A spray forming structure and method for depositing cylindrical ingot blanks using a strip atomizer

Abstract

This invention discloses a spray forming structure and method for depositing cylindrical ingots using a strip atomizer, belonging to the field of metal spray forming. The device includes a slug and a deposition chamber. The slug is located at the top of the deposition chamber, and a strip atomizer is positioned below it. The strip atomizer is fixed to the top plate of the deposition chamber and consists of a primary atomizer, a secondary atomizer, and a liquid guide tube. A collector is located below the strip atomizer. The spatial arrangement of the atomized droplets ejected by the strip atomizer forms a wedge-shaped atomizing cone. The collector is connected to a rotating lifting assembly. In use, because the atomizer changes from the existing annular structure to a long and narrow strip structure, the distribution range of the wedge-shaped atomizing cone is expanded, allowing for the spray forming of large-diameter ingots using only a single atomizer.

Description

Technical Field

[0001] This invention relates to the field of metal spray forming, and in particular to a spray forming structure and method for depositing cylindrical ingot blanks using a strip atomizer. Background Technology

[0002] Spray forming is a preparation technology for high-alloy metal materials based on the principle of rapid solidification. The principle involves molten alloy being atomized into fine liquid droplets by a high-pressure inert gas in an atomizer. During flight, the droplets rapidly cool and deposit in a semi-solid form on a collector, forming a billet of the desired shape, such as a cylindrical billet, slab, or tube. Cylindrical billets are the most widely used.

[0003] Existing methods for preparing cylindrical ingots by spray forming all employ annular atomizers (including both annular holes and annular slots), resulting in a finite circular or elliptical distribution of the atomized molten material on the collector. To increase the ingot diameter, a reciprocating scanning method of the atomizer is typically used to cover a larger area on the collector; furthermore, a multi-atomizer collaborative method is employed to achieve an even larger ingot diameter. However, the multi-atomizer collaborative spray forming process involves numerous atomizer placements and scanning parameters, which can easily lead to uneven distribution of the atomized material on the deposition surface. Atomizer scanning requires complex motion mechanisms and involves many components. More importantly, if one set of atomizers fails, the entire spraying process will fail. Therefore, extremely high requirements are placed on process parameter optimization and atomizer reliability.

[0004] Based on this, the present invention discloses a spray forming process for large-diameter ingot blanks using a single atomizer, as well as an atomizer device structure, which can greatly simplify the existing spray forming atomizer device structure and improve the reliability of spray forming production. Summary of the Invention

[0005] The purpose of this invention is to provide a spray forming structure and method for depositing cylindrical ingot blanks using a strip atomizer. When the device is in use, because the atomizer changes from the existing annular structure to a long and narrow strip structure, the distribution range of the wedge-shaped atomizing cone formed by atomization is expanded. A single set of atomizers can be used to achieve the spray forming preparation of large-diameter ingot blanks, thereby solving the problems mentioned in the background art.

[0006] To achieve the above objectives, the present invention provides the following technical solution: a spray forming structure for depositing cylindrical ingots using a strip atomizer, comprising a sprue and a deposition chamber. The sprue is disposed at the top of the deposition chamber, and a strip atomizing device is disposed below the sprue. The strip atomizing device is fixed to the top plate of the deposition chamber. The strip atomizing device consists of a primary atomizer, a secondary atomizer, and a liquid guide tube. The primary atomizer includes two symmetrical sets of primary jet devices, each set consisting of a primary air passage cover and a primary detachable air passage. The primary air passage cover and the primary detachable air passage are fixedly connected by bolts. The inward-facing side of the primary air passage cover and the primary detachable air passage forms a primary air outlet. The secondary atomizer includes two symmetrical sets of secondary jet devices, each set consisting of a secondary atomizer air passage cover. It consists of a primary atomizer and a detachable air duct. The secondary atomizer air duct cover and the detachable air duct are fixedly connected by bolts. The inward-facing side of the secondary atomizer air duct cover and the detachable air duct forms a secondary air outlet. The primary air outlet and the secondary air outlet are connected to the air compressor. A collector is provided below the strip atomizing device. The spatial arrangement of the atomized droplets ejected by the strip atomizing device forms a wedge-shaped atomizing cone. The place where the wedge-shaped atomizing cone contacts the collector forms a deposition area, which is located on the radius of the collector. The collector is connected to a rotating lifting assembly. The liquid guide tube includes a liquid guide pipe, which is located in the middle of the left and right sets of primary jet devices. A snap-fit ​​assembly is provided between the primary atomizer and the secondary atomizer. A residual powder treatment mechanism is provided below the deposition chamber.

[0007] Furthermore, the two tangents of the primary air outlet form an angle of α, and the channel sidewall of the primary air outlet is polished.

[0008] Furthermore, the two tangents of the secondary air outlet form an angle of β, and the channel sidewall of the primary air outlet is polished.

[0009] Furthermore, the snap-fit ​​assembly includes a rectangular sealing ring with an octagonal cross-section. The bottom surface of the primary detachable airway and the top surface of the secondary atomizer airway cover are respectively provided with snap-fit ​​grooves that match the rectangular sealing ring. The lower end of the primary airway cover is inserted into the inner side of the rectangular sealing ring.

[0010] Furthermore, the residual powder handling mechanism includes a powder collection box, a cyclone dust collector, and an exhaust fan. The top of the powder collection box is covered with two layers of wire mesh, the upper layer of which is coarse wire mesh and the lower layer of which is fine wire mesh. The cyclone dust collector is equipped with a spiral-shaped adsorption sponge block inside. The exhaust fan is located at the exhaust port at the bottom of the powder collection box.

[0011] Furthermore, the rotary lifting assembly includes a support frame in the middle of the sedimentation chamber, a rotary motor is mounted on the support frame, a lifting motor is mounted on the output shaft of the rotary motor, and the collector is fixed on the telescopic shaft of the lifting motor.

[0012] Furthermore, the primary detachable airway and the secondary atomizer detachable airway can be replaced with a perforated detachable airway and a slit detachable airway, respectively. The perforated detachable airway and the slit detachable airway are fixedly connected to the primary airway cover and the secondary atomizer airway cover through screw holes.

[0013] Furthermore, the following steps are included: S1. The melt is poured into the sluice box and then falls into the interior of the liquid guide tube under its own gravity. The melt droplets falling from below the liquid guide tube form a thin waterfall shape. After passing through the primary gas outlet and the secondary gas outlet, they are broken into a mist. The mist-like melt droplets hit the collector and begin to deposit. During the deposition process, the collector rotates and moves downward. One layer is deposited on the surface of the billet after one rotation. The descending speed of the collector is matched with the deposition speed. Through continuous accumulation, the billet is formed. S2. During the spray forming process, the exhaust fan discharges the high-temperature gas from the deposition chamber. The oversprayed powder is collected by the powder collection box and cyclone dust collector. The powder collection box and cyclone dust collector are periodically removed, cleaned of debris, and then reinstalled.

[0014] In summary, due to the adoption of the above-mentioned technologies, the beneficial effects of this invention are: Firstly, because the atomizer has changed from the existing ring structure to a long and narrow strip structure, the distribution range of the wedge-shaped atomizing cone formed by atomization has been expanded, and large-diameter ingots can be prepared by spray forming using a single atomizer.

[0015] Secondly, compared to the method of multiple ring atomizers working together to spray, the structure is simple, the number of parts is reduced, and there is no need for a scanning motion mechanism, which greatly improves the reliability and maintainability of the equipment.

[0016] Third, it avoids the uneven deposition caused by multi-atomizer spraying.

[0017] Fourth, the air outlet channels of the first and second stage atomizers are detachable and replaceable, which can meet the requirements of different spray forming processes. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the spray forming based on a strip atomizer according to the present invention.

[0019] Figure 2 This is a diagram of the strip atomizing device of the present invention.

[0020] Figure 3 This is a three-dimensional diagram of the strip atomizing device of the present invention.

[0021] Figure 4 This is a schematic diagram of the detachable gas outlet structure of the upper atomizer.

[0022] Figure 5 This is a schematic diagram of the detachable air duct with perforation and the detachable air duct with slits of the present invention.

[0023] Explanation of reference numerals in the attached figures: 1. Leaking bag, 2. Strip atomizing device, 21. Liquid guide tube, 22. Primary airway cover, 23. Primary detachable airway, 23a. Screw hole, 23b. Perforated detachable airway, 23c. Rectangular sealing ring, 24. Secondary atomizer airway cover, 25. Secondary atomizer detachable airway, 26. Collector, 3. Deposition chamber, 4. Powder collection box, 5. Cyclone dust collector, 6. Exhaust fan, 7. Wedge-shaped atomizing cone, 8. Deposition area, 9. Detailed Implementation

[0024] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, 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 a part of the embodiments of the present invention, not all of them. 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. Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to represent selected embodiments of the invention. 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.

[0025] This invention provides, for example Figures 1-5The diagram illustrates a jet forming structure for depositing cylindrical ingots using a strip atomizer. It includes a sprue 1 and a deposition chamber 4. The sprue 1 is positioned at the top of the deposition chamber 4, and a strip atomizing device 2 is located below it. The strip atomizing device 2 is fixed to the top plate of the deposition chamber 4. The strip atomizing device 2 consists of a primary atomizer, a secondary atomizer, and a liquid guide tube. The primary atomizer includes two symmetrical sets of primary jet devices, each set consisting of a primary air passage cover 22 and a detachable primary air passage 23. The primary air duct 23 is fixedly connected to the primary air duct cover 22 by bolts. The inward-facing side of the primary air duct cover 22 and the primary air duct 23 forms the primary air outlet. The secondary atomizer includes two symmetrical sets of secondary jet devices, each set consisting of a secondary atomizer air duct cover 25 and a secondary atomizer air duct 26. The secondary atomizer air duct cover 25 and the secondary atomizer air duct 26 are fixedly connected by bolts. The inward-facing side of the secondary atomizer air duct cover 25 and the secondary atomizer air duct 26 forms the secondary air outlet, and the primary air outlet... The primary and secondary air outlets are connected to the air compressor. A collector 3 is located below the strip-shaped atomizing device 2. The spatial arrangement of the atomized droplets ejected from the strip-shaped atomizing device 2 forms a wedge-shaped atomizing cone 8. A deposition area 9 is formed where the wedge-shaped atomizing cone 8 contacts the collector 3. The deposition area 9 is located on the radius of the collector 3. The collector 3 is connected to the rotating lifting assembly. The liquid guide tube includes a liquid guide tube 21, which is positioned in the middle of the two sets of primary jet devices. A snap-fit ​​assembly is provided between the primary atomizer and the secondary atomizer. Below the deposition chamber 4, there is a residual powder treatment mechanism. The melt is poured into the sluice box 1 and then falls into the interior of the liquid guide tube 21 under its own gravity. The melt droplets falling from the bottom of the liquid guide tube 21 form a thin waterfall shape. After passing through the primary gas outlet and the secondary gas outlet, they are broken into a mist. The mist-like melt droplets hit the collector 3 and begin to deposit. During the deposition process, the collector 3 rotates and descends. One layer is deposited on the surface of the billet after one rotation. The descending speed of the collector 3 is matched with the deposition speed. The billet is formed by continuous accumulation.

[0026] The two tangents of the primary air outlet form an angle of α, and the channel sidewall of the primary air outlet is polished. The angle between the air directions ejected in the two directions is also α. The molten droplets are first blown into a mist at this position.

[0027] The two tangents of the secondary air outlet form an angle of β, and the channel sidewall of the primary air outlet is polished. The angle between the air directions ejected in the two directions is also β. The molten droplets are then blown into a mist at this position.

[0028] The snap-fit ​​assembly includes a rectangular sealing ring 24 with an octagonal cross-section. The bottom surface of the primary detachable airway 23 and the top surface of the secondary atomizer airway cover 25 are respectively provided with snap-fit ​​grooves that match the rectangular sealing ring 24. The lower end of the primary airway cover 22 is inserted into the inner side of the rectangular sealing ring 24. The primary atomizer and the secondary atomizer are snapped together by the rectangular sealing ring 24, thereby preventing the primary atomizer and the secondary atomizer from moving horizontally.

[0029] The residual powder handling mechanism includes a powder collection box 5, a cyclone dust collector 6, and an exhaust fan 7. The top of the powder collection box 5 is covered with two layers of wire mesh, the upper layer being coarse wire mesh and the lower layer being fine wire mesh. The cyclone dust collector 6 has a spiral-shaped adsorption sponge block inside. The exhaust fan 7 is located at the exhaust port at the bottom of the powder collection box 5. During the spray forming process, the exhaust fan 7 discharges the high-temperature gas in the deposition chamber. The oversprayed powder is collected by the powder collection box 5 and the cyclone dust collector 6. The powder collection box 5 and the cyclone dust collector 6 are periodically removed, cleaned of debris, and then reinstalled.

[0030] The rotary lifting assembly includes a support frame in the middle of the deposition chamber 4, a rotary motor is mounted on the support frame, a lifting motor is mounted on the output shaft of the rotary motor, and the collector 3 is fixed on the telescopic shaft of the lifting motor. For each layer deposited, the lifting motor drives the collector 3 to move downward by one unit distance. The descending speed of the collector 3 is matched with the deposition speed, and ingots are formed through continuous accumulation.

[0031] The primary detachable airway 23 and the secondary atomizer detachable airway 26 can be replaced with perforated detachable airway 23b and slit detachable airway 23c, respectively. The perforated detachable airway 23b and slit detachable airway 23c are fixedly connected to the primary airway cover 22 and the secondary atomizer airway cover 25 through screw holes 23a. The shape and size of the gas outlet can be adjusted according to production needs by replacing the detachable airways with different specifications.

[0032] Includes the following steps: S1. The melt is poured into the sluice box 1 and then falls into the interior of the liquid guide tube 21 under its own gravity. The melt droplets falling from the bottom of the liquid guide tube 21 form a thin waterfall shape. After passing through the primary gas outlet and the secondary gas outlet, they are blown into a mist. The mist-like melt droplets hit the collector 3 and begin to deposit. During the deposition process, the collector 3 rotates and moves downward. One layer is deposited on the surface of the billet after one rotation. The downward speed of the collector 3 is matched with the deposition speed. The billet is formed by continuous accumulation. S2. During the spray forming process, the exhaust fan 7 discharges the high-temperature gas from the deposition chamber and collects the oversprayed powder through the powder collection box 5 and the cyclone dust collector 6. The powder collection box 5 and the cyclone dust collector 6 are periodically removed, cleaned of debris, and then put back in.

[0033] Working principle: The molten material is poured into the sluice box 1 and then falls into the liquid guide tube 21 under its own gravity. The molten droplets falling from below the liquid guide tube 21 form a thin waterfall shape. After passing through the primary and secondary air outlets, they are blown into a mist. The misty molten droplets fall onto the collector 3 and begin to deposit. During the deposition process, the collector 3 rotates and descends. One layer is deposited on the surface of the billet after one rotation. The descending speed of the collector 3 matches the deposition speed. Through continuous accumulation, the billet is formed. The angle between the air directions ejected from the two directions is also α. The molten droplets are first blown into a mist at this position. The angle between the air directions ejected from the two directions is also β. The molten droplets are then blown into a mist at this position. The atomizer is formed into a mist. The primary and secondary atomizers are locked together by a rectangular sealing ring 24, which prevents them from moving horizontally. During the spraying process, the exhaust fan 7 discharges the high-temperature gas from the deposition chamber. The oversprayed powder is collected by the powder collection box 5 and the cyclone dust collector 6. The powder collection box 5 and the cyclone dust collector 6 are periodically removed, cleaned of debris, and then reinstalled. For each layer deposited, the collector 3 is driven down one unit distance by the lifting motor. The descent speed of the collector 3 is matched with the deposition speed. By continuously accumulating, ingots are formed. The shape and size of the gas outlet can be adjusted according to production needs by replacing the detachable gas ducts of different specifications.

[0034] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

[0035] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

Claims

1. A spray forming structure for depositing cylindrical ingots using a strip atomizer, characterized in that: The system includes a leak bag (1) and a sedimentation chamber (4). The leak bag (1) is located at the top of the sedimentation chamber (4), and a strip atomizing device (2) is located below the leak bag (1). The strip atomizing device (2) is fixed to the top plate of the sedimentation chamber (4). The strip atomizing device (2) consists of a primary atomizer, a secondary atomizer, and a liquid guide tube. The primary atomizer includes two sets of symmetrical primary jet devices. Each set of primary jet devices consists of a primary air passage cover (22) and a primary detachable air passage (23). The primary air passage cover (22) and the primary detachable air passage (23) are fixedly connected by bolts. The inward side of the primary air passage cover (22) and the primary detachable air passage (23) forms a primary air outlet. The secondary atomizer includes two sets of symmetrical secondary jet devices. Each set of secondary jet devices consists of a secondary atomizer air passage cover (25) and a secondary atomizer detachable air passage (23). The air outlet (26) is composed of a secondary atomizer air duct cover (25) and a secondary atomizer detachable air duct (26) which are fixedly connected by bolts. The secondary atomizer air duct cover (25) and the secondary atomizer detachable air duct (26) form a secondary air outlet on the inward side. A collector (3) is provided below the strip atomizing device (2). The spatial arrangement shape of the atomized droplets ejected by the strip atomizing device (2) forms a wedge-shaped atomizing cone (8). A deposition area (9) is formed where the wedge-shaped atomizing cone (8) and the collector (3) come into contact. The deposition area (9) is located on the radius of the collector (3). The collector (3) is connected to the rotating lifting assembly. The liquid guide pipe (21) is located in the middle position of the two sets of primary jet devices. A snap-fit ​​assembly is provided between the primary atomizer and the secondary atomizer. A residual powder processing mechanism is provided below the deposition chamber (4). The snap-fit ​​assembly includes a rectangular sealing ring (24), the cross-section of which is octagonal. The bottom surface of the primary detachable airway (23) and the top surface of the secondary atomizer airway cover (25) are respectively provided with snap-fit ​​grooves that match the rectangular sealing ring (24). The lower end of the primary airway cover (22) is inserted into the inner side of the rectangular sealing ring (24).

2. The spray forming structure for depositing cylindrical ingots using a strip atomizer according to claim 1, characterized in that: The residual powder treatment mechanism includes a dust collection box (5), a cyclone dust collector (6), and an exhaust fan (7). The top of the dust collection box (5) is covered with two layers of wire mesh, the upper layer of which is coarse wire mesh and the lower layer of which is fine wire mesh. The cyclone dust collector (6) is equipped with a spiral-shaped adsorption sponge block inside. The exhaust fan (7) is located at the exhaust port at the bottom of the dust collection box (5).

3. The spray forming structure for depositing cylindrical ingots using a strip atomizer according to claim 1, characterized in that: The rotary lifting assembly includes a support in the middle of the sedimentation chamber (4), a rotary motor is provided on the support, a lifting motor is installed on the output shaft of the rotary motor, and the collector (3) is fixed on the telescopic shaft of the lifting motor.

4. The spray forming structure for depositing cylindrical ingots using a strip atomizer according to claim 1, characterized in that: The primary detachable airway (23) and the secondary atomizer detachable airway (26) can be replaced with the perforated detachable airway (23b) and the slit detachable airway (23c) respectively. The perforated detachable airway (23b) and the slit detachable airway (23c) are fixedly connected to the primary airway cover (22) and the secondary atomizer airway cover (25) through screw holes (23a).

5. A method for spray forming a cylindrical ingot structure by depositing a strip atomizer according to any one of claims 1-4, characterized in that, Includes the following steps: S1. The melt in the leak bag (1) falls into the interior of the liquid guide tube (21) under its own gravity. The melt droplets falling from below the liquid guide tube (21) form a thin waterfall shape. After passing through the secondary gas outlet, the melt droplets are broken into a mist. The mist-shaped melt droplets hit the collector (3) and begin to deposit. During the deposition process, the collector (3) rotates and moves downward. One layer is deposited on the surface of the billet after one rotation. The descending speed of the collector (3) matches the deposition speed. The billet is formed by continuous accumulation. S2. During the spray forming process, the exhaust fan (7) discharges the high-temperature gas in the deposition chamber and collects the oversprayed powder through the powder collection box (5) and the cyclone dust collector (6). The powder collection box (5) and the cyclone dust collector (6) are periodically removed to clean up debris and then put back in.

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