WO2000041831A1 - Hot chamber die casting of semisolid metals - Google Patents
Hot chamber die casting of semisolid metals Download PDFInfo
- Publication number
- WO2000041831A1 WO2000041831A1 PCT/US2000/000725 US0000725W WO0041831A1 WO 2000041831 A1 WO2000041831 A1 WO 2000041831A1 US 0000725 W US0000725 W US 0000725W WO 0041831 A1 WO0041831 A1 WO 0041831A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- composition
- die
- hot
- semisolid
- caster
- Prior art date
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
- B22D17/02—Hot chamber machines, i.e. with heated press chamber in which metal is melted
- B22D17/04—Plunger machines
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
- B22D17/007—Semi-solid pressure die casting
Definitions
- This application relates to methods and apparatus for hot chamber die casting of semisolid materials.
- Hot chamber processes are distinguished by the fact that the injection cylinder is at least partially immersed in the molten metal, and thus is at the same temperature as the molten metal.
- Hot chamber die casting is widely used for light alloys such as magnesium- and zinc-based alloys, but has not been found to be commercially viable for casting aluminum alloys. These alloys generally have a higher melting temperature, and thus tend to rapidly degrade steel die casters using a hot chamber process.
- Hot chamber casting process includes higher productivity, reduced scrap and metal losses, reduced die closing pressures, and reduced die wear.
- Both hot and cold chamber processes suffer from the disadvantage that it is difficult to produce fully sound castings. Liquid metal generally enters the die in a turbulent fashion, entrapping mold gases and forming oxide inclusions in the finished part. Further, solidification shrinkage produces porosity and sometimes tears in the finished casting. It is an object of the present invention to provide a hot-chamber die casting system which minimizes or eliminates these disadvantages.
- the present invention supplies a hot chamber method of die casting material in a semisolid state.
- the semisolid material has a high viscosity, which can be controlled by controlling the fraction of solid phase and the morphology of the solid phase.
- turbulence and consequent gas entrapment can be minimized or eliminated.
- shrinkage is substantially reduced, thereby reducing porosity and hot tearing to form stronger, more reliable castings.
- the invention provides a method of die casting, in which a semisolid composition is held between its liquidus and solidus temperatures, and agitated to prevent the formation of interconnected dendritic networks.
- the composition forms a slurry of solid particles in liquid, which is pumped into a die by an immersed pump.
- the material is then cooled to cast it in the die.
- the material may be, for example, a light alloy such as a magnesium, zinc, or aluminum alloy.
- the invention in another aspect, includes a hot chamber die caster adapted to cast semisolid materials.
- the die caster includes a container for holding a composition in the semisolid state, and a pump for pumping the semisolid material into a die.
- Agitation means prevent the formation of dendrites, holding the material in a semisolid slurry state.
- the agitation means may be, for example, mechanical or electromagnetic.
- the caster may be used to cast a variety of light alloys, such as magnesium, zinc, and aluminum alloys.
- the pump may comprise ferrous materials such as stainless steel.
- Figure 1 is an illustration of a typical hot chamber die casting machine
- Figure 2 is an illustration of one embodiment of a hot chamber die caster according to the invention.
- Figure 3 is an illustration of another embodiment of a hot chamber die caster according to the invention.
- Figure 1 shows a typical hot chamber die caster 10, such as is commonly used for casting of magnesium and zinc alloys.
- the caster works on a "sump pump” principle, using an immersed piston 12 to force molten metal into the casting chamber 14.
- a hydraulic cylinder 16 reciprocates the piston 12, within a piston chamber 17 whose end is connected to a gooseneck chamber 18 leading to the casting chamber 14.
- molten metal 20 flows into the piston chamber 17 and the gooseneck chamber 18 through an aperture 22.
- the casting chamber 14 is defined by two mold halves 24 and 26.
- mold half 26 is moved to release the cast part.
- the mold is then closed and another cycle of the system can be performed.
- the gooseneck 18 and cylinder head 16 are thus continuously exposed to molten metal in this process.
- the semisolid (or rheocasting) process was discovered about twenty years ago in the laboratory of one of the present inventors. It was found that mechanical stirring of a material between the liquidus and solidus temperatures could break up dendrites, forming a slurry of spheroidized solid particles in liquid.
- the viscosity of the material can be set to a value in the range of 10 " '-10 8 poise, simply by controlling the stirring rate.
- Detailed descriptions of semisolid processing techniques can be found, for example, in U.S. Patent Nos. 3,954,455 and 3,948,650 to Flemings, et al, both of which are incorporated herein by reference.
- Rheocast castings are generally of more uniform strength and of lower porosity than conventional castings.
- the present invention uses semisolid processing to die cast materials using a hot chamber process.
- Figure 2 shows a die caster designed to carry out this process. It is similar to the die caster shown in Figure 1, but includes a mechanical stirrer 28 for agitating semimolten metal 21.
- the furnace is provided with a cover 29 and a pressure inlet 30 to aid in forcing semimolten metal 21 through the aperture 22 into the piston chamber 17.
- Added pressure is not necessary in standard hot-chamber casting processes, because of the very low viscosity of fully molten metal (typically on the order of 10 "2 poise).
- the higher viscosity of the semisolid compositions of the present invention may make applied pressure preferable or even essential, depending on the properties of the semisolid composition and of the caster material.
- the optimum applied pressure for any given embodiment depends on the solid fraction of the semisolid metal and the speed with which it is desired to fully fill the piston chamber 17. It is preferred that die casters according to the invention be able to apply a pressure of at least 30 psi gauge ⁇ i.e., 30 psi above atmospheric pressure). If desired, applied pressure and the viscosity of the semisolid metal can be adjusted to provide a relatively high fill rate while minimizing the turbulence of flow into the casting chamber 14.
- a temperature controller maintains the melt 20 within a relatively narrow temperature range, in order to ensure that it stays between the liquidus and solidus temperatures.
- the liquidus and solidus temperatures differ by about
- Figure 3 depicts an embodiment of the die caster related to that of Figure 2, but using electromagnetic, rather than mechanical, stirring means.
- a set of coils 32 is provided for heating and stirring the semimolten metal 20.
- the use of electromagnetic stirring and heating may simplify the application of pressure, since the coils 32 do not need to be placed within the semimolten metal 21.
- Hot chamber die casting of semisolid materials offers several advantages.
- the lower temperatures required may provide reduced energy costs and reduced wear rates for casters, and may expand the list of materials which can be inexpensively die cast by the hot chamber method.
- the increased viscosity of the melt reduces turbulence as the melt enters the die. Reduced turbulence leads to minimal gas entrapment and thus to a reduced concentration of oxide inclusions.
- the shrinkage from the semisolid to the solid state is substantially less than that from the fully liquid to the solid state. Thus, shrinkage porosity and hot tearing are reduced in the present process, allowing simpler and less expensive mold designs to be used.
Abstract
A hot chamber method of die casting metals in a semisolid state. The semisolid metal has a high viscosity, which can be controlled by controlling the fraction of solid phase and the morphology of the solid phase. By controlling the viscosity of the melt, turbulence and consequent gas entrapment can be minimized or eliminated. Further, shrinkage is substantially reduced, thereby reducing porosity and hot tearing to form stronger, more reliable castings.
Description
HOT CHAMBER DIE CASTING OF SEMISOLID METALS
Field of the Invention
This application relates to methods and apparatus for hot chamber die casting of semisolid materials.
Background of the Invention
Die casting has traditionally been divided into cold chamber processes and hot chamber processes. Hot chamber processes are distinguished by the fact that the injection cylinder is at least partially immersed in the molten metal, and thus is at the same temperature as the molten metal. Hot chamber die casting is widely used for light alloys such as magnesium- and zinc-based alloys, but has not been found to be commercially viable for casting aluminum alloys. These alloys generally have a higher melting temperature, and thus tend to rapidly degrade steel die casters using a hot chamber process.
Advantages of the hot chamber casting process include higher productivity, reduced scrap and metal losses, reduced die closing pressures, and reduced die wear. Both hot and cold chamber processes, however, suffer from the disadvantage that it is difficult to produce fully sound castings. Liquid metal generally enters the die in a turbulent fashion, entrapping mold gases and forming oxide inclusions in the finished part. Further, solidification shrinkage produces porosity and sometimes tears in the finished casting. It is an object of the present invention to provide a hot-chamber die casting system which minimizes or eliminates these disadvantages.
Summary of the Invention
The present invention supplies a hot chamber method of die casting material in a semisolid state. The semisolid material has a high viscosity, which can be controlled by controlling the fraction of solid phase and the morphology of the solid phase. By controlling the viscosity of the melt, turbulence and consequent gas entrapment can be minimized or eliminated. Further, shrinkage is substantially reduced, thereby reducing porosity and hot tearing to form stronger, more reliable castings.
In one aspect, the invention provides a method of die casting, in which a semisolid composition is held between its liquidus and solidus temperatures, and agitated to prevent the formation of interconnected dendritic networks. The composition forms a slurry of solid particles in liquid, which is pumped into a die by an immersed pump. The material is then cooled to cast it in the die. The material may be, for example, a light alloy such as a magnesium, zinc, or aluminum alloy.
In another aspect, the invention includes a hot chamber die caster adapted to cast semisolid materials. The die caster includes a container for holding a composition in the semisolid state, and a pump for pumping the semisolid material into a die. Agitation means prevent the formation of dendrites, holding the material in a semisolid slurry state. The agitation means may be, for example, mechanical or electromagnetic. The caster may be used to cast a variety of light alloys, such as magnesium, zinc, and aluminum alloys. The pump may comprise ferrous materials such as stainless steel.
Brief Description of the Drawing The invention is described with reference to the several figures of the drawing, in which,
Figure 1 is an illustration of a typical hot chamber die casting machine; Figure 2 is an illustration of one embodiment of a hot chamber die caster according to the invention; and
Figure 3 is an illustration of another embodiment of a hot chamber die caster according to the invention.
Detailed Description
Figure 1 shows a typical hot chamber die caster 10, such as is commonly used for casting of magnesium and zinc alloys. The caster works on a "sump pump" principle, using an immersed piston 12 to force molten metal into the casting chamber 14. A hydraulic cylinder 16 reciprocates the piston 12, within a piston chamber 17 whose end is connected to a gooseneck chamber 18 leading to the casting chamber 14. As the piston 12 reaches the top of its stroke, molten metal 20 flows into the piston
chamber 17 and the gooseneck chamber 18 through an aperture 22. When the piston 12 then moves down into the chamber 18, it seals the aperture 22 and forces molten metal into the casting chamber 14. The casting chamber 14 is defined by two mold halves 24 and 26. Once the molten metal 20 in the casting chamber 14 has solidified, mold half 26 is moved to release the cast part. The mold is then closed and another cycle of the system can be performed. The gooseneck 18 and cylinder head 16 are thus continuously exposed to molten metal in this process.
The semisolid (or rheocasting) process was discovered about twenty years ago in the laboratory of one of the present inventors. It was found that mechanical stirring of a material between the liquidus and solidus temperatures could break up dendrites, forming a slurry of spheroidized solid particles in liquid. The viscosity of the material can be set to a value in the range of 10"'-108 poise, simply by controlling the stirring rate. Detailed descriptions of semisolid processing techniques can be found, for example, in U.S. Patent Nos. 3,954,455 and 3,948,650 to Flemings, et al, both of which are incorporated herein by reference. Rheocast castings are generally of more uniform strength and of lower porosity than conventional castings.
The present invention uses semisolid processing to die cast materials using a hot chamber process. Figure 2 shows a die caster designed to carry out this process. It is similar to the die caster shown in Figure 1, but includes a mechanical stirrer 28 for agitating semimolten metal 21. In the embodiment shown, the furnace is provided with a cover 29 and a pressure inlet 30 to aid in forcing semimolten metal 21 through the aperture 22 into the piston chamber 17. Added pressure is not necessary in standard hot-chamber casting processes, because of the very low viscosity of fully molten metal (typically on the order of 10"2 poise). The higher viscosity of the semisolid compositions of the present invention may make applied pressure preferable or even essential, depending on the properties of the semisolid composition and of the caster material.
The optimum applied pressure for any given embodiment depends on the solid fraction of the semisolid metal and the speed with which it is desired to fully fill the piston chamber 17. It is preferred that die casters according to the invention be able to apply a pressure of at least 30 psi gauge {i.e., 30 psi above atmospheric pressure). If desired, applied pressure and the viscosity of the semisolid metal can be adjusted to
provide a relatively high fill rate while minimizing the turbulence of flow into the casting chamber 14.
A temperature controller maintains the melt 20 within a relatively narrow temperature range, in order to ensure that it stays between the liquidus and solidus temperatures. For example, the liquidus and solidus temperatures differ by about
120°C for Mg-8%Al-l%Zn, a common magnesium casting alloy. Known process- control techniques can be used to ensure that the metal temperature and viscosity are kept within acceptable limits.
Figure 3 depicts an embodiment of the die caster related to that of Figure 2, but using electromagnetic, rather than mechanical, stirring means. A set of coils 32 is provided for heating and stirring the semimolten metal 20. The use of electromagnetic stirring and heating may simplify the application of pressure, since the coils 32 do not need to be placed within the semimolten metal 21.
Hot chamber die casting of semisolid materials offers several advantages. The lower temperatures required may provide reduced energy costs and reduced wear rates for casters, and may expand the list of materials which can be inexpensively die cast by the hot chamber method. Further, the increased viscosity of the melt reduces turbulence as the melt enters the die. Reduced turbulence leads to minimal gas entrapment and thus to a reduced concentration of oxide inclusions. In addition, the shrinkage from the semisolid to the solid state is substantially less than that from the fully liquid to the solid state. Thus, shrinkage porosity and hot tearing are reduced in the present process, allowing simpler and less expensive mold designs to be used.
Other embodiments of the invention will be apparent to those skilled in the art from a consideration of the specification or practice of the invention disclosed herein. It is intended that the specification and examples be considered as exemplary only, with the true scope and spirit of the invention being indicated by the following claims. What is claimed is:
Claims
L A method of die casting, comprising holding a composition at a temperature between the liquidus temperature and the solidus temperature of the composition; agitating the composition to form a slurry of primary solids comprising discrete solid particles in liquid while preventing the formation of interconnected solid dendritic networks; pumping the composition into a die with a pump at least partially immersed in the composition; and solidifying the material in the die.
2. The method of claim 1, wherein agitating is accomplished by mechanical stirring.
3. The method of claim 1, wherein agitating is accomplished by electromagnetic stirring.
4. The method of claim 1, wherein the composition comprises a majority component of a metal selected from the group consisting of magnesium, zinc, and aluminum.
5. The method of claim 4, wherein a surface of the pump in contact with the composition comprises a ferrous material.
6. The method of claim 1, further comprising applying a pressure greater than atmospheric pressure to the slurry.
7. A hot-chamber die caster, comprising: a container for holding a semisolid composition between its liquidus and solidus temperatures; means for agitating the semisolid composition to form a slurry of primary solids comprising discrete solid particles in liquid while preventing the formation of interconnected solid dendritic networks; a die for casting the composition; and a pump, at least partially immersed in the semisolid composition and arranged to pump the composition into the die.
8. The hot-chamber die caster of claim 7, wherein the agitation means comprise a mechanical agitator.
9. The hot-chamber die caster of claim 7, wherein the agitation means comprise an electromagnetic agitator.
10. The hot-chamber die caster of claim 7, wherein the caster is adapted to cast an alloy comprising a metal selected from the group consisting of aluminum, magnesium, and zinc.
11. The hot-chamber die caster of claim 10, wherein a surface of the pump in contact with the semisolid composition comprises a ferrous material.
12. The hot-chamber die caster of claim 7, further comprising a pressure inlet for applying a pressure greater than atmospheric pressure to the semisolid composition.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP2000593432A JP2002534272A (en) | 1999-01-12 | 2000-01-12 | Hot-pressurized chamber die casting of semi-solid metal |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US09/228,965 US20010037868A1 (en) | 1999-01-12 | 1999-01-12 | Hot chamber die casting of semisolids |
US09/228,965 | 1999-01-12 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2000041831A1 true WO2000041831A1 (en) | 2000-07-20 |
Family
ID=22859280
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US2000/000725 WO2000041831A1 (en) | 1999-01-12 | 2000-01-12 | Hot chamber die casting of semisolid metals |
Country Status (3)
Country | Link |
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US (3) | US20010037868A1 (en) |
JP (1) | JP2002534272A (en) |
WO (1) | WO2000041831A1 (en) |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US7152658B2 (en) | 2002-08-10 | 2006-12-26 | Demag Ergotech Gmbh | Process and apparatus for casting metallic materials |
CN113084123A (en) * | 2021-04-06 | 2021-07-09 | 将乐瑞沃康普机械设备有限公司 | Semi-solid die-casting forming process for aluminum alloy automobile parts |
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US6645323B2 (en) * | 2000-09-21 | 2003-11-11 | Massachusetts Institute Of Technology | Metal alloy compositions and process |
JP4175602B2 (en) * | 2001-07-02 | 2008-11-05 | 徹一 茂木 | Casting pouring equipment |
US6964199B2 (en) * | 2001-11-02 | 2005-11-15 | Cantocor, Inc. | Methods and compositions for enhanced protein expression and/or growth of cultured cells using co-transcription of a Bcl2 encoding nucleic acid |
US7513962B2 (en) * | 2002-09-23 | 2009-04-07 | Worcester Polytechnic Institute | Alloy substantially free of dendrites and method of forming the same |
JP3549055B2 (en) * | 2002-09-25 | 2004-08-04 | 俊杓 洪 | Die casting method for metal material molding in solid-liquid coexistence state, apparatus therefor, die casting method for semi-solid molding and apparatus therefor |
JP3549054B2 (en) * | 2002-09-25 | 2004-08-04 | 俊杓 洪 | Method and apparatus for producing metallic material in solid-liquid coexistence state, method and apparatus for producing semi-solid metal slurry |
US20040261970A1 (en) * | 2003-06-27 | 2004-12-30 | Cyco Systems Corporation Pty Ltd. | Method and apparatus for producing components from metal and/or metal matrix composite materials |
JP3630327B2 (en) * | 2003-07-15 | 2005-03-16 | 俊杓 洪 | Solid-liquid coexistence state metal slurry production equipment |
US20050126737A1 (en) * | 2003-12-04 | 2005-06-16 | Yurko James A. | Process for casting a semi-solid metal alloy |
KR100682372B1 (en) * | 2006-05-26 | 2007-02-16 | 주식회사 퓨쳐캐스트 | Hot chamber die casting apparatus for semi-solid metal alloy and the manufacturing method using the same |
DE102009057197B3 (en) * | 2009-11-30 | 2011-05-19 | Oskar Frech Gmbh + Co. Kg | Casting unit for a die casting machine |
CN102806329A (en) * | 2012-07-17 | 2012-12-05 | 南昌大学 | Continuous blank casting system capable of performing semi-solid processing on non-ferrous alloy |
KR101373758B1 (en) | 2013-05-09 | 2014-03-13 | 해동이엠티(주) | Appparatus for supplying melted magnesium |
US20200038946A1 (en) * | 2015-11-03 | 2020-02-06 | Fujian Rheomet Light Metal Co., Ltd. | Aluminum alloy semi-solid molding method and device |
CA3091705A1 (en) | 2017-02-24 | 2018-08-30 | Innomaq 21, S.L. | Method for the economic manufacture of light components |
CN112775420B (en) * | 2020-12-28 | 2022-06-21 | 湖南文昌新材科技股份有限公司 | Rotating device for preparing composite material and preparation method of aluminum-based composite material |
Citations (4)
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---|---|---|---|---|
US3999593A (en) * | 1976-02-19 | 1976-12-28 | International Lead Zinc Research Organization, Inc. | Method and apparatus for pore-free die casting |
US4534403A (en) * | 1980-10-14 | 1985-08-13 | Harvill John I | Hot chamber die casting machine |
EP0733421A1 (en) * | 1995-03-22 | 1996-09-25 | Hitachi Metals, Ltd. | Die casting method |
US5836372A (en) * | 1995-09-01 | 1998-11-17 | Takata Corporation | Method and apparatus for manufacturing light metal alloy |
-
1999
- 1999-01-12 US US09/228,965 patent/US20010037868A1/en not_active Abandoned
-
2000
- 2000-01-12 WO PCT/US2000/000725 patent/WO2000041831A1/en active Application Filing
- 2000-01-12 JP JP2000593432A patent/JP2002534272A/en not_active Withdrawn
-
2002
- 2002-02-28 US US10/086,393 patent/US20020084053A1/en not_active Abandoned
- 2002-11-29 US US10/306,947 patent/US20030079854A1/en not_active Abandoned
Patent Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3999593A (en) * | 1976-02-19 | 1976-12-28 | International Lead Zinc Research Organization, Inc. | Method and apparatus for pore-free die casting |
US4534403A (en) * | 1980-10-14 | 1985-08-13 | Harvill John I | Hot chamber die casting machine |
EP0733421A1 (en) * | 1995-03-22 | 1996-09-25 | Hitachi Metals, Ltd. | Die casting method |
US5836372A (en) * | 1995-09-01 | 1998-11-17 | Takata Corporation | Method and apparatus for manufacturing light metal alloy |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US7152658B2 (en) | 2002-08-10 | 2006-12-26 | Demag Ergotech Gmbh | Process and apparatus for casting metallic materials |
CN113084123A (en) * | 2021-04-06 | 2021-07-09 | 将乐瑞沃康普机械设备有限公司 | Semi-solid die-casting forming process for aluminum alloy automobile parts |
Also Published As
Publication number | Publication date |
---|---|
US20030079854A1 (en) | 2003-05-01 |
US20010037868A1 (en) | 2001-11-08 |
US20020084053A1 (en) | 2002-07-04 |
JP2002534272A (en) | 2002-10-15 |
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