Casting diverter and method of designing a casting diverter

Abstract

The application provides a casting flow divider and a design method of the casting flow divider. The casting flow divider comprises a first flow cavity, a second flow cavity, a first inlet and a first outlet. The first inlet is a melt inlet, the first inlet is located at the top of the first flow cavity, and the first outlet is located on the side wall of the first flow cavity. The second flow cavity is independently arranged with the first flow cavity, the second flow cavity comprises a second inlet and a second outlet, the second inlet is located at the bottom of the second flow cavity, the first inlet is located above the second inlet, the second outlet is located on the side wall of the second flow cavity, the second inlet is used for being communicated with the bottom of a crystallizer casting cavity, and the second outlet is arranged adjacent to the first outlet. Through the technical scheme, the problem that the flow performance of the melt is poor in the prior art can be solved.

Description

Technical Field

[0001] This invention relates to the field of metal casting technology, and more specifically, to a casting distributor and a design method for the casting distributor. Background Technology

[0002] Currently, metal ingot casting is the primary process in metal processing, especially in the field of aluminum alloy casting. The quality of the ingot largely determines the material properties of the subsequent processed products. In the process of aluminum alloy ingot casting, the molten aluminum alloy is cooled and shaped using a crystallizer. However, with the increasing demand for large aluminum alloy structures in my country's aerospace, shipbuilding, and rail transportation industries, the size of aluminum alloy ingots is also getting larger and larger. The larger the ingot size, the greater the difference in cooling rate between the inside and outside of the ingot, and the more serious the macrosegregation of the ingot. The scale of macrosegregation runs through the entire ingot and cannot be eliminated by subsequent processing and heat treatment. Therefore, macrosegregation is a permanent and irreversible defect that seriously affects the stability of product quality.

[0003] In existing technologies, semi-continuous casting of aluminum alloy flat ingots mainly uses glass fiber cloth combined with a flow divider bag to divert the melt and control the flow direction of the fluid. This allows the solid and liquid phases of the aluminum alloy to move relative to each other during the casting process, reducing the degree of macroscopic segregation. However, the traditional flow divider bag has a relatively small proportion of melt exiting from the bottom, which has limited improvement on the melt flow inside the liquid cavity in the casting chamber. This can cause negative segregation in the core of the ingot. As the ingot size increases, the degree of segregation can reach more than 20%, and sometimes the composition may exceed the range of the alloy standard grade. Summary of the Invention

[0004] This invention provides a casting distributor and a design method for the casting distributor to solve the problem that the existing distributor bag has poor melt flow performance.

[0005] According to one aspect of the present invention, a casting distributor is provided, comprising: a first distribution chamber having a first inlet and a first outlet disposed opposite to each other, the first inlet being a melt inlet located at the top of the first distribution chamber, and the first outlet located on the side wall of the first distribution chamber; and a second distribution chamber, which is independently disposed from the first distribution chamber, having a second inlet and a second outlet disposed opposite to each other, the second inlet located at the bottom of the second distribution chamber, the first inlet located above the second inlet, and the second outlet located on the side wall of the second distribution chamber, the second inlet being used to communicate with the bottom of the casting chamber of a crystallizer, and the second outlet being disposed adjacent to the first outlet.

[0006] Furthermore, multiple first outlets and multiple second outlets are provided. Multiple first outlets are symmetrically arranged on the first diversion cavity with the center of the first diversion cavity, and the first outlets and second outlets are arranged in a one-to-one correspondence.

[0007] Furthermore, the circulation area at the first exit is 0.8 to 1.2 times that at the second exit.

[0008] Furthermore, the second outlet is characterized in that its flow direction is parallel to that of the first outlet, and the end face of the second inlet is arranged in a horizontal direction.

[0009] Furthermore, a filter assembly is installed at the first outlet.

[0010] Furthermore, the casting distributor includes a housing and a partition plate. The partition plate is disposed inside the housing to form a first distribution cavity and a second distribution cavity distributed vertically. The top of the housing has a first inlet, and the side wall of the housing has a first outlet and a second outlet. The first outlet is located above the partition plate, the second outlet is located below the partition plate, and the bottom of the housing has a second inlet.

[0011] Furthermore, a guide pipe is provided at the second inlet, and the guide pipe is connected to the second inlet.

[0012] Furthermore, the casting distributor includes a first inlet pipe, a first outlet pipe, a second inlet pipe, and a second outlet pipe. The first inlet pipe and the first outlet pipe are interconnected. The first inlet pipe is located above the first outlet pipe. The end of the first inlet pipe forms a first inlet, and the end of the first outlet pipe forms a first outlet. The second inlet pipe and the second outlet pipe are interconnected. The second inlet pipe is located below the second outlet pipe. The end of the second inlet pipe forms a second inlet, and the end of the second outlet pipe forms a second outlet. The first outlet pipe is sleeved on the outside of the second outlet pipe.

[0013] Furthermore, the first inlet pipe and the second inlet pipe are coaxially arranged, and the first outlet pipe and the second outlet pipe are coaxially arranged.

[0014] According to another aspect of the present invention, a design method for a casting distributor is provided. The casting distributor is the casting distributor described above. The design method includes: Step 1: Obtaining the dimensions of the casting cavity of the crystallizer, and determining the dimensions of the casting distributor based on the dimensions of the casting cavity of the crystallizer; Step 2: Establishing a steady-state thermal-fluid coupling model of the casting process based on the dimensions of the casting cavity of the crystallizer, the dimensions of the casting distributor, and the casting process, and obtaining the flow field distribution inside the casting cavity of the crystallizer based on the steady-state thermal-fluid coupling model; Step 3: Performing CFD analysis based on the flow field distribution. If the melt velocity at the second inlet meets a preset standard, then the casting distributor is prepared according to the dimensions of the casting distributor; if the melt velocity at the second inlet does not meet the preset standard, then the dimensions of the casting distributor are re-determined and Step 2 and Step 3 are repeated until the melt velocity at the second inlet meets the preset standard.

[0015] Further, the casting distributor includes a shell and a partition. The partition is disposed inside the shell to form a first and second distribution chamber distributed vertically. The top of the shell has a first inlet, and the side wall of the shell has a first outlet and a second outlet. The first outlet is located above the partition, and the second outlet is located below the partition. The bottom of the shell has a second inlet. Step one specifically includes: Step 101: Obtain the dimensions of the casting chamber of the crystallizer and calculate the depth of the liquid cavity in the casting chamber of the crystallizer based on the dimensions of the casting chamber of the crystallizer; Step 102: Determine the length of the guide tube based on the depth of the liquid cavity; Step 103: Obtain the melt flow velocity at the first outlet and calculate the flow area of ​​the first outlet and the second outlet based on the vertical cross-sectional area of ​​the casting chamber of the crystallizer, the casting speed, and the melt flow velocity at the first outlet.

[0016] Furthermore, the flow area of ​​the first outlet is S1, the flow area of ​​the second outlet is S2, the area of ​​the vertical cross-section of the crystallizer casting cavity is S3, the flow area at the first outlet is V1, and the casting speed is V2. The flow areas of the first outlet and the second outlet are calculated using the following formula. S2 is 0.8 to 1.2 times that of S1.

[0017] Furthermore, in step three, if the melt flow rate at the second inlet does not meet the preset standard, the dimensions of the casting distributor are redefined. Specifically, this includes: when the melt flow rate at the second inlet is less than the preset standard, reducing the flow area of ​​the first outlet or reducing the length of the guide tube; when the melt flow rate at the second inlet is greater than the preset standard, increasing the flow area of ​​the first outlet or increasing the length of the guide tube.

[0018] By applying the technical solution of this invention, during the casting process, when the melt enters the first diversion chamber through the first inlet, the melt will quickly flow out through the first outlet. The melt flow near the first outlet will generate a high flow velocity. According to Bernoulli's theorem, a negative pressure will be generated at the second outlet adjacent to the first outlet. The melt in the liquid cavity of the crystallizer casting chamber will enter the second diversion chamber through the second inlet and flow back into the liquid cavity through the second outlet. In this way, the natural flow of the melt during the casting process can drive the flow of the melt inside the crystallizer casting chamber, so that the melt in the casting chamber can be convection, thereby reducing the influence of macroscopic segregation, improving the quality of the metal ingot, and enhancing the performance of subsequent processed products. Attached Figure Description

[0019] The accompanying drawings, which form part of this application, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an undue limitation of the invention. In the drawings:

[0020] Figure 1 A schematic diagram of the structure of the casting distributor provided according to a first embodiment of the present invention is shown;

[0021] Figure 2 A cross-sectional view of a casting distributor provided according to a first embodiment of the present invention is shown;

[0022] Figure 3 A schematic diagram of the structure of the casting distributor provided according to a second embodiment of the present invention is shown;

[0023] Figure 4 A schematic diagram illustrating the effect of the casting distributor provided according to an embodiment of the present invention in guiding the melt within the casting cavity of a crystallizer is shown.

[0024] Figure 5 The diagram shows the flow field distribution in the experimental group of the design method for the casting distributor provided by this invention.

[0025] Figure 6 The flow field distribution diagram in the control group of the design method of the casting distributor provided by the present invention is shown.

[0026] The above figures include the following reference numerals:

[0027] 100. First shunt chamber; 110. First inlet; 120. First outlet;

[0028] 200, Second shunt chamber; 210, Second inlet; 220, Second outlet;

[0029] 10. Shell; 20. Partition plate; 30. Flow guide tube;

[0030] 40. First inlet pipe; 50. First outlet pipe; 60. Second inlet pipe; 70. Second outlet pipe. Detailed Implementation

[0031] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The following description of at least one exemplary embodiment is merely illustrative and is in no way intended to limit the present invention or its application or use. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0032] like Figure 1 and Figure 4As shown, according to one aspect of the present invention, a casting distributor is provided, comprising a first distribution chamber 100 and a second distribution chamber 200. The first distribution chamber 100 has a first inlet 110 and a first outlet 120 disposed opposite to each other. The first inlet 110 is a melt inlet located at the top of the first distribution chamber 100, and the first outlet 120 is located on the side wall of the first distribution chamber 100. The second distribution chamber 200 is disposed independently of the first distribution chamber 100, and has a second inlet 210 and a second outlet 220 disposed opposite to each other. The second inlet 210 is located at the bottom of the second distribution chamber 200, the first inlet 110 is located above the second inlet 210, and the second outlet 220 is located on the side wall of the second distribution chamber 200. The second inlet 210 communicates with the bottom of the casting chamber of the crystallizer, and the second outlet 220 is disposed adjacent to the first outlet 120.

[0033] By applying the technical solution of this invention, during the casting process, when the melt enters the first diversion chamber 100 through the first inlet 110, the melt will quickly flow out through the first outlet 120. The melt flow near the first outlet 120 will generate a high flow velocity. According to Bernoulli's theorem, a negative pressure will be generated at the second outlet 220 adjacent to the first outlet 120. The melt in the liquid cavity of the crystallizer casting chamber will enter the second diversion chamber 200 through the second inlet 210 and flow back into the liquid cavity through the second outlet 220. In this way, the natural flow of the melt during the casting process can drive the flow of the melt inside the crystallizer casting chamber, so that the melt in the casting chamber can be convection, thereby reducing the influence of macrosegregation, improving the quality of the metal ingot, and improving the performance of subsequent processed products.

[0034] Specifically, multiple first outlets 120 and second outlets 220 are provided. These multiple first outlets 120 are symmetrically arranged around the center of the first diversion cavity 100, with each first outlet 120 corresponding to a second outlet 220. This arrangement, with multiple first outlets 120 and second outlets 220, allows for molten material convection, further enhancing the melt flow within the cavity, reducing the difference in cooling rates between the inside and outside of the ingot, and minimizing the impact of macroscopic deviations. Specifically, the number of first outlets 120 and second outlets 220 can be 2, 4, or 6, adjustable according to the specific ingot shape to adapt to different ingot casting scenarios.

[0035] Furthermore, the flow area at the first outlet 120 is 0.8 to 1.2 times the flow area at the second outlet 220. When the ratio of the flow area at the first outlet 120 to the flow area at the second outlet 220 is less than 0.8, the flow area at the second outlet 220 is too small, affecting the flow effect of the melt at the second outlet 220. When the ratio of the flow area at the first outlet 120 to the flow area at the second outlet 220 is greater than 1.2, the flow area at the second outlet 220 is too large. Under the condition that the negative pressure at the second outlet 220 remains unchanged, the excessively large flow area at the second outlet 220 will lead to a decrease in the flow rate at the second outlet 220, reducing the flow effect of the melt inside the liquid cavity. In this application, by setting the flow area at the first outlet 120 to be 0.8 to 1.2 times the flow area at the second outlet 220, the flow effect of the melt at the second outlet 220 can be guaranteed while ensuring the flow performance of the melt inside the liquid cavity. Specifically, the circulation area at the first exit 120 can be set to be 0.8 times, 1.0 times, or 1.2 times the circulation area at the second exit 220.

[0036] Specifically, the flow direction of the second outlet 220 is parallel to that of the first outlet 120, and the end face of the second inlet 210 is horizontal. This arrangement ensures that the flow direction of the second outlet 220 is consistent with that of the first outlet 120, thereby guaranteeing stable flow of the molten material in the casting cavity, reducing the possibility of turbulence within the cavity, and ensuring the stability of the molten material flow during the casting process.

[0037] Furthermore, a filter assembly is installed at the first outlet 120. Through this arrangement, the filter structure can reduce the content of impurities and oxides in the melt, thereby improving the material properties of the ingot.

[0038] Specifically, the filter component can be set as a filter screen.

[0039] like Figure 2As shown, in the first embodiment of this application, the casting distributor includes a housing 10 and a partition 20. The partition 20 is disposed within the housing 10 to form a first distribution cavity 100 and a second distribution cavity 200 distributed vertically. The top of the housing 10 has a first inlet 110, and the sidewalls of the housing 10 have a first outlet 120 and a second outlet 220. The first outlet 120 is located above the partition 20, and the second outlet 220 is located below the partition 20. The bottom of the housing 10 has a second inlet 210. With the above arrangement, the partition 20 can divide the inner cavity of the housing 10 into the first distribution cavity 100 and the second distribution cavity 200, thereby facilitating the processing of the casting distributor. Furthermore, when it is necessary to adjust the ratio between the first outlet 120 and the second outlet 220, it is not necessary to remanufacture the housing 10; only the position of the partition 20 within the housing needs to be adjusted, making it easy to adjust the casting distributor according to production needs.

[0040] Furthermore, a guide pipe 30 is provided at the second inlet 210, and the guide pipe 30 is connected to the second inlet 210. Through the above arrangement, the guide pipe 30 can penetrate deep into the bottom of the casting cavity, so that the negative pressure generated at the second outlet 220 can drive the melt at the bottom of the cavity to convect, improve the effect of the casting distributor on the fluid flow in the cavity, and further reduce macroscopic segregation.

[0041] like Figure 3 As shown, in the second embodiment of this application, the casting distributor includes a first inlet pipe 40, a first outlet pipe 50, a second inlet pipe 60, and a second outlet pipe 70. The first inlet pipe 40 and the first outlet pipe 50 are interconnected, with the first inlet pipe 40 located above the first outlet pipe 50. The end of the first inlet pipe 40 forms a first inlet 110, and the end of the first outlet pipe 50 forms a first outlet 120. The second inlet pipe 60 and the second outlet pipe 70 are interconnected, with the second inlet pipe 60 located below the second outlet pipe 70. The end of the second inlet pipe 60 forms a second inlet 210, and the end of the second outlet pipe 70 forms a second outlet 220. The first outlet pipe 50 is sleeved on the outside of the second outlet pipe 70. With the above arrangement, the first outlet 120 can surround the outer periphery of the second outlet 220, improving the suction effect of the negative pressure at the first outlet 120 on the melt at the second outlet 220, thereby improving the flow effect of the melt.

[0042] Furthermore, the first inlet pipe 40 and the second inlet pipe 60 are coaxially arranged, as are the first outlet pipe 50 and the second outlet pipe 70. This arrangement ensures that the flow direction at the second outlet 220 is consistent with the flow direction at the first outlet 120, and the flow direction at the second inlet 210 is consistent with the flow direction at the first inlet 110. This guarantees stable flow of the molten material in the casting cavity, reduces the possibility of turbulence within the cavity, and further reduces macroscopic segregation in the ingot.

[0043] According to another aspect of the present invention, a design method for a casting distributor is provided. The casting distributor is the casting distributor described above. The design method includes the following steps: Step 1: Obtaining the dimensions of the casting cavity of the crystallizer, and determining the dimensions of the casting distributor based on the dimensions of the casting cavity. Step 2: Establishing a steady-state thermo-fluid coupling model of the casting process based on the dimensions of the casting cavity of the crystallizer, the dimensions of the casting distributor, and the casting process, and obtaining the flow field distribution inside the casting cavity of the crystallizer based on the steady-state thermo-fluid coupling model. Step 3: Performing CFD analysis based on the flow field distribution. If the melt velocity at the second inlet 210 meets the preset standard, then the casting distributor is prepared according to the dimensions of the casting distributor; if the melt velocity at the second inlet 210 does not meet the preset standard, then the dimensions of the casting distributor are re-determined and steps 2 and 3 are repeated until the melt velocity at the second inlet 210 meets the preset standard.

[0044] With the technical solution of this invention, when it is necessary to use the casting distributor provided in this application to divide the melt, in step three, CFD analysis of the flow field distribution can be performed to obtain the flow velocity of the melt at the second inlet 210. Based on the flow velocity of the melt at the second inlet 210, the flow condition of the melt inside the liquid cavity can be determined. And according to the design scheme in steps one and two, the size of the casting distributor can be adjusted so that the casting distributor can achieve a better effect of melting flow, improve the use effect of the casting distributor, reduce macrosegregation that occurs during the casting process, and ensure the product performance of the ingot.

[0045] Specifically, the casting distributor is the casting distributor of the first embodiment of this application. The casting distributor includes a guide pipe 30. Step one specifically includes step 101: obtaining the dimensions of the crystallizer casting cavity and calculating the depth of the liquid cavity in the crystallizer casting cavity based on the dimensions of the crystallizer casting cavity. Step 102: determining the length of the guide pipe 30 based on the liquid cavity depth. Step 103: obtaining the melt flow velocity at the first outlet 120 and calculating the flow area of ​​the first outlet 120 and the second outlet 220 based on the vertical cross-sectional area of ​​the crystallizer casting cavity, the casting speed, and the melt flow velocity at the first outlet 120.

[0046] Specifically, in step 101, the dimensions of the crystallizer casting cavity are obtained, including the length L0 and width W0 of the crystallizer casting cavity. Based on the length L0 and width W0 of the crystallizer casting cavity, the length L1, width W1 and height H1 of the shell 10 can be determined. Specifically, L1 = L0 / 3, W1 = W0 / 5, 0.8W ≤ H1 ≤ 1.2W.

[0047] The depth of the liquid cavity H2 can be calculated based on the width W1 of the shell 10. Specifically, it can be set as follows: 0.8H1≤H2≤1.2H1.

[0048] Specifically, in step 102, the length of the guide tube 30 is H3. The length H3 of the guide tube 30 should be less than H2-H1 to prevent the second inlet 210 from directly contacting the bottom of the liquid cavity and to ensure the guiding effect of the guide tube 30. Specifically, it can be set as follows: 0.1*(H2-H1)≤H3≤0.8*(H2-H1). If H3<0.1*(H2-H1), the guide tube 30 cannot enter the liquid cavity and cannot play a good guiding role for the melt inside the liquid cavity; if H3>0.8*(H2-H1), the guide tube 30 goes too deep into the bottom of the liquid cavity and cannot play a good guiding role for the melt in the overall casting cavity. Specifically, H3 can be set to 0.1*(H2-H1), H3 = 0.5*(H2-H1), or H3 = 0.8*(H2-H1) to ensure that the second inlet 210 is located in the middle of the liquid cavity, thereby improving the casting distributor's ability to guide the melt in the liquid cavity and enhancing the flow performance of the melt in the casting cavity.

[0049] Furthermore, the flow area of ​​the first outlet 120 is S1, the flow area of ​​the second outlet 220 is S2, the vertical cross-sectional area of ​​the casting chamber of the crystallizer is S3, the melt velocity at the first outlet 120 is V1, and the casting speed is V2. The flow areas of the first outlet 120 and the second outlet 220 are calculated using the following formula: Wherein, S2 is 0.8 to 1.2 times that of S1. Specifically, the flow velocity of the melt at the first outlet 120 can be set to 0.3-0.5 m / s. When V1 is less than 0.3 m / s, the speed at which the melt enters the casting cavity is relatively slow, and the negative pressure generated by the melt at the first outlet 120 on the melt at the second outlet 220 is relatively small, which is not conducive to the flow of the melt in the casting cavity. When V1 is greater than 0.5 m / s, the speed at which the melt enters the casting cavity is relatively fast, which is not conducive to the forming of the ingot. Preferably, V1 can be set to 0.5 m / s to ensure the forming effect of the ingot while ensuring that the melt in the casting cavity has a certain flow performance. Specifically, V1 can be set to 0.3 m / s, 0.4 m / s, and 0.5 m / s.

[0050] Specifically, in step three, if the melt flow velocity at the second inlet 210 does not meet the preset standard, the dimensions of the casting distributor are redefined. Specifically, when the melt flow velocity at the second inlet 210 is less than the preset standard, the flow area of ​​the first outlet 120 is reduced, or the length of the guide pipe 30 is reduced; when the melt flow velocity at the second inlet 210 is greater than the preset standard, the flow area of ​​the first outlet 120 is increased, or the length of the guide pipe 30 is increased. Specifically, the melt flow velocity at the second inlet 210 can be preset to 0.05-0.2 m / s to ensure that the melt within the cavity has a certain flow velocity.

[0051] The design method provided by this invention will be described in detail below with reference to control experiments.

[0052] Experimental group:

[0053] The experimental group cast 6050 aluminum alloy flat ingots with dimensions of 520×1620mm at a casting speed of 50mm / min and a water flow rate of 90m³. 3 / h, casting temperature is 600℃. The length of the crystallizer casting cavity L0 = 1620mm, the width of the crystallizer casting cavity W0 = 520mm, the casting distributor uses the casting distributor of the first embodiment of this application, and the dimensions of the casting distributor are determined according to step 101: L1 = 540mm, W1 = 104mm, H1 = W1 = 104mm, and the liquid cavity depth H2 is calculated to be 500mm, and H3 = 0.5*(H2-H1) = 200mm is set, V1 is preset to 0.5m / s, and S3 = 600mm is calculated. 2 Based on the aforementioned alloy composition, casting process parameters, and flow distribution bag structure, a steady-state temperature-flow coupling model for the casting process was established. Then, CFD analysis was performed on the internal flow field distribution of the crystallizer casting cavity obtained from the steady-state heat-flow coupling model. The flow field distribution is shown below. Figure 5 As shown, the melt velocity at the second outlet 220 is 0.4 m / s, which exceeds 0.2 m / s. Therefore, the side outlet area S3 is reduced to 600 mm². 2 After remodeling, calculating and analyzing, the bottom suction velocity of the melt was found to be 0.2. Based on this, the structure of the casting distributor was determined. The casting distributor of this specification was prepared by mold making, installed on the casting platform and baked.

[0054] According to the alloy composition, the main alloying elements are: 6.2% Zn, 2.0% Mg, 2.2% Cu, 0.1% Zr, and 0.02% Ti. Aluminum blocks, Al-Cu master alloys, and Al-Zr master alloys are melted in a melting furnace. Mg ingots are heated to 730–750°C, and the composition is measured and fine-tuned to meet the target composition. The melt is then transferred to a settling furnace for refining with a refining agent. After slag removal, it is allowed to stand for 2 hours, followed by degassing and filtration. An Al-Ti-C rod refining agent is added online. The melt is introduced into the casting distributor through a flow channel and casting nozzle, flowing into the molten pool from the first outlet 120, achieving continuous online casting. The high-velocity fluid promotes flow inside the bottom cavity, achieving a suction effect on the melt at the bottom of the molten pool, improving the flow field at the bottom of the molten pool. Simultaneously, it draws the melt with low solute content from the bottom into the upper part of the molten pool, achieving repeated mixing and reducing segregation.

[0055] After casting, the cross-section of the ingot was sampled and analyzed to evaluate the segregation degree of the ingot. The results showed that the segregation degree of the main element Zn in the ingot was 5.1%, which significantly reduced the segregation degree of large-size ingots.

[0056] Control group:

[0057] The control group consisted of 520×1620mm 6050 aluminum alloy flat ingots, cast at a speed of 50mm / min, a water flow rate of 90m³ / h, and a casting temperature of 600℃. The crystallizer inner cavity length L0 = 1620mm and the crystallizer inner cavity width W0 = 520mm. A conventional flow divider bag was used, installed on the casting platform and heated. The flow field distribution was as follows: Figure 6 As shown.

[0058] According to the alloy composition, the main alloying elements are: 6.2% Zn, 2.0% Mg, 2.2% Cu, 0.1% Zr, and 0.02% Ti. Aluminum blocks, Al-Cu master alloys, and Al-Zr master alloys are melted in a melting furnace. Mg ingots are heated to 730–750°C, and the composition is measured and fine-tuned. The melt is then transferred to a settling furnace for refining with a refining agent. After slag removal, it is allowed to stand for 2 hours, followed by degassing and filtration. An Al-Ti-C rod refining agent is added online. The melt flows into the molten pool through a runner and casting nozzle via a distribution bag, achieving continuous online casting. After casting, cross-sections of the ingot are sampled and analyzed to evaluate the segregation degree. The results show that the segregation degree of the main element Zn in the ingot is 8.9%, with severe negative segregation at the ingot center.

[0059] Based on the above comparative experiments, it can be concluded that using the casting distributor provided by the present invention can significantly reduce the degree of segregation of the ingot.

[0060] According to another aspect of this application, a metal casting method is provided. The casting method uses the casting distributor provided in this application to divide the melt. The casting method specifically includes: fixing the casting distributor on the casting platform and baking and drying it, and distributing the alloy according to the alloy composition, and sequentially melting the alloy, fine-tuning the composition, degassing and slag removal, settling, degassing and filtering, adding a fine agent online, and completing the casting.

[0061] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments according to this application. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0062] Unless otherwise specifically stated, the relative arrangement, numerical expressions, and values ​​of the components and steps set forth in these embodiments do not limit the scope of the invention. It should also be understood that, for ease of description, the dimensions of the various parts shown in the drawings are not drawn to actual scale. Techniques, methods, and devices known to those skilled in the art may not be discussed in detail, but where appropriate, such techniques, methods, and devices should be considered part of the specification. In all examples shown and discussed herein, any specific values ​​should be interpreted as merely exemplary and not as limitations. Therefore, other examples of exemplary embodiments may have different values. It should be noted that similar reference numerals and letters in the following figures denote similar items; therefore, once an item is defined in one figure, it need not be further discussed in subsequent figures.

[0063] In the description of this invention, it should be understood that the orientation or positional relationship indicated by directional terms such as "front, back, up, down, left, right", "horizontal, vertical, horizontal" and "top, bottom" is generally based on the orientation or positional relationship shown in the accompanying drawings, and is only for the convenience of describing this invention and simplifying the description. Unless otherwise stated, these directional terms do not indicate or imply that the device or element referred to must have a specific orientation or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation on the scope of protection of this invention; the directional terms "inner" and "outer" refer to the inner and outer contours relative to the outline of each component itself.

[0064] For ease of description, spatial relative terms such as "above," "on top of," "on the upper surface of," "above," etc., are used herein to describe the spatial positional relationship of a device or feature as shown in the figures to other devices or features. It should be understood that spatial relative terms are intended to encompass different orientations in use or operation beyond the orientation of the device as described in the figures. For example, if the device in the figures were inverted, a device described as "above" or "on top of" other devices or structures would subsequently be positioned as "below" or "under" other devices or structures. Thus, the exemplary term "above" can include both "above" and "below." The device may also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatial relative descriptions used herein will be interpreted accordingly.

[0065] Furthermore, it should be noted that the use of terms such as "first" and "second" to define components is merely for the purpose of distinguishing the corresponding components. Unless otherwise stated, the above terms have no special meaning and therefore should not be construed as limiting the scope of protection of this invention.

[0066] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A casting distributor, characterized in that, The casting distributor includes: The first flow divider (100) has a first inlet (110) and a first outlet (120) disposed opposite to each other. The first inlet (110) is a melt inlet and is located at the top of the first flow divider (100). The first outlet (120) is located on the side wall of the first flow divider (100). The second diversion chamber (200) is independently arranged from the first diversion chamber (100). The second diversion chamber (200) has a second inlet (210) and a second outlet (220) arranged opposite to each other. The second inlet (210) is located at the bottom of the second diversion chamber (200), the first inlet (110) is located above the second inlet (210), and the second outlet (220) is located on the side wall of the second diversion chamber (200). The second inlet (210) is used to communicate with the bottom of the crystallizer casting chamber, and the second outlet (220) is arranged adjacent to the first outlet (120). The circulation area at the first exit (120) is 0.8 to 1.2 times the circulation area at the second exit (220); The flow direction of the second outlet (220) is parallel to the flow direction of the first outlet (120), and the end face of the second inlet (210) is arranged in the horizontal direction; The casting diverter includes a housing (10) and a partition (20). The partition (20) is disposed inside the housing (10) to form a first diverting cavity (100) and a second diverting cavity (200) distributed vertically. The top of the housing (10) has a first inlet (110). The side wall of the housing (10) is provided with a first outlet (120) and a second outlet (220). The first outlet (120) is located above the partition (20), and the second outlet (220) is located below the partition (20). The bottom of the housing (10) is provided with a second inlet (210).

2. The casting distributor according to claim 1, characterized in that, Both the first outlet (120) and the second outlet (220) are provided in multiples. The multiple first outlets (120) are symmetrically arranged on the first diversion cavity (100) with the center of the first diversion cavity (100). The first outlet (120) and the second outlet (220) are provided in a one-to-one correspondence.

3. The casting distributor according to claim 1, characterized in that, A filter assembly is provided at the first outlet (120).

4. The casting distributor according to claim 1, characterized in that, A guide pipe (30) is provided at the second inlet (210), and the guide pipe (30) is connected to the second inlet (210).

5. A casting distributor, characterized in that, The casting distributor includes: The first flow divider (100) has a first inlet (110) and a first outlet (120) disposed opposite to each other. The first inlet (110) is a melt inlet and is located at the top of the first flow divider (100). The first outlet (120) is located on the side wall of the first flow divider (100). The second diversion chamber (200) is independently arranged from the first diversion chamber (100). The second diversion chamber (200) has a second inlet (210) and a second outlet (220) arranged opposite to each other. The second inlet (210) is located at the bottom of the second diversion chamber (200), the first inlet (110) is located above the second inlet (210), and the second outlet (220) is located on the side wall of the second diversion chamber (200). The second inlet (210) is used to communicate with the bottom of the crystallizer casting chamber, and the second outlet (220) is arranged adjacent to the first outlet (120). The casting distributor further includes a first inlet pipe (40), a first outlet pipe (50), a second inlet pipe (60), and a second outlet pipe (70). The first inlet pipe (40) is connected to the first outlet pipe (50). The first inlet pipe (40) is located above the first outlet pipe (50). The end of the first inlet pipe (40) forms the first inlet (110), and the end of the first outlet pipe (50) forms the first outlet (120). The second inlet pipe (60) is connected to the second outlet pipe (70). The second inlet pipe (60) is located below the second outlet pipe (70). The end of the second inlet pipe (60) forms the second inlet (210), and the end of the second outlet pipe (70) forms the second outlet (220). The first outlet pipe (50) is sleeved on the outside of the second outlet pipe (70).

6. The casting distributor according to claim 5, characterized in that, The first inlet pipe (40) and the second inlet pipe (60) are coaxially arranged, and the first outlet pipe (50) and the second outlet pipe (70) are coaxially arranged.

7. A design method for a casting distributor, characterized in that, The casting distributor is the casting distributor according to any one of claims 1 to 6, and the design method includes: Step 1: Obtain the dimensions of the crystallizer casting cavity, and determine the dimensions of the casting distributor based on the dimensions of the crystallizer casting cavity; Step 2: Based on the dimensions of the casting cavity of the crystallizer, the dimensions of the casting distributor, and the casting process, establish a steady-state thermal-fluid coupling model of the casting process, and obtain the flow field distribution inside the casting cavity of the crystallizer based on the steady-state thermal-fluid coupling model; Step 3: Perform CFD analysis based on the flow field distribution. If the melt velocity at the second inlet (210) meets the preset standard, then prepare the casting distributor according to the size of the casting distributor. If the melt velocity at the second inlet (210) does not meet the preset standard, then redetermine the size of the casting distributor and repeat Step 2 and Step 3 until the melt velocity at the second inlet (210) meets the preset standard.

8. The design method according to claim 7, characterized in that, The casting distributor is the casting distributor as described in claim 4, and step one specifically includes: Step 101: Obtain the dimensions of the crystallizer casting cavity, and calculate the depth of the liquid cavity in the crystallizer casting cavity based on the dimensions of the crystallizer casting cavity; Step 102: Determine the length of the guide tube (30) based on the depth of the cavitation cavity; Step 103: Obtain the melt flow rate at the first outlet (120), and calculate the flow area of ​​the first outlet (120) and the second outlet (220) based on the vertical cross-sectional area of ​​the casting cavity of the crystallizer, the casting speed, and the melt flow rate at the first outlet (120).

9. The design method according to claim 8, characterized in that, The flow area of ​​the first outlet (120) is S1, the flow area of ​​the second outlet (220) is S2, the area of ​​the vertical cross-section of the casting cavity of the crystallizer is S3, the flow velocity of the melt at the first outlet (120) is V1, and the casting speed is V2. The flow areas of the first outlet (120) and the second outlet (220) are calculated by the following formula. ； S2 is 0.8 to 1.2 times that of S1.

10. The design method according to claim 9, characterized in that, In step three, if the melt flow rate at the second inlet (210) does not meet the preset standard, the dimensions of the casting distributor are re-determined, specifically including: When the melt flow rate at the second inlet (210) is less than the preset standard, the flow area of ​​the first outlet (120) is reduced, or the length of the guide tube (30) is reduced; When the melt flow rate at the second inlet (210) is greater than the preset standard, the flow area of ​​the first outlet (120) is increased, or the length of the guide tube (30) is increased.

Images