Multidirectionally-coupled wall-surface-vibration three-dimensional ultrasonic metal solidification device and method

Abstract

The invention discloses a multidirectionally-coupled wall-surface-vibration three-dimensional ultrasonic metal solidification device and method. The device comprises a metal solidification device body and a metal solidification data acquisition and control device, wherein the metal solidification device body comprises a casting mold assembly, an ultrasonic vibration assembly and an anti-thrust rod; and the metal solidification data acquisition and control device comprises a sound signal acquisition circuit, a computer, a multi-channel signal generator, a multi-channel signal amplifier and a sound pressure sensor. The method comprises the following steps: step 1, loading alloy raw materials; step 2, installing the metal solidification device body; step 3, installing the sound pressure sensor; step 4, setting initial values of vibration parameters; step 5, smelting a master alloy; step 6, pouring a melt; step 7, carrying out wall-surface-vibration three-dimensional ultrasonic metal solidification under phase and amplitude feedback control; and step 8, unloading a casting. The multidirectionally-coupled wall-surface-vibration three-dimensional ultrasonic metal solidification device and method are novel and reasonable in design, the ultrasonic transmission efficiency is increased, effective control over an ultrasonic field in the large-size alloy melt is realized, the metal casting condition can be improved, component structure homogenization is promoted, and the material performance is improved.

Description

technical field [0001] The invention belongs to the field of advanced material preparation and processing, in particular to a multi-directional coupling wall surface vibration three-dimensional ultrasonic metal solidification device and method. Background technique [0002] The casting process is a process in which the metal melt gradually solidifies in the cavity. Metal parts prepared by casting process are widely used in aerospace vehicle engine parts, airfoil support components, automobile engine cylinders and gearbox casings, automobile hubs and complex parts of many mechanical devices. The materials used include most common metal materials such as aluminum alloy, magnesium alloy, copper alloy and nickel-based superalloy. The key to improving the performance of castings is to improve their internal microstructure. [0003] Applying ultrasonic vibration during the solidification of metal or alloy is one of the effective methods to improve its structure and performance. ...

AI Technical Summary

Problems solved by technology

However, the current ultrasonic casting has not really entered the field of industrial casting, mainly due to the following defects in the prior art:

[0004] (1) In the prior art, the ultrasonic horn is mostly immersed in the melt to emit ultrasonic waves. This method will cause the horn to overheat, and the propagation speed of sound inside it will change, thereby changing the resonance characteristics of the horn. and stop working

When dealing with high-temperature alloys (such as Fe alloys and Ni alloys), the horn may even soften, plastically deform or crack, resulting in damage to the horn

[0005] (2) In a small number of existing technologies, the horn is rigidly connected to the outer wall of the mold to form an integral special-shaped structure, resulting in changes in vibration characteristics

And because the overall mass of the casting mold is large, the vibration transmission efficiency is very low, and the vibration load of the ultrasonic system will be too large, and the ultrasonic power supply cannot bear it and stop working

[0006] (3) In the prior art, the one-dimensional ultrasonic wave with fixed frequency and amplitude is directly applied to the metal melt, the vibration energy decays rapidly, and the range of action is small. Generally, the effective length of grain refinement is only a few centimeters

[0007] (4) In the prior art, one-dimensional ultrasound can only realize a one-dimensional gradient field along the ultrasonic emission direction, but cannot realize a uniform field and other distributed field forms. The distribution form of the ultrasonic field cannot be adjusted, and the liquid-solid phase Real-time fine control of variable process

[0008] (5) The existing technology generally can only adjust the ultrasonic transmission power, but lacks the measurement of the actual sound pressure and its distribution in the melt, and cannot accurately specify effective process parameters, so that effective control of the solidified structure cannot be realized

[0009] In view of the fact that the existing advanced material preparation and processing fields have not yet solved the problem of effective and controllable application of ultrasonic fields in high-temperature, large-volume liquid and semi-solid metal melts, a three-dimensional ultrasonic metal melt feedback adjustment process for free vibration of the mold wall is developed. Devices and methods become imperative

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