Electric Arc Induction, Ultrasonic Hybrid Melting Device and Method for RGO Reinforced Copper Composite Production

Abstract

The invention relates to a device and method for the production of composite materials with a copper (Cu) matrix reinforced with reduced graphene oxide (rGO). Within the scope of the invention, ultrasonic vibration is applied through a sonotrode (4) immersed in molten metal (8) within the copper matrix, which is melted by an electric arc induction unit (1). The vibrations produced by the ultrasonic transducer (3) are transferred into the molten metal (8) simultaneously with the electric arc induction melting process, thus ensuring controlled mixing in the molten phase. The ultrasonic vibration parameters and the electric arc induction parameters can be adjusted independently via the control unit (6). The invention combines the effects of electric arc induction melting and ultrasonic mixing within the same system, offering a production structure in which the distribution of nano-reinforcement in the molten metal can be controlled.

Description

1 TARIFF ELECTRIC ARC FOR THE PRODUCTION OF RGO REINFORCED COPPER COMPOSITE. INDUCTION-ULTRASONIC HYBRID MELTING DEVICE AND METHOD TECHNICAL AREA 5 The invention relates to electric arc induction melting systems, assisted by ultrasonic energy. metal processing technologies and metal matrix containing graphene-derived nanoreinforcements This relates to the technical field of composite production. Specifically, reduced graphene oxide (rGO). Production of reinforced copper matrix composites with homogeneous distribution in the molten phase It involves a hybrid melting-mixing system that provides 10 STATE OF THE ART The production of metal matrix composites (MMCs) is particularly suitable for applications requiring high conductivity and mechanical properties. Significant research and development in applications requiring strength and thermal stability. It stands out as a development area. In this context, 15 copper (Cu) matrix is ​​embedded. Carbon-based nanotechnologies such as graphene, graphene oxide (GO), and reduced graphene oxide (rGO) Composite materials, developed by adding reinforcements, are widely discussed in the literature. This has been examined in this way. These nano-reinforcements have a high surface area and superior properties. Due to its electrical conductivity and mechanical strength properties, Cu matrix It provides performance-enhancing contributions to systems. 20 The main techniques currently used for the production of such composites are powder metallurgy, mechanical alloying, spark plasma sintering (SPS), electrodeposition, and melting. Mixing methods are used. Powder metallurgy and mechanical alloying. Although these techniques allow for a certain degree of homogeneous distribution of nano-reinforcements, methods have 25 disadvantages such as high cost, limited production volume and process complexity. It has disadvantages. Melt mixing methods, on the other hand, offer industrial scalability. While advantageous in this respect, especially with nano-sized reinforcements in molten metal serious technical limitations regarding its stable and homogeneous distribution within it It includes. Ultrasonic stirring technology creates a cavitation effect in molten metal. 30 It is an important method developed to improve particle dispersion by creating a filter. These systems typically use piezoelectric devices operating in the 20–40 kHz frequency range. Formation of microbubbles in liquid metal using transducers This is achieved by the collapse of these bubbles, causing local pressure and temperature increases. 2 This effect leads to the breakdown of particle agglomerates and the matrix. It is possible to achieve a more homogeneous distribution within it. However, Long-term and stable operation of ultrasonic systems in high-temperature molten metal environments. operation in terms of the durability of piezoelectric elements and cavitation continuity It presents significant technical challenges. 5 On the other hand, electric arc induction melting systems operate at high temperatures. These are known as metallurgical processes that can provide rapid and intensive energy transfer. In these systems, arc plasma and induction magnetic field are used together. The melting process is carried out, thus achieving high heating efficiency, rapid melting, and Controlled chemical composition can be obtained. Electric arc induction systems 10 especially widely used in the smelting and processing of copper and copper alloys It is used. However, when the current technology is examined, ultrasonic mixing systems... Electric arc induction melting systems are generally independent of each other. It is observed that these two energy fields are used simultaneously and in a controlled manner. 15 A system in which it is integrated is only briefly mentioned in the literature, especially rGO. In the context of reinforced copper composite production, such a hybrid approach There is no systematic solution for its implementation. In addition, the behavior of nanoreinforcements in molten metal is highly... Due to surface energy, density difference and wettability problems, it is quite 20 It is complex. Low-density, high-surface-energy materials like rGO, in melt form... Tendency to form agglomerations, rise to the surface, or precipitate within copper. This indicates that the homogeneity and performance of the composite structure are negatively affected. This has an effect. Furthermore, graphene derivatives undergo structural degradation under high temperatures. The risk of failure limits the desired technical benefits. 25 Various patent documents in the literature describe electric arc and induction. Different applications where these systems are used together (for example, duplex in steel production) melting, laser-assisted arc processes, multi-frequency induction systems, and arc Although additive manufacturing techniques (source-based) have been described, these solutions It is not directly aimed at the production of nano-reinforced copper composites. Specifically, rGO 30 production of reinforced Cu matrix composites by electric arc induction method and this a technical instruction on the integrated use of ultrasonic stirring in the process It is not available. 3 In conclusion, the current technique is suitable for the production of rGO reinforced copper composites. Ensuring homogeneous distribution, strong interfacial bonding, and stable process control. It falls short in this regard; the equation of electric arc induction with ultrasonic energy an integrated production system is needed where it is used in a timely and controlled manner It is heard. 5 THE TECHNICAL PROBLEM TO BE SOLVED In the production of metal matrix composites, especially reduced graphene oxide (rGO) during the incorporation of nano-sized reinforcements such as these into a copper (Cu) matrix The main technical problem that emerged was whether this reinforcement phase would be stable in the molten metal medium, 10 The problem is that it cannot be placed with a homogeneous and controllable distribution. The high rGO level. Agglomeration in molten copper due to surface energy and low density. The tendency of the composite structure to form, rise to the surface or precipitate, micro- This compromises the structural integrity and causes mechanical, electrical and other problems with the resulting material. This leads to undesirable heterogeneities in thermal properties. 15 In addition, the difference in wettability between Cu matrix and rGO reinforcement and Insufficient interfacial interactions result in a strong bond between the reinforcing phase and the matrix. This prevents the formation of load transfer; this improves the load transfer capability of the composite material. This limits and makes it difficult to achieve the expected performance increase. The structural stability of graphene derivatives, especially under high temperatures, is 20 The inability to protect the interface and the risk of oxidative degradation further negatively impact interface quality. This is another technical problem that is affecting things. The melt mixing methods used in current production techniques are nano Sufficient turbulence and micro-scale mixing to improve the distribution of additives. It is unable to produce the same effect; ultrasonic mixing systems, on the other hand, are used with high-temperature metal 25 Limitations in terms of long-term and stable cavitation production in the environment. It includes. In addition, the use of ultrasonic systems alone, molten metal It is insufficient in terms of temperature control and energy density; however, When electric arc induction systems are used alone, nano-reinforcements It does not offer an effective mixing mechanism to ensure dispersion. 30 Another technical problem is the combination of electric arc induction energy and ultrasonic energy. Control of parameter interactions that occur during simultaneous use The inability to do so is due to arc current, induction magnetic field, ultrasonic frequency, and melt. Process parameters such as temperature change in an interdependent and unstable manner. 4 this reduces repeatability in the production process and the resulting composite material. This leads to significant variations in their properties. This situation is particularly relevant in industrial settings. A significant technical limitation that prevents reliable production on a large scale. It constitutes. Furthermore, the literature also describes the process of inducing rGO-reinforced copper 5-core electromagnetic radiation (EAR) using the electric arc induction method. The lack of a systematic solution for the production of matrix composites is one of these two problems. process parameters for the combined use of the energy field, interface their interactions and nanoreinforcement behaviors have not been sufficiently elucidated. This is the reason why there is such a deficiency, both in theory and in practice. This creates a significant technical gap. 10 In short, the technical problem to be solved is rGO in a molten copper medium. The tendency of nano-reinforcements to precipitate or rise to the surface without forming agglomerations. matrix-reinforcement interface that ensures homogeneous distribution without showing any signs. strengthens the bond, and also uses electric arc induction and ultrasonic energy. 15 a repeatable and industrially applicable production system and method It is the development of. A BRIEF DESCRIPTION OF THE INVENTION The invention relates to a copper (Cu) matrix composite 20 reinforced with reduced graphene oxide (rGO). Electric arc induction melting system for use in the production of materials. and integrating an ultrasonic mixing mechanism within the same process It relates to the device and the production method carried out with this device. Within the scope of the invention, a copper matrix is ​​melted using an electric arc induction unit. During transport, the liquid is 25 via an ultrasonic sonotrode immersed in the molten metal. High-frequency acoustic energy is applied in the phase. Thanks to this structure, the molten material... Cavitation, microturbulence, and local pressure fluctuations within the metal. By forming rGO nano-reinforcements, agglomerations are broken down and the matrix A homogeneous distribution is achieved within it. The invention's fundamental technical contribution is the high 30 provided by electric arc induction. Ultrasonic stirring provides energy-intensive and controlled melting capabilities. Simultaneous and controlled dispersion effect at the micro level within a single system. It is the integration of techniques that were previously used separately. The disadvantages of these two energy fields are eliminated, and in the molten phase Direct control is provided over the distribution of nano-reinforcements. Acoustic results are obtained by directly immersing the ultrasonic probe into molten metal. Energy is transferred directly to the liquid phase; this enables rGO particles. Effective cavitation occurs, particle clusters break apart, and reinforcement 5 It is possible for the phase to spread thinly and evenly within the molten Cu matrix. This is happening. At the same time, ultrasonic microflow effects occur in the matrix-reinforcement interface. It enhances diffusion-based bonding by increasing wettability on its surface. The invention also includes ultrasonic frequency, ultrasonic power, arc current, Process parameters such as induction field strength and melt temperature are controlled by a control group. They can be adjusted and recorded independently through the unit. This feature increases the repeatability of the production process and controlled acquisition of microstructural properties of composite material It provides. Thanks to this technical structure; 15  Ultrasonic cavitation and microturbulence effects are created,  Flow conditions affecting the dispersion of the nano-reinforcement phase in molten metal is being improved,  Wettability and diffusion interactions at the matrix-reinforcement interface is being increased, 20  Controlled and repeatable application of process parameters is provided. In conclusion, the invention controls the dispersion of nanoreinforcement in the molten phase. capable of independently managing process parameters and high An integrated technique that enables the production of high-performance rGO-reinforced copper composites. 25 The system offers LIST OF FIGURES Figure 1: XRD analysis results Figure 2: Raman analysis results 30 Figure 3: EDS analysis results (Cu), Figure 4: EDS analysis results (Cu-1rGO) Figure 5: EDS analysis results (Cu-2rGO) Figure 6: Results of electrical conductivity. 6 Figure 7: General view of the arc induction casting machine. Figure 8: Detailed view of the casting process. The reference numbers in the figures are as follows: 1. Electric arc induction unit 5 2. Melting crucible 3. Ultrasonic transducer 4. Sonotrode (ultrasonic probe) 5. Ultrasonic connection line 6. Control unit 10 7. Power supply (including ultrasonic power unit) 8. Molten metal (Cu + rGO) 9. Protective atmosphere system (inert gas system) 10. Carrier body / chassis 11. Lid / reaction chamber top cover 15 12. Temperature measuring sensor 13. Sample / casting mold 14. Induction coil 15. Arc electrode 16. Ultrasonic generator 20 DESCRIPTION OF THE FIGURES Figures 1–6 show the characterization results of the produced composites. Figure 7 shows the electric arc induction–ultrasonic hybrid melting invention. This shows the general appearance of the device. Figure 8 shows the 25 inside the melting pot. This is a cross-sectional view showing the behavior of molten metal during ultrasonic mixing. DETAILED DESCRIPTION OF THE INVENTION The invention relates to a reduced graphene oxide (rGO) reinforced copper (Cu) matrix composite. 30 used in the production of materials, with electric arc induction melting system a device that integrates an ultrasonic mixing mechanism and with this device It relates to the production method used. The system developed within the scope of the invention is an electric arc induction unit (1), melting pot (2), induction coil (14), arc electrode (15), ultrasonic transducer 7 (3), sonotrode (4), ultrasonic connection line (5), ultrasonic generator (16), control unit (6), power supply (7), protective atmosphere system (9), carrier body (10), It consists of cover (11) and temperature measurement sensor (12) components. Melting pot (2) is made of high temperature resistant refractory material. It has been prepared, and the starting material containing Cu and rGO has been placed and the molten material 5 It defines the main processing volume in which the formation of metal (8) takes place. The said crucible (2), magnetic field created by induction coil (14) and arc electrode heated by arc plasma provided by (15) the copper matrix inside It causes it to become molten. Electric arc induction unit (1), arc electrode (15) and induction coil (14) 10 high energy density and thanks to the combined energy field created between them It performs a rapid melting process. This structure creates a homogeneous melt metal (8) within the molten metal. The temperature distribution can be adjusted via the control unit (6) It is operated using parameters. During the melting process, the system is protected by a protective atmosphere system (9) 15 Oxidative degradation of rGO supplement, in particular, by placing it in an inert gas environment. It is prevented. The lid (11) surrounds the reaction volume, ensuring a gas tightness and It increases process stability. The temperature of the molten metal is measured by the temperature measurement sensor (12). It is adjusted by continuous monitoring and feedback via the control unit (6). After the copper matrix becomes molten, the ultrasonic transducer (3) 20 The sonotrode (4), driven by the immersion of molten metal (8) into a certain immersion It is placed at a certain depth. Ultrasonic transducer (3), ultrasonic generator (16) It is powered through this process, converting electrical energy into mechanical vibration. It transfers the molten medium through the sonotrode (4). This transfer is via the ultrasonic coupling line. (5) is performed via. 25 Ultrasonic by immersing the sonotrode (4) directly into the molten metal (8). Energy is transferred directly to the liquid phase, thereby causing cavitation within the molten volume. It occurs on a micro scale with the formation and collapse of cavitation bubbles. High pressure and temperature zones occur. These local effects reinforce rGO. by breaking down the agglomerates formed by the particles into smaller pieces, 30 It causes it to break down into dispersed particles. At the same time, ultrasonic vibrations create microscopic vibrations in molten metal (8). by creating turbulent and convective flows within the copper matrix of rGO particles It ensures homogeneous distribution. These microflows are based on the difference in density. 8 by suppressing the tendency of the reinforcement phase to settle or rise to the surface. It makes it possible for the molten material to remain suspended within the volume. Ultrasonic mixing time, frequency and power are controlled via the control unit (6) It is adjustable and independent of electric arc induction parameters. is controlled. Thanks to this independent control capability, the arc current is controlled by the induction field 5. Process parameters such as intensity, ultrasonic frequency, and melt temperature interact with each other. It can be optimized in a way that won't cause disruption. This is a situation encountered in previous techniques. It eliminates parameter interaction problems. This structure provides acoustic solutions in the molten phase. In multiple systems, the effects of energy transfer and electromagnetic induction are controlled together. It creates a multi-physics process environment. 10 Ultrasonic effects also increase wettability at the matrix-reinforcement interface. By increasing it, it strengthens diffusion-based bond formation. Thus, rGO and Cu matrix A stronger interfacial interaction is achieved between them. This interaction, the composite the mechanical strength, electrical conductivity and thermal stability of the material It creates a technical effect that directly improves. 15 After the specified ultrasonic mixing time is completed, sonotrode (4) molten metal (8) is removed and the homogenized composite melt is added to the sample or transferred to the casting mold (13). The solidification process is controlled. By performing this procedure, the desired microstructure is obtained. The carrier body (10) is the structure that mechanically supports all components of the system. It creates and ensures vibration and mechanical stability during the process. Power supply (7), the energy needs of both the electric arc induction unit (1) and the ultrasonic system It is structured to meet this need. Thanks to this integrated system, ultrasonic waves are produced in molten metal (8). Cavitation and microflow effects are created, and momentum 25 is generated within the molten phase. Transfer and local turbulence intensity are increased, rGO reinforcement improves phase dispersion. The influencing flow and energy conditions are brought under control, matrix-reinforcement interface. Interactions are improved and process parameters are stable and repeatable. It is applicable. In conclusion, the invention combines the effects of electric arc induction and ultrasonic stirring in a single 30°C. By integrating them into the system, the dispersion of nano-reinforcement in the molten phase is directly controlled. a technique that enables the production of high-performance Cu-rGO composites. It offers a solution. 9 Using the system developed within the scope of the invention, rGO reinforced copper (Cu– An example application of rGO (rGroup) composite production is described below. Firstly, high-purity copper raw material and a specific weight ratio. Reduced graphene oxide (rGO) is supplied. The amount of rGO is determined by the target composite. Depending on their properties, they can be selected in a range of, for example, 0.5%–2%. These materials are 5 It is placed inside the melting pot (2). The system is inert under argon gas via the protective atmosphere system (9) It is then prepared and the lid (11) is closed to minimize the risk of oxidation. By commissioning the electric arc induction unit (1), the induction coil (14) and the arc The copper matrix is ​​melted by means of the electrode (15). The molten metal (8) 10 The melting temperature of copper is monitored by the temperature measurement sensor (12). It is kept within a controlled range that will not disrupt the rGO structure. After the molten metal (8) has stabilized, the ultrasonic transducer (3) The sonotrode (4), driven by the shunt, is immersed into the molten metal to a certain depth. With the energy supplied through the ultrasonic generator (16), the sonotrode (4) approximately 20–40 15 Ultrasonic mixing in molten metal by vibrating in the kHz frequency range. It is started. At this stage, intense cavitation occurs within the molten metal. Micropressure waves generated by the collapse of cavitation bubbles, rGO It breaks down the agglomerates formed by the particles. The microturbulence that occurs simultaneously 20 Thanks to the currents, rGO particles are homogeneously distributed within the molten copper matrix. They disperse, and the tendencies for sedimentation or rising to the surface due to density differences are suppressed. The ultrasonic mixing process is continued for, for example, 5–15 minutes. This Duration and parameters depend on the targeted microstructure and reinforcement ratio. It can be optimized. During this time, the ultrasonic frequency, power level, arc current, and 25 The induction power is adjusted independently via the control unit (6) and the process The parameters are kept constant. After the mixing process is completed, the ultrasonic sonotrode (4) The molten metal is extracted and the resulting homogeneous Cu–rGO composite melt, It is transferred to a pre-prepared casting mold (13). With controlled cooling, 30 The solidified sample is subjected to microstructure analysis. XRD, Raman, and EDS analyses revealed that rGO reinforcement affects the copper matrix. it is more homogeneously distributed within it and the tendency for agglomeration is reduced. This has been observed. In electrical conductivity measurements, it has been improved compared to pure copper. Performance values ​​are obtained. These results relate to ultrasonic and electromagnetic effects. Their combined application has a direct effect on the dispersion behavior of nano-reinforcements. This shows that. These results relate to the electric arc induction-ultrasonic system developed within the scope of the invention. The hybrid system effectively controls the dispersion of nano-reinforcement in the molten phase. 5 that it was able to do so and that it made high-performance composite production possible The following table shows the hardness of composites obtained as examples. The values ​​are given. Sample Hardness (HV30) Cu 65 ±4 Cu-1rGO 175 ±5 Cu-2rGO 225 ±3 Table 1. Hardness (HV30) values ​​of composites with different rGO ratios. Alternatively, ultrasonic vibration application can be pulsed instead of continuous mode. It can be performed in (pulse) mode and sonotrod (4) at different immersion depths. can be positioned. The invention is not limited to the example application described here, but extends to 15 different materials within the framework of the technical specifications defined in the requirements. These ratios can also be applied with process parameters and system configurations. Variations are evaluated within the scope of the request. 25

Claims

11 REQUESTS 1. It is a device for the production of rGO reinforced copper matrix composites, - an electric arc induction unit (1), - a melting pot (2), 5 - an induction coil (14) associated with the melting pot (2) and a arc electrode (15), - an ultrasonic transducer (3), - connected to the ultrasonic transducer (3) and into the molten metal (8) a submersible sonotrode (4), 10 - a device containing a control unit (6), the feature of which is; molten metal (8) formed in the melting pot (2) of the sonotrode (4) positioned so that it will be directly immersed in it, ultrasonic Ultrasonic vibrations generated through the transducer (3) cause an electric arc Simultaneously with the melting process carried out with the induction unit (1), 15 structured in such a way as to enable its application into molten metal (8) and the ultrasonic vibration parameters and electricity via the control unit (6) Arc induction parameters can be adjusted independently. It is the fact that.

2. The device is as per claim 1, and its characteristic is that the sonotrode (4) has a conical tip geometry of 20 It is having.

3. The device is as per claim 1 and its feature is; ultrasonic transducer (3) 20–40 kHz It is configured to operate within the specified frequency range.

4. The device is as per claim 1 and its feature is that it has an ultrasonic transducer (3). It is powered via an ultrasonic generator (16). 25 5. The device according to claim 1, its features are: ultrasonic transducer (3) and sonotrode (4) there is an ultrasonic connection line (5) between them.

6. The device is in accordance with claim 1 and its characteristic is that the melting pot (2) provides inert gas. It is surrounded by a protective atmosphere system (9).

7. The device is as per claim 1 and its feature is that it measures the temperature of molten metal (8). It contains a temperature sensor (12).

8. The device is according to claim 1 and its characteristic is that the system is mounted on a carrier body (10). It is the placement of. 12 9. rGO reinforced copper matrix composite production method, - electric arc in a melting pot (2) of copper-containing material melting via induction unit (1), - after molten metal (8) is formed, a sonotrode (4) is in question immersion in molten metal (8), 5 - ultrasonic vibration into molten metal (8) via sonotrode (4) It is characterized by the fact that it includes the steps of its implementation; The application of ultrasonic vibration is equivalent to the electric arc induction melting process. performed in a timely manner and with ultrasonic vibration parameters The electric arc induction parameters are controlled independently of each other. 10 It is done.

10. The method according to claim 9, characterized by its use of ultrasonic vibration at a frequency of 20–40 kHz. It is implemented within this range.

11. The method according to claim 9, characterized by its melting process in an inert gas atmosphere. It is carried out under 15.

12. The method according to claim 9, its characteristic is; ultrasonic vibration of molten metal It is applied in a way that will create cavitation within it.

13. The method according to claim 9, its characteristic is; ultrasonic application to molten metal This is done in a way that creates micro-turbulence within it.

14. The method according to claim 9, its characteristic is; molten metal into a casting mold (13) 20 It involves the transfer and solidification steps. 30

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