Metal ingot preparation method and device based on melt flow limiting and fast cooling

Abstract

This invention discloses a method and apparatus for preparing metal ingots based on melt flow-limited stacking casting and rapid cooling forming, relating to the field of metal forming technology. This method is based on continuous or intermittent advancement of melt flow-limited bottom casting, layer-by-layer reciprocating stacking, and layer-by-layer relay rapid cooling forming. It can achieve continuous rapid cooling forming of the molten metal, refining grains, and by limiting atomic diffusion, achieve layer-by-layer freezing-type rapid solidification forming with uniform atomic distribution in the molten metal, reducing component segregation. It can also simultaneously achieve the relay upward movement or reduction of casting defects such as shrinkage cavities and porosity layer by layer. The flow-limiting guide nozzle is equipped with a liquid outlet and a parallel and similarly shaped anti-oxidation coolant spray nozzle, located at the bottom of a crucible with a filter to reduce inclusions. This invention can simultaneously and rapidly reduce and coordinately control defects such as coarse grains, shrinkage cavities, porosity, component segregation, and inclusions during the solidification of the molten metal in a short process, achieving short-process, high-quality manufacturing of metal ingots, especially large metal ingots (including amorphous ingots).

Description

Technical Field

[0001] This invention relates to the field of metal melt casting technology, and more specifically to the field of metal ingot preparation apparatus based on melt flow limiting stacking casting and rapid cooling forming. Background Technology

[0002] The manufacturing of existing round, ring, and square metal ingots, especially large metal ingots, is prone to defects such as element segregation, shrinkage cavities, porosity, and coarse grains due to low cooling rates. These defects seriously affect the compositional uniformity of large metal ingots and the performance of subsequent products. Therefore, high-quality large metal ingot manufacturing technology has always been a key technical problem that countries urgently need to overcome and a core technology that is kept secret. Due to the unavoidable series of defects mentioned above, the existing large metal ingot manufacturing technology can only adopt the method of processing a number of small-sized components with easily controllable quality, stacking them up, and then achieving metallurgical bonding through high temperature and pressure diffusion of interface atoms over a long period of time. In other words, the "casting" manufacturing technology has to be adopted. However, this technology has the disadvantages of long process time, high cost, and non-metallurgical bonding risks, which not only affect the quality and application reliability of subsequent products, but also does not conform to the development direction of short process and energy saving and consumption reduction. Furthermore, the existing technology for preparing amorphous metallic materials is the rapid cooling technology of molten metal. Due to the limitation that the cooling rate is difficult to maintain continuously, the size of amorphous materials (amorphous ribbons and amorphous bulk materials) currently produced in the industry is relatively small. The thickness of amorphous ribbons is generally ≤50um, and although the size of amorphous bulk materials is larger than that of amorphous ribbons, the diameter is generally no more than 80mm. This seriously restricts the breadth and depth of industrial preparation and application of large-size amorphous materials, which urgently needs to be solved. Summary of the Invention

[0003] The purpose of this invention is to address the aforementioned defects and difficulties that cannot be avoided in existing large metal ingot (including large-size amorphous materials) manufacturing technologies. This invention provides a method and apparatus for preparing metal ingots based on melt flow limiting stacking and rapid cooling forming.

[0004] The present invention specifically adopts the following technical solutions to achieve the above objectives: One aspect of the present invention provides a method for preparing metal ingots based on melt flow-limited stacking casting and rapid cooling forming. By continuously or intermittently advancing the continuous or intermittent advancement of melt flow-limited bottom casting, layer-by-layer reciprocating stacking, and melt layer-by-layer relay rapid cooling forming, the continuous rapid cooling forming of the metal melt is achieved, resulting in grain refinement. Rapid cooling restricts the atomic diffusion rate, achieving layer-by-layer freezing rapid solidification forming of the metal melt in a state of long-range disordered uniform distribution of atoms, reducing component segregation, and simultaneously achieving the layer-by-layer relay upward movement or reduction of casting defects such as shrinkage cavities and porosity. The flow-limiting guide nozzle is provided with a liquid outlet gate with a square and narrow slit cross-section, or a circular liquid outlet gate, or a liquid outlet gate of other shapes. The flow-limiting guide nozzle is also provided with an anti-oxidation coolant spray port that is parallel to the liquid outlet gate and has a similar shape. The melt flows through a filter and flows out from the bottom of the crucible to reduce inclusions.

[0005] In one embodiment, the specific method of continuous or intermittent advancement of melt flow-limited bottom casting, layer-by-layer reciprocating superposition, and melt layer-by-layer relay rapid cooling forming is as follows: S1. A smelting crucible with a filter is required. The filter is located in the lower part of the smelting crucible and above the flow-limiting nozzle. The stopper rod adjustment device in the smelting crucible drives the stopper rod assembly to move downward to block the flow-limiting nozzle at the bottom of the smelting crucible. The feeding system adds metal master alloy or melt into the smelting crucible. The heater heats and keeps the melt warm or melts the metal master alloy in the smelting crucible. S2. Adjust the position of the metal ingot water-cooled support platform through the motion mechanism so that the metal ingot water-cooled support platform is aligned with the flow-limiting guide nozzle of the melting crucible and maintains the set distance, and start the metal ingot water-cooled support platform. S3. A flow-limiting control device is adopted. Through a fixed gap mode or a dynamic gap adjustment mode, the distance between the plug rod assembly and the flow-limiting guide nozzle is adjusted so that the flow-limiting guide nozzle is in the open state. The molten metal in the melting crucible flows through the filter and flows out from the bottom of the crucible to reduce inclusions. The pure molten metal flows out from the liquid outlet of the flow-limiting guide nozzle and flows continuously to the metal ingot water-cooled support platform in a flow-limiting stacking method. S4. Activate the crucible or metal ingot water-cooled support platform movement device. Through continuous or intermittent advancement based on melt flow-limited casting, layer-by-layer reciprocating stacking, and melt relay rapid cooling forming, continuous flow-limited stacking and rapid cooling forming of the metal melt are achieved. By restricting the atomic diffusion rate through rapid cooling, the long-range disordered uniform distribution of metal melt atoms is achieved through freeze-type rapid solidification and layer-by-layer rapid solidification forming. This eliminates component segregation and achieves the relay upward movement or reduction of casting defects such as shrinkage cavities and porosity. Thus, the inclusions, shrinkage cavities, porosity, and component segregation defects of the metal ingot are effectively reduced and synergistically controlled, resulting in high-quality cylindrical or ring-shaped metal ingot products.

[0006] A second aspect of the present invention provides a metal ingot preparation apparatus based on melt flow-limited stacking casting and rapid cooling forming, for realizing the above-mentioned metal ingot forming apparatus based on melt flow-limited stacking casting and rapid cooling forming, including a melting crucible with a filter, a heater surrounding the outer wall of the melting crucible, a flow-limiting guide nozzle disposed at the bottom of the melting crucible, a plug rod assembly disposed inside the melting crucible for controlling the flow rate and flow volume of the melt flowing through the flow-limiting guide nozzle, a metal ingot water-cooling support platform disposed at the bottom of the flow-limiting guide nozzle for realizing rapid cooling of the melt, and a drive mechanism for driving the movement of the metal ingot water-cooling support platform, and further including a shaping mechanism for the layered stacking casting solidified layer; The plug rod assembly is equipped with a plug rod adjustment device that drives the plug rod to adjust in multiple directions via a lead screw, so as to achieve precise alignment between the plug rod and the flow guide nozzle during installation. It also includes a flow control device for adjusting the distance between the plug rod assembly and the flow-limiting flow guide nozzle, and realizing online control of melt flow rate and flow rate. A feeding system is provided at the upper opening of the smelting crucible to ensure that the smelting crucible has the set melt height, melt volume and melt flow rate.

[0007] The drive mechanism that drives the water-cooled support platform of the metal ingot, the stopper rod adjustment device, the flow limiting control device, the solenoid valve and the smelting control device on the stopper rod assembly are all integrated into the equipment control system.

[0008] In one embodiment, the plug assembly includes a plug at the bottom of the plug that mates with a flow-limiting guide nozzle and a flow-limiting control plug disposed on the plug, wherein a thermocouple for temperature measurement is disposed inside the flow-limiting control plug and is electrically connected to the equipment control system. The stopcock adjustment device is a multi-directional translation platform disposed between the top of the flow-limiting control stopcock and the flow-limiting control device.

[0009] In one embodiment, the flow limiting control device is an electric screw or a lifting cylinder, with the bottom of the telescopic rod of the electric screw or lifting cylinder fixed to the top of the plug rod adjustment device. The lifting height of the electric screw or lifting cylinder is a fixed value or a dynamically adjustable set value. The equipment control system obtains feedback and optimization instructions based on the online detection of the melt temperature in the melting crucible, the temperature field of the solidified layer on the ingot, and their criteria. The distance between the flow limiting control plug rod and the flow limiting guide nozzle is adjusted by lifting the screw or cylinder, thereby realizing the online on-demand adjustment of the flow rate and flow of the molten metal.

[0010] In one embodiment, the feeding system is a constant liquid level feeding system, which includes a feeding pipe connected to the inlet of the smelting crucible, a first solenoid valve installed on the feeding pipe, and a melt level gauge installed inside the smelting crucible. Both the melt level gauge and the first solenoid valve are connected to the equipment control system via signals. When the liquid level in the smelting crucible drops, the liquid level drop signal from the melt level gauge is transmitted to the equipment control system, which then transmits an opening signal to the first solenoid valve. The first solenoid valve opens, and the feeding pipe injects molten metal or master alloy material into the smelting crucible, causing the crucible liquid level to rise. When the liquid level in the smelting crucible is at the set level, the liquid level signal from the melt level gauge is transmitted to the equipment control system. The equipment control system then transmits a shut-off signal to the first solenoid valve. The first solenoid valve closes, and the feeding pipeline stops injecting molten metal or master alloy into the smelting crucible, ensuring that the liquid level in the smelting crucible remains constant at a certain height.

[0011] In one embodiment, the feeding system is a dynamic liquid level feeding system; the dynamic liquid level feeding system includes a feeding pipe connected to the inlet of the smelting crucible, a first solenoid valve installed on the feeding pipe, and a melt level gauge installed inside the smelting crucible. The current limiting control device is an electric screw or a lifting cylinder. The bottom of the electric screw or the bottom of the telescopic rod of the lifting cylinder is fixed to the top of the plug rod assembly. A second solenoid valve is provided at the bottom of the electric screw or on the lifting cylinder. A distance detection sensor is provided at the bottom of the plug rod assembly to detect the distance between the plug rod assembly and the flow-limiting guide nozzle; The melt level gauge, the first solenoid valve, the second solenoid valve, and the distance detection sensor are all connected to the equipment control system via signals. When the liquid level in the melting crucible drops to the bottom set water level line, the liquid level signal of the melt level gauge is transmitted to the equipment control system. The equipment control system transmits the opening signal to the first solenoid valve, controls the first solenoid valve to open, and injects molten metal or master alloy material into the melting crucible through the feeding pipe. When the liquid level in the melting crucible rises to the top set liquid level line, the liquid level signal of the melt level gauge is transmitted to the equipment control system. The equipment control system transmits the shut-off signal to the first solenoid valve, controls the first solenoid valve to close, and stops the feeding pipeline from injecting molten metal or master alloy into the melting crucible. The melt level gauge transmits the liquid level signal and the distance detection sensor transmits the distance signal to the equipment control system. The equipment control system dynamically adjusts the opening and closing of the second solenoid valve according to the set liquid level signal and distance signal, so as to realize the dynamic adjustment of the distance between the plug rod assembly and the flow limiting guide nozzle. The equipment control system also includes temperature sensors, level sensors, flow rate sensors, flow sensors, and distance sensors for online parameter monitoring; The heater is an induction heater or a resistance heater that surrounds the outside of the melting crucible.

[0012] In one embodiment, the device also includes a support frame, a water-cooled metal ingot support platform located on the support frame, an electromagnetic vibration coupled water-cooled ingot mold for wrapping the metal ingot on the support frame, a flow-limiting guide nozzle located above the electromagnetic vibration coupled water-cooled ingot mold, a uniform up-and-down and rotational motion mechanism at the bottom of the water-cooled metal ingot support platform, and a spray cooling device for spraying coolant onto the outer wall of the metal ingot on the support frame, the spray cooling device including spray heads distributed circumferentially on the outside of the metal ingot.

[0013] Specifically, the main function of the electromagnetic vibration coupled water-cooled ingot mold is to prevent the melt from overflowing during continuous casting and to further cool it, thus assisting in achieving rapid cooling and forming. The molten metal is limited and cast onto the rotating water-cooled ingot support platform to achieve rapid cooling of the ingot. The water-cooled ingot support platform moves the ingot downwards at a certain speed, dynamically adjusting the distance between the ingot and the flow-limiting guide nozzle to a certain range to ensure that the melt flow-limiting casting and rapid cooling forming can continue as needed.

[0014] In summary, the functions of the water-cooled ingot support platform are: first, to support the water-cooled ingot mold and the ingot guide, and to achieve rotation and vertical movement through its motion mechanism; second, to allow the molten material to pass through the flow-limiting and stacking process onto the rotating water-cooled ingot mold and the ingot guide for rapid cooling to form a metal ingot; and third, to allow the metal ingot to move at a certain speed, so that the distance between the metal ingot and the flow-limiting guide nozzle is dynamically adjusted to a certain range, so as to ensure that the flow-limiting stacking and rapid cooling forming process of the molten material can be carried out continuously as needed.

[0015] In one embodiment, a liquid outlet is provided inside the flow-limiting guide nozzle; The maximum size of the liquid outlet gate shall not exceed the radius, diameter or length of the metal ingot water-cooled support platform for drawing the ingot; One or both ends of the orthographic projection of the liquid outlet gate are located on the ingot on the water-cooled support platform and near the edge.

[0016] Specifically, the flow-limiting nozzle is equipped with a liquid outlet with a square, narrow slit cross-section, a circular liquid outlet, or other shapes of liquid outlet.

[0017] In one embodiment, the flow-limiting guide nozzle is provided with an anti-oxidation coolant spray port that is spaced a certain distance from and parallel to the liquid outlet.

[0018] Specifically, depending on the preparation requirements, an anti-oxidation coolant spray nozzle can be matched on the flow-limiting guide nozzle and parallel to the liquid outlet gate at a certain distance. The coolant is an anti-oxidation cooling gas or liquid, which is used for timely anti-oxidation protection of the laminar flow casting melt and works in conjunction with the ingot and water-cooled crystallizer to help achieve rapid cooling of the laminar flow casting melt.

[0019] The beneficial effects of this invention are as follows: 1. The metal ingot preparation method based on melt flow-limited stacking casting and rapid cooling forming is reasonable and feasible. It is based on the continuous or intermittent advancement of melt flow-limited bottom casting, layer-by-layer reciprocating stacking and layer-by-layer relay rapid cooling forming. It can not only realize the continuous rapid cooling forming of the metal melt and refine the grains, but also realize the layer-by-layer freezing rapid solidification forming of the metal melt with uniform atomic distribution by limiting atomic diffusion, thereby reducing component segregation. It can also simultaneously realize the layer-by-layer relay upward movement or reduction of casting defects such as shrinkage cavities and shrinkage porosity.

[0020] 2. The flow-limiting guide nozzle is equipped with a liquid outlet and a parallel and similarly shaped anti-oxidation coolant spray nozzle, which is located at the bottom of the crucible with a filter, and can simultaneously reduce the inclusions in the melt flowing through the flow-limiting guide nozzle.

[0021] 3. The present invention is a method and apparatus for preparing metal ingots based on melt flow limiting stacking casting and rapid cooling forming. It can simultaneously realize the one-time, short-process rapid reduction and coordinated control of defects such as coarse grains, shrinkage cavities, shrinkage porosity, compositional segregation and inclusions during the solidification and forming of metal melt, and can realize the short-process, high-quality manufacturing of metal ingots, especially large metal ingots.

[0022] 4. In the process of preparing large-size metal ingots, this invention can realize continuous flow restriction and stacking of molten metal on the ingot and rapid cooling and forming, providing a feasible original new technology for achieving continuous layer-by-layer freezing and rapid solidification forming of molten metal atoms in a long-range disordered and uniformly distributed state, and obtaining high-quality large-size amorphous metal ingots. Attached Figure Description

[0023] Based on the technical principles, structure, and embodiments of this invention, all other structural modifications and related embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this invention.

[0024] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some typical structures and embodiments of the present invention, and therefore should not be regarded as a limitation on the scope of protection. For those skilled in the art, other related structures and drawings can be obtained from these drawings without creative effort, and the related structures and drawings obtained are all within the scope of protection of the present invention.

[0025] Figure 1 This is a schematic diagram of a structure for producing solid metal ingots according to the present invention; Figure 2 This is a schematic diagram of the structure for producing ring-shaped metal ingots according to the present invention; Figure 3This is a schematic diagram of another ingot-drawing movement structure for producing solid and ring-shaped metal ingots according to the present invention; Figure 4 This is a cross-sectional schematic diagram of the flow-limiting guide nozzle structure; Reference numerals: 1. Ingot drawing; 2. Metal ingot; 3. Molten metal flow; 4. Shaping mechanism; 5. Crucible rotation device; 6. Melting crucible with filter; 7. Molten metal; 8. Feeding system; 9. Crucible lifting device; 10. Plug rod adjustment device; 11. Flow limiting control device; 12. Plug rod assembly; 13. Molten metal level gauge; 14. Heater; 15. Flow limiting guide nozzle; 16. Electromagnetic vibration coupled water-cooled ingot mold; 17. Spray cooling device; 18. Metal ingot water-cooled support platform; 19. Ingot drawing motion mechanism; 20. Equipment support; 21. Equipment control system. Detailed Implementation

[0026] To make the technical problems, technical solutions, and technical effects 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 some embodiments of the present invention, and not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0027] Therefore, the detailed description of the embodiments of the present invention provided in the following figures is not intended to limit the scope of the claimed invention, but merely to illustrate representative structures and embodiments selected by the invention. All structural modifications and related embodiments obtained by those skilled in the art based on the technical principles, structures, and embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0028] It should be noted that similar reference numerals and letters in the following figures indicate similar items; therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures. Furthermore, the terms "first," "second," etc., are used only to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0029] In the description of the embodiments of the present invention, it should be noted that the terms "inner", "outer", "upper", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship in which the product of the invention is usually placed when in use. They are only for the convenience of describing the present invention and simplifying the description, and 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. Therefore, they should not be construed as limiting the present invention.

[0030] Example 1 like Figure 1 and Figure 2As shown, this embodiment provides a metal ingot preparation device based on melt flow-limited stacking casting and rapid cooling forming, including a melting crucible 6 with a filter, a heater 14 surrounding the outer wall of the melting crucible 6, a flow-limiting guide nozzle 15 disposed at the bottom of the melting crucible 6, a plug rod assembly 12 disposed inside the melting crucible 6 to control the flow rate and flow of the molten metal 7 through the flow-limiting guide nozzle 15, a metal ingot guide 1 disposed at the bottom of the flow-limiting guide nozzle 15 to achieve rapid cooling of the molten metal flow 3, a water-cooled support platform 18, and a guide motion mechanism 19 for driving the metal ingot guide 1 to rotate and lift. It also includes a solidification layer shaping mechanism 4 for achieving the finishing of the solidification layer of the layered stacking casting. The heater 14 is an induction heater or a resistance heater wrapped around the outside of the melting crucible 6. A feeding system 8 is provided at the upper edge opening of the melting crucible 6 to ensure that the melting crucible 6 has a set relatively constant melt height and melt volume; The plug rod assembly 12 includes a plug at the bottom that mates with the flow limiting guide nozzle 15 and a flow limiting control plug rod disposed at the top of the plug. A thermocouple for temperature measurement is disposed inside the flow limiting control plug rod and is connected to the equipment control system 21. The stopper rod assembly 12 is provided with a stopper rod adjustment device 10 that drives the stopper rod assembly 12 to rise and fall, and also includes a flow limiting control device 11 for adjusting the distance between the stopper rod assembly 12 and the flow limiting guide nozzle 15, the melt flow rate and flow rate; The stopcock adjustment device 10 is a multi-directional translation platform disposed between the top of the flow limiting control stopcock and the flow limiting control device 11.

[0031] The flow limiting control device 11 is an electric screw or a lifting cylinder. The bottom of the electric screw or the bottom of the telescopic rod of the lifting cylinder is fixed to the top of the plug rod adjustment device 10. The lifting height of the electric screw or the lifting cylinder is a fixed value or a set value that can be dynamically adjusted. The equipment control system 21 obtains feedback and optimization instructions based on the online detection of the melt temperature in the melting crucible 6, the temperature field of the solidified layer on the ingot, and its criteria. The distance between the flow limiting control plug rod and the flow limiting guide nozzle 15 is adjusted by lifting the screw or the cylinder, so as to realize the online adjustment of the flow rate and flow of the molten metal.

[0032] The feeding system 8 is a constant liquid level feeding system. The constant liquid level feeding system 8 includes a feeding pipe connected to the inlet of the smelting crucible 6, a first solenoid valve installed on the feeding pipe, and a melt level gauge 13 installed in the smelting crucible 6. The melt level gauge 13 and the first solenoid valve are both connected to the equipment control system 21 via signals. When the liquid level in the smelting crucible 6 drops, the liquid level drop signal of the melt level gauge 13 is transmitted to the equipment control system 21. The equipment control system 21 transmits an opening signal to the first solenoid valve, the first solenoid valve opens, and the feeding pipe injects molten metal or master alloy into the smelting crucible 6, causing the liquid level in the crucible to rise. When the liquid level in the smelting crucible 6 rises to the set level, the liquid level signal of the melt level gauge 13 is transmitted to the equipment control system 21. The equipment control system 21 transmits a shut-off signal to the first solenoid valve, and the first solenoid valve closes. The feeding pipe stops injecting molten metal or master alloy into the smelting crucible 6 to ensure that the liquid level in the smelting crucible 6 remains constant at a certain height.

[0033] Example 2 like Figure 1 As shown, this embodiment is based on embodiment 1, except that the feeding system 8 is replaced with a dynamic liquid level feeding system, as detailed below: The dynamic liquid level feeding system is connected to the feeding pipe of the melting crucible 6, the first solenoid valve is installed on the feeding pipe, and the melt liquid level gauge 13 is installed in the melting crucible 6. The current limiting control device 11 is an electric screw or a lifting cylinder. The bottom of the electric screw or the bottom of the telescopic rod of the lifting cylinder is fixed to the top of the plug rod assembly 12. A second solenoid valve is provided at the bottom of the electric screw or on the lifting cylinder. A distance detection sensor is provided at the bottom of the plug rod assembly 12 for detecting the distance between the plug rod assembly 12 and the flow limiting guide nozzle 15; The melt level gauge 13, the first solenoid valve, the second solenoid valve, and the distance detection sensor are all connected to the equipment control system 21 via signals; When the liquid level in the melting crucible 6 drops to the bottom set water level line, the liquid level signal of the melt level gauge 13 is transmitted to the equipment control system 21. The equipment control system 21 transmits the opening signal to the first solenoid valve, controls the first solenoid valve to open, and injects molten metal or master alloy material into the melting crucible 6 through the feeding pipe. When the liquid level in the melting crucible 6 rises to the set liquid level line of the crucible, the liquid level signal of the melt level gauge 13 is transmitted to the equipment control system 21. The equipment control system 21 transmits the shut-off signal to the first solenoid valve, controls the first solenoid valve to close, and stops the feeding pipeline from injecting molten metal or master alloy into the melting crucible 6. The melt level gauge 13 transmits the liquid level signal and the distance signal from the distance detection sensor to the equipment control system 21. The equipment control system 21 dynamically adjusts the opening and closing of the second solenoid valve according to the set liquid level signal and distance signal matching, thereby realizing the dynamic adjustment of the distance between the plug rod assembly 12 and the flow limiting guide nozzle 15.

[0034] The heater 14 is an induction heater 14 or a resistance heater 14 that surrounds the outside of the melting crucible 6.

[0035] Example 3 like Figure 1 and 2 As shown, this embodiment is a further optimization based on embodiment 1 or 2, as detailed below: It also includes an equipment support 20, a metal ingot water-cooled support platform 18 located on the equipment support 20, an electromagnetic vibration coupled water-cooled ingot mold 16 for wrapping the metal ingot on the equipment support 20, a flow-limiting guide nozzle 15 located above the electromagnetic vibration coupled water-cooled ingot mold 16, an ingot guide 1 on the metal ingot water-cooled support platform 18, and an ingot guide motion mechanism 19 with uniform downward movement and rotation at the bottom. The equipment support 20 is also equipped with a spray cooling device 17 for spraying condensate onto the outer wall of the metal ingot 2, and the spray cooling device 17 includes spray heads distributed circumferentially on the outside of the metal ingot 2.

[0036] In this embodiment, the electromagnetic vibration coupling water-cooled ingot mold 16 prevents the molten metal flow 3 from overflowing and further cools it, assisting in the rapid cooling and forming of the metal ingot 2; the molten metal flow 3 is limited by the melt flow and stacked onto the ingot 1 of the rotating metal ingot water-cooled support platform 18 to achieve rapid cooling of the metal ingot 2; the metal ingot water-cooled support platform 18 moves the metal ingot 2 downward at a certain speed through the ingot motion mechanism 19, so that the distance between the metal ingot and the flow limiting guide nozzle 15 is dynamically adjusted to a certain range to ensure that the melt flow limiting stacking and rapid cooling forming can be carried out continuously as needed.

[0037] Example 4 like Figure 1 As shown, this embodiment is a further optimization based on embodiment 3, as detailed below: The flow-limiting guide nozzle 15 has a liquid outlet inside; The maximum size of the liquid outlet gate shall not exceed the radius, diameter, length, or ring wall thickness of the ingot 1 drawn from the water-cooled support platform 18 of the metal ingot.

[0038] One or both ends of the orthographic projection of the liquid outlet are located at the edge of the metal ingot 1 and the metal ingot 2 on the metal ingot water-cooled support platform 18.

[0039] In this embodiment, the flow-limiting guide nozzle 15 is provided with a liquid outlet with a square and narrow slit cross-section, a circular liquid outlet, or a liquid outlet of other shapes.

[0040] In this embodiment, the shape of the liquid outlet gate can be a long strip with rounded corners (including but not limited to a regular rectangle and other irregular long strips), or it can be an arc (including but not limited to a regular circle, an ellipse or other irregular arcs); the long strip can be of uniform width or non-uniform width. like Figure 4As shown, in this embodiment, the elongated liquid outlet gate (including but not limited to square slits) can be a single elongated liquid outlet gate or a densely packed elongated liquid outlet gate composed of multiple rectangular or square liquid outlet gates, depending on the manufacturing requirements. Depending on the manufacturing requirements, the dimensions of the elongated liquid outlet gate (including rectangular slits) are as follows: length ≥ 0.1 mm (including but not limited to 0.1-30000 mm), width ≥ 0.01 mm (including but not limited to 0.01-100 mm), and depth ≥ 0.1 mm (including but not limited to 0.1-100 mm). In this embodiment, the arc-shaped liquid outlet gate can be an independent arc-shaped liquid outlet gate or a closely spaced arc-shaped gate composed of two or more arc-shaped liquid outlet gates, depending on the preparation requirements; the size of a single arc-shaped liquid outlet gate is: diameter ≥ 0.1 mm (including but not limited to 0.1-200 mm) and depth ≥ 0.1 mm (including but not limited to 0.1-100 mm).

[0041] Example 5 like Figure 1 As shown, this embodiment is a further optimization based on embodiment 3, as detailed below: It also includes a crucible rotating device 5 and a crucible lifting device 9 that drive the melting crucible 6 to rotate.

[0042] The flow-limiting guide nozzle 15 is equipped with an anti-oxidation coolant spray nozzle that is parallel to the liquid outlet and at a certain distance from it.

[0043] In this embodiment, according to the preparation requirements, an anti-oxidation coolant spray nozzle can be matched on the flow limiting guide nozzle 15 and parallel to the liquid outlet gate at a certain distance. The coolant can be an anti-oxidation cooling gas or liquid, which is used for timely anti-oxidation protection of the laminar flow casting molten metal 3, and also works in conjunction with the water-cooled ingot mold 16 to help achieve rapid cooling of the laminar flow casting molten metal 3.

[0044] Example 6 like Figure 3 As shown, this embodiment is a further optimization based on embodiment 1, as detailed below: The motion mode of the spindle motion mechanism 19 in Example 1 is changed from Figure 1 , Figure 2 The horizontal rotation shown is replaced with Figure 3 The horizontal rotation shown.

[0045] Example 7 This embodiment provides a method for forming cylindrical metal ingots based on melt flow-limited stacking casting and rapid cooling, including the following steps: S1. The stopper rod adjusting device 10 drives the stopper rod assembly 12 to move downward to block the flow limiting guide nozzle 15. The feeding system 8 adds molten metal or metal master alloy to the melting crucible 6. The heater 14 heats the molten metal or melts the metal master alloy in the melting crucible 6 to obtain molten metal 7. S2. Adjust the position of the ingot 1 on the metal ingot water-cooled support platform 18 by the ingot movement mechanism 19 so that the position of the ingot 1 on the metal ingot water-cooled support platform 18 is aligned with the flow limiting guide nozzle 15 of the melting crucible 6, and start the crucible rotation device 5 or the ingot movement mechanism 19 on the metal ingot water-cooled support platform 18. S3. The flow limiting control device 11 adjusts the distance between the plug rod assembly 12 and the flow limiting guide nozzle 15 through a fixed gap mode or a gap dynamic adjustment mode, so that the flow limiting guide nozzle 15 is in the open state, and the molten metal 7 in the melting crucible 6 flows from the flow limiting guide nozzle 15 into the ingot 1 of the water-cooled support platform 18. S4. The rotating crucible rotating device 5 or the ingot moving mechanism 19 of the water-cooled support platform 18 makes the molten metal flow 3 uniformly laminate and stacked, thereby obtaining a large cylindrical metal ingot 2.

[0046] Example 8 This embodiment provides a method for producing high-quality ring-shaped metal ingots based on molten metal flow-limited stacking casting and rapid cooling forming, including the following steps: S1. The stopper rod adjustment device 10 drives the stopper rod assembly 12 to move downward to block the flow limiting guide nozzle 15. The feeding system 8 adds molten metal or master alloy material into the melting crucible 6. The heater 14 heats and melts the molten metal material in the melting crucible 6 to obtain molten metal 7. S2. Adjust the position of the ingot 1 on the water-cooled support platform 18 of the metal ingot by the ingot movement mechanism 19, so that the position of the metal ingot ingot 1 is aligned with the flow-limiting guide nozzle 15 of the melting crucible 6, and start the crucible rotation device 5 or the ingot movement mechanism 19 to rotate the water-cooled support platform 18. S3. The flow limiting control device 11 is used in a fixed gap mode or a gap dynamic adjustment mode to adjust the distance between the plug rod assembly 12 and the flow limiting guide nozzle 15 so that the flow limiting guide nozzle 15 is in the open state, and the molten metal flow 3 in the melting crucible 6 flows from the flow limiting guide nozzle 15 into the ingot 1 of the water-cooled support platform 18. S4. Rotate the crucible rotating device 5 or the ingot moving mechanism 19 to rotate the water-cooled support platform 18, so that the molten metal flow 3 is uniformly laminated and stacked onto the ingot 1. Through its uniform downward movement and electromagnetic vibration coupled with the water-cooled ingot mold 16, it is rapidly cooled and formed. This process is continued to obtain a high-quality ring-shaped metal ingot.

[0047] In this embodiment, the molten metal 7 becomes molten metal flow 3 after flowing through the flow-limiting guide nozzle 15. The molten metal flow 3 is continuously or intermittently limited and stacked onto the ingot 1 of the water-cooled support platform 18, which is capable of rotation and three-dimensional movement. The rotating ingot 1 and the metal ingot 2 enable the "uniform stacking of molten metal flow 3, flow-limited stacking and rapid cooling forming" to be carried out continuously as needed, that is, to obtain high-quality solid metal ingots or ring-shaped metal ingot components with reduced casting defects.

[0048] This scheme is based on the continuous or intermittent advancement of "melt flow limiting stacking, layer-by-layer reciprocating stacking and layer-by-layer relay rapid cooling forming" to achieve "continuous rapid cooling forming of molten metal 3". By restricting the atomic diffusion rate through rapid cooling, it achieves "freezing" rapid solidification and layer-by-layer rapid solidification forming of the "long-range disorder" distribution state of the atoms in the molten metal 7. This enables the one-time, short-process agile reduction and coordinated control of defects such as coarse grains, shrinkage cavities, shrinkage porosity, compositional segregation and inclusions during the solidification forming of molten metal, thereby achieving short-process, high-quality manufacturing of metal ingots, especially large metal ingots.

[0049] Example 9 Metallic amorphous materials are a new type of material that is amorphous and lacks crystal structure and grain boundary structure due to the long-range disorder and short-range ordered arrangement of metal atoms. Because of their amorphous and grain boundary structure, they have some unique properties, such as excellent mechanical properties and corrosion resistance, and are the main direction of high-performance development of metallic materials. The existing technology for preparing amorphous metallic materials is the rapid cooling technology of molten metal. Due to the limitation that the cooling rate is difficult to maintain continuously, the size of the amorphous materials (amorphous ribbons and amorphous bulk materials) currently produced in the industry is relatively small. The thickness of amorphous ribbons is generally ≤50um, and although the size of bulk amorphous materials is larger than that of amorphous ribbons, the diameter is generally no more than 80mm. This seriously restricts the breadth and depth of the industrial application of amorphous metallic materials and urgently needs to be solved. To address the aforementioned issues, this embodiment provides a method for manufacturing large amorphous products based on metal flow-limited stacking casting and rapid cooling forming. The method and related equipment described in Embodiments 7 and 8 are used for manufacturing large amorphous products. This method rotates the ingot 1 via a rotating crucible rotating device 5 or an ingot moving mechanism 19. Through continuous or intermittent advancement based on melt flow limiting bottom casting, layer-by-layer reciprocating superposition, and layer-by-layer relay rapid cooling forming of the molten metal flow 3, continuous rapid cooling forming of the molten metal flow 3 is achieved. By restricting the atomic diffusion rate through rapid cooling, the method achieves frozen rapid solidification forming and layer-by-layer continuous rapid solidification forming of the long-range disordered uniform distribution of atoms in the molten metal flow 3. This method not only maintains the cooling rate and obtains large amorphous products, but also achieves the layer-by-layer relay upward movement or reduction of defects such as shrinkage cavities, shrinkage porosity, and inclusions. Thus, it simultaneously achieves the effective reduction and synergistic control of defects such as shrinkage cavities, shrinkage porosity, and compositional segregation in the preparation of amorphous metal ingots, especially large-size amorphous metal ingots, thereby obtaining high-quality large-size amorphous metal ingots.

[0050] The method in this embodiment can continuously achieve rapid cooling of molten metal, thereby effectively solving the bottleneck problem of reduced cooling rate and crystallization caused by ordered atomic arrangement during the preparation of large-size amorphous ingots. This provides an innovative technology for obtaining high-quality large-size amorphous ingots.

Claims

1. A method for preparing metal ingots based on melt flow-limited stacking casting and rapid cooling forming, characterized in that, By continuously or intermittently advancing the melt through bottom casting with flow restriction, layer-by-layer reciprocating superposition, and rapid cooling and forming of the melt layer by layer, continuous rapid cooling and forming of the molten metal is achieved. This process refines the grains, limits the atomic diffusion rate through rapid cooling, and achieves a layer-by-layer freezing-type rapid solidification forming of the molten metal with a long-range disordered and uniform atomic distribution. It also reduces component segregation and simultaneously achieves the layer-by-layer relay upward movement or reduction of casting defects such as shrinkage cavities and porosity. The flow restriction nozzle is equipped with a liquid outlet gate with a square and narrow slit cross-section, or a circular liquid outlet gate, or other shapes of liquid outlet gate. The flow restriction nozzle is also equipped with an anti-oxidation coolant spray port that is parallel to the liquid outlet gate and has a similar shape. The melt flows through the filter and flows out from the bottom of the crucible to reduce inclusions.

2. The method for preparing metal ingots based on melt flow-limited stacking casting and rapid cooling forming according to claim 1, characterized in that, The specific methods for continuous or intermittent advancement of melt flow-limited bottom casting, layer-by-layer reciprocating superposition, and melt layer-by-layer relay rapid cooling forming are as follows: S1. A smelting crucible with a filter is required. The filter is located in the lower part of the smelting crucible and above the flow-limiting nozzle. The stopper rod adjustment device in the smelting crucible drives the stopper rod assembly to move downward to block the flow-limiting nozzle at the bottom of the smelting crucible. The feeding system adds metal master alloy or melt into the smelting crucible. The heater heats and keeps the melt warm or melts the metal master alloy in the smelting crucible. S2. Adjust the position of the metal ingot water-cooled support platform through the motion mechanism so that the metal ingot water-cooled support platform is aligned with the flow-limiting guide nozzle of the melting crucible and maintains the set distance, and start the metal ingot water-cooled support platform. S3. A flow limiting control device is adopted. By adjusting the distance between the plug rod assembly and the flow limiting guide nozzle in a fixed gap mode or a gap dynamic adjustment mode, the flow limiting guide nozzle is in the open state. The molten metal in the melting crucible flows out from the liquid outlet of the flow limiting guide nozzle and flows to the metal ingot water-cooled support platform ingot through the flow limiting stacking method. S4. Activate the crucible or metal ingot water-cooled support platform motion device. Through continuous or intermittent advancement based on melt flow-limited casting, layer-by-layer reciprocating superposition, and melt relay rapid cooling forming, the continuous rapid cooling forming of the metal melt is achieved. By restricting the atomic diffusion rate through rapid cooling, the long-range disordered uniform distribution of metal melt atoms is achieved through freeze-type rapid solidification and layer-by-layer rapid solidification forming. This enables the layer-by-layer relay upward movement or reduction of casting defects such as shrinkage cavities and porosity. Thus, the shrinkage cavities, porosity, and compositional segregation defects of the metal melt and metal ingot are effectively reduced and synergistically controlled, resulting in cylindrical or ring-shaped metal ingot products.

3. A metal ingot preparation apparatus based on melt flow-limited stacking casting and rapid cooling forming, used to implement the metal ingot preparation method based on melt flow-limited stacking casting and rapid cooling forming as described in claim 2, characterized in that, The equipment includes a smelting crucible with a filter, a heater surrounding the outer wall of the smelting crucible, a flow-limiting nozzle disposed at the bottom of the smelting crucible, a plug rod assembly disposed inside the smelting crucible for controlling the flow rate and volume of the melt flowing through the flow-limiting nozzle, a metal ingot water-cooling support platform disposed at the bottom of the flow-limiting nozzle for rapid cooling of the melt, a drive mechanism for driving the movement of the metal ingot water-cooling support platform, and an equipment control system, and also includes a shaping mechanism for the solidified layer of the layered casting. The stopper rod assembly is provided with a stopper rod adjustment device for precise alignment and adjustment with the flow limiting nozzle during the installation of the stopper rod assembly, and also includes a flow limiting control device for controlling the lifting and lowering of the stopper rod assembly and realizing online adjustment of the distance between the stopper rod assembly and the flow limiting nozzle, melt flow rate and flow rate; A feeding system is provided at the upper opening of the smelting crucible to ensure that the smelting crucible has a set melt height, melt volume and melt flow rate.

4. The metal ingot preparation apparatus based on melt flow limiting stacking casting and rapid cooling forming according to claim 3, characterized in that, The plug rod assembly includes a plug at the bottom that mates with the flow-limiting guide nozzle and a flow-limiting control plug rod disposed on the plug. The flow-limiting control plug rod contains a thermocouple for temperature measurement that is connected to the equipment control system. The stopcock adjustment device is a multi-directional translation platform disposed between the top of the flow-limiting control stopcock and the flow-limiting control device.

5. The metal ingot preparation apparatus based on melt flow-limited stacking casting and rapid cooling forming according to claim 3 or 4, characterized in that, The flow limiting control device is an electric screw or a lifting cylinder. The bottom of the telescopic rod of the electric screw or lifting cylinder is fixed to the top of the plug rod adjustment device. The lifting height of the electric screw or lifting cylinder is a fixed value or a set value that can be dynamically adjusted. The equipment control system obtains feedback and optimization instructions based on the online detection of the melt temperature in the melting crucible, the temperature field of the solidified layer on the ingot, and their criteria. The distance between the flow limiting control plug rod and the flow limiting guide nozzle is adjusted by lifting the screw or cylinder, so as to realize the online adjustment of the flow rate and flow of the molten metal.

6. The metal ingot preparation apparatus based on melt flow restriction stacking and rapid cooling forming according to claim 5, characterized in that, The feeding system is a constant liquid level feeding system, which includes a feeding pipe connected to the inlet of the smelting crucible, a first solenoid valve installed on the feeding pipe, and a melt level gauge installed inside the smelting crucible. Both the melt level gauge and the first solenoid valve are connected to the equipment control system via signals. When the liquid level in the smelting crucible drops, the liquid level drop signal from the melt level gauge is transmitted to the equipment control system. The equipment control system then transmits an opening signal to the first solenoid valve, which opens the valve. The feeding pipe then injects molten metal or metal master alloy into the smelting crucible, causing the crucible liquid level to rise. When the liquid level in the smelting crucible is at or above the set level, the liquid level signal of the melt level gauge is transmitted to the equipment control system. The equipment control system then transmits a shutdown signal to the first solenoid valve, which closes. The feeding pipe stops injecting molten metal or metal master alloy into the smelting crucible to ensure that the liquid level in the smelting crucible remains constant at a certain height.

7. The metal ingot preparation apparatus based on melt flow limiting stacking and rapid cooling forming according to claim 6, characterized in that, The feeding system is a dynamic liquid level feeding system, which includes a feeding pipe connected to the inlet of the smelting crucible, a first solenoid valve installed on the feeding pipe, and a melt level gauge installed inside the smelting crucible. The current limiting control device is an electric lead screw or a lifting cylinder. The bottom of the electric lead screw or the bottom of the telescopic rod of the lifting cylinder is fixed to the top of the plug rod assembly. A second solenoid valve is provided on the bottom of the electric lead screw or the lifting cylinder. The stopper assembly is equipped with a distance detection sensor for detecting the distance between the stopper assembly and the flow-limiting guide nozzle; The melt level gauge, the first solenoid valve, the second solenoid valve, and the distance detection sensor are all connected to the equipment control system via signals. When the liquid level in the smelting crucible drops to the set liquid level line, the liquid level signal of the melt level gauge is transmitted to the equipment control system. The equipment control system transmits the opening signal to the first solenoid valve, controls the first solenoid valve to open, and the feeding pipe injects molten metal or metal master alloy into the smelting crucible. When the liquid level in the smelting crucible rises to the set liquid level line, the liquid level signal of the melt level gauge is transmitted to the equipment control system. The equipment control system transmits a shut-off signal to the first solenoid valve, controls the first solenoid valve to close, and the feeding pipe stops injecting molten metal or metal master alloy into the smelting crucible. The melt level gauge transmits the liquid level signal and the distance detection sensor transmits the distance signal to the equipment control system. The equipment control system dynamically adjusts the second solenoid valve according to the set liquid level signal and distance signal, thereby realizing the dynamic adjustment of the distance between the plug rod assembly and the flow limiting guide nozzle. The heater is an induction heater or a resistance heater that surrounds the outside of the melting crucible.

8. The metal ingot preparation apparatus based on melt flow limiting stacking casting and rapid cooling forming according to claim 3, characterized in that, It also includes an equipment support, on which the metal ingot water-cooled support platform is located. The equipment support is provided with an electromagnetic vibration coupled water-cooled ingot mold for wrapping the metal ingot. The flow-limiting guide nozzle is located above the electromagnetic vibration coupled water-cooled ingot mold. The bottom of the metal ingot water-cooled support platform is provided with a uniform downward movement and rotation mechanism. The equipment support is also provided with a spray cooling device for spraying coolant onto the outer wall of the metal ingot. The spray cooling device includes spray heads distributed circumferentially on the outside of the metal ingot.

9. The metal ingot preparation apparatus based on melt flow-limited stacking casting and rapid cooling forming according to any one of claims 3 to 8, characterized in that, The flow-limiting guide nozzle is provided with a liquid outlet; The maximum size of the liquid outlet gate is not greater than the radius, diameter or length of the ingot on the metal ingot water-cooling support platform; one or both ends of the orthographic projection of the liquid outlet gate are located on the edge of the metal ingot water-cooling support platform near the ingot.

10. The metal ingot preparation apparatus based on melt flow limiting stacking casting and rapid cooling forming according to claim 9, characterized in that, The flow-limiting guide nozzle is provided with an anti-oxidation coolant spray nozzle that is spaced at a certain distance from and parallel to the liquid outlet.

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