Immersive three-dimensional ultrasonic metal solidification device and method with controllable sound field

Abstract

The invention discloses an immersed three-dimensional ultrasonic metal solidification device and method with controllable sound field. The device comprises a metal solidification device body and a metal solidification data acquisition and controller. The metal solidification device body includes a casting mold and an ultrasonic vibration component; metal solidification data Acquisition and controller include acoustic signal acquisition circuit, computer, multi-channel signal generator, multi-channel signal amplifier and sound pressure sensor group; the method includes steps: 1. Install alloy raw materials; 2. Install metal solidification device body; 3. Install Sound pressure sensor; 4. Setting the initial value of vibration parameters; 5. Master alloy smelting; 6. Melt pouring; 7. Three-dimensional ultrasonic metal solidification of wall vibration under vibration frequency, phase and amplitude feedback control; 8. Unloading castings. The invention can automatically realize the tracking of the input target sound field through the acoustic signal feedback in the melt, realizes the controllable ultrasonic treatment of the large-volume melt, improves the performance of the casting, and is convenient for popularization and use in the foundry industry.

Description

technical field [0001] The invention belongs to the field of advanced material preparation and processing, and in particular relates to an immersive three-dimensional ultrasonic metal solidification device and method with controllable sound field. Background technique [0002] Casting is one of the important metal forming technologies, with a wide range of applications, such as aerospace vehicle engine parts, airfoil support components, automotive engine cylinders and gearbox housings, automotive hubs and complex parts of many mechanical devices. Specific materials involve aluminum alloys, magnesium alloys, copper alloys, nickel-based superalloys, and the like. Continuously improving the performance of castings is of great significance to the development of various industries. [0003] The casting process is a process in which the metal melt gradually solidifies in the cavity. Studies have shown that applying an ultrasonic field during the metal solidification process can ...

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 horn at the ultrasonic emitting end is submerged in the melt to emit ultrasonic waves, which will be heated by the heat transfer of the melt, causing the sound velocity and wavelength to change inside it, thus causing the horn to deviate from the station. Wave resonance point and stop working

Even when the temperature rises higher, it will lead to changes in the structure of the horn, plastic deformation or cracks, resulting in permanent failure of the horn, so it is not suitable for ultrasonic solidification of high-temperature metals

[0005] (2) In the prior art, the one-dimensional ultrasonic wave with fixed frequency and amplitude is directly applied to the metal melt, the vibration energy attenuates rapidly, and the range of action is small. Generally, the length distance for effective grain refinement is only 4-5 cm

[0006] (3) In the prior art, the one-dimensional ultrasonic vibration with the top extending into the ultrasonic horn is mostly used. The one-dimensional ultrasonic can only realize the one-dimensional gradient field along the ultrasonic emission direction, but cannot realize the uniform intensity field and other distributions. The form of the ultrasonic field and the distribution form of the ultrasonic field cannot be adjusted, and it is impossible to finely control the liquid-solid phase transition process; if the multi-directional vibration is used to penetrate into the melt, the metal melt is easy to leak, or the horn is restricted by the wall of the mold and cannot work problem

[0007] (4) 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

[0008] To sum up, the existing ultrasonic solidification technology cannot cool and protect the horn that emits ultrasonic vibrations, the volume of ultrasonic treatment is limited, the actual sound pressure measurement in the melt is lacking, and the shape of the sound field cannot be precisely controlled

These are the bottlenecks that restrict ultrasound from actually entering industrial applications

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