Ultrasonic treatment for microstructural refinement of continuous casting products

Abstract

Techniques are described herein for improving the grain structure of a continuously cast metal product by applying ultrasonic energy to a continuously cast metal product at a location downstream of a casting zone and allowing the ultrasonic energy to propagate through the metal product to a solidification zone where the ultrasonic energy may interact with growing metal grains to deagglomerate and disperse nucleation particles and disrupt and break up dendrites as they grow, which may promote additional nucleation and result in smaller grain size.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of and priority to U.S. Provisional Application No. 62 / 977,067, filed on February 14, 2020, which is hereby incorporated by reference in its entirety. Technical Field

[0003] The present disclosure relates generally to metallurgy and, more particularly, to techniques for controlling the microstructure of continuously cast products using ultrasonic processing. Background Art

[0004] Ultrasonic energy can be applied to metal products to change the structure and mechanical properties. For example, ultrasonic impact treatment can be used to strengthen metal products, such as at or near weld joints, especially those that may lose strength due to exposure to high temperatures. For example, by subjecting metal products or joints to ultrasonic energy using mechanical impact treatment at ultrasonic frequencies, residual stresses within the material can be controlled to enhance mechanical properties, strength, fatigue resistance, and corrosion resistance. Ultrasonic treatment can also be used to refine the microstructure during solidification when casting metal products. Summary of the invention

[0005] The term embodiment and similar terms are intended to refer broadly to all subject matter of the present disclosure and the appended claims. Statements containing these terms should not be understood to limit the subject matter described herein, or to limit the meaning or scope of the appended claims. The embodiments of the present disclosure covered by this article are defined by the appended claims rather than by this disclosure. This disclosure is a high-level overview of various aspects of the present disclosure and introduces some concepts that are further described in the following detailed description section. This disclosure is not intended to identify the key features or essential features of the claimed subject matter, nor is it intended to be used to determine the scope of the claimed subject matter in isolation. This subject matter should be understood by reference to the entire specification of the present disclosure, any or all drawings, and the appropriate parts of each claim.

[0006] By introducing ultrasonic cavitation into the solidifying melt, grain refinement can be achieved by wetting, deagglomerating and dispersing nucleating particles and activating the substrate by dendrite breakage. For casting techniques with large diameter open-top billets or ingots, such as direct chill (DC) casting, ultrasonic energy can be applied by inserting an ultrasonic transducer or sonotrode directly into the molten metal.

[0007] However, this configuration may present some disadvantages. For example, the ultrasonic processing pole or ultrasonic transducer must be made of a material that can withstand high temperatures, and must also be made of an inert material to limit the damage to the ultrasonic processing pole or ultrasonic transducer and the contamination of the molten metal. Example inert materials used may include niobium, tungsten, sialon, graphite, etc. Although these materials may be inert in some metals (e.g., steel), they are not necessarily inert in all molten metals. In addition, these materials may still be corroded when placed in molten metal. For example, inert materials may erode at a rate of 1-10 μm / hour. Such erosion rates may make it difficult for ultrasonic energy to be effectively coupled to the desired position in the casting material. For example, the ultrasonic processing pole or ultrasonic transducer may need to be positioned at a certain position and use an ultrasonic frequency that positions the maximum value or node of the ultrasonic wave in the solidification region in the casting metal, and takes into account the thermal expansion of the ultrasonic processing pole or ultrasonic transducer. In addition, since the inert material erodes over time, the optimal frequency or position may change over time. Additionally, due to erosion, the sonication pole or ultrasonic transducer may need to be replaced, which is often accompanied by significant operational costs and complexity, including downtime and costs associated with removal and replacement.

[0008] For the application of ultrasonic energy to continuous casting machines, such as twin roll casters, block casters, and belt casters, access to the molten metal into the continuous casting zone may be limited by the narrow gauges of the launder, tundish, and nose used to deliver the molten metal into the continuous casting zone. Therefore, it may be difficult or impractical to place the sonication pole or ultrasonic transducer directly into the molten metal in a continuous casting system. This configuration also does not overcome the above-mentioned disadvantages related to materials and erosion.

[0009] Placing the sonicator or transducer in contact with the launder, tundish, or nose but not directly within the molten metal may be useful, although coupling of ultrasonic energy from the launder, tundish, or nose through the molten metal to the solidification zone may be inefficient. Furthermore, access to such a configuration may still be limited, depending on the process or equipment being used.

[0010] In a continuous casting system, the cast slab can be fed into a pair of pinch rolls downstream of the continuous caster to provide negative tension, thereby addressing problems with improper feeding or tearing. At the pinch rolls, pressure can be applied directly to the cast slab, providing an opportunity to couple ultrasonic energy into the cast slab. Due to the pressure applied by the pinch rolls, the transmission of ultrasonic energy from the pinch rolls to the cast slab is very efficient, allowing the ultrasonic energy to be transmitted to the solidification zone where it helps with grain refinement.

[0011] Another method of providing ultrasonic energy to the solidification region may be to generate forces directly within the cast metal or molten metal in the solidification region, for example, by generating a magnetohydrodynamic force generated by the interaction of the metal with externally applied magnetic and electric fields. In one example, a static magnetic field source (e.g., a permanent magnet or an electromagnet) and a variable electric field source (e.g., an alternating current (AC) voltage source) may be used to generate the magnetohydrodynamic force. In another example, a variable magnetic field source (e.g., an electromagnet driven by a variable current) and an electrostatic field source (e.g., a direct current (DC) voltage source) may be used to generate the magnetohydrodynamic force.

[0012] Other objects and advantages of the invention will become apparent from the following detailed description given by way of non-limiting example. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The description refers to the following drawings, in which the same reference numerals are used in different drawings to indicate the same or similar components.

[0014] Figure 1 is a schematic diagram of an example continuous casting process in which ultrasonic energy is applied to a cast metal slab.

[0015] Figure 2 is a schematic diagram showing an expanded view of a solidification zone in a continuous casting process.

[0016] Figure 3 is a schematic diagram of an example continuous casting process in which ultrasonic frequency mechanical vibrations are applied to a cast metal slab.

[0017] Figure 4 is a schematic diagram of an example continuous casting process in which ultrasonic frequency magnetohydrodynamic forces are applied to a cast metal slab. DETAILED DESCRIPTION

[0018] Techniques for improving the grain structure of a metal product by applying ultrasonic energy to a continuously cast metal product at a location downstream of a casting zone and allowing the ultrasonic energy to propagate through the metal slab to a solidification zone where the ultrasonic energy can interact with the growing metal grains to deagglomerate and disperse nucleation particles and disrupt and break up dendrites as they grow, which can promote additional nucleation and result in smaller grain size.

[0019] Definition and Description:

[0020] As used herein, the terms "invention," "the invention," "this invention," and "present invention" are intended to refer broadly to all subject matter of this patent application and the appended claims. Statements containing these terms should not be construed as limiting the subject matter described herein, or limiting the meaning or scope of the appended patent claims.

[0021] Throughout this specification, reference may be made to alloys identified by AA numbers and other related designations, such as "Series" or "7xxx." For information on the numbering system most commonly used to name and identify aluminum and its alloys, refer to the "International Alloy Designations and Chemical Limits for Wrought Aluminum and Wrought Aluminum Alloys" or the "Aluminum Association Register of Alloy Designations and Chemical Limits for Aluminum Alloys in Casting and Ingot Form" published by the Aluminum Association.

[0022] As used herein, terms such as "cast metal product", "cast product", "cast alloy product" are interchangeable and refer to products produced by direct chill casting (including direct chill casting) or semi-continuous casting, continuous casting (including, for example, by using a twin-belt caster, a twin-roll caster, a block caster or any other continuous casting machine), electromagnetic casting, hot top casting or any other casting method.

[0023] All ranges disclosed herein should be understood to encompass any and all subranges contained therein. For example, a range of "1 to 10" should be considered to include any and all subranges between a minimum of 1 and a maximum of 10 (and including 1 and 10); that is, all subranges start with a minimum of 1 or greater (such as 1 to 6.1) and end with a maximum of 10 or less (such as 5.5 to 10).

[0024] As used herein, the meanings of "a," "an," and "the" include both singular and plural referents unless the context clearly dictates otherwise.

[0025] Production methods for metal products

[0026] Figure 1 A schematic diagram of an example continuous casting system 100 is shown. Here, molten metal 105 is transferred from a launder 110 to a tundish 115 and into a nose or nozzle 120 of a twin-belt caster 125, where the molten metal 105 solidifies and cools to form a cast slab 130. Downstream of the twin-belt caster 125, pinch rolls 135 apply pressure to the cast slab 130 and pull the cast slab 130 away from the twin-belt caster 125. Although Figure 1 While described as producing a cast slab 130 , other cast metal products such as cast metal bars, cast metal billets, cast metal sheets, cast metal plates, etc. may be produced according to the disclosed techniques. Figure 1 The continuous casting system 100 shown shows a twin belt caster 125, but such a configuration is not limiting, and other continuous casting systems, such as twin roll casters and block casters, can be used. In addition, other configurations that do not employ a tundish or launder can be used. A vertical casting orientation can also be used.

[0027] Pinch roller 135 Figure 1130 is depicted as coupled to an ultrasonic transducer 140 that generates ultrasonic waves 145. The ultrasonic waves 145 are transmitted into the casting slab 130 through the pinch rolls 135. The ultrasonic transducer 140 may be arranged or configured relative to the pinch rolls 135 to couple the upstream ultrasonic waves 145 within the casting slab 130 toward the nose or nozzle 120. For example, the orientation and / or position of the ultrasonic transducer 140 may optionally be configured to couple the ultrasonic waves 145 primarily in the upstream direction and limit the amount or amplitude of the ultrasonic waves 145 propagating in the downstream direction within the casting slab 130. Additionally or alternatively, there may be a phase shift between the ultrasonic transducers 140 to directionally direct the ultrasonic waves 145 toward the twin-belt caster 125. In this manner, energy from the ultrasonic waves 145 may be coupled to a solidification region adjacent to the nose or nozzle 120 within the twin-belt caster 125 and achieve grain refinement of the casting slab 130.

[0028] The configuration of the twin-belt caster 125 in supporting and / or cooling the cast slab 130 may be such that the ultrasonic waves 145 cannot be effectively coupled from the cast slab 130 into the belts of the twin-belt caster 125. For example, the cast slab 130 and the twin-belt caster 125 may not be firmly mechanically coupled to allow for effective transmission of ultrasonic energy.

[0029] For example, depending on the configuration and materials used, the ultrasonic transducer 140 may generate ultrasonic waves 145 at a frequency of about 10 kHz to 70 kHz or up to about 3 MHz. The ultrasonic transducer 140 may have a controllable or variable frequency output to directionally affect the transmission of the ultrasonic waves 145 and / or change the location of the minimum and maximum values ​​of the ultrasonic waves 145 within the solidification region, thereby controlling the grain refinement that occurs.

[0030] Figure 2 An expanded view of a continuous casting system 100 is provided, showing a solidification zone. Within the solidification zone, molten metal 105 transitions through a partially solid region between the liquidus temperature and the solidus temperature and ultimately solidifies at the output of the nose tip or nozzle 120 and within the twin-belt caster 125. Example liquidus isotherms 106 are shown, identifying where the temperature of the metal reaches the liquidus temperature. Example coherence isotherms 107 are also shown, identifying where the temperature of the metal reaches the coherence temperature. Example solidus isotherms 108 are also shown, identifying where the temperature of the metal reaches the solidus temperature and beyond which the metal is completely solid. It should be understood that Figure 2 The liquidus isotherm 106, coherence isotherm 107, and solidus isotherm 108 shown are exemplary and are used to illustrate the structure of the solidification region. The actual location and shape of the isotherms may vary depending on the configuration, geometry, materials, temperature, cooling rate, etc. used in the continuous casting system 100.

[0031] Between the liquidus isotherm 106 and the coherence line 107, the temperature of the metal is between the liquidus temperature and the coherence temperature. Here, the metal includes molten metal and suspended solid metal particles, which are generally not large enough to contact each other. As the temperature decreases toward the coherence temperature, the metal grains grow and form dendrites until the coherence isotherm is reached, at which time the metal grains are large enough so that contact with each other is inevitable. Between the coherence isotherm 107 and the solidus isotherm 108, the temperature of the metal is between the coherence temperature and the solidus temperature, and the metal includes molten metal between the solid metal particles. As the temperature decreases toward the solidus temperature, the metal grains continue to grow until all of the molten metal is fully combined by solidification.

[0032] Ultrasonic 145 Figure 2 1 and is depicted and shown as being transmitted into the solidification zone along the length of the cast slab 130. The ultrasonic waves 145 may correspond to, for example, high frequency longitudinal pressure waves and may physically interact with the growing metal grains to refine and reduce the grain size, such as by breaking up dendrites, dispersing and deagglomerating small grains or nucleation sites. Since the cast slab 130 is solid at a location downstream of the solidus isotherm 108, the transmission of the ultrasonic waves 145 through the cast metal slab 130 may be effective. As the ultrasonic waves 145 reach the solidification zone, their energy may begin to be absorbed and dispersed by the molten metal 105.

[0033] return Figure 1 , one or more acoustic receivers 150 may be positioned upstream of the nose tip or nozzle 120. For example, the acoustic receiver 150 may be used to detect residual ultrasonic energy transmitted to the launder 110 or the tundish 115 by the molten metal 105. The information detected by the acoustic receiver 150 may be used to feedback control the ultrasonic transducer 140 so as to control the amplitude, frequency, phase shift, etc. of the ultrasonic waves 145 generated by the ultrasonic transducer 140. Further feedback may be provided by examining the grain structure of the cast slab 130, which may indicate whether the ultrasonic transducer is operating to effectively refine the grain structure of the cast slab 130.

[0034] Figure 3 A schematic diagram of another example continuous casting system 300 is shown. Here, molten metal 305 is transferred from a ladle 310 to a tundish 315 and into a nose or nozzle 320 of a twin-belt caster 325, where the molten metal 305 solidifies and cools to form a cast slab 330. Downstream of the twin-belt caster 325, pinch rolls 335 apply pressure to the cast slab 330 and pull the cast slab 330 away from the twin-belt caster 325. Although Figure 3 Described as producing a cast slab 330 , other cast metal products such as cast metal bars, cast metal billets, cast metal sheets, cast metal plates, etc. may be produced according to the disclosed techniques. Figure 3The continuous casting system 300 shown shows a twin belt caster 325, but such a configuration is not limiting, and other continuous casting systems, such as twin roll casters and block casters, can be used. In addition, other configurations that do not employ a tundish or launder can be used. A vertical casting orientation can also be used.

[0035] Pinch roller 335 Figure 3 340 as coupled to a movable support. Here, translation of the pinch rolls 335 in the vertical direction allows for vibratory movement of the cast slab 330. Figure 3 A vertical translation is depicted in FIG, but may also or alternatively be Figure 3 The slab 330 is laterally translated in / out of the view or plane shown. The translation may be caused by a mechanical actuator or an electromechanical actuator coupled to the pinch rolls 335 or the support 340. The translation may generate shear waves 345 in the cast slab 330. Figure 3 The shear wave 345 depicted in FIG. 3 shows exaggerated amplitude and wavelength for illustrative purposes and, depending on the frequency and amplitude, may not be visually perceptible.

[0036] For example, depending on the configuration and materials used, an example frequency of the shear wave 345 may be about 10 kHz to about 100 kHz, such as a frequency of 10 kHz to 20 kHz, 20 kHz to 30 kHz, 30 kHz to 40 kHz, 40 kHz to 50 kHz, 50 kHz to 60 kHz, 60 kHz to 70 kHz, 70 kHz to 80 kHz, 80 kHz to 90 kHz, or 90 kHz to 100 kHz. The motion actuation of the pinch rollers 335 may have a controllable or variable frequency and a controllable or variable amplitude to change the location of the minimum and maximum values ​​of the shear wave 345 within the solidification region, thereby controlling the grain refinement that occurs. The pinch rollers 335 may also be translated in a horizontal direction to control the location of the minimum and maximum values ​​of the shear wave 345. Auxiliary pinch rollers 336 may be used to limit the propagation of the transverse waves in the downstream direction.

[0037] The configuration of the twin-belt caster 325 in supporting and / or cooling the cast slab 330 may be such that the shear waves 345 cannot effectively couple from the cast slab 330 into the belts of the twin-belt caster 325. For example, the cast slab 330 and the twin-belt caster 325 may not be firmly mechanically coupled.

[0038] One or more high frequency sensors 350 may be positioned upstream of the nose tip or nozzle 320. For example, the high frequency sensors 350 may be used to detect residual vibration energy transmitted to the launder 310 or tundish 315 via the molten metal 305. Information detected by the high frequency sensors 350 may be used to provide feedback control to a mechanical or electromechanical actuator to adjust the position of the pinch rolls 335 that generate the shear waves 345 in order to control the amplitude and frequency of the shear waves 345. Further feedback may be provided by examining the grain structure of the cast slab 330, which may indicate whether the vibration energy is affecting the grain structure of the cast slab 330.

[0039] Figure 4 A schematic diagram of another example continuous casting system 400 is shown. Here, molten metal 405 is transferred from a ladle 410 to a tundish 415 and into a nose or nozzle 420 of a twin-belt caster 425, where the molten metal 405 solidifies and cools to form a cast slab 430. Downstream of the twin-belt caster 425, pinch rolls 435 apply pressure to the cast slab 430 and pull the cast slab 430 away from the twin-belt caster 425. Although Figure 4 Described as producing a cast slab 430 , other cast metal products such as cast metal bars, cast metal billets, cast metal sheets, cast metal plates, etc. may be produced according to the disclosed techniques. Figure 4 The continuous casting system 400 shown shows a twin belt caster 425, but such a configuration is not limiting, and other continuous casting systems, such as twin roll casters and block casters, can be used. In addition, other configurations that do not employ a tundish or launder can be used. A vertical casting orientation can also be used.

[0040] Instead of applying acoustic or mechanical ultrasonic energy within the solidification zone to control the grain refinement that occurs, Figure 4 The configuration depicted in is arranged to apply ultrasonic energy via magnetohydrodynamics. Magnetohydrodynamics can be generated by simultaneously applying a static magnetic field and an alternating electric field to a molten or solidifying metal. Further details on magnetohydrodynamics are described in Vivès, Journal of Crystal Growth 173, 541-549, 1997, which is hereby incorporated by reference.

[0041] Pinch roller 435 Figure 4 4 is depicted as being electrically coupled to an AC (alternating current) voltage source 440. The tundish 415 is also shown as being electrically coupled to the AC voltage source 440. In this configuration, the AC voltage source is used to apply an AC current and / or voltage to the molten metal 405 as it is cast and solidified into the cast slab 430 to generate an alternating electric field in the solidification region. An example AC frequency of the AC voltage source may be derived from ultrasonic frequencies, such as 10 kHz to 100 kHz. Other configurations for applying an AC voltage or current may be used, such as a configuration in which the twin belt caster 425 or the nozzle 420 is electrically coupled to the AC voltage source 440.

[0042] A static magnetic field 445 is applied to the twin-belt casting machine 425. Figure 4 A downward direction of the static magnetic field 445 is shown in FIG, but other directions may be used, such as Figure 4 The magnetic field 445 may be generated using, for example, a permanent magnetic field source or an electromagnet. When magnetohydrodynamic forces are generated, these forces may be generated directly in the solidification zone, or may be coupled to the solidification zone through the action of the cast slab 430.

[0043] One or more high frequency sensors 450 may be positioned upstream of the nose tip or nozzle 420. For example, the high frequency sensor 450 may be used to detect residual vibration energy transmitted to the launder 410 or tundish 415 by the molten metal 405. Information detected by the high frequency sensor 450 may be used to provide feedback control of the AC voltage source 440. Further feedback may be provided by examining the grain structure of the cast slab 430, which may indicate whether the magnetohydrodynamic ultrasonic energy affects the grain structure of the cast slab 430.

[0044] Despite the above Figure 4 The description of the present invention describes the use of a static magnetic field 445 and an AC voltage source 440, but the aspects described herein may alternatively be implemented by using a variable magnetic field (e.g., an electromagnet driven by a variable current source) and a DC voltage source to generate magnetohydrodynamic force through the interaction of the variable magnetic field and the electrostatic field within the coagulation region.

[0045] Any suitable continuous casting method can be used with the currently disclosed technology. The continuous casting system may include a pair of moving relative casting surfaces (e.g., moving relative belts, rollers or blocks), a casting cavity between the pair of moving relative casting surfaces, and a molten metal injector (also referred to herein as a nose tip or nozzle). The molten metal injector may have an end opening from which the molten metal can leave the molten metal injector and be injected into the casting cavity.

[0046] The cast slab, cast billet, cast rod or other cast product can be processed by any suitable means. Such processing steps include, but are not limited to, homogenization, hot rolling, cold rolling, solution heat treatment and optional pre-aging steps. For example, the cast products described herein can also be used to make products in the form of sheets, plates, rods, billets or other suitable products.

[0047] For example, in the homogenization step, the cast product may be heated to a temperature in the range of about 400°C to about 500°C, or any suitable temperature. For example, the cast product may be heated to a temperature of about 400°C, about 410°C, about 420°C, about 430°C, about 440°C, about 450°C, about 460°C, about 470°C, about 480°C, about 490°C, or about 500°C. Then, the product is allowed to be soaked (ie, maintained at a specified temperature) for a period of time to form a homogenized product. In some examples, the total time of the homogenization step (including the heating stage and the soaking stage) may be up to 24 hours. For example, in a homogenization step with a total time of up to 18 hours, the product may be heated to up to 500°C and soaked. Optionally, in a homogenization step with a total time of more than 18 hours, the product may be heated to less than 490°C and soaked. In some cases, the homogenization step includes multiple processes. In some non-limiting examples, the homogenizing step includes heating the cast product to a first temperature and holding it for a first period of time, and then heating it to a second temperature and holding it for a second period of time. For example, the cast product may be heated to about 465° C. and held for about 3.5 hours, and then heated to about 480° C. and held for about 6 hours.

[0048] After the homogenization step, a hot rolling step may be performed. Before starting hot rolling, the homogenized product may be allowed to cool to a temperature between 300°C and 450°C or other suitable temperature. For example, the homogenized product may be allowed to cool to a temperature between 325°C and 425°C or from 350°C to 400°C. The homogenized product may then be hot rolled at a suitable temperature, such as between 300° C. and 450° C., to form a hot rolled plate, hot rolled Saudi plate or hot rolled sheet having a specification of 3 mm to 200 mm (e.g., 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 15 mm, 20 mm, 25 mm, 30 mm, 35 mm, 40 mm, 45 mm, 50 mm, 55 mm, 60 mm, 65 mm, 70 mm, 75 mm, 80 mm, 85 mm, 90 mm, 95 mm, 100 mm, 110 mm, 120 mm, 130 mm, 140 mm, 150 mm, 160 mm, 170 mm, 180 mm, 190 mm, 200 mm or any value therebetween).

[0049] Cold rolling mills can be used to cold roll cast products, homogenized products or hot rolled products into thinner products, such as cold rolled sheets. The cold rolled product can have a specification of about 0.5 mm to 10 mm, for example about 0.7 mm to 6.5 mm. Optionally, the cold rolled product can have a specification of 0.5 mm, 1.0 mm, 1.5 mm, 2.0 mm, 2.5 mm, 3.0 mm, 3.5 mm, 4.0 mm, 4.5 mm, 5.0 mm, 5.5 mm, 6.0 mm, 6.5 mm, 7.0 mm, 7.5 mm, 8.0 mm, 8.5 mm, 9.0 mm, 9.5 mm or 10.0 mm. For example, cold rolling may be performed to obtain a final gauge thickness representing a gauge reduction of up to 85% (e.g., a reduction of up to 10%, up to 20%, up to 30%, up to 40%, up to 50%, up to 60%, up to 70%, up to 80%, or up to 85%) compared to the gauge before cold rolling begins. Optionally, an intermediate annealing step may be performed during the cold rolling step, such as applying a first cold rolling process, then applying an annealing process (intermediate annealing), and then applying a second cold rolling process. The intermediate annealing step may be performed at a suitable temperature such as from about 300° C. to about 450° C. (e.g., about 310° C., about 320° C., about 330° C., about 340° C., about 350° C., about 360° C., about 370° C., about 380° C., about 390° C., about 400° C., about 410° C., about 420° C., about 430° C., about 440° C., or about 450° C.). In some cases, the intermediate annealing step includes multiple processes. In some non-limiting examples, the intermediate annealing step includes heating a portion of the cold-pressed product to a first temperature and maintaining it for a first period of time, and then heating it to a second temperature and maintaining it for a second period of time. For example, the portion of the cold-pressed product may be heated to about 410°C and maintained for about 1 hour, and then heated to about 330°C and maintained for about 2 hours.

[0050] Subsequently, the cast product, homogenised product or rolled product may, in certain cases, be subjected to a solution heat treatment step and / or a pre-aging step.

[0051] Methods of using the disclosed metal products

[0052] The metal products described herein can be used in automotive applications and other transportation applications, including aircraft and railroad applications. For example, the disclosed products can be used to prepare automotive structural parts such as bumpers, side beams, roof beams, cross beams, pillar reinforcements (e.g., A-pillars, B-pillars, and C-pillars), interior panels, exterior panels, side panels, inner covers, outer covers, or trunk covers. The metal products and methods described herein can also be used in applications in aircraft or railroad vehicles to prepare, for example, exterior and interior panels.

[0053] The metal products and methods described herein can also be used in electronic applications or any other desired application. For example, the metal products and methods described herein can be used to prepare housings for electronic devices, including mobile phones and tablet computers. In some examples, the metal products can be used to prepare housings for mobile phones (e.g., smart phones), tablet chassis, and other portable electronic devices.

[0054] Metals and Metal Alloys

[0055] Methods for preparing metal and metal alloy products are described herein, including products including aluminum, aluminum alloys, magnesium, magnesium alloys, magnesium composites, and steel, etc. In some examples, the metal used in the methods described herein includes an aluminum alloy, for example, a 1xxx series aluminum alloy, a 2xxx series aluminum alloy, a 3xxx series aluminum alloy, a 4xxx series aluminum alloy, a 5xxx series aluminum alloy, a 6xxx series aluminum alloy, a 7xxx series aluminum alloy, or an 8xxx series aluminum alloy. In some examples, the material used in the methods described herein includes a non-ferrous material, including aluminum, an aluminum alloy, magnesium, a magnesium-based material, a magnesium alloy, a magnesium composite, titanium, a titanium-based material, a titanium alloy, copper, a copper-based material, a composite material, a sheet used in a composite material, or any other suitable metal, non-metal, or material combination. In some examples, an aluminum alloy containing iron can be used in the methods described herein.

[0056] As non-limiting examples, exemplary 1xxx series aluminum alloys for use in the methods described herein may include AA1100, AA1100A, AA1200, AA1200A, AA1300, AA1110, AA1120, AA1230, AA1230A, AA1235, AA1435, AA1145, AA1345, AA1445, AA1150, AA1350, AA1350A, AA1450, AA1370, AA1275, AA1185, AA1285, AA1385, AA1188, AA1190, AA1290, AA1193, AA1198, or AA1199.

[0057] Non-limiting exemplary 2xxx series aluminum alloys useful in the methods described herein may include AA2001, AA2002, AA2004, AA2005, AA2006, AA2007, AA2007A, AA2007B, AA2008, AA2009, AA2010, AA2011, AA2011A, AA2111, AA2111A, AA2111B, AA2012, AA2013, AA2014, AA2015, AA2016, AA2017, AA2018, AA2019, AA2020, AA2021 4A, AA2214, AA2015, AA2016, AA2017, AA2017A, AA2117, AA2018, AA2218, AA2618, AA2618A, AA2219, AA2 319, AA2419, AA2519, AA2021, AA2022, AA2023, AA2024, AA2024A, AA2124, AA2224, AA2224A, AA2324, AA2 424, AA2524, AA2624, AA2724, AA2824, AA2025, AA2026, AA2027, AA2028, AA2028A, AA2028B, AA2028C, A A2029, AA2030, AA2031, AA2032, AA2034, AA2036, AA2037, AA2038, AA2039, AA2139, AA2040, AA2041, AA2 044, AA2045, AA2050, AA2055, AA2056, AA2060, AA2065, AA2070, AA2076, AA2090, AA2091, AA2094, AA209 5. AA2195, AA2295, AA2196, AA2296, AA2097, AA2197, AA2297, AA2397, AA2098, AA2198, AA2099 or AA2199.

[0058] Non-limiting exemplary 3xxx series aluminum alloys useful in the methods described herein may include AA3002, AA3102, AA3003, AA3103, AA3103A, AA3103B, AA3203, AA3403, AA3004, AA3004A, AA3104, AA3204, AA3304, AA3005, AA3005A, AA3105, AA3105A, AA3105B, AA3003, AA3403, AA3004, AA3004A, AA3104, AA3204, AA3304, AA3005 AA3019, AA3020, AA3021, AA3025, AA3026, AA3030, AA3130, or AA3065.

[0059] Non-limiting exemplary 4xxx series aluminum alloys for use in the methods described herein may include AA4004, AA4104, AA4006, AA4007, AA4008, AA4009, AA4010, AA4013, AA4014, AA4015, AA4015A, AA4115, AA4016, AA4017, AA4018, AA4019, AA4020, AA4021, AA4026, AA4032, AA4043, AA4043A, AA4143, AA4343, AA4643, AA4943, AA4044, AA4045, AA4145, AA4145A, AA4046, AA4047, AA4047A, or AA4147.

[0060] Non-limiting exemplary 5xxx series aluminum alloys useful in the methods described herein may include AA5182, AA5183, AA5005, AA5005A, AA5205, AA5305, AA5505, AA5605, AA5006, AA5106, AA5010, AA5110, AA5110A, AA5210, AA5310, AA5016, AA5017, AA5018, AA5018A, AA5019, AA5019A, AA5119, AA5110A, AA5210, AA5310, AA5016, AA5017, AA5018, AA5018A, AA5019, AA5019A, AA5110, AA5111A, AA5210, AA5310, AA5311 19A, AA5021, AA5022, AA5023, AA5024, AA5026, AA5027, AA5028, AA5040, AA5140, AA5041, AA5042, AA5043, AA5049, A A5149, AA5249, AA5349, AA5449, AA5449A, AA5050, AA5050A, AA5050C, AA5150, AA5051, AA5051A, AA5151, AA5251, AA 5251A, AA5351, AA5451, AA5052, AA5252, AA5352, AA5154, AA5154A, AA5154B, AA5154C, AA5254, AA5354, AA5454, AA5 554, AA5654, AA5654A, AA5754, AA5854, AA5954, AA5056, AA5356, AA5356A, AA5456, AA5456A, AA5456B, AA5556, AA55 56A, AA5556B, AA5556C, AA5257, AA5457, AA5557, AA5657, AA5058, AA5059, AA5070, AA5180, AA5180A, AA5082, AA518 2. AA5083, AA5183, AA5183A, AA5283, AA5283A, AA5283B, AA5383, AA5483, AA5086, AA5186, AA5087, AA5187 or AA5088.

[0061] Non-limiting exemplary 6xxx series aluminum alloys useful in the methods described herein may include AA6101, AA6101A, AA6101B, AA6201, AA6201A, AA6401, AA6501, AA6002, AA6003, AA6103, AA6005, AA6005A, AA6005B, AA6005C, AA6105, AA6205, AA6305, AA6006, AA6106, AA6206, AA6306, AA6007, AA6108, AA6109, AA6210, AA6211, AA6212, AA6213, AA6214, AA6215, AA6216, AA6217, AA6218, AA6219, AA6220, AA6221A, AA6222, AA6223, AA6224, AA6225, AA6226, AA6227, AA6228, AA6229, AA6330, AA6331, AA6332, AA6333 08. AA6009, AA6010, AA6110, AA6110A, AA6011, AA6111, AA6012, AA6012A, AA6013, AA6113, AA6014, AA6015, AA60 16. AA6016A, AA6116, AA6018, AA6019, AA6020, AA6021, AA6022, AA6023, AA6024, AA6025, AA6026, AA6027, AA6028 ,AA6031,AA6032,AA6033,AA6040,AA6041,AA6042,AA6043,AA6151,AA6351,AA6351A,AA6451,AA6951,AA6053, AA6055, AA6056, AA6156, AA6060, AA6160, AA6260, AA6360, AA6460, AA6460B, AA6560, AA6660, AA6061, AA6061A, AA6261, AA6361, AA6162, AA6262, AA6262A, AA6063, AA6063A, AA6463, AA6463A, AA6763, A6963, AA6064, AA6064A, AA6065, AA6066, AA6068, AA6069, AA6070, AA6081, AA6181, AA6181A, AA6082, AA6082A, AA6182, AA6091, or AA6092.

[0062] Non-limiting exemplary 7xxx series aluminum alloys useful in the methods described herein may include AA7011, AA7019, AA7020, AA7021, AA7039, AA7072, AA7075, AA7085, AA7108, AA7108A, AA7015, AA7017, AA7018, AA7019A, AA7024, AA7025, AA7028, AA7108A, AA7019A, AA7024, AA7025, AA7028, AA7108A, AA7019B, AA7024C, AA7024D, AA7024E, AA7024F, AA7024F, AA7024A, AA7024 ...A, AA7024A 7030, AA7031, AA7033, AA7035, AA7035A, AA7046, AA7046A, AA7003, AA7004, AA7005, AA7009 ,AA7010,AA7011,AA7012,AA7014,AA7016,AA7116,AA7122,AA7023,AA7026,AA7029,AA712 9. AA7229, AA7032, AA7033, AA7034, AA7036, AA7136, AA7037, AA7040, AA7140, AA7041, AA70 49. AA7049A, AA7149, 7204, AA7249, AA7349, AA7449, AA7050, AA7050A, AA7150, AA7250, AA7 7055, AA7055, AA7255, AA7056, AA7060, AA7064, AA7065, AA7068, AA7168, AA7175, AA7475, AA7076, AA7178, AA7278, AA7278A, AA7081, AA7181, AA7185, AA7090, AA7093, AA7095, or AA7099.

[0063] Non-limiting exemplary 8xxx series aluminum alloys for use in the methods described herein may include AA8005, AA8006, AA8007, AA8008, AA8010, AA8011, AA8011A, AA8111, AA8211, AA8112, AA8014, AA8015, AA8016, AA8017, AA8018, AA8019, AA8021, AA8021A, AA8021B, AA8022, AA8023, AA8024, AA8025, AA8026, AA8030, AA8130, AA8040, AA8050, AA8150, AA8076, AA8076A, AA8176, AA8077, AA8177, AA8079, AA8090, AA8091, or AA8093.

[0064] Illustrative aspects

[0065] As used below, any reference to a series of aspects should be understood as a reference to each of those aspects individually (eg, "Aspects 1 to 4" should be understood as "Aspect 1, Aspect 2, Aspect 3 or Aspect 4").

[0066] Aspect 1 is a method for manufacturing metal products, the method comprising: continuously casting molten metal in a continuous casting machine to form a cast product; applying ultrasonic frequency energy to the cast product at a position downstream of the continuous casting machine, wherein the ultrasonic frequency energy propagates through the cast product to a solidification area of ​​the cast product within the continuous casting machine.

[0067] Aspect 2 is a method as described in any previous or subsequent aspect, wherein the ultrasonic frequency energy corresponds to ultrasonic longitudinal waves generated by a sonication pole or ultrasonic transducer coupled to a pinch roll located at the position downstream of the continuous casting machine.

[0068] Aspect 3 is a method as described in any previous or subsequent aspect, wherein the ultrasonic frequency energy corresponds to ultrasonic shear waves generated by a mechanical or electromechanical actuator and applied by the pinch rolls located at the location downstream of the continuous casting machine.

[0069] Aspect 4 is a method as in any preceding or subsequent aspect, wherein the ultrasonic frequency energy corresponds to ultrasonic frequency magnetohydrodynamic force generated using a static magnetic field and an ultrasonic frequency electric field.

[0070] Aspect 5 is the method of any preceding or subsequent aspect, wherein the ultrasonic frequency electric field is generated using an alternating voltage source.

[0071] Aspect 6 is a method as in any preceding or subsequent aspect, wherein the static magnetic field is generated using a permanent magnet or an electromagnet.

[0072] Aspect 7 is a method as in any preceding or subsequent aspect, wherein the ultrasonic frequency energy corresponds to ultrasonic frequency magnetohydrodynamic force generated using ultrasonic frequency magnetic fields and electrostatic fields.

[0073] Aspect 8 is the method of any preceding or subsequent aspect, wherein the ultrasonic frequency magnetic field is generated using an electromagnet driven by an alternating current power source.

[0074] Aspect 9 is a method as in any preceding or subsequent aspect, wherein the electrostatic field is generated using a DC voltage source.

[0075] Aspect 10 is the method of any preceding or subsequent aspect, wherein the ultrasonic frequency energy has a frequency of about 10 kHz to about 100 kHz.

[0076] Aspect 11 is the method of any preceding or subsequent aspect, further comprising: detecting ultrasonic frequency energy using an acoustic sensor or receiver positioned at a location upstream of the coagulation zone.

[0077] Aspect 12 is a method as in any preceding or subsequent aspect, further comprising: controlling one or more of the amplitude, frequency, or phase of the ultrasonic frequency energy using a signal derived from the ultrasonic frequency energy detected using the acoustic sensor or receiver.

[0078] Aspect 13 is a method as in any preceding or subsequent aspect, further comprising: modifying a position, frequency, or phase of the ultrasonic frequency energy using a signal derived from the ultrasonic frequency energy detected using the acoustic sensor or receiver.

[0079] Aspect 14 is the method of any preceding or subsequent aspect, wherein the acoustic sensor or receiver is coupled to a launder or tundish that provides the molten metal to the continuous casting machine.

[0080] Aspect 15 is the method of any preceding or subsequent aspect, wherein the ultrasonic frequency energy physically interacts with growing metal grains in the solidification zone.

[0081] Aspect 16 is the method of any preceding or subsequent aspect, wherein the ultrasonic frequency energy breaks up dendrites or disperses or deagglomerates nucleation sites in the solidification zone.

[0082] Aspect 17 is the method of any preceding aspect, wherein the molten metal comprises an aluminum alloy.

[0083] Aspect 18 is a metal product manufactured by or using the method of any preceding aspect.

[0084] All patents, publications and abstracts cited above are incorporated herein by reference in their entirety. The foregoing description of the embodiments (including the illustrated embodiments) is presented for the purpose of illustration and description only and is not intended to be exhaustive or to limit the precise forms disclosed. Various modifications, variations and uses thereof will be apparent to those skilled in the art.

Claims

1. A method for manufacturing an aluminum alloy product, the method comprising: continuously casting a molten aluminum alloy in a continuous casting machine to form a cast aluminum alloy product; applying ultrasonic frequency energy to the cast aluminum alloy product at a location downstream of the continuous casting machine, wherein applying the ultrasonic frequency energy comprises subjecting the cast aluminum alloy product to ultrasonic frequency magnetohydrodynamic forces, wherein the ultrasonic frequency energy propagates through the cast aluminum alloy product to a solidification region of the cast aluminum alloy product within the continuous casting machine; detecting ultrasonic frequency energy using an acoustic sensor or receiver positioned at a location upstream of the solidification zone, wherein the acoustic sensor or receiver is coupled to a launder or tundish that provides the molten aluminum alloy to the continuous caster; as well as A signal derived from the ultrasonic frequency energy detected using the acoustic sensor or receiver is used to control one or more of the amplitude, frequency, or phase of the ultrasonic frequency energy.

2. The method of claim 1, wherein the ultrasonic frequency energy corresponds to ultrasonic longitudinal waves generated by a sonication pole or ultrasonic transducer coupled to a pinch roll at the location downstream of the continuous casting machine.

3. The method of claim 1 wherein said ultrasonic frequency energy corresponds to ultrasonic shear waves generated by a mechanical or electromechanical actuator and applied by pinch rolls located at said location downstream of said continuous casting machine.

4. The method of claim 1, wherein the ultrasonic frequency energy corresponds to an ultrasonic frequency magnetohydrodynamic force generated using a static magnetic field and an ultrasonic frequency electric field.

5. The method of claim 4, wherein the ultrasonic frequency electric field is generated using an alternating voltage source. The method of claim 4 , wherein the static magnetic field is generated using a permanent magnet or an electromagnet.

7. The method of claim 1, wherein the ultrasonic frequency energy corresponds to an ultrasonic frequency magnetohydrodynamic force generated using an ultrasonic frequency magnetic field and an electrostatic field.

8. The method of claim 7, wherein the ultrasonic frequency magnetic field is generated using an electromagnet driven by an alternating current power source.

9. The method of claim 7, wherein the electrostatic field is generated using a DC voltage source.

10. The method of claim 1, wherein the ultrasonic frequency energy has a frequency of 10 kHz to 100 kHz.

11. The method of claim 1, further comprising: A signal derived from the ultrasonic frequency energy detected using the acoustic sensor or receiver is used to modify the position, frequency or phase of the ultrasonic frequency energy.

12. The method of claim 1, wherein the ultrasonic frequency energy physically interacts with growing metal grains in the solidification zone.

13. The method of claim 1, wherein the ultrasonic frequency energy breaks up dendrites or disperses nucleation sites in the solidification zone.

14. The method of claim 1, wherein the ultrasonic frequency energy breaks up dendrites or deagglomerates nucleation sites in the solidification zone.

15. A metal product manufactured by the method of any one of claims 1 to 14.

Images