps shown in Fig. 32; Fig. 33 compares the temperature profiles through two semisolid
metals, one being held within a vessel in step (3) shown in Fig. 32 and the other
being treated by the prior art without using any outer vessel; Fig. 34 is a diagrammatic
representation of a micrograph showing the metallographic structure of a shaped part
according to the prior art; and Fig. 35 is a diagrammatic representation of a micrograph
showing the metallographic structure of a shaped part according to the invention.
[0078] According to the invention, semisolid metal forming will proceed by the following
specific procedure. In step (1) of the process shown n Figs. 32 and 4, a complete
liquid form of metal M is contained in a ladle 10. In step (2), the low-temperature
melt which contains an element that is added to promote the generation of crystal
nucleit is directly poured into the holding vessel 29 which is preliminarily maintained
at a temperature not higher than the liquidus temperature.
[0079] In subsequent step (3), the holding vessel 29 is accommodated within the outer vessel
31 lined with a heat insulator 33 on the bottom and then fitted with a lid. Thereafter,
the alloy in the holding vessel is held in a semisolid condition with its temperature
being lowered, whereby fine particulate (nondendritic) primary crystals are generated
from the introduced crystal nuclei. In order to ensure that the temperature in the
holding vessel 29 is lowered under the temperature conditions specified in Figs. 9
and 10, the outer vessel 31 is temperature managed such as by internal or external
heating or by induction heating, with the heating being performed only before or after
the insertion of the holding vessel 29 or for a continued period starting prior to
the insertion of the holding vessel and ending after its insertion.
[0080] The "holding vessel" as used in the invention is a metallic or nonmetallic vessel,
or a metallic vessel having a surface coated with nonmetallic materials or semiconductors,
or a metallic vessel compounded of nonmetallic materials or semiconductors. Coating
the surface of the metallic vessel with a nonmetallic material is.effective in preventing
the sticking of the metal.
[0081] The "outer vessel" as used in the invention serves to ensure that the alloy in the
holding vessel will be cooled within a specified time. To this end, the outer vessel,
must have the ability to cool the holding vessel 29 rapidly in addition to a capability
for heat-retaining or heating said vessel. To meet this requirement, the temperature
of the outer vessel 31 should be lowered to the level equal to the molding temperature
within a specified time.
[0082] In order to provide a more uniform temperature profile through the alloy within the
holding vessel 29, the outer vessel 31 may be provided with a temperature profile
by,for example, heating the top and bottom portions of the outer vessel 31 in a high-frequency
heating furnace by a greater degree than the middle portion. In the case where the
outer vessel 31 starts to be heated before the holding vessel 29 is inserted and continues
to be heated until after its insertion, the heating of the outer vessel 31 may be
interrupted temporarily if it is necessary for adjusting the temperature of the alloy
within the holding vessel 29.
[0083] The inside diameter of the outer vessel 31 is made sufficiently larger than the outside
diameter of the holding vessel 29 to provide a clearance between the outer vessel
31 and the holding vessel 29 accommodated in it. To insure the clearance, a plurality
of projections are provided along the outer circumference of the holding vessel 29
and/or the inner circumference of the outer vessel 31. Alternatively, the clearance
may be insured by replacing the projections with recesses formed in either the outer
circumference of the holding vessel or the inner circumference of the outer vessel.
[0084] The gap between the holding vessel 29 and the outer vessel 31 is typically filled
with air but various other gases may be substituted such as inert gases, carbon dioxide
and SF
6.
[0085] Metal M thus obtained at a specified fraction solid is inserted into a die casting
injection sleeve 70 and thereafter pressure formed within a mold cavity 50a on a die
casting machine to produce a shaped part.
[0086] The casting, spheroidizing and molding conditions that are respectively set for the
steps shown in (see Fig. 9), namely, the step of pouring the molten metal on to the
cooling jig, the step of generating and spheroidizing primary crystals and the forming
step, are set forth below more specifically. Also discussed below is the criticality
of the numerical limitations set forth in claim 8.
[0087] The holding vessel 29 is used to hold the molten metal until it is cooled to a specified
fraction solid after its temperature has dropped just below the liquidus line. If
the thermal conductivity of the vessel 29 is less than 1.0 kcal/hr·m·°C (at room temperature),
it has such a good heat insulating effect that an unduly prolonged time is required
for the molten metal M in the holding vessel 29 to be cooled to the temperature where
a specified fraction solid is established, thereby reducing the operational efficiency.
In addition, the generated spherical primary crystals become coarse to deteriorate
the formability of the alloy.
[0088] It should, however, be mentioned that if the holding vessel contains a comparatively
small quantity of the melt, the holding time necessary to achieve the intended cooling
becomes short even if the thermal conductivity of the vessel is less than 1.0 kcal/hr·m·°C
at room temperature. If the temperature of the holding vessel 29 is higher than the
liquidus temperature, the molten metal M as poured into the vessel is higher than
the liquidus line, so that only a few crystal nuclei will remain in the liquid phase
to produce large primary crystals. In order to endure a more uniform temperature profile
through the alloy within the holding vessel 29 by means of the outer vessel 31 while
the molten metal M is cooled to a temperature where the fraction solid appropriate
for shaping is established, either one of the following conditions should be satisfies:
the top of the holding vessel 29 should be fitted with a lid; an adequate clearance
should be provided between the holding vessel 29 and the outer vessel 31; a heat insulator
should be provided in the area where the bottom of the holding vessel 29 contacts
the outer vessel 31; or projections or recesses should be provided on either the holding
vessel 29 or the outer vessel 31.
[0089] In the example under discussion, the crystal nuclei were generated by the method
of the invention recited in claims 2, 9 and 10.
[0090] Table 3 shows the conditions of the holding vessel, the alloy within the holding
vessel, and the outer vessel, as well as the qualities of shaped parts. As shown in
Fig. 32, the shaping operation consisted of inserting the semisolid metal into an
injection sleeve and subsequent forming on a squeeze casting machine. The forming
conditions were as follows: pressure, 950 kgf/cm
2; injection speed; 1.0m/s; casting weight (including biscuits), 2 kg; mold temperatures,
250°C.
[0091] With Comparative Samples 10 and 11 which did not use the outer vessel, the temperature
of the alloy within the holding vessel dropped so rapidly that fine primary crystals
formed but, on the other hand, the temperature profile through the semisolid alloy
in the holding vessel was poor as shown in the graph on left side of Fig. 33. With
Comparative Sample 12, the semisolid metal holding time within the holding vessel
was sufficiently long to provide a good temperature profile through the metal in the
holding vessel but, on the other hand, unduly large primary crystals formed. With
Comparative Sample 13, the casting temperature was so high that the alloy as poured
into the holding vessel acquired a sufficiently high temperature to either substantially
preclude the generation of crystal nuclei or cause rapid disappearance of crystal
nuclei, thereby yielding unduly large primary crystals. With Comparative Sample 14,
the fraction liquid in the semisolid metal was high whereas the holding time was short,
thereby providing only a poor temperature profile through the semisolid alloy within
the holding vessel.
[0092] In Invention Samples 1 - 9, the metal in the vessel was rapidly cooled with its temperature
profile being maintained sufficiently uniform that semisolid metals having nondendritic
fine primary crystals were produced in a convenient and easy way. Such alloys were
then fed into a mold and pressure formed to produce shaped parts of a homogeneous
structure having fine (<200µm) spherical primary crystals.
Example 5
[0093] Examples of the invention will now be described in detail with reference to accompanying
drawings 36 - 49 and 53, in which: Fig.36 is a plan view showing the general layout
of molding equipment (its first embodiment) according to an example of the invention;
Fig.37 is a plan view of a temperature management unit (its first embodiment) according
to the example of the invention; Fig. 38 is a graph showing the specific positions
of temperature measurement within a vessel according to an example of the invention;
Figs. 39, 40 and 41 are graphs showing the temperature history of cooling within the
vessel under different conditions; Fig. 42 is a longitudinal section of a semisolid
metal cooling furnace according to another example of the invention; Fig. 43 is a
plan view of a temperature management unit (its second embodiment) according to yet
another example of the invention;Fig.44 is a longitudinal section A - A of Fig.43;
Fig.45 shows the temperature profiles in the vessel fitted with heat insulators according
to an example of the invention; Fig. 46 is a plan view of a temperature management
unit (its third embodiment) according to another example of the invention; Fig. 47
shows schematically the composition of a temperature controller for a semisolid metal
cooling furnace (its first embodiment) according to an example of the invention; Fig.
48 shows schematically the composition of a temperature controller (its second embodiment)
for a semisolid metal cooling furnace according to another example of the invention;Fig.49
is a longitudinal section of a vessel rotating unit according to an example of the
invention; and Fig. 53 is a longitudinal section of a semisolid metal cooling furnace
as it is equipped with a vessel vibrator according to another example of the invention.
[0094] As Fig.36 shows, the molding equipment generally indicated by 300 consists of a melt
holding furnace 14 for feeding the molten metal as a molding material (containing
a large number of crystal nuclei), a molding machine 200, and a temperature management
unit 104 for managing the temperature of the melt until it is fed to the molding machine
200. The molten metal held within the furnace 14 contains a large number of crystal
nuclei.
[0095] As also shown in Fig.36, the temperature management unit 104 consists of a semisolid
metal cooling section 110 and a vessel temperature control section 140; the semisolid
metal cooling section 110 is composed of a semisolid metal cooling furnace 120 and
a semisolid metal slowly cooling furnace 130 which are connected in a generally rectangular
arrangement by means of a transport mechanism such as a conveyor 170 whereas the vessel
temperature control section 140 is composed of a vessel cooling furnace 150 and a
vessel heat-retaining furnace 160. The temperature management unit 104 is also equipped
with a robot 180 which grips the vessel 102 and transports it to one of the specified
positions A - F (to be described below).
[0096] The temperature management unit 104 is operated as follows. An empty vessel 102 is
first located in the heating vessel pickup position A. The robot 180 then transfers
the vessel 102 to the position B, where the vessel is charged with a prescribed amount
of the molten metal from the melt holding furnace 14. Thereafter, the robot 180 transports
the vessel 102 to the filled vessel rest position C; subsequently, the vessel is cooled
as it is carried by the conveyor 170 to pass through the semisolid metal cooling furnace
120 in a specified period of time. The vessel 102 leaving the furnace 120 reaches
the slurry vessel rest position D, from which it is immediately transferred to the
sleeve position E by the robot 180 if the injection sleeve 202 in the molding machine
200 is ready to accept the molten metal; at position E, the slurry ofsemisolid metal
in the vessel is poured into the injection sleeve 202. If the injection sleeve 202
is not ready to acceptthe molten metal when the vessel 102 has reached the slurry
vessel rest position D (i. e., if the molding machine is operating to perform pressure
forming), the slurry of semisolid metal within the vessel will progressively solidify
upon cooling while it is waiting for acceptance in the position D, thereby making
it impossible for all the slurry to be discharged from the vessel or the crystal nuclei
in the slurry will disappear to cause deterioration in the quality of the shaped part.
In order to avoid these problems, the vessel 102 is forwarded to the semisolid metal
slowly cooling furnace 130,where it waits for the molding machine 200 to become completely
ready for the acceptance of the molten metal while ensuring against its rapid cooling.
[0097] The vessel 102 from which the slurry of semisolid metal having satisfactory properties
has been emptied into the injection sleeve 202 is then transferred to the empty vessel
rest position F by means of the robot 180, carried by the conveyor 170 into the vessel
cooling furnace 150, where it is cooled for a specified time, passed through the vessel
heat-retaining furnace 160 as it is held at a suitable temperature, and is thereafter
returned to the heating vessel pick up position A.
[0098] A specific embodiment of the temperature management unit 104 is shown in Fig.37.
In this first embodiment, aluminum alloys are to be treated at a comparatively small
scale with the molten metal being poured in an amount of no more than 10 kg; the system
configuration is such that the molding cycle on the molding machine 200 is about 75
seconds and the time of passage through the semisolid metal cooling furnace 120 and
the vessel temperature controller 140 (i. e., consisting of the vessel cooling furnace
150 and the vessel heat-retaining furnace 160) is 600 seconds in total. If the total
passage time is longer than 600 seconds, the overall equipment becomes impractically
bulky and the volume of the slurry in process which results from machine troubles
and which has to be discarded is increased and these are by no means preferred or
the purpose of constructing commercial production facilities. Considering these points
and in order to achieve consistent temperature management for a small quantity of
slurry having good properties, the vessel 102 is made of an Al
2O
3 · SiO
2 composite having a small thermal conductivity (0.3 kcal/hr·m·°C). As a result, a
slurry of semisolid metal having satisfactory properties can be obtained if only the
temperature of the vessel 102 is retained by circulation of hot air the temperature
of which is set at a constant value of 120°C.
[0099] The system shown in Fig.37 has the following differences from the system of Fig.36.
Since the vessel 102 is made of the Al
2O3 · SiO
2 composite, it has a sufficiently small thermal conductivity that one only need supply
the interior of the semisolid metal cooling furnace 120 (which is set at a temperature
of 200°C) with a circulating hot air flow of a constant temperature from a hot air
generating furnace 122. In addition, one only need equip the semisolid metal slowly
cooling furnace 130 (which is set at a temperature of 550 °C) and the vessel heat-retaining
furnace 160 (which is set at a temperature of 100°C) with heaters 132 and 162, respectively.With
these provisions, the temperature in the vessel 102 can be managed correctly to ensure
that slurries of semisolid metal having satisfactory properties can be produced in
a short time while assuring farily consistent temperature management. The temperature
in the vessel is optimally at 70°C; to ensure that the temperature in the vessel is
consistently managed at the optimal 70°C, adequate heat removal must be effected in
the vessel cooling furnace 150; otherwise, the temperature in the vessel 102 becomes
undesirably high. To deal with this problem, the vessel cooling furnace 150 is fitted
with a blower 152 and a blow nozzle 152a such that a fast air flow is blown at room
temperature to achieve forced cooling.
[0100] For system assessment on the management of the temperature in the vessel 102, a sheathed
thermocouple was set up in the vessel and temperature data were taken under various
conditions. Fig. 38 shows five different positions (A) - (E) of temperature measurement
in the vessel 102, into which the 1.0- mm thick sheathed thermocouple was inserted.
[0101] Fig.39 shows the temperature history of cooling under condition I, i. e., the vessel
temperature control section 140 was not divided into the vessel cooling furnace 150
and the vessel heat-retaining furnace 160 and a hot air flow having the target temperature
of 70°C was circulated within the monolithic vessel temperature control section 140
at a velocity of about 5 m/sec. With this approach, the temperature in the vessel
dropped to only about 200 °C which was far from the target value.
[0102] Fig.40 shows the temperature history of cooling under condition II, i. e., a hot
air flow having a temperature of 70°C was circulated at a higher velocity of about
30 m/sec. This approach was effective in further reducing the temperature in the vessel
but not to the desired level of 70°C.
[0103] Fig.41 shows the temperature history of cooling under condition III, i. e., the vessel
temperature control section 140 was divided into the vessel cooling furnace 150 and
the vessel heat-retaining furnace 160, with an air flow at ordinary temperature being
circulated within the cooling furnace 150 at a velocity of 30 m/sec whereas the atmosphere
in the vessel heat-retaining furnace 160 had its temperature raised to 70°C by means
of an electric heater. It was only with this system that the temperature in the vessel
could be managed to be stable at the intended 70°C.
[0104] If, in the case of treating aluminum alloys at a large scale, the vessel 102 is made
of ceramics having thermal conductivities of no more than 1 kcal/m·hr·°C, the time
to cool the slurry of semisolid metal becomes impractically long. Therefore, in the
second embodiment of the temperature management unit 104 which is adapted for handling
comparatively large volumes of aluminum alloys such that the molten alloy is poured
in an amount of 20 kg or more, the vessel 102 is made of SUS304 (see Fig.43) rather
than the ceramics which are used with the first embodiment shown in Fig.37 and which
require a prolonged cooling time. The resulting differences between the first embodiment
of the temperature management unit 104 (Fig.37) and the second embodiment are as follows.
[0105] In order to ensure smooth recovery of the slurry from the vessel 102, its inner surfaces
have to be coated with a water-soluble (which is desirable for ensuring against gas
evolution) spray of a lubricant and, to this end, a spray position (spray equipment)
is provided between the vessel cooling furnace 150 and the vessel heat-retaining furnace
160. Accordingly, the vessel 102 emerging from the vessel cooling furnace 150 must
be kept at a sufficient temperature (200 °C) to allow for the deposition of the spray
solution; to meet this requirement, hot air at 200°C is applied against the vessel
through a blow nozzle. As the result of the application of the water-soluble spray,
the vessel 102 experiences a local temperature drop. In order to ensure that the vessel
102 has a uniform temperature of 200 °C throughout, a hot air flow at 200 °C is circulated
within the vessel heat-retaining furnace 160 while it is agitated by a rotating fan
to ensure uniformity in the temperature of the vessel 102.
[0106] The vessel 102 which is made of SUS304 allows thermal diffusion through it, so even
if the semisolid metal cooling furnace 120 is of the design shown in Fig.42, no sharp
border line can be drawn between the high-temperature range of the vessel (consisting
of its top and bottom portions) and the low-temperature range (the middle portion
of the vessel). To deal with this problem, a preheating furnace 190 is provided as
accessory equipment on a lateral side of the semisolid metal cooling furnace 120 and,
as shown in Fig.44, a lid 102a made of a ceramic material (Al
2O
3 · SiO
2 composite) and a plinth 102b are used to heat-retain the top and bottom of the vessel
102 while it is heated in the preheating furnace 190 before it is charged into the
semisolid metal cooling furnace 120.
[0107] The interior of the semisolid metal cooling furnace 120 is supplied with hot air
from the hot air generating furnace via two sets of blow nozzles 124, one being in
the upper position and the other in the lower position. The supplied hot air is circulated
within the cooling furnace 120 with its temperatureand velocity being 220°C and 5
m/sec at the entrance and 180 C and 20 m/sec at the exit, whereby the semisolid metal
is cooled comparatively slowly in the initial cooling period but cooled rapidly in
the latter period.
[0108] Thus, the present invention provides a method of temperature management in which
the step of managing the temperature in the vessel 102 at an appropriate level before
it is supplied with the molten metal is distinctly separated from the step of managing
the temperature in the vessel 102 in such a way that the as poured molten metal can
be cooled at a desired appropriate rate; the invention also provides the apparatus
for temperature management 104 which is capable of automatic performance of these
steps in an efficient and continuous manner. Also proposed by the invention is a system
configuration that implements the respective steps by means of the vessel temperature
control section 140 and the semisolid metal cooling section 110.
[0109] In a specific embodiment, the vessel temperature control section 140 is composed
of the vessel cooling furnace 150 capable of forced cooling with a circulating hot
air flow that provides an appropriate cooling capacity by controlling the temperature
and velocity of the air passing through the furnace and the vessel heat-retaining
furnace 160 which controls the temperature of the atmosphere to lie at the target
value in the vessel 102 and which maintains the vessel 102 at said temperature of
the atmosphere. It should be noted here that the temperature to which the vessel cooling
furnace 150 and the vessel heat-retaining furnace 160 should be controlled differs
between aluminum and magnesium alloys. In the case of aluminum alloys, the interior
of the vessel cooling furnace 150 is controlled to lie between room temperature and
300 °C whereas the interior of the vessel heat-retaining furnace 160 is controlled
to lie between 50 °C and 350 °C; in the case of magnesium alloys, the interior of
the vessel cooling furnace 150 is controlled to lie between room temperature and 350°C
whereas the interior of the vessel heat-retaining furnace 160 is controlled to lie
between 200 °C and 450 °C.
[0110] The semisolid metal cooling section 110 is composed of the semisolid metal cooling
furnace 120 which is adapted to circulate hot air at an appropriate temperature such
as to accomplish cooling within the shortest possible time that produces the slurry
of semisolid metal with satisfactory properties and the semisolid metal slowly cooling
furnace 130 which is designed to maintain the slurry of semisolid metal for 2 - 5
minutes in a temperature range appropriate for shaping such as to be adaptive for
the specific molding cycle on the molding machine 200. Again, the temperature to which
the semisolid metal cooling furnace 120 should be controlled differs between aluminum
and magnesium alloys. In the case of aluminum alloys, the temperature should be controlled
to lie between 150 °C and 350 °C and in the case of magnesium alloys, the temperature
should be controlled to lie between 200 °C and 450 °C. On the other hand, the interior
of the semisolid metal slowly cooling furnace 130 should be controlled to be at 500
°C and above in both cases.
[0111] If the injection sleeve 202 on the molding machine 200 is ready to accept the molten
metal just at time when the vessel 102 holding the metal has left the semisolid metal
cooling furnace 120, the metal is immediately fed (poured) into the molding machine
200 without being directed into the semisolid metal slowly cooling furnace 130. Conversely,
if the injection sleeve 202 is not ready to accept the molten metal since the molding
machine 200 is operating, the vessel 102 leaving the semisolid metal cooling furnace
120 is transferred to the semisolid metal slowly cooling furnace 130.
[0112] As shown in Figs.37 and 42, the semisolid metal cooling furnace 120 has the vessel
102 carried on the conveyor 170 via a heat insulating plate 120c and the inner surfaces
on the sidewall of the furnace 120 is partitioned by an upper and a lower heat insulating
plate 120b in the middle portion of its height, with hot air (set at an appropriate
temperature of 120°C) being circulated through the partitioned area to establish a
low-temperature region; at the same time, the inner surfaces of both top and bottom
portions of the furnace 120 are heated with electric heaters 120a (set at a temperature
of 500°C) to establish a high-temperature (ca. 500 °C) region, thereby ensuring that
a uniform temperature is provided throughout the molten metal in the vessel 102.
[0113] A first version of the heating system in the semisolid metal cooling furnace 120
according to the invention is such that either the temperature or the velocity of
the circulating hot air is controlled to vary appropriately with the lapse of time
or, alternatively, both the temperature and the velocity of the hot air are controlled
to vary simultaneously with the lapse of time.
[0114] The first specific embodiment of the heating system is as shown in Fig.47 and comprises
a hot air line for supplying a hot air flow into the semisolid metal cooling furnace
120, an air line from which an air flow at ordinary temperature emerges to combine
with the hot air to lower its temperature, a damper for controlling the quantity of
the air flowing through the air line, and a damper opening controller.
[0115] The second specific embodiment of the heating system is as shown in Fig.48 and comprises
a temperature sensor installed within the semisolid metal cooling furnace 120, a hot
air line for supplying a hot air flow into the furnace, an air line that combines
with the hot air line, an automatic damper installed on the air line, and a damper
opening controller that performs feed back control on the damper opening on the basis
of the data obtained by measurement with the temperature sensor. The opening of the
automatic damper is controlled on the basis of the data for the temperature in the
furnace and the hot air is mixed with an appropriate amount of air and fed into the
furnace, whereby the temperature and the velocity of the circulating hot air are controlled
such that the molten metal will be cooled at a desired rate.
Example 6
[0116] An example of the invention will now be described specifically with reference to
accompanying Figs. 43 - 53, in which: Fig.50 is a plan view showing the general layout
of molding equipment; Fig. 43 is a plan view of the temperature management unit (its
first embodiment); Fig.51 is a longitudinal sectional view showing in detail the position
of temperature measurement within the holding vessel; Fig. 52 is a graph showing the
temperature history of cooling within the holding vessel; Fig.44 is a longitudinal
section A - A of Fig.43; Fig.46 is a plan view of the temperature management unit
(its second embodiment) according to another example of the invention; Fig. 45 shows
the temperature profiles in the vessel fitted with heat insulators as compared with
the temperature profile in the absence of such heat insulators; Fig.47 shows schematically
the composition of the temperature control unit (its first embodiment) for a semisolid
metal cooling furnace; Fig.48 shows schematically the composition of the temperature
control unit (its second embodiment) for a semisolid metal cooling furnace according
to another example of the invention; Fig.49 is a longitudinal section of the semisolid
metal cooling furnace according to the second embodiment in which it is equipped with
a vessel rotating mechanism; and Fig.53 is a longitudinal section of the semisolid
metal cooling furnace according to the third embodiment in which it is equipped with
a vessel vibrating mechanism.
[0117] As shown in Fig.50, the molding equipment generally indicated by 104 consists of
a melt holding furnace 10 for feeding the molten metal as a molding material, a molding
machine 200 and a temperature management unit 100 for managing the temperature of
the melt until it is fed to the molding machine 200.
[0118] As also shown in Fig.50, the temperature management unit generally indicated by 104
consists of a semisolid metal cooling section 110 and a vessel temperature control
section 140; the semisolid metal cooling section 110 is composed of a semisolid metal
cooling furnace 120 and a semisolid metal slowly cooling furnace 130 which are connected
in a generally rectangular arrangement by means of a transport mechanism such as a
conveyor 170 whereas the vessel temperature control section 140 is composed of a vessel
cooling furnace 150 and a vessel heat-retaining vessel 160. The temperature management
unit 100 is also equipped with a robot 180 which grips the vessel 102 and transports
it to one of the specified positions A F (to be described below). The vessel 102 moves
in the direction of arrows.
[0119] In the first embodiment of the temperature management unit 104, the preheating furnace
190 is provided near and parallel to the semisolid metal cooling furnace as shown
in Figs.43 and 44. The purpose of the preheating furnace 190 is to ensure that both
the plinth 102b placed under the melt containing vessel 102 and the lid 102a placed
on top of the vessel 102 are preliminarily heated to a higher temperature than the
hot air to be passed through the semisolid metal cooling furnace 120 such that uniformity
will be assured for the temperature of the melt within the vessel as it is cooled
in the semisolid metal cooling furnace 120. To this end, both the lid 102a and the
plinth 102b which are carried on the conveyor 170 will be heated by the hot air being
injected through the blow nozzle 192 as they move together with the conveyor 170 (see
Fig.44).
[0120] The temperature management unit 104 is operated as follows. An empty vessel 102 is
first located in the heating vessel pickup position A. The robot 180 then transfers
the vessel 102 to the position B, where the vessel is charged with a prescribed amount
of the molten metal from the melt holding furnace 10 (which holds the molten metal
containing a large number of crystal nuclei). Thereafter, the robot 180 transports
the vessel 102 to the filled vessel rest position C, where it is placed on the plinth
102b and has its top covered with the lid 102a (both the lid 102a and the plinth 102b
are preliminarily heated with the preheater 190); subsequently, the vessel is cooled
as it is carried by the conveyor 170 to pass through the semisolid metal cooling furnace
120 in a specified period of time. The vessel 102 leaving the furnace 120 reaches
the slurry vessel rest position D, from which it is immediately transferred to the
sleeve position E by the robot 180 if the injection sleeve 202 in the molding machine
200 is ready to accept the molten metal; at position E, the slurry of semisolid metal
in the vessel is poured into the injection sleeve 202. If the injection sleeve 202
is not ready to accept the molten metal when the vessel 202 has reached the slurry
vessel rest position D (i. e., if the molding machine is operating to perform pressure
forming), the slurry of semisolid metal within the vessel will progressively solidify
upon cooling while it is waiting for acceptance in position D, thereby making it impossible
for all the slurry to be discharged from the vesselor the crystal nuclei in the slurry
will disappear to cause deterioration in the quality of the shaped part. In order
to avoid these problems, the vessel 102 is forwarded to the semisolid metal slowly
cooling furnace 130, where it waits for the molding machine 200 to become completely
ready for the acceptance of the molten metal while ensuring against its rapid cooling.
[0121] The vessel 102 from which the slurry of semisolid metal having satisfactory properties
has been emptied into the injection sleeve 202 is then transferred to the empty vessel
rest position F by means of the robot 180, carried by the conveyor 170 into the vessel
cooling furnace 150, where it is cooled for a specified time, passed through the vessel
heat-retaining furnace 160 as it is held at a suitable temperature, and is thereafter
returned to the heating vessel pickup position A.
[0122] A specific embodiment of the temperature management unit 104 is shown in Fig.43.
In this first embodiment, aluminum alloys are to be treated on a comparatively large
scale with the molten metal being poured in an amount of at least 20 kg; the system
configuration is such that the molding cycle on the molding machine 200 is about 150
seconds and the time of passage through the semisolid metal cooling furnace 120 and
the vessel temperature control section 140 (i. e. consisting of the vessel cooling
furnace 150 and the vessel heat-retaining furnace 160) is 600 seconds in total. If
the total passage time is longer than 600 seconds, the overall equipment becomes impractically
bulky and the volume of the slurry in process which results from machine troubles
and which has to be discarded is increased and these are by no means preferred for
the purpose of constructing commercial production facilities.
[0123] To satisfy these cycle conditions and yet to produce slurries of good properties,
details of the system have been determined as follows. SUS304 was adopted as the constituent
material of the vessel (in the case of a comparatively small-scale operation with
the molten metal being poured in an amount of no more than 10 kg, materials of small
thermal conductivity provide comparative ease in temperature management; however,
in a large-scale operation like the case under discussion, the use of ceramics and
other materials of small thermal conductivity as the constituent material of the vessel
requires an unduly prolonged time to cool the slurry, resulting in the failure to
satisfy the cycle time requirementset forth above).
[0124] In order to ensure smooth recovery of the slurry from the vessel 102, its inner surfaces
had to be coated with a water-soluble (which is desirable for ensuring against gas
evolution) spray of a lubricant and, to this end, a spray position was provided between
the vessel cooling furnace 150 and the vessel heat-retaining furnace 160. The vessel
102 emerging from the vessel cooling furnace 150 had to be cooled within 5 minutes
down to a temperature (200 °C - 250 °C) that would allow for effective deposition
of the spray; to meet this requirement, hot air at 100 °C was applied against the
vessel through a blow nozzle.
[0125] As the result of the application of the water-soluble spray, the vessel 102 experienced
a local temperature drop. In order to ensure that the vessel 102 would have a uniform
temperature of 180°C - 190 °C throughout to provide a uniform temperature profile
through the slurry, the vessel 102 was heated in the vessel heat-retaining furnace
160 in which a hot air flow at 190 °C was circulated by means of a fan.
[0126] In order to provide a uniform temperature profile through the slurry in the vessel,
preheating furnace 190 was installed as an accessory and the plinth 102b and lid 102a
which were each made of a heat insulator (Al
2O
3 • SiO
2 composite) were heated at 350 °C before they were set up on the vessel 102; this
arrangement allowed the vessel 102 to be inserted into the semisolid metal cooling
furnace 120 together with the lid 102a and plinth 102b.
[0127] The interior of the semisolid metal cooling furnace 120 was equipped with two sets
each of hot air generating furnaces and blow nozzles, through which hot air was supplied
to circulate within the furnace 120, with its temperature and velocity being 220°C
and 5 m/sec at the entrance and 180 °C and 20 m/sec at the exit, whereby the semisolid
metal was cooled comparatively slowly in the initial cooling period but cooled rapidly
in the latter period.
[0128] For management of the temperature in the vessel 102, a sheathed thermocouple was
set in the vessel to take data on the temperature. Detailed discussion will follow
based on the thus taken temperature data.
[0129] Fig.51 shows the position of temperature measurement in the vessel 102. As shown
enlarged on the right-hand illustration, a hole was made in the outer surface of the
sidewall of the vessel to a depth at one half the wall thickness and thermocouple
was inserted into the hole and spotwelded.
[0130] Fig.52 shows the temperature history of cooling of the vessel 102. The vessel temperature
control section 140 was divided into the vessel cooling furnace 150 and the vessel
heat-retaining furnace 160 and, as already mentioned above, the vessel cooling furnace
150 was so adapted that "hot air at 100 °C was applied against the vessel through
the blow nozzles" whereas the vessel heat-retaining vessel 160 was designed to "permit
circulation of hot air at 190 °C."
[0131] The system under discussion requires that the " spray should be deposited" within
a limited time period while "a uniform temperature (180°C - 190 °C) should be established
throughout the vessel 102". To meet these requirements, the vessel temperature control
section 140 was divided into the vessel cooling furnace 150 and the vessel heat-retaining
furnace 160 and optimal temperature management was performed in each furnace.
[0132] The second embodiment of the temperature management unit 100 shown in Fig. 46 was
chiefly intended for the treatment of magnesium alloys. As typically shown in Fig.49,
the temperature management unit 100 comprises a plurality of linearly arranged housings
120A in a generally cubic shape, each being fitted with a top cover 120B that could
be opened or closed by means of an air cylinder 120C. Hot air could be forced into
the housings 120A. With the cover 120B open, the melt containing vessel 102 was placed
on the plinth 102b at the bottom of each housing 120A and a lid 102a fixed to the
inside surface of the cover 120B was fitted over the top of the vessel 102 so that
it would ensure a heat insulating effect during the cooling of the vessel 102. The
vessel was adapted for transfer into or out of the housing 120A by manipulation of
the robot 180.
[0133] Thus, the semisolid metal cooling furnace 120 according to the first embodiment shown
in Fig.44 is of a continuous type in which the vessel 102 is carried by the conveyor
170 while the furnace is operating and, in contrast, the semisolid metal cooling furnace
120 according to the second embodiment shown in Fig.46 is of a batch system.
[0134] As also shown in Fig.49, the plinth 102b seated on the bottom of the housing 120A
is coupled to a rotational drive mechanism consisting of a motor 121a, a chain 121b,
a sprocket121c, a bearing 121d, etc. and this drive mechanism allows the vessel 102
to rotate freely during its cooling operation.
[0135] Another embodiment of the semisolid metal cooling furnace 120 is shown in Fig.53;
it is fitted with not only a vibrator 121f that is actuated with an ultrasonic oscillator
121e but also a water-cooled booster 121g and this arrangementwill provide effective
vibrations to the vessel 102.
[0136] Fig.45 shows the temperature profiles obtained by fitting the top and bottom of the
vessel with the lid 102a and the plinth 102b which were each made of a heat insulator
(Al
2O
3 • SiO
2 composite). Obviously, the use of the heat insulator produced uniform temperature
profiles as compared with the case of using no such heat insulators. The uniformity
in temperature profile was further improved by preheating the insulator.
[0137] We next discuss the "high-viscosity region". The alloy to be treated in the case
at issue is AC4C which has a eutectic temperature of 577 °C. Within a narrow temperature
range centered at this eutectic point, the fraction solid increases sharply from 56
% to 100 % and the viscosity will inturn rises noticeably. Hence, the region of 56
% to 100 % fraction solid may well be considered as the "high-density region". When
no heat insulator was used, both the top and bottom portions of the vessel were entirely
covered with the "high-density region" and in a case like this, the desired slurry
would not form smoothly. In contrast, the mere use of the heat insulator resulted
in a significant decrease in the "high-density region", which barely remained at the
corners. Obviously, the "high-density region" totally disappeared when the heat insulator
was heated. In the case under discussion, the heat insulator had to be heated but
with smaller vessel sizes, there was no particular need to heat the heat insulator.
[0138] Magnesium alloys involve difficulty in temperature management since they have small
latent heat and will cool rapidly. To deal with this problem, the semisolid metal
cooling furnace 120 according to the second embodiment shown in Fig.46 have the following
differences from the first embodiment shown in Fig.43.
[0139] First, silicon nitride was used as the constituent material of the vessel but it
was difficult to obtain a uniform temperature profile through the slurry in the vessel.
Under the circumstances, the semisolid metal cooling furnace 120 for handling vessels
having a diameter of more than 100 mm had to be equipped with a vessel rotating mechanism
as indicated by 120X in Fig.49 or a vessel vibrator as indicated by 120Y in Fig.53.
(With vessels having diameters ranging from 50 mm to less than 100 mm, neither the
vessel rotating mechanism nor the vessel vibrator had to be installed. With vessel
diameters of 100 mm - 200 mm, a vessel vibrator as indicated by 120Y in Fig. 53 was
necessary and with vessel diameters of more than 200 mm, a vessel rotating mechanism
capable of more vigorous agitation as indicated by 120X in Fig. 49 had to be employed.)
[0140] It was also necessary to perform the temperature management in such a manner as to
be flexible with time; to meet this need, a furnace temperature controller as indicated
by 120Z in Fig.47 or 48 was installed. (With vessel diametersof less than 100 mm,
the rate of cooling the slurry was so sensitive to the variations in the temperature
within the furnace that it was necessary to control the temperature in the furnace
by the mechanism shown in Fig.47. With vessel diameters of less than 70 mm, not only
the furnace temperature controller but also a feedback control system as shown in
Fig.48 was necessary.)
[0141] In order to permit the addition of these capabilities, the semisolid metal cooling
furnace 120 was designed as a batch system of the type shown in Fig.46 and the timing
for the transfer of the vessel into and out of the furnace 120 was controlled by the
robot 180.
[0142] Thus, the present invention provides a method of temperature management in which
the step of managing the temperature in the vessel 102 at an appropriate level before
it is supplied with the molten metal is distinctly separated from the step of managing
the temperature in the vessel 102 in such a way that the as poured molten metal can
be cooled at a desired appropriate rate; the invention also provides the apparatus
for temperature management 104 which is capable of automatic performance of these
steps in an efficient and continuous manner. Also proposed by the invention is a system
configuration that implements the respective steps by means of the vessel temperature
control section 140 and the semisolid metal cooling section 110.
[0143] In a specific embodiment, the vessel temperature control section 140 is composed
of the vessel cooling furnace 150 capable of forced cooling with a circulating hot
air flow that provides an appropriate cooling capacity by controlling the temperature
and velocity of the air passing through the furnace and the vessel heat-retaining
furnace 160 which controls the temperature of the atmosphere to lie at the target
value in the vessel 102 and which maintains the vessel 102 at said temperature of
the atmosphere. It should be noted here that the temperature to which the vessel cooling
furnace 150 and the vessel heat-retaining furnace 160 should be controlled differs
between aluminum and magnesium alloys. In the case of aluminum alloys, the interior
of the vessel cooling furnace 150 is controlled to lie between room temperature and
300 °C whereas the interior of the vessel heat-retaining furnace 160 is controlled
to lie between 50 °C and 350 °C; in the case of magnesium alloys, the interior of
the vessel cooling furnace 150 is controlled to lie between room temperature and 350°C
whereas the interior of the vessel heat-retaining vessel 160 is controlled to lie
between 200 °C and 450 °C.
[0144] The semisolid metal cooling section 110 is composed of the semisolid metal cooling
furnace 120 which is adapted to circulate hot air at an appropriate temperature such
as to accomplish cooling within the shortest possible time that produces the slurry
of semisolid metal with satisfactory properties and the semisolid metal slowly cooling
furnace 130 which is designed to maintain the slurry of semisolid metal for 2 - 5
minutes in a temperature range appropriate for shaping such as to be adaptive for
the specific molding cycle on the molding machine 200. Again, the temperature to which
the semisolid metal cooling furnace 120 should be controlled differs between aluminum
and magnesium alloys. In the case ofaluminum alloys, the temperature should be controlled
to lie between 150 °C and 350 °C and in the case of magnesium alloys, the temperature
should be controlled to lie between 200 °C and 450 °C. On the other hand, the interior
of the semisolid metal slowly cooling furnace 130 should be controlled to be at 500
°C and above in both cases.
[0145] If the injection sleeve 202 on the molding machine 200 is ready to accept the molten
metal just at the time when the vessel 102 holding the metal has left the semisolid
metal cooling furnace 120, the metal is immediately fed (poured) into the molding
machine 200 without being directed into the semisolid metal slowly cooling furnace
130. Conversely, if the injection sleeve 202 is not ready to accept the molten metal
since the molding machine 200 is operating, the vessel 102 leaving the semisolid metal
cooling 120 is transferred to the semisolid metal annealing furnace 130.
[0146] A first version of the heating system in the semisolid metal cooling furnace 120
according to the invention is such that either the temperature or the velocity of
the circulating hot air is controlled to vary appropriately with the lapse of time
or, alternatively, both the temperature and the velocity of the hot air are controlled
to vary simultaneously with the lapse of time.
[0147] The first specific embodiment of the heating system (furnace temperature control
unit 120Z) is as shown in Fig. 47 and comprises a hot air line for supplying a hot
air flow into the semisolid metal cooling furnace 120, an air line from which an air
flow at ordinary temperature emerges to combine with the hot air to lower its temperature,
a damper for controlling the quantity of the air flowing through the air line, and
a damper opening controller.
[0148] The second specific embodiment of the heating system (furnace temperature control
unit 120Z) is as shown in Fig.48 and comprises a temperature sensor installed within
the semisolid metal cooling furnace 120, a hot air line for supplying a hot air flow
into the furnace, an air line that combines with the hot air line, an automatic damper
installed on the air line, and a damper opening controller that performs feedback
control on the damper opening on the basis of the data obtained by measurement with
the temperature sensor. The opening of the automatic damper is controlled on the basis
of the data for the temperature in the furnace and the hot air is mixed with an appropriate
amount of air and fed into the furnace, whereby the temperature and the velocity of
the circulating hot air are controlled such that the molten metal will be cooled at
a desired rate.
Example 7
[0149] An example of the invention will now be described specifically with reference to
accompanying drawings. The example was implemented by the same method as in Example
1, except that Fig.3 was replaced by Fig.54 and the top surface of the insulated vessel
30 (or 30A) was fitted with a heat insulating lid 42 (or a ceramics coated metallic
lid 42A). Thus, Figs.1, 2, 54 and 4 - 7 concern Example 8, in which: Fig.1 is a diagram
showing a process sequence for the semisolid forming of a hypoeutectic aluminum alloy
having a composition at or above a maximum solubility limit; Fig.2 is adiagram showing
a process sequence for the semisolid forming of a magnesium or aluminum alloy having
a composition within amaximum solubility limit; Fig. 54 shows a process flow starting
with the generation of spherical primary crystals and ending with the molding step;
Fig.4 shows diagrammatically the metallographic structures obtained in the respective
steps shown in Fig.54; Fig.5 is an equilibrium phase diagram for an Al-Si alloy as
a typical aluminum alloy system; Fig.6 is an equilibrium phase diagram for a Mg-Al
alloy as a typical magnesium alloy system; Fig.7 is a diagrammatic representation
of a micrograph showing the metallographic structure of a shaped part according to
the invention; and Fig.8 is a diagrammatic representation of a micrograph showing
the metallographic structure of a shaped according to the prior art.
[0150] The insulated vessel 30 for holding the molten metal the temperature of which has
dropped to just below the liquidus line shall have a heat insulating effect in order
to ensure that the primary crystals generated will spheroidize and have the desired
fraction liquid after the passage of a specified time. Problems, however, will occur
in certain cases, such as where near-eutectic Al-Si alloys and others that are prone
to form skins are to be held, or where the molten metal is so heavy that it has to
be held in a semisolid condition for more than 10 minutes, or where the height to
diameter ratio of the insulated vessel 30 exceeds 1:2. Although, there is no problem
with the internal microstructure of the molten metal, a solidified layer is prone
to grow on the surface of the melt and can potentially cover the top of the semisolid
metal, thus, making it difficult to insert the metal into the injection sleeve 40.
To deal with this situation, the top of the insulated vessel 30 is fitted with the
heat insulating lid 42 in order to ensure against solidification from the surface
of the molten metal which is being held within the insulated vessel 30, thereby enabling
the metal to be cooled while providing uniformity in temperature throughout the metal.
[0151] The constituent material of the insulated vessel 30 and the heat-insulating lid 42
is in no way limited to metals and those which have a heat-retaining property and
which yet wet with the melt only poorly are preferred. If a gas-permeable ceramic
vessel is to be used as the insulated vessel 30 and the heat-insulating lid 42 for
holding magnesium alloys which are easy to oxidize and burn, the exterior to the vessel
is preferably filled with a specified atmosphere (e. g. an inert or vacuum atmosphere).
For preventing oxidation, it is desired that Be or Ca is preliminarily added to the
molten metal. The shape of the insulated vessel 30 and the heat-insulating lid 42
is by no means limited to a tubular or cylindrical form and any other shapes that
are suitable for the subsequent forming process maybe adopted. The molten metal need
not be poured into the insulated vessel 30 but it may optionally be charged directly
into the ceramic injection sleeve 40.
[0152] Table 4 shows how the presence or absence of the heat insulating lid 42 affected
the procedure of making shaped parts. Comparative Samples 19 - 22 refer to the case
of holding the molten metal without the insulating lid. In Comparative Sample 19,
the insulated vessel 30 held the melt of an alloy that was prone to form a skin and,
hence, a solidified layer formed over the semisolid metal, making it impossible to
recover the metal from the vessel 30. In Comparative Sample 20, it was attempted to
have the semisolid metal inserted into the injection sleeve with the molding temperature
lowered; in Comparative Sample 22, the metal was unduly heavy.
[0153] Hence, in both cases, the holding time was prolonged and the result was substantially
the same as with Comparative Sample 1 shown in Table 1. In Comparative Sample 21,
the height-to-diameter ratio of the insulated vessel 30 was greater than 1:2 and,
hence, the temperature profile through the semisolid metal was so poor that the result
was substantially the same as with Comparative Sample 1 shown in Table 1.
[0154] Invention Samples 23 - 26 refer to the case of using the insulated vessel 30 fitted
with the heat-insulating lid 42; they showed better results than Comparative Samples
19 - 22 in the recovery of the semisolid metal.
Example 8
[0155] An example of the invention will now be described in detail with reference to Figs.1,
3, 4 and 65 - 67, in which: Fig.1 is a diagram showing a process sequence for the
semisolid forming of an Al-Mg alloy; Fig.3 shows a process flow starting with the
generation of granular primary crystals and ending with the molding step; Fig.4 shows
diagrammatically the metallogrphic structures obtained in the respective steps shown
in Fig.3; Fig.65 is an equilibrium phase diagram for a binary Al-Mg alloy; Fig. 66
is a. diagrammatic representation of a micrograph showing the metallographic structure
of a shaped part according to the invention; and Fig.67 is a diagrammatic representation
of a micrograph showing the metallographic structure of a shaped part according to
the prior art.
[0156] As shown in Figs.1 and 65, the invention recited in claim 33 is such that:
the melt of an Al-Mg alloy that contains an element to promote the generation of crystal
nuclei and that is held superheated to less than 100°C above the liquidus temperature
is directly poured into the insulated vessel without cooling the melt with a jig.
[0157] The poured metal is held within the insulated vessel at a temperature not higher
than the liquidus temperature but higher than the eutectic or solidus temperature
for a period from 5 seconds to 60 minutes until a specified liquid fractionis established,
whereby a large number of fine granular primary crystals are generated to produce
a semisolid Al-Mg alloy at the specified fraction liquid.
[0158] The specific procedure of semisolid metal forming to be performed in Example 11 is
essentially the same as described in Example 1.
[0159] Silicon (Si) is added in order to promote the spheroidization of the generated granular
primary crystals. If the Si addition is less than 0.3 %, the intended effect in promoting
the spheroidization is not expected; adding more than 2.5 % of Si will merely result
in deteriorated properties of the alloy and no further improvement in spheroidization
is expected. Hence, the Si addition is controlled to lie between0.3 % and 2.5 %.
[0160] It should be noted that the Al-Mg alloy of the invention may incarporate up to 1
% of Mn or up to 0.5 % of Cu with a view to improving its strength.
[0161] Table 7 sets forth the conditions for the preparation of semisolid metal samples
and the results of evaluation of their metallorgraphic structures by microscopic examination.
[0162] In Comparative Sample 9, the temperature of jig 20 with which the melt M was contacted
was so high that the number of crystal nuclei generated was insufficient to produce
fine primary crystals; instead, coarse primary crystals formed. In Comparative Sample
10, the casting temperature was so high that very few crystal nuclei remained within
the ceramic vessel 30, yielding the same result as with Comparative Sample 9. In Comparative
Sample 11, the holding time was so long that the fraction liquid in the metal to be
shaped was low, making the alloy unsuitable for shaping. In addition, the size of
primary crystals was undesirably large. In Comparative Sample 12, the holding time
within the ceramic vessel 30 was short whereas the fraction liquid in the metal to
be shaped was high; hence, only coarse primary crystals formed. In addition, the high
fraction liquid caused many segregations of components within the shaped part. In
Comparative Sample 13, the hot molten metal was directly poured into the insulated
vessel, where it was solidified as such, yielding coarse, dendritic primary crystals
(see Fig.67).
[0163] In each of Invention Sample 5 and 6, there was obtained a homogeneous microstructure
having fine (< ca. 100 µm) granular primary crystals that were adapted for pressure
forming.
Example 9
[0164] An example of the invention (as recited in claim 11 will now be described in detail
with reference to accompanying Figs.69 - 73, in which Fig.69 shows two process sequences
for the semisolid forming of a hypoeutectic aluminum alloy; Fig.70 shows a process
flow starting with the generation of spherical primary crystals and ending with the
molding step; Fig.71 shows diagrammatically the metallographic structures obtained
in the respective steps shown in Fig.70; Fig.72 is a diagrammatic representation of
a micrograph showing the metallographic structure of a shaped part according to the
invention; and Fig.73 is a diagrammatic representation of a micrograph showing the
metallographic structure of a shaped part according to the prior art.
[0165] The invention concerns a process which starts with either one of the following steps:
(1) two or more liquid alloys having different melting points that are held superheated
to less than 50°C above the liquidus temperature are mixed either directly within
an insulated vessel having a heat insulating effect or along a trough in a channel
into the insulated vessel, thereby generating crystal nuclei in the alloy solution
(see Fig.69); or
(2) two or more metals to be mixed are preliminarily contacted with respective cooling
plates so as to generate crystal nuclei and the metals that have attained temperatures
just above or below the liquidus temperature are mixed either directly within an insulated
vessel having a heat insulating effect or along a trough in a channel into the insulated
vessel, thereby generating more crystal nuclei (see Fig.70).
[0166] Either of the metals thus obtained is held within the insulated vessel for a period
from 5 seconds to 60 minutes as it is cooled to a molding temperature where a specified
fraction liquid is established, whereby the fine grains that have formed within the
alloy solution are crystallized out as no dendrites, and the metal is then fed into
a mold, where it is subjected to pressure forming.
[0167] The "specified fraction liquid" and the "insulated vessel " have the same meanings
as defined in Example 1.
[0168] According to the invention, semisolid metal forming will proceed by the following
specific procedure. In step (1) of the process shown in Figs.70 and 71, two complete
liquid forms of metals MA and MB are contained in ladles 10 and poured into a ceramic
container 30 (or ceramic-coated metal container30A) which is an insulated vessel having
a heat insulating effect. As a result, an alloy having a large number of crystal nuclei
is obtained at a temperature either just below or above the liquidus line. Molten
metals MA and MB may be poured either simultaneously or successively with one coming
after the other. Alternatively, molten metals MA and MB may be poured into partitioned
compartments in the insulated vessel 30 and the partition is removed all of a sudden
so as to achieve mutual contact between the two metals.
[0169] In subsequent step (2), the alloy mixture MC is held partially molten within the
insulated vessel 30. In the meantime, extremely fine primary crystals result from
the introduced crystal nuclei [step (2)-a] and grow into spherical primary crystals
as the fraction solid increases with the decreasing temperature of the alloy mixture
MC [steps (2)-b and (2)-c]. Alloy mixture MC thus obtained at a specified fraction
liquid is inserted into an injection sleeve 40 [step (2)-d] and, thereafter, pressure
formed within a mold cavity 50a on a die casting machine to produce a shaped part
[step (3)].
[0170] The semisolid metal forming process of the invention shown in Figs.69, 70 and 71
has obvious differences from the conventional thixocasting and rheocasting methods.
[0171] The casting, spheroidizing and molding conditions that are respectively set for the
steps shown in Fig.69, namely, the step of generating and spheroidizing primary crystals
and the forming step, are set forth below. Also discussed below is the criticality
of the numerical limitations set forth in claims 36 and 37.
[0172] If the molten (liquid) metals MA and MB to be mixed have been superheated to more
than 50°C above the liquidus temperature, the temperature of either metal just after
the mixing will neither be just above or below the liquidus temperature of the alloy
mixture MC to be eventually formed. If the mixed metals are held within the insulated
vessel 30, a microstructure consisting of coarse dendrites will form rather than a
structure of uniform, near-spherical nondendritic crystals. To avoid these problems,
the temperatures of molten (liquid) metals MA and MB to be mixed need be superheated
to no more than 50 °C above the liquidus temperature. The "temperature either just
above or below the liquidus temperature of the metal mixture to be eventually formed"
means a temperature within the liquidus temperature ±15°C. The liquid metals to be
mixed shall include alloys. The insulated vessel 30 for holding the metals the temperature
of which have dropped to be within the defined range after the mixing shall have a
heat insulating effect in order to ensure that the crystal nuclei generated will grow
into nondendritic (near-spherical) primary crystals and have the desired fraction
liquid after a specified time. The constituent material of the insulated vessel is
in no way limited to metals and those which have a heat-retaining property and which
yet wet with the melt only poorly are preferred. If a gas-permeable ceramic container
is to be used as the insulated vessel 30 for holding magnesium alloys which are prone
to oxidize and burn, the exterior to the vessel is preferably filled with a specified
atmosphere (e. g. an inert or vacuum atmosphere).
[0173] If the holding time within the insulated vessel is less than 5 seconds, it is not
easy to attain the temperature for the desired fraction liquid and it is also difficult
to generate spherical primary crystals. What is more, semisolid metals of a uniform
temperature profile cannot be attained. If the holding time exceeds 60 minutes, coarse
spherical primary crystals will be generated.
[0174] It should also be mentioned that if the fraction liquid in the alloy which is about
to be shaped by high-pressure casting is less than 20 %, the resistance to deformation
during the shaping is so high that it is not easy to produce shaped parts of good
quality. If the fraction liquid exceeds 90 %, shaped parts having a homogeneous structure
cannot be obtained. Therefore, as already mentioned, the fraction liquid in the alloy
to be shaped is preferably controlled to lie between 20 % and 90 %. More preferably,
the fraction liquid should be adjusted to range between 30 % and 70 % in order to
ensure that shaped parts of high quality can easily be produced by pressure forming.
The means of pressure forming are in no way limited to high-pressure casting processes
typified by squeeze casting and die casting and various other method of pressure forming
may be adopted, such as extruding and casting operations.
[0175] By mixing two or more aluminum alloys having different liquidus temperature and holding
the mixture within the insulated vessel 30, one can produce a semisolid metal of a
fine spherical structure. If it is desired to generate more crystal nuclei so as to
yield uniform and more fine-grained spherical structure in aluminum alloys, Ti and
B may be added to the alloys. If the Ti content of the alloy mixture is less than
0.003 %, the intended refining effect of Ti is not attained; beyond 0.30 %, a coarse
Ti compound will form to cause deterioration in ductility. Hence, the Ti addition
is controlled to lie between 0.003 % and 0.30 %. Boron (B) in the mixed metal MC cooperates
with Ti to promote the refining of crystal grains but its refining effect is small
if the addition is less than 0.0005 %; on the other hand, the effect of B is saturated
at 0.01 % and no further improvement is expected beyond 0.01 %. Hence, the B addition
is controlled to lie between 0.0005 % and 0.01 %.
[0176] Table 9 sets forth the conditions for the preparation of semisolid samples and the
qualities of shaped parts. As shown in Fig.70, the shaping operation consisted of
inserting the semisolid metal into an injection sleeve and subsequent forming on a
squeeze casting machine. The forming conditions were as follows: pressure, 950 kgf/cm
2 ; injection speed, 1.5m/s; mold cavity dimensions, 100 x 150 x 10; mold temperature,230
°C.
[0177] In Comparative Sample 9, the holding time was so long that undesirably large primary
crystals formed. In Comparative Sample 10, the temperatures of the alloys to be mixed
were high and so was the temperature of the resulting mixture; hence, the number of
the crystal nuclei generated was small enough to produce only dendritic primary crystals.
In Comparative Sample 11, the holding time was short whereas the liquid fraction in
the alloy mixture was high and this caused extensive segregations in the interior
of the sharped part.
[0178] In each of Invention Samples 1 - 8, a homogeneous microstructure comprising fine
(< 150 µm) spherical primary crystals was obtained to enable the production of a shaped
part having no internal segregations.
Example 10
[0179] This example was implemented by the same method as in Example 1, except that at the
end of the step of holding the alloy partially molten within the insulated vessel
30 (or 30A), an oxide W forming on the semisolid metal was removed by means of a metallic
or nonmetallic jig [step (3)-c in Fig.74].
[0180] As also shown in Fig.74, the shaping operation consisted of inserting the semisolid
metal into an injection sleeve and subsequent forming on a squeeze casting machine.
The forming conditions were as follows: pressure, 950 kgf/cm
2 ; injection speed, 1.5 m/s; mold cavity dimensions, 100 x 150 x 10; mold temperature,
230°C.
[0181] Table 10 shows how the quality of shaped parts was affected by the presence or absence
of the oxide. Obviously, Invention Samples 23 - 26 had better results than Comparative
Samples 21 and 22.