Magnesium alloy heterogeneous flow integral coordination pouring process

Abstract

The invention relates to the technical field of alloy pouring processes, in particular to a magnesium alloy heterogeneous flow overall coordination pouring process which comprises the steps of conducting pouring numerical simulation through simulation software, optimizing pouring design and determining a composite flow guide structure, a mold temperature control scheme and an alloy component regulation and control strategy. Magnesium alloy smelting and refining are conducted; preheating the mold by using an intelligent temperature control system; during the period, the intelligent temperature control system monitors and adjusts the temperature of the mold, and the online alloy adding system and the impurity adsorption filtering device keep the components of the melt uniform and pure; and after pouring is completed, controlling the mold temperature according to a preset cooling curve to slowly and uniformly solidify the melt. The design of the bionic branch-shaped flow dividing structure, the dynamic adjustable flow guide plate and the like reduces casting defects, and the casting forming quality is improved. And on-line alloy adding and impurity adsorption filtering ensure that melt components are stable, and the casting performance is improved.

Description

Technical Field

[0001] The invention relates to the technical field of alloy casting technology, in particular to a magnesium alloy heterogeneous flow integral coordinated casting process. Background Art

[0002] In the field of alloy casting technology, magnesium alloys are widely used in many industries due to their excellent properties. With the development of industry, the quality and performance requirements of magnesium alloy castings are constantly increasing, and traditional magnesium alloy casting processes are gradually unable to meet the needs. On the one hand, in the fields of aerospace, automobile manufacturing, etc., the number of magnesium alloy castings with complex shapes and high performance requirements has increased. Traditional processes cannot ensure the uniform flow and solidification of the melt in the mold, resulting in uneven internal structure and defects in the casting, affecting the reliability and service life of the product. On the other hand, with the emphasis on resource utilization efficiency and production cost control, more efficient and precise casting processes are needed to reduce scrap rates and lower production costs. The existing casting design lacks precise optimization, and it is difficult to comprehensively consider key parameters such as melt flow rate and mold temperature, resulting in uneven melt flow, turbulence, air entrainment, cold shut, insufficient pouring and other defects, affecting the molding quality of the casting; the alloy composition control is not precise enough, and it is impossible to monitor in real time and add alloy elements and remove impurities in time, resulting in large deviations in alloy composition and low melt purity, which in turn reduces the mechanical properties and corrosion resistance of the casting; the mold temperature control is not precise, and the temperature cannot be adjusted in real time according to the characteristics of the casting, resulting in uneven melt solidification shrinkage, concentrated thermal stress, and causing deformation, cracks and other problems in the casting, affecting the quality of the casting.

[0003] Therefore, it is necessary to propose a magnesium alloy heterogeneous flow overall coordinated casting process to solve the above problems. Summary of the Invention

[0004] The purpose of the present invention is to provide a magnesium alloy heterogeneous flow overall coordinated casting process to solve the problems of lack of precise optimization of casting design, imprecise mold temperature control, and imprecise alloy composition regulation.

[0005] To achieve the above object, the present invention provides the following technical solutions: The overall coordinated casting process of magnesium alloy heterogeneous flow includes the following steps: S1: Numerical simulation of casting: Use computer simulation software to simulate the casting process according to the casting design requirements, optimize the casting design, and determine the composite guide structure, mold temperature control scheme and alloy composition control strategy; Magnesium alloy smelting, after smelting, impurities and gases are removed through refining treatment to achieve the specified smelting temperature and composition requirements; S2: Casting mold, using the intelligent temperature control system to preheat the mold to the set temperature; S3: According to the composite induction structure, the magnesium alloy melt flows out of the ladle and enters the composite induction system. Under the action of the composite induction system, the magnesium alloy melt fills the mold evenly and smoothly; According to the mold temperature control plan, during the melt flow process, the intelligent temperature control system monitors and adjusts the mold temperature in real time; According to the alloy composition control strategy, the online alloy addition system and impurity adsorption and filtration device work synchronously to maintain the uniform and pure melt composition; S4: After pouring is completed, the intelligent temperature control system controls the mold temperature according to the preset cooling curve, so that the magnesium alloy melt solidifies slowly and evenly.

[0006] Preferably, in step S1, the simulation parameters of the numerical simulation include melt flow rate, mold temperature, melt solidification shrinkage rate and solute element distribution, the casting design is optimized by orthogonal experiment, and the casting design is analyzed by numerical simulation to obtain a composite guide structure and structural parameters, including a bionic dendritic diversion structure and a dynamically adjustable guide plate. The mold temperature control scheme includes the zoned temperature control parameters of the water cooling-induction heating dual-mode temperature control system, and the alloy composition control strategy includes the element compensation threshold of the online alloy addition system and the filtration accuracy of the impurity adsorption filtration device.

[0007] Preferably, the composite guide structure parameters include the number of hierarchical layers of the bionic dendritic diversion structure, the cross-sectional area ratio of each layer of the flow channel, and the distribution density of the terminal gate; the dynamically adjustable guide plate structure parameters include the initial angle, the maximum adjustment stroke, and the response speed; The zoned temperature control parameters of the mold temperature control solution include the cooling water flow threshold of each cooling area, the power density distribution of the induction heating coil, and the melt temperature fluctuation range of the intelligent temperature control system.

[0008] Preferably, the bionic dendritic shunt structure has 3-5 hierarchical layers, the ratio of the cross-sectional area of ​​the first-stage main runner to the total cross-sectional area of ​​the final runner is 1:2, and the terminal gates are evenly distributed along the edge of the mold cavity with a spacing of 20-50 mm.

[0009] Preferably, in the water cooling-induction heating dual-mode temperature control system, the mold cooling water channel adopts a spiral nested design, the cooling water flow in a single cooling area is monitored in real time by an electromagnetic flowmeter and controlled and adjusted by a proportional valve, and the induction heating coil adopts a high-frequency induction power supply.

[0010] Preferably, the online alloy addition system includes a storage bin, a high-precision metering pump and a spiral conveying pipeline. When the spectrometer detects that the deviation of the alloy element content exceeds the trigger threshold, the control system calculates the additional amount; the impurity adsorption and filtration device includes a three-stage filtration structure, the first-stage filtration structure is a ceramic foam filter plate, the second-stage filtration structure is a fiber filter mesh, and the third-stage filtration structure is a magnetic adsorption layer with a built-in permanent magnet.

[0011] Preferably, the dynamically adjustable guide plate is made of nickel-based alloy, the surface of the guide plate is coated with a ceramic coating, and is driven by a servo motor.

[0012] Preferably, in step S2, before preheating the mold, a micro-arc oxidation treatment is performed on the mold surface using a specific voltage and electrolyte to form a ceramic oxide film with good insulation, wear resistance and thermal stability on the mold surface; The intelligent temperature control system combines zoned intelligent induction preheating with infrared-assisted preheating. The system divides the mold into multiple temperature control zones, setting different initial preheat temperatures for each zone based on the degree of contact with the magnesium alloy melt and the difference in heat dissipation rate during the subsequent casting process. Infrared heating devices are placed around the mold to provide auxiliary heating on the mold surface, ensuring a uniform temperature rise. The temperature of each area is monitored in real time through temperature sensors, and the intelligent temperature control system dynamically adjusts the heating power according to the feedback data, so that the mold can accurately reach the set preheating temperature.

[0013] Preferably, in step S3, when the magnesium alloy melt enters the composite flow guide system, the melt is vibrated in real time by an ultrasonic vibration device; during the melt flow process, when the intelligent temperature control system of the mold temperature control solution detects that the temperature deviation exceeds the set range, the intelligent temperature control system immediately initiates corresponding heating or cooling measures for adjustment.

[0014] Preferably, in step S4, when the intelligent temperature control system controls the mold temperature according to a preset cooling curve, the cooling rate of the cooling curve is dynamically adjusted according to the structural complexity and alloy composition of the casting.

[0015] The technical effects and advantages of the present invention are as follows: 1. Through numerical simulation and orthogonal experiments on parameters such as melt flow rate and mold temperature, key parameters such as the composite guide structure and mold temperature control scheme are determined, making the casting system more scientific and reasonable and improving process reliability and stability. The bionic dendritic diversion structure and dynamically adjustable guide plate guide the melt to fill the mold evenly and smoothly, reducing casting defects and improving the quality of castings.

[0016] 2. The online alloy addition system and impurity adsorption and filtration device work together. The spectrum analyzer monitors the deviation of alloy element content and adds alloy elements in time. The three-stage filtration structure removes various impurities and gases to ensure the uniform and stable composition of the magnesium alloy melt and improve the mechanical properties and corrosion resistance of the casting.

[0017] 3. The water cooling and induction heating dual-mode temperature control system, combined with spiral nested cooling water channels, electromagnetic flowmeters, proportional valves and high-frequency induction power supplies, accurately controls the mold temperature, ensures uniform melt solidification shrinkage, reduces thermal stress concentration, prevents casting deformation and cracks, controls the distribution of solute elements, and improves the consistency of casting structure and performance. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 Schematic diagram of the overall coordinated casting process of the magnesium alloy heterogeneous flow according to the present invention. DETAILED DESCRIPTION

[0019] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0020] The present invention provides Figure 1 The magnesium alloy heterogeneous flow overall coordinated casting process shown includes the following steps: S1: Numerical simulation of casting: Use computer simulation software to simulate the casting process according to the casting design requirements, optimize the casting design, and determine the composite guide structure, mold temperature control scheme and alloy composition control strategy; Magnesium alloy smelting, after smelting, impurities and gases are removed through refining treatment to achieve the specified smelting temperature and composition requirements; S2: Casting mold, using the intelligent temperature control system to preheat the mold to the set temperature; S3: According to the composite induction structure, the magnesium alloy melt flows out of the ladle and enters the composite induction system. Under the action of the composite induction system, the magnesium alloy melt fills the mold evenly and smoothly; According to the mold temperature control plan, during the melt flow process, the intelligent temperature control system monitors and adjusts the mold temperature in real time; According to the alloy composition control strategy, the online alloy addition system and impurity adsorption and filtration device work synchronously to maintain the uniform and pure melt composition; S4: After pouring is completed, the intelligent temperature control system controls the mold temperature according to the preset cooling curve, so that the magnesium alloy melt solidifies slowly and evenly.

[0021] Furthermore, in step S1, the simulation parameters of the numerical simulation include melt flow rate, mold temperature, melt solidification shrinkage rate and solute element distribution. The casting design is optimized by orthogonal experiment. The casting design is analyzed by numerical simulation to obtain a composite guide structure and structural parameters, including a bionic dendritic diversion structure and a dynamically adjustable guide plate. The mold temperature control scheme includes the zoned temperature control parameters of the water cooling-induction heating dual-mode temperature control system. The alloy composition control strategy includes the element compensation threshold of the online alloy addition system and the filtration accuracy of the impurity adsorption filtration device.

[0022] By analyzing simulation parameters such as melt flow rate, mold temperature, melt solidification shrinkage, and solute element distribution, and utilizing orthogonal experiments to optimize casting design, the impact of multiple factors on the casting process can be comprehensively considered. Taking melt flow rate as an example, a reasonable velocity distribution can avoid defects such as turbulence and air entrainment, ensuring that the magnesium alloy melt fills the mold evenly and smoothly. Precise control of mold temperature helps optimize the melt solidification process and reduce thermal stress and deformation. Orthogonal experiments can quickly identify the optimal combination of parameters, thereby determining the parameters of composite guide structures, such as the bionic dendritic diversion structure and the dynamically adjustable guide plate, to achieve optimized casting system design and improve the reliability and stability of the casting process.

[0023] Determining the composite flow guide structure parameters, including the number of bionic dendritic flow diversion layers, the cross-sectional area ratio of each layer, the density of the terminal gate distribution, and the initial angle, maximum adjustment stroke, and response speed of the dynamically adjustable flow guide, can effectively guide the magnesium alloy melt to evenly and smoothly fill the mold. The bionic dendritic flow diversion structure evenly disperses the melt and reduces flow velocity differences. The dynamically adjustable flow guide can adjust in real time based on the melt flow state, further optimizing the flow path and avoiding localized excessive flow speeds. This ensures uniform melt flow within the mold, reduces casting defects caused by uneven flow, such as cold shuts and under-giving, and improves casting quality.

[0024] The mold temperature control solution utilizes a dual-mode water cooling and induction heating system, with defined zone temperature control parameters. These include the cooling water flow threshold for each cooling zone, the power density distribution of the induction heating coils, and the melt temperature fluctuation range of the intelligent temperature control system. This precise temperature control method allows for real-time adjustment of mold temperature based on the heat dissipation requirements of different parts of the casting and the characteristics of the melt solidification. During melt flow, this ensures uniform mold surface temperature, even melt solidification shrinkage, reduces thermal stress concentration, and prevents defects such as deformation and cracking in the casting. It also helps control the distribution of solute elements, improving the structural uniformity and performance consistency of the casting.

[0025] The alloy composition control strategy determines the element compensation threshold of the online alloy addition system and the filtration accuracy of the impurity adsorption filter. When the spectrometer detects that the alloying element content deviation exceeds the trigger threshold, the online alloy addition system promptly and accurately adds alloying elements to ensure that the alloy composition meets the design requirements. The three-stage filtration structure of the impurity adsorption filter effectively removes inclusions, gases, and harmful impurities from the melt, improving the melt's purity. These two factors work together to ensure a uniform and stable composition of the magnesium alloy melt, avoid differences in casting performance caused by composition deviation, and enhance the casting's overall mechanical properties, corrosion resistance, and other properties.

[0026] Furthermore, the composite guide structure parameters include the number of hierarchical layers of the bionic dendritic diversion structure, the cross-sectional area ratio of each layer of the flow channel, and the distribution density of the terminal gate. The dynamically adjustable guide plate structure parameters include the initial angle, maximum adjustment stroke, and response speed. The rational design of the bionic dendritic diversion structure's hierarchical number of layers, the cross-sectional area ratio of each layer, and the distribution density of the terminal gates ensures uniform dispersion of the magnesium alloy melt upon entering the mold cavity, ensuring that the melt fills all locations at the appropriate flow rate and flow rate, thereby reducing casting defects caused by velocity differences. The dynamically adjustable guide plate, with precise control of its initial angle, maximum adjustment stroke, and response speed, can rapidly adjust the direction and degree of diversion based on the melt's real-time flow state, further optimizing the melt flow path and avoiding abnormal flow phenomena such as turbulence and eddy currents. This ensures that the melt fills the mold evenly and smoothly, significantly improving the molding quality of the casting, reducing internal defects, and enhancing the product's qualification rate and overall performance.

[0027] The zoned temperature control parameters of the mold temperature control solution include the cooling water flow threshold of each cooling area, the power density distribution of the induction heating coil, and the melt temperature fluctuation range of the intelligent temperature control system.

[0028] Furthermore, the bionic dendritic diversion structure has 3-5 levels, the ratio of the cross-sectional area of ​​the first-stage main runner to the total cross-sectional area of ​​the last-stage runner is 1:2, and the terminal gates are evenly distributed along the edge of the mold cavity with a spacing of 20-50 mm.

[0029] Furthermore, in the water cooling-induction heating dual-mode temperature control system, the mold cooling water channel adopts a spiral nested design, the cooling water flow in a single cooling area is monitored in real time by an electromagnetic flowmeter and controlled and adjusted by a proportional valve, and the induction heating coil uses a high-frequency induction power supply.

[0030] In the water-cooling and induction heating dual-mode temperature control system, the spiral nested design of the mold cooling water channel increases the cooling area and heat exchange efficiency, making the mold cooling more even. The electromagnetic flowmeter monitors the cooling water flow in a single cooling area in real time, and with the proportional valve for precise adjustment, the cooling intensity can be flexibly controlled according to the heat dissipation requirements of different parts. The high-frequency induction power supply powers the induction heating coil, which can achieve fast, efficient and precise heating and quickly compensate for heat loss in the mold. These designs work together to ensure that the mold temperature is precisely controlled during the magnesium alloy casting process, making the melt solidification process more reasonable, effectively reducing thermal stress, deformation and internal defects, and improving the quality and performance stability of the casting.

[0031] Furthermore, the online alloy addition system includes a storage bin, a high-precision metering pump and a spiral conveying pipeline. When the spectrometer detects that the deviation of the alloy element content exceeds the trigger threshold, the control system calculates the additional amount; the impurity adsorption and filtration device includes a three-stage filtration structure, the first-stage filtration structure is a ceramic foam filter plate, the second-stage filtration structure is a fiber filter mesh, and the third-stage filtration structure is a magnetic adsorption layer with a built-in permanent magnet.

[0032] The online alloy addition system works in conjunction with the impurity adsorption and filtration device to improve the quality of magnesium alloys. The online alloy addition system's storage bin, high-precision metering pump, and spiral conveying pipeline accurately calculate and add alloys when the spectrometer detects alloy element content deviations exceeding the threshold, ensuring the stability of the magnesium alloy composition and preventing composition deviations from affecting casting performance. The impurity adsorption and filtration device's three-stage filtration structure, with its ceramic foam filter, fiber filter, and magnetic adsorption layer with built-in permanent magnets, sequentially filters inclusions of varying sizes, fine impurities, and magnetic impurities, effectively removing various impurities and gases from the melt and improving melt purity. This, in turn, enhances the mechanical properties, corrosion resistance, and other comprehensive properties of the casting, reducing casting defects and ensuring product quality.

[0033] Furthermore, the dynamically adjustable deflector is made of nickel-based alloy, the surface of the deflector is coated with a ceramic coating, and is driven by a servo motor.

[0034] Furthermore, in step S2, before preheating the mold, a micro-arc oxidation treatment is performed on the mold surface using a specific voltage and electrolyte to form a ceramic oxide film with good insulation, wear resistance and thermal stability on the mold surface; The intelligent temperature control system combines zoned intelligent induction preheating with infrared-assisted preheating. The system divides the mold into multiple temperature control zones, setting different initial preheat temperatures for each zone based on the degree of contact with the magnesium alloy melt and the difference in heat dissipation rate during the subsequent casting process. Infrared heating devices are placed around the mold to provide auxiliary heating on the mold surface, ensuring a uniform temperature rise. The temperature of each area is monitored in real time through temperature sensors, and the intelligent temperature control system dynamically adjusts the heating power according to the feedback data, so that the mold can accurately reach the set preheating temperature.

[0035] The ceramic oxide film generated on the mold surface by micro-arc oxidation treatment has excellent insulation, wear resistance and thermal stability, which not only prolongs the service life of the mold, but also reduces the interaction between the magnesium alloy melt and the mold during the casting process, thereby improving the surface quality of the casting. The intelligent temperature control system adopts a combination of zoned intelligent induction preheating and infrared assisted preheating. Differentiated initial preheating temperatures are set according to the heat dissipation characteristics of different parts of the mold. With the auxiliary heating of the infrared heating device, it can ensure that the surface temperature of the mold rises evenly and avoids thermal stress caused by excessive local temperature differences. The temperature sensor monitors the temperature of each area in real time, and the intelligent temperature control system dynamically adjusts the heating power accordingly to achieve precise preheating of the mold, creating good conditions for the subsequent stable filling and uniform solidification of the magnesium alloy melt, improving the molding quality and dimensional accuracy of the casting, and reducing the scrap rate.

[0036] Furthermore, in step S3, when the magnesium alloy melt enters the composite flow guide system, the melt is vibrated in real time by an ultrasonic vibration device; during the melt flow process, when the intelligent temperature control system of the mold temperature control solution detects that the temperature deviation exceeds the set range, the intelligent temperature control system immediately initiates corresponding heating or cooling measures for adjustment.

[0037] Real-time ultrasonic vibration treatment of the magnesium alloy melt entering the composite induction system can effectively refine the grains, improve the internal structure of the melt, and enhance the mechanical properties of the casting, such as improving strength and toughness. At the same time, vibration can also promote the discharge of gas and impurities in the melt, reducing defects such as pores and inclusions. The intelligent temperature control system in the mold temperature control solution monitors the temperature in real time when the melt flows. Once the temperature deviation exceeds the set range, it will quickly initiate heating or cooling measures to adjust. This measure ensures that the temperature of the melt is stable during the flow process, avoids problems such as uneven solidification and cold shut caused by temperature fluctuations, ensures the consistency and stability of the casting solidification process, and ultimately significantly improves the overall quality of the casting and reduces the scrap rate.

[0038] Furthermore, in step S4, when the intelligent temperature control system controls the mold temperature according to the preset cooling curve, the cooling rate of the cooling curve is dynamically adjusted according to the structural complexity and alloy composition of the casting.

[0039] For complex castings, where different parts shrink significantly during solidification, dynamic adjustment of the cooling rate ensures uniform cooling and contraction across all parts, avoiding thermal stress concentration caused by uneven cooling and effectively reducing casting deformation and cracking. Magnesium alloys with different alloy compositions exhibit distinct solidification characteristics, and proper adjustment of the cooling rate can adapt to these characteristics, promoting uniform grain refinement, optimizing the casting's internal structure, and enhancing its mechanical properties, such as strength and toughness. This dynamic cooling control approach, tailored to the specific characteristics of the casting, comprehensively improves casting quality, reduces scrap rates, enhances product reliability and stability, and meets the diverse needs of industrial production.

[0040] The above shows and describes the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The above embodiments and descriptions merely illustrate the principles of the present invention. Various changes and modifications may be made to the present invention without departing from the spirit and scope of the present invention. Such changes and modifications are intended to fall within the scope of the present invention. The scope of protection claimed by the present invention is defined by the appended claims and their equivalents.

Claims

1. The overall coordinated casting process of magnesium alloy heterogeneous flow is characterized by: The following steps are involved: S1: Numerical simulation of casting: Use computer simulation software to simulate the casting process according to the casting design requirements, optimize the casting design, and determine the composite guide structure, mold temperature control scheme and alloy composition control strategy; Magnesium alloy smelting, after smelting, impurities and gases are removed through refining treatment to achieve the specified smelting temperature and composition requirements; S2: Casting mold, using the intelligent temperature control system to preheat the mold to the set temperature; S3: According to the composite induction structure, the magnesium alloy melt flows out of the ladle and enters the composite induction system. Under the action of the composite induction system, the magnesium alloy melt fills the mold evenly and smoothly; According to the mold temperature control plan, during the melt flow process, the intelligent temperature control system monitors and adjusts the mold temperature in real time; According to the alloy composition control strategy, the online alloy addition system and impurity adsorption and filtration device work synchronously to maintain the uniform and pure melt composition; S4: After pouring is completed, the intelligent temperature control system controls the mold temperature according to the preset cooling curve, so that the magnesium alloy melt solidifies slowly and evenly.

2. The magnesium alloy heterogeneous flow integral coordinated casting process according to claim 1, characterized in that: In step S1, the simulation parameters of the numerical simulation include melt flow rate, mold temperature, melt solidification shrinkage rate and solute element distribution. The casting design is optimized by orthogonal experiment. The casting design is analyzed by numerical simulation to obtain a composite guide structure and structural parameters, including a bionic dendritic diversion structure and a dynamically adjustable guide plate. The mold temperature control scheme includes the zoned temperature control parameters of the water cooling-induction heating dual-mode temperature control system. The alloy composition control strategy includes the element compensation threshold of the online alloy addition system and the filtration accuracy of the impurity adsorption filtration device.

3. The magnesium alloy heterogeneous flow integral coordinated casting process according to claim 2, characterized in that: The composite guide structure parameters include the number of hierarchical layers of the bionic dendritic diversion structure, the cross-sectional area ratio of each layer, and the distribution density of the terminal gates. The dynamically adjustable guide plate structure parameters include the initial angle, maximum adjustment stroke, and response speed. The zoned temperature control parameters of the mold temperature control solution include the cooling water flow threshold of each cooling area, the power density distribution of the induction heating coil, and the melt temperature fluctuation range of the intelligent temperature control system.

4. The magnesium alloy heterogeneous flow integral coordinated casting process according to claim 3, characterized in that: The bionic dendritic diversion structure has 3-5 levels, the ratio of the cross-sectional area of ​​the first-stage main runner to the total cross-sectional area of ​​the last-stage runner is 1:2, and the terminal gates are evenly distributed along the edge of the mold cavity with a spacing of 20-50 mm.

5. The magnesium alloy heterogeneous flow integral coordinated casting process according to claim 2, characterized in that: In the water cooling and induction heating dual-mode temperature control system, the mold cooling water channel adopts a spiral nested design. The cooling water flow in a single cooling area is monitored in real time by an electromagnetic flowmeter and controlled and adjusted by a proportional valve. The induction heating coil uses a high-frequency induction power supply.

6. The magnesium alloy heterogeneous flow integral coordinated casting process according to claim 2, characterized in that: The online alloy addition system includes a storage bin, a high-precision metering pump and a spiral conveying pipeline. When the spectrometer detects that the deviation of the alloy element content exceeds the trigger threshold, the control system calculates the additional amount; the impurity adsorption and filtration device includes a three-stage filtration structure. The first-stage filtration structure is a ceramic foam filter, the second-stage filtration structure is a fiber filter, and the third-stage filtration structure is a magnetic adsorption layer with a built-in permanent magnet.

7. The magnesium alloy heterogeneous flow integral coordinated casting process according to claim 2, characterized in that: The dynamically adjustable deflector is made of nickel-based alloy, the surface of the deflector is coated with ceramic coating and is driven by a servo motor.

8. The magnesium alloy heterogeneous flow integral coordinated casting process according to claim 1, characterized in that: In step S2, before preheating the mold, a micro-arc oxidation treatment is performed on the mold surface using a specific voltage and electrolyte to form a ceramic oxide film with good insulation, wear resistance and thermal stability on the mold surface; The intelligent temperature control system combines zoned intelligent induction preheating with infrared-assisted preheating. The system divides the mold into multiple temperature control zones. Different initial preheating temperatures are set for each zone based on the degree of contact between the mold and the magnesium alloy melt and the heat dissipation rate during the subsequent casting process. Arrange infrared heating devices around the mold to provide auxiliary heating for the mold surface to ensure that the mold surface temperature rises evenly; The temperature of each area is monitored in real time through temperature sensors, and the intelligent temperature control system dynamically adjusts the heating power according to the feedback data, so that the mold can accurately reach the set preheating temperature.

9. The magnesium alloy heterogeneous flow integral coordinated casting process according to claim 1, characterized in that: In step S3, when the magnesium alloy melt enters the composite flow guide system, the melt is vibrated in real time by an ultrasonic vibration device; during the melt flow process, when the intelligent temperature control system of the mold temperature control solution detects that the temperature deviation exceeds the set range, the intelligent temperature control system immediately initiates the corresponding heating or cooling measures for adjustment.

10. The magnesium alloy heterogeneous flow integral coordinated casting process according to claim 1, characterized in that: In step S4, when the intelligent temperature control system controls the mold temperature according to the preset cooling curve, the cooling rate of the cooling curve is dynamically adjusted according to the structural complexity and alloy composition of the casting.

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